Material & Rating
- Connector — MC4 plug and socket, with XT60, DC 5.5 x 2.1, SAE 2-pin or bare tinned ends
- Contacts — tinned copper, crimped and rated for the cable cross-section
- Conductor — tinned stranded copper 14–10 AWG, per the current on the drawing
- Insulation and jacket — XLPE or UV-resistant PVC, black or red, rated for outdoor exposure
- Voltage — system voltage stated per drawing; insulation rated accordingly
- Temperature — 80 °C with PVC; XLPE and cross-linked jackets for higher temperature and UV load
- Ingress protection — mated MC4 pairs sealed per drawing; level verified on the sample
Certification
Cactus Electronics is certified to ISO 9001, IATF 16949 and UL and manufactures to the IPC/WHMA-A-620 workmanship standard. Raw materials comply with RoHS. Every assembly passes 100 % electrical testing - continuity, insulation resistance and withstand voltage - before packing, and the QC-to-production personnel ratio is 1:3.
Application
Solar cable assemblies are used anywhere a panel has to reach a controller, battery or inverter through a sealed, UV-resistant link.
- Rooftop and ground mount PV array wiring
- RV, camper and marine solar charging
- Off-grid cabins and portable power stations
- Panel to charge controller and inverter links
- Battery input leads with XT60, DC or SAE ends
- Parallel panel splitters and Y harnesses
Custom Options
- Connector combination: MC4 to MC4, XT60, DC, SAE, Anderson or bare leads
- Cable cross-section 14 to 10 AWG, length and jacket colour (black or red)
- Single lead, extension, Y splitter or bundled harness
- Tinned copper conductor and UV-resistant jacket for permanent outdoor installation
- Samples in 3–7 working days; MOQ confirmed per project
- Customer carton marking and DDP delivery on request
FAQ
What is the operating temperature rating of this harness?
Standard PVC-insulated assemblies are rated to 80 °C; XLPE or TPE insulation raises the rating to 105 °C. Standard builds use a PVC or XLPE jacket rated to 80 °C, which covers roof-mounted runs; cables routed in hot conduit or behind panels are quoted with a cross-linked jacket. The exact operating range for a part number is stated on its drawing and confirmed in the sample test report.
Is this overmolded harness waterproof?
MC4 connectors are sealed at the mated pair and the overmolded cable entry keeps water out, which is why they are used for permanent outdoor installation. The ingress protection level (typically IP67 for a mated pair) is specified on the drawing and verified during sample validation. Non-overmolded assemblies can be supplied with heat-shrink or grommet sealing instead.
Can I customize the pinout and connector type?
Yes. Pinout, connector series and gender, cable length, wire gauge, jacket colour and overmold shape are all customer-defined. Cable cross-section, length, connector combination and polarity are all defined by your system layout. Send a drawing, a sample, or a pinout table and we return a 2D/3D drawing prepared to IPC/WHMA-A-620 for approval before tooling.
What is your MOQ for custom cable?
MOQ is confirmed per project and depends on harness complexity, connector cost and tooling. Prototype and pilot batches are accepted before mass production, so a new programme can start with sample quantities. Samples are produced in 3–7 working days and mass production runs 20–30 days after approval.
What testing standards do you apply for harness?
Production follows IPC/WHMA-A-620. Every assembly is 100 % electrically tested for continuity, insulation resistance and withstand voltage; the in-house lab adds temperature and humidity cycling, salt spray, connector insertion and withdrawal force, and cable bending tests. Inspection records are kept in the ERP system.
