Custom Solar Wire Harnesses for
Reliable DC Power Delivery
WellPCB builds high-performance solar wire harnesses engineered for extreme environments.
From PV panel strings to solar power inverters, our assemblies deliver long term reliability, secure connectors and clean DC transmission for any solar system.
Built to spec, tested to UL standards, and delivered fast.
- UV resistant cable jacket with sealed connectors for outdoor use
- Tailored DC wire harnesses for panels, inverters and charge controller connections
- Fast lead times for utility-scale, rooftop or mobile solar power plant installs
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ISO9001 ISO13485
ISO14001
IATF
16949
IPC-A-610H International
Certification
Fully Automated
AOI Inspection
Solar Wire Harnesses for PV Panels, Inverters and Energy Storage
Solar wire harnesses and solar cable assembly enable safe, efficient routing of DC power between solar panels, inverters and charge controllers. They’re essential in both fixed and mobile solar systems, from rooftop installations to utility-scale PV plants.
As the global solar industry surpasses 2.2 TW in installed capacity according to IEA-PVPS, demand is shifting toward faster, modular deployment methods. WellPCB supports this transformation by delivering custom wiring harness solutions that are pre-tested and tailored to evolving international standards.
WellPCB manufactures harnesses for solar using PV rated components including solar cable, MC4-compatible connectors and sealed junctions. Our wire harness products support wire gauges from 2.5 mm² to 16 mm² and voltage ratings up to 1500V. Cable lengths are cut to spec, labeled for field installation and terminated using crimp-force validated tooling.
Assemblies undergo 100% continuity testing, insulation resistance checks and pull-force verification to ensure mechanical and electrical reliability. We design every solar harness to reduce on site wiring time while minimizing power loss across the PV system.
Our Solar Wire Harness Capabilities
We use PV cable with jackets resistant to UV, ozone and high humidity. Our conductor size capabilities extend from 2.5 mm² to 16 mm² cross-sections, though 4 mm² and 6 mm² cables fulfill the majority of solar project requirements, with larger sizes reserved for high-current DC applications.
Conductors are tinned copper (stranded, Class 5) to improve conductivity and reduce corrosion. Insulation options include XLPE for 90°C/150°C ratings, suitable for harsh outdoor solar industry environments including rooftops, desert ground-mounts and cold climates.
WellPCB supports a wide range of solar connector types including MC4, MC4-Evo2, Amphenol H4 and Staubli. Crimping operations are validated for crimp height, tensile strength (pull tests >100N), and secure mating with manufacturer certified tooling.
Connectors are sealed to IP67 or IP68 ratings using overmolding or pre terminated assemblies with back shells. We also support extension cable assemblies with custom lengths for fast module-to-combiner connections or controller interfaces.
Our wire harness production lines use semi automated cut-strip-crimp machines with strict cutting tolerance. All harnesses are labeled using heat-shrink markers or laser-etched ID.
Each label corresponds to your BOM and layout drawings, simplifying installation and field troubleshooting in dense PV plant or solar power plant environments.
Custom cable harness assemblies are available with 2-in-1, 3-in-1 or 4-in-1 string harness splices for combining multiple solar panels into a combiner box input. These are sealed with molded thermoplastic or adhesive-lined heat shrink tubing for IP68 environmental protection.
We also support branch connectors, diode protection and potted junction boxes for solar module integration and connecting solar into charge controller systems.
All solar harnesses undergo 100% electrical testing for continuity, insulation resistance (>1000 MΩ at 1000V) and pull force validation.
All connectors are validated to maintain contact resistance below 0.35 mΩ, ensuring minimal loss under continuous dc load.
We meet IPC/WHMA-A-620 standards for wire harness workmanship and hold ISO 9001 certification. Ratings follow TUV1500V/UL1500V benchmarks, with current handling up to 45A for 6 mm² PV cable.
WellPCB can handle quantities from 1-off prototypes to 10,000+ harnesses/month. Standard prototypes ship within 3 weeks; full production in 4 to 5 weeks depending on complexity. We apply SPC controls for crimp quality, cut length and connector seating depth.
You can also customize layout, color coding, pinout logic or interface types for modular system builds, portable solar panel kits or branded BESS cabinet wiring.
Why Choose WellPCB?
