solar system wire sizing calculator

http://solarpanelsvenue.com/calculator/wire-sizing-calculator/wire-sizing-calculator.htm

source: http://solarpanelsvenue.com/

comparision of solar,PVC and XLPE Cables

PV Trackers

Four main types of trackers

1.Horizontal singe Axis Tracker HSAT
2.Tilted single axis tracker
3.Azimuth Tracker
4.Dual axix tracker

Mounting Structures Manuacturers list

sl.no	Name of the company	Address
1	Lotus Industries	Plot no. 268, Panchasheela colony, Gandhinagar, Hyderabad, IDA, Balanagar, Hyderabad, Telangana 500037,Phone:093948 26067
2	VIMFAB	Plot No. 11, Phase- 4, Behind Topaz, IDA, Miyapur, Medak Rd, Rajiv Gandhi Nagar,Jeedimetla, Hyderabad, Telangana 500055,Phone:087900 73284
3	Nuevosol Energy Pvt Ltd	Nuevosol Energy Private Limited,Plot # 409, Road No. 81,Phase 3, Jubilee Hills, Hyderabad – 500 033,Telangana, India
4	pennarindia	3rd Floor, DHFLVC Silicon Towers,Kondapur, Hyderabad - 500 084, Telangana, India.Phone: 040-40061621 /22 /23/24.Fax: 040-40061618.E-mail: contact@pennarindia.com /pilhyd@bsnl.in
5	Suyash Metatech Pvt. Ltd	E-63, MIDC, Satpur, Nashik - 422 007. Maharashtra, India, Tel. No.: + 91 - 253 - 6604599, + 91 - 253 - 6563599
6	subhadraindustries	53/1, Kottige Palya, Magadi Main Road, Opp : Unani Medicle College, Hospital., Bangalore, Karnataka, India - 560091
7	krvfabrications	S. N. Balaji (Proprietor),No. 14, SIDCO Industrial Estate, Ambattur ,Chennai - 600098, Tamil Nadu, India.Call Us:  08376806850
8	Green Field Solar Solution Pvt. Ltd	Avinas Rajendran (Director) New No. 29, First Main Road, Shenoy, Nagar East  Chennai - 600030, Tamil Nadu, India.MOB-09643204288
9	Shree Umiya Sheet Metal	Manoj Shekhat (Managing Director) Shed No. 12/A, Rudrax,Complex-II, Near Trikampura Cross Road, Opposite Annapurna , Rest, G. I. D. C. Vatva, Phase III ,Ahmedabad - 382445, Gujarat, India
10	essofabtech	14, Kanjibhai Estate, Nr Bharat Gas Godown, Vinjol Patia,Mehmedabad Road, Vatva, Ahmadabad – 382445.,P: (079) 25841014 / 40041014
11	V N Roofing & Cladding pvt. ltd	V. N. Roofing & Cladding Pvt. Ltd. Naresh Agrawal (Director),Lata Tiwari,  C-14, MIDC, Kalmeshwar  Nagpur - 441501,Maharashtra, India
12	epackpolymers	61 – B & C, Udyog Vihar, Surajpur, Kasna Road, Greater Noida,U.P.) India. Pin – 201306,+91-9818666068, +91-8130444466
13	Aacess Tough Doors Private Limited	Ravi Chandra (Director Marketing)Plot No. B 8 & 9/1, IDA,Kukatpally, Gandhi Nagar,Hyderabad - 500037, Telangana, India
14	jindalsteelandpowerltd	Mohit Srivastava (Deputy Manager)Ist Floor, Tower B, Jindal Centre,Plot-02, Sector-32 Gurgaon - 122001, Haryana, India
15	Mitaso Comtel Limited	Address: Plot No-119-120, Sector 6, Sector 6, Faridabad, Haryana,121006 Phone:0129 408 5064
16	DPW Solar Electric	Albuquerque, NM, United States,Phone:+1 505-889-3585
17	schletter	51B/32 Vrindavan Society •  Majiwade •  Thane (West) ,   Pin- 400601,Tel.: +91 9167 595798   info@schletter.in
18	Professional Solar Products	1551 South Rose Avenue, Oxnard, CA 93033, United States,Phone:+1 805-383-7171
19	Quick Mount PV	2700 Mitchell Dr, Walnut Creek, CA 94598, United States
20	IronRidge	Hayward, CA, United States Phone:+1 800-227-9523
21	Unirac	1411 Broadway Boulevard NE Albuquerque NM 87102-1545 USA,Telephone: 505-242-6411
22	Snapnrack	contact@snapnrack.com,877·732·2860775 Fiero Lane Suite 200,San Luis Obispo, CA 93401
23	Renusol GmbH	Piccoloministraße 2, 51063 Köln, GermanyPhone:+49 221 7887070
24	Up Solar America	600 Montgomery St, San Francisco, CA 94111, United States,Phone:+1 415-263-9920
25	Orion Solar Racking	7012-, 7098 Elm St, Commerce, CA 90040, United States, Phone:+1 310-409-4616
26	prosolar	Professional Solar Products,1551 S Rose Ave Oxnard, CA 93033,contact@prosolar.com
27	solarflexrack	U.S. and International Inquiries:info@solarflexrack.com, Phone: 888.380.8138
28	TOUGH TRAC	NewYork,sales@toughtrac.com
29	hillsmithsolar	UK,  sales@hillsmithsolar.com
30	Chiko Solar	NO.878 Cheng Liu Rd.Jiading District Shanghai ,China,sales@chikolar.com
31	Roller Die	Roller Die + Forming 1172 Industrial Blvd . Louisville , KY 40219,Phone: 502-804-5571
32	Grace Solar	ADD：NO.E,Gaoqi Industrial Park,Huli District, Xiamen, Fujian, China.TEL：0086-592-5239037,Email：info@gracesolar.com
33	Xiamen Sunforson Power Co.,Ltd	Unit 817,An Ling Road No. 993,Hu Li District,Xiamen China.Tel:   86-592-3655325,86-592-5735570,Fax: 86-592-5115756,E-mail:info@sunforson.com
34	patriotsolargroup	1007 Industrial Avenue,Albion, MI, USA 49224,517.629.9292
35	K2 Systems	Unit 46 Easter Park,Benyon Road,Aldermaston, Berkshire RG 7 2PQ, United Kingdom,Tel. +44 (0) 1189 701280

