Correct Use of Aluminum Core Cables in PV Systems

Jan 13, 2024

In PV systems, it is recommended to use copper core AC cables. If you need to use aluminum wires, pay attention to the transition method when connecting aluminum cables to copper wires or equipment with copper terminals.

Article from | Solis Inverters

Grid transmission cables are usually aluminum core. Therefore, in the construction of PV plant projects in residential and commercial areas (especially household PV plant), many users will use aluminum core cables to directly interface with inverter output ports or circuit breakers ports. This can cause many safety problems. This Solis seminar will share with you the correct connection of copper and aluminum cables.

Figure1: In PV plant electrical connection problems, AC side faults account for 30%,

Formation of galvanic cell reaction: When copper and aluminum conductors are directly connected, the contact surfaces of these two metals easily form galvanic cells in the air. This causes galvanic corrosion of aluminum and increases the contact resistance at the junction of copper and aluminum conductors.

Increase contact resistance: The elastic modulus and thermal expansion coefficient of copper and aluminum are very different. After multiple cooling and heating cycles (power-on and power-off) during operation, a larger contact gap will be generated at the contact point, which increases the contact resistance. The increase in contact resistance will cause the temperature of the contact point to rise, and finally lead to the burning of cables and equipment interfaces.

The resistivity of aluminum wire and copper wire are different.

Figure2: Resistivities of common metals

Aluminum wire is easily oxidized by air, and a layer of oxide is formed on its surface, which will increase the contact resistance of the contact point between the aluminum wire and the copper wire. When the current passes through this contact point, the heat will be increased at the connection point and could potentially result in a fire.

Figure3: Copper wire and aluminum wire cannot be directly connected

According to safety operation regulations, aluminum wires cannot be directly connected to copper wires or copper conductor terminals.

To connect single strands of small cross-section copper and aluminum wires, a tin-plate on the copper wires should be done and then it can be connected to the aluminum wires.

Figure4: Soldering Cu-Al cable

When connecting multiple large cross-section aluminum wires with copper wires or circuit breakers containing copper conductor terminals, a Cu-Al Wire connector should be used.

Figure5: Cu-Al Wire Connector

In a dry room, copper conductors should be tinned and then connect to Al wire. Outdoors or where the relative humidity of the air is close to 100%, a Cu-Al Wire connector should be used along with tin-plating the copper terminals.

For terminal crimping, always use professional equipment and crimp the wires tightly.

In PV systems, it is recommended to use copper core AC cables. If you need to use aluminum wires, pay attention to the transition method when connecting aluminum cables to copper wires or equipment with copper terminals. If the method is incorrect, the cables could cause a catastrophic event.

If you have any other questions, you can contact your local Solis support engineer: www.solisinverters.com/aftersales.html. Solis is one of the world's largest and most experienced string inverter manufacturers with a global network of service teams.

Ginlong's cost-effective solutions for residential, commercial, and utility-scale users deliver value at every level of the solar supply chain, engaging both homeowners and businesses, as well as power producers and renewable energy investors across the globe. Presented under the Solis brand, the company's solar inverter product line uses innovative string technology to deliver first-class reliability, validated under the most stringent international certifications. Combining a global supply chain with world-class R&D and manufacturing capabilities, Ginlong optimizes its Solis inverters for each regional market, servicing and supporting its customers with its team of local experts.

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