By Shreegopal Kabra, Managing Director, RR Kabel
As India forges ahead with its bold target of achieving 500 GW of non-fossil fuel energy capacity by 2030, key enablers of this transition that often operate behind the scenes are stepping into the limelight. Within this space, solar cables and connectors form an invisible yet indispensable part of solar power systems. Once considered simple components, today, they have become critical to ensuring safety, durability and performance in modern solar installations.
Evolution of the solar cabling ecosystem
Over the past decade, the Indian solar wire and cables 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 per cent of the total electricity generation in 2015 to around 20.75 per cent in FY2023-24. 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 technology 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 of the insulation and sheath materials, making cables more durable for the typical 25-year life expectancy of solar projects.
Other advancements include the mandatory use of halogen-free solar cables, which release low smoke and are non-toxic in the case of fire outbreaks. A major regulatory shift came with the Quality Control Order (QCO) issued by the Ministry of Commerce and Industry and the Bureau of Indian Standards (BIS), making it mandatory for all solar DC cables used in India to conform to IS 17293. This 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 PV 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, including the residential and commercial and industrial (C&I) sectors, the highest demand is currently observed in the C&I sector. This segment typically involves 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, such as 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.
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 PV modules to inverters or battery systems, a solar project includes various cables connecting PV arrays to inverters and to the battery bank. Low tension (LT) power cables are used to connect panels to combiners, combiners to inverters, and inverters to transformers. Meanwhile, high tension (HT) power cables are used for connection with substations and the electric grid. In a solar project, data cables are critical for data interface, monitoring and remote communication. The cables segment has evolved accordingly, with offerings such as:
DC solar cables: These solar cables connect PV modules to inverters or charge controllers and require high flexibility, UV resistance and long-term thermal stability.
Floating solar cables: These cables are designed for submerged or waterborne applications, featuring high resistance to moisture and environmental degradation.
LT and HT power cables: These power cables are used for power transmission from panels to transformers and other components through distribution grids.
Control and instrumentation cables: These cables support real-time monitoring, communication and control functions critical to system performance.
These cable types are designed to operate in diverse environmental conditions such as indoors and outdoors, industrial sites, hazardous zones and agricultural settings, making versatility and resilience key features of modern solar cabling solutions.
Trends in connector technologies
While cables often receive much of the attention, connectors – especially MC4 and compatible variants – are witnessing innovation. Trends include tool-free installation, which reduces human error and installation time. Connectors now have waterproof and dustproof ratings (IP68), ensuring safe operation in outdoor and harsh environments. They also feature anti-arc and reverse polarity protection, enhancing safety during connection and disconnection cycles. The integration of smart monitoring into connectors is also being explored for fault detection and predictive maintenance.
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 research and development, advanced testing protocols, and compliance with global standards to cater to both domestic and export markets.
Despite this progress, major challenges include 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 economically upfront, often result in higher maintenance costs, energy losses and system failures over time.
In response, regulatory measures such as the QCO that mandates compliance with IS 17293 have been implemented to curb substandard production. Enforcement by BIS is helping to level the playing field and raise the baseline for product quality across the sector.
Growth outlook
As of April 2025, India has installed over 107 GW of solar power, with a target to reach 280 GW by 2030. 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 of 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.
