Single Conductor Cables (Hook-Up Wire)

Part Number	Description / PDF	Quantity
9978 003100 Belden	HOOK-UP SOLID 30AWG ORANGE 100'	19600
8500 005100 Belden	HOOK-UP STRND 16AWG GREEN 100'	1399
8502 003100 Belden	HOOK-UP STRND 20AWG ORANGE 100'	3
8522 0081000 Belden	HOOK-UP STRND 18AWG GRAY 1000'	2
9985 001100 Belden	HOOK-UP STRND 26AWG BROWN 100'	7
83043 009100 Belden	HOOK-UP STRND 30AWG WHITE 100'	700
83007 001100 Belden	HOOK-UP STRND 20AWG BROWN 100'	18
83023 005100 Belden	HOOK-UP STRND 24AWG GREEN 100'	6200
9921 003100 Belden	HOOK-UP STRND 22AWG ORANGE 100'	14
9921 002100 Belden	HOOK-UP STRND 22AWG RED 100'	32
8521 0151000 Belden	HOOK-UP STRD 16AWG WHT/RED 1000'	0
83005 002100 Belden	HOOK-UP STRND 22AWG RED 100'	64
83000 006100 Belden	HOOK-UP STRND 30AWG BLUE 100'	1
9919 007100 Belden	HOOK-UP STRND 20AWG VIOLET 100'	4
8503 0101000 Belden	HOOK-UP STRND 22AWG BLACK 1000'	3
8918 013100 Belden	HOOK-UP STRND 18AWG BLUE 100'	18100
83028 005100 Belden	HOOK-UP STRND 20AWG GREEN 100'	0
8523 002100 Belden	HOOK-UP STRND 20AWG RED 100'	4
9899 002500 Belden	TEST LEAD 18AWG 5000V RED 500'	0
9985 013100 Belden	HOOK-UP STRND 26AWG BLUE 100'	4

Single Conductor Cables (Hook-Up Wire)

1. Overview

Single conductor cables, also known as hook-up wires, are insulated electrical conductors used for low-current signal and power transmission in electronic devices. They serve as fundamental components for internal wiring in PCBs, appliances, and control systems. Their importance lies in enabling reliable electrical connections while maintaining space efficiency and design flexibility in modern electronics.

2. Main Types and Functional Classification

Type	Functional Characteristics	Application Examples
PVC-Insulated Wire	Cost-effective, flexible, 105 C temperature rating	Consumer electronics, HVAC systems
Silicone Rubber Insulated Wire	High flexibility (-55 C to 200 C), excellent thermal resistance	Industrial ovens, medical devices
PTFE/Teflon Insulated Wire	Chemical resistance, 200 C operational stability	Aerospace sensors, chemical processing equipment
High-Temperature Wire	Special polymer jackets for 150-300 C environments	Automotive engine compartments, lighting ballasts
Shielded Hook-Up Wire	Braided/aluminum foil shielding for EMI protection	Telecommunications equipment, measurement instruments

3. Structure and Composition

Typical construction includes:

Conductor: Annealed copper (most common), aluminum, or tinned copper (stranded or solid)
Insulation: Thermoplastic (PVC, polyethylene), thermoset (silicone rubber), or fluoropolymer materials
Shielding: Optional braided copper/aluminum foil layer for EMI protection
Jacket: Abrasion-resistant outer layer (PVC, polyurethane) in specific variants

Stranded conductors (e.g., 7/30, 19/34 stranding) optimize flexibility while maintaining conductivity.

4. Key Technical Specifications

Parameter	Description	Importance
Conductor Gauge (AWG/mm )	Defines current-carrying capacity (e.g., 30 AWG to 10 AWG)	Determines power transmission capability
Insulation Thickness	0.1-0.8 mm depending on voltage rating	Ensures dielectric strength and safety
Temperature Range	-65 C to 300 C operational limits	Dictates environmental suitability
Voltage Rating	30V to 1000V depending on insulation material	Safety and insulation performance indicator
Bending Life	500-50,000 flex cycles (MIL-W-5088L standard)	Crucial for dynamic applications
Shielding Effectiveness	60-100 dB coverage (100 kHz-1 GHz)	EMI/RFI interference reduction metric

5. Application Fields

Consumer Electronics: PCB interconnects in smartphones, printers, and home appliances
Automotive: Sensor wiring, ABS system connections, battery management systems
Medical: ECG machine internal wiring, diagnostic equipment signal transmission
Industrial: PLC cabinet wiring, robotics joint connections
Aerospace: Avionics harnesses, flight control system terminations

6. Leading Manufacturers and Products

Manufacturer	Representative Product	Key Features
Alpha Wire (Alpha Technologies)	EZ-Hook 1385 Series	105 C PVC insulation, UL 1015/CSA Type TEW certification
Lapp Group	UNITRONIC LiYY	Oil-resistant PVC jacket, 300/500V rating
Panduit Corp.	Panfluor 200 Series	PTFE-insulated, meets FAA 25.853 flammability requirements
TE Connectivity	Raychem Hook-Up Wire	Heat-shrinkable insulation, aerospace qualified
Sumitomo Electric Industries	AeroElite Series	Lightweight composite insulation for aircraft wiring

7. Selection Recommendations

Key considerations:

Operating temperature range vs material thermal stability
Voltage/current requirements vs conductor cross-section
Mechanical stress environment (flexing, vibration)
Regulatory certifications (UL, CSA, MIL-SPEC)
Chemical exposure resistance (oil, coolant, cleaning agents)
EMI sensitivity requiring shielded variants

Example: Automotive engine control units typically require 150 C-rated silicone-insulated wires with vibration-resistant stranded conductors.

8. Industry Trend Analysis

Current development trends include:

Miniaturization: 32 AWG+ ultra-fine wires for wearable electronics
Material innovation: Halogen-free flame-retardant compounds
High-speed capability: Controlled impedance designs for data transmission
Automated manufacturing: Laser-marking and precision stripping compatibility
Sustainability focus: Recyclable insulation materials and lead-free production

The global hook-up wire market is projected to grow at 5.2% CAGR through 2027, driven by EV and IoT device demand according to MarketsandMarkets research.