One-Stop Solar Harness Manufacturing
PV-Rated, Field-Ready Materials
Fast Turnaround for Any Project
No Counterfeit Components
Engineered for Harsh Environments
Standards-Driven Workmanship
Applications of Solar Wire Harnesses
WellPCB manufactures specialized solar wire harnesses for a wide range of fixed, mobile and hybrid solar power environments.
Rooftop PV Systems
Ground-Mounted Utility Arrays
Hybrid Battery Storage Systems
Microinverter & Optimizer Connections
Combiner Boxes & Rapid Shutdown Circuits
Off-Grid & Mobile Solar Systems
Testing and Quality Assurance for Solar Wire Harnesses
Continuity and Polarity Testing
Insulation Resistance Testing
Pull-Force Validation
Seal Integrity and IP Testing
Visual and Final Inspection
Design Considerations for Solar Wire Harnesses
Designing a solar wire harness requires careful attention to electrical, mechanical and environmental parameters. The right choices in wire sizing, routing, connector selection and protection methods directly impact system performance, lifespan and ease of installation in solar panel and PV system configurations.
Voltage and Current Ratings
Wire Gauge and Conductor Type
Connector Compatibility and Locking Mechanism
Routing, Bending and Strain Relief
Environmental Exposure and Protection
How to Order Your Solar Wire Harness
Submit Your Design
Send us your design details (Drawing or Detailed Specifications).
Get a Fast Quote
Once your design and specs are received, a fast quote will be sent to you within 24 hours.
Confirm Order & Make Payment
When the quotation is approved, please send the PO or order confirmation, we will proceed with the production after receiving your payment.
Arrange Production & Inspection
Before production, our technical team will review all details of the drawing/specs again. If everything is OK, the order will start. We'll keep you updated throughout the manufacturing process. After the production is completed, the products will be 100% inspected.
Packaging & Delivery
When completed, your order will be carefully packed and shipped to you, with shipping documents and tracking information provided.
WellPCB is trusted by millions of
businesses and innovators.
Why Choose WellPCB as Your Wire Harness Manufacturer?
WellPCB stands out among USA wire harness manufacturers by delivering superior quality, advanced solutions, and unmatched reliability. With years of experience serving global markets, WellPCB has earned a reputation as one of the top wire harness manufacturers in the USA.
WellPCB specializes in custom wire harnesses for complex electronic and industrial applications. You can order these assemblies with $100 off using our special offer—delivering high-quality, tailor-made harnesses at competitive rates for your most demanding projects.
Hommer Zhao
Founder and Chief Editor – Hommer Zhao
Welcome! I’m Hommer Zhao, the founder and Chief Editor of WellPCB. With years of experience in the PCB industry, I’m committed to making sure our content is both accurate and helpful. We’re proud to serve a growing community of over 4,000 customers worldwide, and our goal is to provide you with the best resources and support. Your satisfaction is our top priority, and we’re here to help you every step of the way!
Jesse Holland
Technical Manager – Jesse Holland
Hi, I’m Jesse Holland, an Engineer and Technical Manager at WellPCB. With years of experience in PCB design and engineering, I’m here to ensure that every project we work on meets the highest technical standards. I lead our team, focusing on precision and innovation, collaborating closely with clients to provide tailored solutions and expert guidance. Whether you’re facing a complex design challenge or need advice on technical aspects, I’m here to ensure your project is a success from start to finish.
Nathan Jensen
Purchasing Manager – Nathan Jensen
Hi, I’m Nathan Jenson, the Purchasing Manager at WellPCB. I’m responsible for sourcing the best materials and components to ensure our products meet the highest quality standards. With my extensive experience in procurement, I work closely with suppliers to secure reliable and cost-effective solutions while maintaining strong relationships to support our operations. I aim to ensure every project runs smoothly by providing the resources needed to deliver on time and to your satisfaction.
Emma
Sales Manager – Emma
Hey, I am Emma, sales manager at WellPCB. I studied electronic science and technology at university and have served customers for PCB and PCB Assembly service for several years.

I enjoy communicating with customers and our technicians to solve problems, and customers always say, "It's great to have you onboard".

It is my pleasure and honour to be helpful. Contact me now, and you'll know.
Bella and Cassiel
Sales Representatives – Bella and Cassiel
We’re Bella and Cassiel, your dedicated sales representatives at WellPCB. With our extensive knowledge of the PCB industry, we’re here to provide exceptional service and support. We take the time to understand your unique needs and are always ready to offer tailored solutions and advice. Whether you need product recommendations, assistance with your orders, or simply have a question, we’re here to ensure your experience is smooth and seamless at every step.