Solar Cable Maufacturers

S.No	Company	Address	phone	email
1	Eland Cables	Highgate Studios, 53-79 Highgate Rd, London NW5 1TL, United Kingdom	+44 20 7241 8787	sales@elandcables.com
2	QC Solar cables	No.31 Xinfa Road, SIP, Suzhou, Jiangsu, China		market@quick-contact.com  (sales)
3	Thermocables	No 28, Nagarjuna Hills, Punjagutta, Punjagutta, Hyderabad, Telangana 500082	040 2309 0040	info@thermocables.com
4	Radox solar	Skyline place Frenchs Forest Sydney Australia	+61 2 8977 1200	radoxaustralia@hubersuhner.com
5	Centurion solar cables	F-1775, DSIIDC Indl. Estate, Narela, Delhi - 110040, India		info@centurioncables.org
6	olex-nexans	1300 CABLES ,Australia,Business Phone: 1300 222 537 E-mail address: olex.customerservice@nexans.com	+ 61 3 9281 4444	olexmktmgr.photovoltaic@nexans.com
7	TECHSUN-prysmian group	Italy		marketing.energy@prysmiangroup.com
8	amson solar cables()	Uttarpradesh	-4542080	amson@amon.info
9	APAR Industries ltd	907,9th Floor, BabuKhan Estates, Basheer Bagh, Hyderabad, Telangana 500001	040 2329 8514	apar.hyderabad@apar.com
10	Betaflam solar cables	switzerland	+41 (0)62-288-8282	infrastructure-datacom@leoni.com
11	Axiom Solar pvt ltd	Kushaiguda,Hyderabad	+91-99590 55156	suresh@axiomsolar.com
12	Tamradhatu	205/212, Iind Floor, 32, Ezra Street, Kolkata, West Bengal 700001	033 2221 8583	enquiry@tamradhatu.com
13	Advance cable	G-1,Sunrise Serenity,No.1,M.R.Garden,Gedallahalli,Aswanthnagar,Bangalore-560094.India	91-80-23516733/34	sales@advancecable.in
14	Havells solar cables	QRG Towers,Noida	91- 120- 3331000	marketing@havells.com
15	Hanferd Cables	Plot No-14/1A, Site IV, Industrial Area, Sahibabad,Uttar Pradesh -201010,India	91 0120 2775892	info@hanferd.com
16	Supreme cables	No:159,Linghi Chetty St,Parrys,Chennai-600001	9841060801	supreme_ec@rediffmail.com
17	Relema cables	Plot No. 92, Sec.56,Phase IV,Kundli Industrial Area HSIIDC, Sonipat, Haryana-131028 (INDIA)	91-130-6549900	info@relemacindia.com
18	Amersol-nexans	350 Bailey Road,El Dorado, Arkansas 71730,USA	800-643-1516
19	Spectrum cables	Tech Nr Amber Gum Industries, Nr Maria Park, Canal Road, Opp Hotel Cozy, Narol, Ahmedabad- 382 405, Gujarat India	9824011251	spectrumcabletech@gmail.com
20	XLPE Cables	No. 234, 3rd Floor, Garudachar Complex, Chickpet, Bangalore, Karnataka, India - 560053	91-9341285508	kflexcables@gmail.com
21	Belden solar cables	Belden - India ,Unit 503, Wellington-II , Wellington Business Park, Off Andheri ,Kurla Road, Opp. Skyline Ikon ,Mumbai , Maharashtra 400059 ,India
22	Erico Solar power Solutions
23	Shilpi cables	A-19/B-1 Extension,Mohan Co-op. Industrial Estate,Mathura Road, P.O. Badarpur ,New Delhi - 110044, India	91 11 43117900	info@shilpicabletech.com
24	Polycab	208-209, 2nd Floor Bhuvana Towers S D Road, Secunderabad, Telangana 500003	040 6632 6228	info@polycab.com,
25	southwire
26	https://www.civicsolar.com
27	http://www.siechem.com/
28	http://www.finolex.com/
29	http://cablecorporation.com/
30	http://www.unistar.co.in/
31	http://www.bhuwalcable.com/

