Custom Solar Wiring Assemblies

Frigate delivers utility-scale Custom Solar Wiring Assemblies engineered to minimize voltage drop and withstand the harshest environmental conditions. Our plug-and-play harness solutions streamline on-site installation, significantly reducing field labor costs and boosting overall photovoltaic system reliability.

Conductor Material

High-strand Annealed Tinned Copper (Class 5/6)

Insulation Material

Cross-linked Polyethylene (XLPE) / Electron-beam XLPO

Jacket Material

Sunlight-resistant, Low Smoke Zero Halogen (LSZH) compound

Voltage Rating

600V / 1000V / 1500V DC

Temperature Range

$-40^\circ\text{C}$ to $+90^\circ\text{C}$ (ambient), $+120^\circ\text{C}$ (maximum conductor)

Order Type

Quantity Range

Lead Time*

Prototype / First Article

1 – 10 Assemblies

1 – 2 Weeks

Low-Volume Production

11 – 250 Assemblies

3 – 4 Weeks

Medium-Volume Production

251 – 1,000 Assemblies

5 – 6 Weeks

High-Volume / Utility Scale

1,000+ Assemblies

6 – 8 Weeks

*Note: Timelines are indicative and vary by component availability, raw material sourcing, production capacity, and custom engineering design approvals.

Product Description

Tailored to match your exact site layouts and electrical schematics, Frigate manufactures custom solar wiring assemblies that seamlessly integrate into complex commercial and utility PV systems. Our advanced, automated production line guarantees precision crimping and robust junction insulation, delivering a highly reliable, maintenance-free DC distribution network.

Connector Types

MC4, MC4-Evo 2, Inline Fused Connectors, Molded T-Junctions

Flammability Rating

UL 94 V-0, VW-1, EN 50618 compliant

UV & Ozone Resistance

EN 50618 / UL 4703 certified for long-term outdoor exposure

Protection Class

IP67 / IP68 (mated condition)

Wire Gauge Range

14 AWG to 4/0 AWG ($2.5\text{ mm}^2$ to $120\text{ mm}^2$)

Overmolding Material

Thermoplastic Vulcanizate (TPV) / UV-stabilized Polyurethane

Short Circuit Rating

Compliant with IEC 60364-7-712 structural safety limits

Bending Radius

Fixed: $4 \times \text{OD}$; Flexing: $6 \times \text{OD}$

Salt Spray Resistance

ASTM B117 compliant for coastal and marine environments

Certifications

UL 4703, TÜV Rheinland EN 50618, CE, RoHS

Technical Advantages

Our proprietary overmolding technology forms an impenetrable, IP68-rated seal at all junction points, preventing moisture ingress and eliminating catastrophic field failures. Additionally, integrated inline fuses and custom branch configurations drastically simplify string combined wiring, ensuring minimal voltage drop across massive arrays.

Let's Get Started

Need reliable Enclosure for your next project? Get in touch with us today, and we’ll help you find exactly what you need!

Industry Applications

Utility-Scale Solar Farms

Engineered to withstand heavy environmental stress, providing reliable high-voltage DC power transmission across thousands of ground-mounted tracking arrays.

Commercial & Industrial (C&I) Rooftops

Compact, fire-rated wiring configurations optimized for complex building layouts, ensuring rapid deployment and strict compliance with local safety codes.

Floating Solar (FPV) Arrays

Specialized moisture-resistant, salt-tolerant overmolded assemblies designed to operate reliably on pontoons and highly humid water body environments.

Solar Tracking Systems

High-flexibility wire harnesses engineered to endure continuous mechanical torsion and repetitive movement without material fatigue or degradation.

Agrivoltaics (Solar + Agriculture)

Elevated cabling solutions featuring robust mechanical jackets that guard against physical impacts, agricultural chemicals, and pest damage.

Solar-Powered EV Charging Hubs

Integrated DC distribution assemblies that streamline power routing directly from localized solar canopies to commercial battery storage and charging stations.

Frigate Approved Quality Management System

At Frigate, quality is built into every stage of manufacturing. Our approved Quality Management System ensures that every material component.

Incoming Material Checking

Before production begins, all incoming materials are checked against specifications, drawings, and supplier documents.

In-Process Inspection

Quality is monitored during manufacturing to prevent defects and maintain process consistency.

Final Dimensional Checking

Finished parts are inspected before dispatch to confirm compliance with customer drawings and tolerances.

Packaging Control

Finished components are packed safely to prevent damage during handling and transportation.

Incoming Material Checking

In-Process Inspection

Final Dimensional Checking

Packaging Control

Quality Document

To help buyers evaluate our quality systems, we provide sample documents that reflect our inspection and reporting standards.

How We Delivered

Complex geometries engineered solutions that move businesses forward.

Solar Inverter Enclosure

units per month

Bento Boxes for D2C Segment

Units Manufactured Monthly

0 +

Defence-Grade Cable Supply

Cost savings

0 %

Flange Assembly for Pump

Faster Production

0 %

Having Doubts? Our FAQ

Can Frigate manufacture solar assemblies according to our proprietary engineering drawings?

Yes. We specialize in build-to-print contract manufacturing, using your exact schematics, Bill of Materials (BOM), and routing requirements while ensuring full compliance with international testing standards.

What testing procedures do the custom solar wiring assemblies undergo prior to dispatch?

Every single assembly undergoes rigorous end-to-end quality control, including automated pull-force testing, continuity checking, insulation resistance mapping, and high-potency (Hi-Pot) dielectric testing to guarantee zero-defect delivery.

Are the connectors and wires UV-rated for long-term desert or tropical deployments?

Absolutely. We utilize specialized XLPE/XLPO insulated cables certified under UL 4703 or EN 50618, alongside genuine UV-stabilized connectors, to ensure stable performance under intense ultraviolet radiation and extreme heat.

Do you offer customization options for inline fuses and branch junctions?

Yes, we provide fully customized molded T-, Y-, and X-junctions with integrated inline fuses rated up to 32A. This reduces the need for external combiner boxes and simplifies field layout architecture.

How does Frigate ensure the reliability of crimped connections over time?

We employ calibrated, automated crimping machinery equipped with real-time crimp force monitoring (CFM). This ensures every terminal joint achieves optimal mechanical compression and gas-tight electrical contact, eliminating hotspots.

We'd love to Manufacture for you!

Submit the form below and our representative will be in touch shortly.

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Operations Office

9/1, Poonthottam Nagar, Ramanandha Nagar, Saravanampatti, Coimbatore-641035, Tamil Nadu, India. ㅤ

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

10-A, First Floor, V.V Complex, Prakash Nagar, Thiruverumbur, Trichy-620013, Tamil Nadu, India.

Components Built for Critical Performance

Engineered Products for Critical Applications

Custom Solar Wiring Assemblies

Order Type

Quantity Range

Lead Time*

Product Description

Connector Types

Flammability Rating

UV & Ozone Resistance

Protection Class

Wire Gauge Range

Overmolding Material

Short Circuit Rating

Bending Radius

Salt Spray Resistance

Certifications

Technical Advantages

Let's Get Started

Industry Applications

Frigate Approved Quality Management System

Quality Document

How We Delivered

Having Doubts? Our FAQ

We'd love to Manufacture for you!

LOCATIONS

Registered Office

Operations Office

Other Locations

GENERAL ENQUIRIES

LOCATIONS

Registered Office

Other Locations

GENERAL ENQUIRIES

Get Your Quote Now

Custom Solar Wiring Assemblies

Get Latest Price

Custom Solar Wiring Assemblies

Get Latest Price