Trends in Solar Cables and Connectors
Over the past decade, the Indian solar wire and cable segment has witnessed remarkable growth. What began as a niche within the electrical cable industry is now a vital part of the country’s renewable energy push.
June 25, 2025. By News Bureau
Evolution of the Indian Solar Cabling Ecosystem
Over the past decade, the Indian solar wire and cable segment has witnessed remarkable growth. What began as a niche within the electrical cable industry is now a vital part of the country’s renewable energy push. The demand for robust and high-performing solar cables has surged, in tandem with the expansion of solar capacity from just 0.5 percent of the total electricity generation in 2015 to around 20.75 percent in the financial year 2023–24. This significant increase underscores the vital role solar energy now plays in India's power mix. This expansion has driven innovation and regulatory standardisation in cable manufacturing, with increasing alignment to global benchmarks.
Advancements in Cable Technology
At the core of technological advancements in solar cabling is electron beam (E-Beam) irradiation technology. This process enhances the thermal, mechanical, and environmental resistance of cables, ensuring long-term reliability even under harsh conditions. Unlike traditional cross-linking methods, E-Beam provides more uniform cross-linking, better thermal and mechanical stability, high UV stability, and eliminates issues like under-curing or over-curing the insulation and sheath materials, making cables more durable for the 25-year life expectancy typical of solar projects.
Other advancements include the mandatory use of halogen-free solar cables, which release low smoke and are non-toxic in case of fire. A major regulatory shift came with the Quality Control Order (QCO) issued by the Ministry of Commerce and BIS (Bureau of Indian Standards), making it mandatory for all solar DC cables used in India to conform to IS 17293. This Indian Standard is based on cross-linked halogen-free insulated cables, aligning with IEC 62930 and even exceeding the stringent safety, thermal, and UV-resistance benchmarks set by EN 50618—the globally recognised standard for photovoltaic cables.
This move ensures that only high-performance, long-lasting, and environmentally safe solar cables are used in critical installations, offering protection against degradation, fire hazards, and electrical failures. It also addresses the earlier influx of inferior or non-compliant imports, strengthening both quality and safety across solar projects in India.
Meeting the Needs of Diverse Segments
While solar cabling is essential across all end-user categories—residential, commercial, and industrial—the highest demand is currently observed in the industrial and commercial sectors. These segments typically involve large-scale installations that require highly reliable, long-lasting cables capable of handling higher loads with minimal energy loss.
The residential sector is also emerging as a fast-growing market for solar cables. With increased rooftop solar adoption driven by financial incentives and greater awareness of clean energy benefits, cable solutions that are efficient, compact, and easy to install are gaining importance.
Geographically, demand is concentrated in states with abundant solar resources and proactive policy frameworks—Rajasthan, Gujarat, Maharashtra, and Tamil Nadu. These regions combine high solar irradiance with supportive regulatory environments, making them hotspots for both utility-scale and distributed solar projects.
A Broader Product Spectrum for Evolving Needs
The evolution of solar projects—ranging from grid-connected utility-scale plants to floating solar systems—has necessitated a more diverse product portfolio. Beyond conventional DC solar cables used to connect photovoltaic (PV) modules to inverters or battery systems, a solar project includes various cables connecting PV arrays to inverters and to the battery bank. There are LT power cables used to connect panels to combiners, combiners to inverters, and inverters to transformers. Further, HT power cables are used for connection with the substations and electric grid. In a solar project, data cables are critical for data interface, monitoring, and remote communication. The cable portfolio has evolved accordingly:
- DC Solar Cables: Connect PV modules to inverters or charge controllers. Require high flexibility, UV resistance, and long-term thermal stability.
- Floating Solar Cables: Designed for submerged or waterborne applications, featuring high resistance to moisture and environmental degradation.
- Low-Tension (LT) and High-Tension (HT) Power Cables: For power transmission from panels to transformers and beyond through distribution grids.
- Control and Instrumentation Cables: Support real-time monitoring, communication, and control functions critical to system performance.
Trends in Connector Technologies
While cables get much attention, connectors—especially MC4 and compatible variants—are also seeing innovation. Trends include:
- Tool-Free Installation: Reducing human error and installation time.
- Waterproof & Dustproof Ratings (IP68): Ensuring safe operation in outdoor and harsh environments.
- Anti-Arc and Reverse Polarity Protection: Enhancing safety during connection/disconnection cycles.
Domestic Manufacturing and Quality Enforcement
India’s domestic manufacturing capacity for solar cables and connectors has grown in tandem with demand. Modern production units are leveraging R&D, advanced testing protocols, and compliance with global standards to cater to both domestic and export markets.
Despite this progress, a major challenge continues to be the proliferation of low-cost, low-quality imports and non-compliant local products, which threaten both the efficiency and safety of solar systems. These substandard cables, while seemingly economical upfront, often result in higher maintenance costs, energy losses, and system failures over time.
In response, regulatory measures such as the Quality Control Order (QCO) mandating IS 17293 compliance have been implemented to curb substandard production. Enforcement by the Bureau of Indian Standards (BIS) is helping to level the playing field and raise the baseline for product quality across the sector.
Growth Outlook: Opportunities on the Horizon
As of May 2024, India has installed over 84 GW of solar power, with a target to reach 280 GW by 2030 within the broader 500 GW renewable energy goal. This rapid expansion opens vast opportunities for domestic solar cable and connector manufacturers. The growth is not just quantitative but also qualitative—with increasing demand for advanced, intelligent, and durable solutions.
The cable industry’s role in this ecosystem is foundational. High-performance cables are not only conduits for electricity—they are the backbone of efficiency, safety, and long-term value in solar projects. With continued investment in technology, quality, and sustainability, India’s solar cable manufacturers are well-positioned to power the country’s clean energy journey.
please contact: contact@energetica-india.net.
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