Tips To Buy Solar Cable

Solar Cables are used as an interconnection cable in photovoltaic power generation. Solar panels and other components of the photovoltaic system are interconnected using Solar Cables. The Solar Cables are UV resistant and can bear harsh weather conditions. Solar Cables are mostly laid outdoors and they have the capacity to function properly in extreme temperatures.

Nowadays, many factories and offices have their own photovoltaic systems, on which the power supply needs of the whole factory or office relies. A  small error in any part of this system, even in the Solar Cables, may shut down the supply in the whole system and can result in tremendous loss. Therefore, selecting a properly functioning Solar Cable is an important aspect that needs to be considered. Following are few tips that you must consider while selecting Solar Cables:

• Solar Cables that you select must be of high-grade material. Solar Cables made from low quality material may not function as efficiently as the ones made with high-grade material.
• The material used for making Solar Cables must be sunlight-resistant, corrosion-resistant and must be protected against agents like water and dust.
• The Solar Cables that you are selecting should also be resistant from flame, oil, UV and ozone.
• The Solar Cables should also be free from halogen and should be flame retardant so as to prevent fire.
• The Solar Cables that you select for installation must comply with EC Low-Voltage Directives.
• The material that is used for making Solar Cables must be flexible enough to facilitate easy installation.

HOW TO USE MC4 CONNECTORS AND EXTENSION CABLES

What is an MC4 connector and an MC4 extension cable? If you're asking this question, you've probably noticed that most modern high power solar modules are manufactured with wire leads that have MC4 connectors on the ends. Years ago, solar modules were built with a junction box on the back that required the installer to manually attach wires to the positive and negative terminal posts. This method is still used, but it's slowly becoming a thing of the past. Modern solar modules tend to use the MC4 connectors because they make wiring your solar array much simpler and faster. The connectors come in both male and female types which are designed to snap together. They meet the requirements of the National Electric Code, they're UL certified and the preferred connection method of electrical inspectors. Due to the locking mechanism of the MC4 connectors, they will not come unplugged and are well suited for outdoor environments. The connectors can be separated but it requires a special MC4 unlocking tool.


Wiring MC4 Equipped Modules in Series:

If you have two or more solar modules to wire in series, the MC4 connectors make it very simple. Take a look at the first module and you'll notice that it has two wires extending from the junction box. One wire is the DC positive (+) and the other is the DC negative (-). Generally, the male MC4 connector is associated with the positive lead and the female connector is associated with the negative lead. This may not always be the case, so it's always a good idea to look at the markings on the junction box or test the polarity with a digital volt meter. A series connection is when you wire the modules together by connecting the positive lead on one module to the negative lead on another module. The male connector will snap directly into the female connector. Here's a simple diagram illustrating this.

As you can see, the two modules are now connected together by the two leads. This increases the voltage of the circuit. For example, if your modules are rated for 18 volts at maximum power (Vmp), then two of them connected in series will measure 36 Vmp. If you connected three modules in series, the total Vmp would be 54 volts. The current at max power (Imp) will be constant when wiring a series circuit.

