How to Replace a Solar Panel Cable

How to Replace a Solar Panel Cable

Overview

In this article you will learn how to remove and replace a solar panel cable on a USAutomatic solar panel. This is useful if the original cable has been damaged or if the solar panel needs to be moved further away from the gate opener. The chart below can be used to determine the size of wire needed given the length required. We recommend measuring the output of the solar panel after replacing the cable to ensure the new cable is working correctly.

Solar Extension Wire Chart

15 to 100 feet
100 to 250 feet
250 to 500 feet
18 gauge wire
16 gauge wire
14 gauge wire

Applies to Part Number(s)

  1. 520026
  2. 520030

What You Need

  1. Small phillips Screw Driver
  2. Replacement cable
  3. A voltage meter capable of reading DC voltage. The fuse in the meter must be good.

Procedure

Remove Original Cable

  1. Unplug / disconnect the cable from the charge controller.
  2. Locate the black box where the cable goes into the back of the solar panel.
  3. Press in on the lines and slide the cover towards the arrow until the cover is removed.
  4. Loosen the two Phillip's head screws holding down the small ring terminals.
  5. Loosen the two screws holding down the wire retention bar.
  6. Remove the original cable from the solar panel

Install New Cable

  1. Line up the ring terminal at the end of the black wire over the left screw hole, ensuring the wire crimp is facing up, then secure it using the Phillip's head screw.
  2. Line up the ring terminal with the red wire over the right screw hole, ensuring the wire crimp is facing up, then secure it using the Phillip's head screw.
  3. Feed the wire into the back of the panel.
  4. Reinstall the wire retention bar using the two Phillip's head screws.
  5. Reinstall the black cover to the back of the panel.
  6. Plug / connect new cable to charge controller.

Test New Cable

Refer to the following article to measure the output of your solar panel once the cable has been replaced How to Measure Solar Panel Output (Barrel Plug) . This should read above 17.2v, anything lower than this indicates the cable may not be making good connection or is potentially damaged.