That goes for even the cheaper wiring components of an electronic assembly – hookup wires. Learn the ins and outs of hookup wire types and ideal applications based on project needs, and give your purchasing team the right perspective:
But first, let’s clean up the terminology of lead wires vs. hookup wires. Lead wires simply connect a component to a circuit or another component. This tends to be a singular wire, rather than a multiconductor cable (which is multiple wires housed in a single cable).
Hookup wires are a type of lead wire, but with a simpler material makeup. Hookup wires tend to be a much less expensive product, intended for everyday low-current and low-voltage enclosed electronics. These wires generally connect:
While purchasing department folks don’t need to be engineers, a basic understanding of wiring will help you source more effectively (rather than by price only). Seeing the “guts” of the product can make it easier to find the best hookup wire.
The conductor's role in hookup wire is to provide a path for the electric current to travel from one point to another within a circuit or system. Most hookup wire cores consist of copper, which is used for its properties of conductivity and flexibility (especially for stranded conductors).
The core of a hookup wire is typically a single solid or stranded copper conductor. Solid and stranded conductors differ in construction and intended use:
|
Solid Conductor |
Stranded Conductor |
|
Single wire |
Multiple wires twisted together |
|
Rigid |
Flexible |
|
Lower cost |
Higher cost |
Insulation protects the conductor from physical and environmental damage, while also preventing electrical leaks. The insulation also determines the wire’s heat resistance, voltage rating, and suitability for specific environments (such as high temperatures).
Common materials include:
The labeling process for any electronic component should make it easy to identify the right wires in a pinch. Hookup wires often come in various colors of insulation to help identify connections within an electronic or electrical system, simplifying installation and maintenance.
Some hookup wires include voltage ratings or manufacturer details printed along the insulation for easy identification and to ensure proper use.
Hookup wiring is for low-voltage, low-current use. These wires must also meet specific standards, depending on the application. These standards may include UL, CSA, and National Electric Code (NEC).
Common industries for hookup wires include:
In short, hookup wire can connect to just about anything, including many of the same applications as multiconductor cables. For industrial jobs requiring electrical signals and power, there are many wires and cable types up to the task. Here’s a quick guide to popular types and materials:
|
Electrical |
Automotive |
Automation |
|
|
Features |
▪️ Usually bare copper ▪️ Low stranding ▪️ Often 600 V |
▪️ Usually bare copper |
▪️ Usually plated copper |
|
Materials |
TFFN, THHN, MTW, THW, RHH/RHW, XHHW |
GPT, HPT, SXL, TXL, GXL |
GPT, HPT, SXL, TXL, GXL |
|
Insulation |
PVC, PVC/nylon, XLPE, UL/CSA |
PVC, XLPE, Tefzel, SAE specs |
UL styles, MIL specs |
Hookup wires are often classified by their insulation material. The most common size is 22 AWG (American Wire Gauge, or thickness).
Specific products often meet specific regulations, such as friction resistance levels. The most common types of UL hookup wire include:
Teflon, aka polytetrafluoroethylene or PTFE, is a nonflammable resin. This makeup allows PTFE to offer excellent high-temperature resistance and chemical stability.
Teflon PTFE wire also has a non-stick coating and is thin, meaning friction is minimal between components. Even if you have to pull PTFE wires through tight conduits or bundle them closely, you’re unlikely to damage them.
Electricians commonly use Teflon PTFE for wiring:
UL 1007 and 1569 wiring belongs in projects where the connection must resist degradation or maintain flexibility in a low-temperature environment.
The tinned copper conductor on these products adds corrosion resistance, solderability, and compatibility with a wide range of materials. These wire types are also resistant to abrasion, acid, and promotion of fungus growth.
UL 1007 and UL 1569 even have the same maximum rating: 300 V. So, why do both products exist?
The answer is inside – literally. UL 1007 typically has thinner insulation than UL 1569. This makes it more durable, but also slightly less flexible. The two types might also have slightly different temperature ratings, depending on product-by-product specs.
Overall, this category is effective in numerous applications, including:
These highly similar UL wire types combine to cover most industrial and commercial applications. They’re common in appliances, electrical equipment, and control panels.
All three rely on PVC insulation.
General benefits include:
While these UL wire types generally function the same way, there are nuances that make them specialized for certain project types.
|
Type |
Superpower |
Uses |
|
UL 1015 |
Thick insulation, durable |
Heavy-duty systems (i.e. control panels, point-to-point wiring) |
|
UL 1028 |
High flexibility |
Tight or complex spaces, fluctuating temperatures |
|
UL 1283 |
Reduces EMI |
Data equipment, power supplies, machine tools, control cabinets |
UL 1061 is a semi-rigid PVC wire that can consist of either a solid or stranded copper conductor. While this wire generally comes with PVC insulation as well, it’s typically thinner than the insulation used for 1028.
UL 1061 wire is ideal for use in temperatures within the -20 to 80°C range. This type of wire is useful in situations where space is limited, such as within computer casing or other electronic housings.
Of course, choosing the right wire includes comparing hookup wire manufacturers. But before you get to that point, performance factors to discuss with the team include:
Having everyone on the same page when it comes to supply management can keep production moving, even during shortages and supplier concerns. By knowing exactly what hookup wire is and isn’t, the types of conductors available, and any project-specific flexibility and size concerns, you can more easily identify hookup wire suppliers.
For more education on sourcing wires, cables, and other electronic parts, see our full blog library.