Wiring MC4 Equipped Modules in Parallel: 

Parallel wiring requires the positive leads to be connected together and the negative leads to be connected together. This method will increase the current at max power (Imp) while keeping the voltage constant. For example, let's say your modules are rated for 8 amps Imp, and 18 volts Vmp. If you connect two of them in parallel, your total amps would be 16 amps Imp and the voltage would remain at 18 volts Vmp. When wiring two or more modules in parallel, you will need some additional equipment. If you're only using two modules, the easiest method is to use MC4 multibranch connectors. You obviously can't connect two male connectors or two female connectors together, so we use the multibranch connectors to accomplish that. There are two different multibranch connectors. One type accepts two male MC4 connectors on the input side and has a male MC4 connector for its output. The other type accepts two female MC4 connectors and has a female MC4 connector for its output. Essentially, you've stepped down the number of wires from two positive and two negative to one positive and one negative. Here's a diagram so that you can see what it's doing.

If you are paralleling more than two modules or you're paralleling strings of modules, that requires a device called a PV combiner box. You no longer need the multibranch connectors because the combiner box will be performing the same function. The multibranch connectors are only suitable for paralleling two modules together. If you need to connect more than two modules or strings in parallel, a combiner box is used. The total number of modules that can be combined will depend upon the electrical rating and physical size of the combiner box. Whether you've combined your modules with the multibranch connectors or with a combiner box, you'll need to understand how to select and use MC4 extension cables.

What is an MC4 Extension Cable and How do I use Them?

Don't feel bad if you're confused by the MC4 extension cables. If you've never worked with solar modules before, they can be a little intimidating. First of all, they're expensive. Nobody wants to purchase an expensive cable and later find out the length is too short after its been cut. Cut cables cannot be returned, so we want to be sure you fully understand how to choose the appropriate length and how to use them to connect your panels together.

An MC4 extension cable is very similar in concept to an electrical extension cord. Just like an extension cord has a male plug on one end and a female plug on the other, an MC4 extension cable has a male connector on one end and a female connector on the opposite end. They are available in many different lengths from 8 feet to 100 feet long. Lets go back to our first example of wiring two modules in series. Once you've got the two modules connected in series, you need to use MC4 cables to bring that power to wherever your electrical equipment is located (usually a circuit breaker and a solar charge controller). Systems using two modules are generally used for RV's and boats, so you can usually use the extension cables along the entire distance. When you use solar panels on a house or cabin, the distance that the wire must travel is normally so long that using an extension cable is no longer practical. In those situations, the extension cables are used to connect the panels to a combiner box. That way you can use less expensive wiring (such as THHN rated insulation) inside electrical conduit to cover greater distances at substantially less cost than the MC4 cables. Let's say that the total length of wire needed to go from the two modules to your electrical equipment is 20 feet. Note: This is where most people start getting confused. You only need one extender cable. We offer an extender cable in a 50 foot length, which is best suited for this situation. Remember that the two solar modules that you've already connected together have one positive lead with a male MC4 connector and one female lead with a female MC4 connector. To travel the 20 foot distance to your equipment, you will need a 20 foot wire with a male connector and a 20 foot wire with a female connector. This is achieved by cutting the 50 foot extension cable in half. That will give you a 25 foot wire with a male connector and a 25 foot wire with a female connector. That allows you to plug into both leads of your solar panel and it gives you plenty of wire to get to your destination. Sometimes cutting the cable in half is not always the best solution. Depending upon the location of the combiner box, there may be a greater distance from one side of the panel string to the combiner box than from the opposite side of the panel string. In this case, you will want to cut the extender cable at a spot that allows both cut ends to reach the combiner box with a little slack to work with. This diagram shows you an example of that scenario:

For systems using a combiner box, you simply choose a length that, when cut, is long enough to be terminated into the box. You can then strip back the insulation from the cut ends and terminate them to a bus bar or circuit breakers.

Disconnecting MC4 Connectors:

This is an MC4 disconnect tool. If for some reason you need to disconnect your MC4 cables, you will need one of these. You must insert the two extended posts on the end of the tool into the side of the female MC4 connector. This disengages the locking mechanism on the male connector and allows the two connectors to separate. The disconnect tool is sold as a set of two. Two tools are required if you ever need to disassemble the connectors. This is almost never necessary. Generally, one tool is all you will need.

MC4 Connector Specifications:

Manufacturer: Multi-Contact USA

Rated for 30 amps max (the connector itself, not the wire)

Rated for 1,000 volts max

Rated temperature range: -40 degrees C to +90 degrees C (-40 F to 194 F)

Note: Do not cut the MC4 connectors off of your solar modules. That voids the warranty of most manufacturers.

Source:http://www.solar-electric.com/how-to-use-mc4-connectors-cables.html/