Mandy and Wendy
Sales Representatives – Mandy and Wendy
We’re Mandy and Wendy, your friendly sales representatives at WellPCB. Passionate about helping our customers, we bring a wealth of experience in the PCB industry to provide you with the best solutions and service. We take pride in building strong relationships with our clients, understanding their specific needs, and offering personalised support to ensure their satisfaction. Whether you’re looking for advice, product information, or assistance with any part of your order, we’re here to make your experience as smooth and efficient as possible.
Our Team
Our skilled engineers and technicians bring expertise and precision to every PCB assembly project. Committed to quality, efficiency, and innovation, our team ensures every order meets the highest UL, IPC, ROHS & REACH standards, delivering reliable solutions tailored to your needs.
- Founder and Chief Editor – Hommer Zhao
- Technical Manager – Jesse Holland
- Purchasing Manager – Nathan Jensen
- Sales Manager – Emma
- Sales Representatives – Bella and Cassiel
- Sales Representatives – Mandy and Wendy
Solar Wire Harness Case Studies
PCB Assembly
This case study showcases a high-performance solar panel wiring harness for outdoor photovoltaic systems, requiring high and low temperature resistance, UV resistance, and efficient electrical conductivity.
We select high-quality, weather-resistant cables, precisely process terminals and connectors, and rigorously control insulation and sealing processes. This product can stably transmit power even in extreme environments, enabling efficient power generation in photovoltaic systems and fully demonstrates our expertise in solar panel wiring harness and photovoltaic cable manufacturing.
PCB Assembly
This project shows a solar wire harness specifically designed for DC combiner boxes in photovoltaic systems. The harness integrates multiple input strings from solar panels and safely channels the combined current toward the inverter.
High Current Capacity: Built with thick, tinned copper conductors to handle the combined output of multiple PV strings without overheating.
Safety and Protection: Incorporates fuse holders and ring terminals for secure grounding, reducing the risk of short circuits and electrical faults.
Easy Installation: Pre-terminated connectors allow for quick assembly on-site, lowering labor costs and installation time.
PCB Assembly
This case study highlights a customized wire harness developed for solar tracking systems that adjust panel angles throughout the day. The harness carries both control signals and power, ensuring the motorized trackers operate smoothly in outdoor environments.
Advantages:
- •Uses UV-resistant, flexible cables that withstand constant movement and bending without damage.
- •Multi-core design keeps power and data transmission reliable, even under continuous rotation.
- •Robust insulation and sealed connectors provide protection against dust, moisture, and temperature fluctuations.
Solar Wire Harness Client Feedback
As an R&D manager, I have had an outstanding experience working with WELL-PCB. For many years, our company has entrusted them with the production, assembly, and programming of the boards developed in our R&D unit, and they have consistently exceeded our expectations.
Hamid Reza Moshayedi
R&D Manager
Their work is very impressively perfect. Today, when they check our company PCB board after assemble. They found a fake short point which many engineers has never found in the past years. But that is just designed so. The PCB board quality is excellent. Their service is also excellent.
MikeZ
My friend introduced WellPCB to me, the first try, a little look forward to. I ordered a 47*72 10ps PCB, and I can’t wait to receive my PCB. So I used expedited service and received my PCB in three days. I tested and soldered the PCB, Quality is really good, silkscreen, plating also great.
Warren Cliton
Solar Wire Harness FAQs
Do your harnesses support NEC and UL compliance for U.S. installations?
Yes, we build all wire harnesses to IPC/WHMA-A-620 Class 2 or 3 standards, and label them per NEC 690.31 requirements. Harnesses for shutdown systems meet UL 1741 SB, and components are traceable and UL listed where required.
Can you customize the harness layout for our solar project?
Yes, we can manufacture wire harnesses to your exact requirements, including conductor lengths, connector types, labeling, bundling and interface configurations. We follow the information on your technical drawings.
Can you provide harnesses for 1500V DC systems?
Do you provide overmolded or potted connections?
Your Solar Wire Harness Manufacturer for All Your Solar Cable Needs
Get $100 Off Your First Order!
WellPCB delivers pre-tested, standards-compliant solar wire harnesses built for performance, safety and long-term field reliability. Contact us to get a free quote today.
