Belden has been a leading manufacturer of hook-up and lead wire for nearly one
century. The basic elements of this type of cable follow:
Belden uses Uni-Strand tinned copper conductors. In this type of
construction, the bare copper wires are stranded, then tinned to coat
the strands - and also to fill in the interstices between the strands.
This allows for easier wire stripping with no re-twisting operation.
PVC (vinyl plastic)
insulation is fast stripping, resists oil, solvents, and ozone. The
colors are bright and remain distinct after processing. Applications
include motors, transformers, fluorescent ballasts and fixtures,
switch-boards, panels, controls, rectifiers and electronic circuits.
Meets VW-1 Vertical Wire Flame Test in many cases.
Teflon is a fluorinated
thermoplastic with outstanding thermal, physical, and electrical
properties. Teflon is generally restricted to applications requiring its
special characteristics because its basic resin and processing costs
are relatively high.
Belden Teflon wire products are highly recommended for miniature
cable applications because of their superior thermal and electrical
properties. Teflon is especially suitable for internal wiring-soldering
applications where insulation melt back is a specific problem. Belden
wiring products insulated with Teflon are outstanding in their
resistance to oil, oxidation, heat, sunlight and flame; and also in
their ability to remain flexible at low temperatures. They have
excellent resistance to ozone, water, alcohol, gasoline, acids, alkalis,
aromatic hydrocarbons and solvents.
diene elastomer) is a chemically cross-linked elastomer with excellent
flexibility at high and low temperatures (+150°C to -60°C). It has good
insulation and dielectric strength, as well as excellent abrasion
resistance and mechanical properties. EPDM also has better cut-through
resistance than Silicone rubber, which it replaces in some applications.
EPDM is compatible with most varnishes. After the dip and bake cycle,
however, the varnish tends to adhere to the insulation because EPDM,
unlike some rubber insulations, does not exude oils or waxes. As the
lead wires are pulled apart for termination or flexed, the varnish
cracks, sometimes tearing the insulation.
To help this problem, a stearic solution is applied to the lead
wire during the manufacturing process. However, many varnishes may still
bond to the insulation unless other special coatings are applied.
(Other slip coats are available at additional cost.) Because
most cleaning processes will remove these coatings from the EPDM lead
wire, cleaning EPDM lead wire before using in the process is not
(Due to the above, it is recommended that
the compatibility between the individual lead wire size, the
bake/varnish process and varnish used always be checked; and if
possible, do not allow any varnish to extend beyond a point where the
lead wire will be flexed or bent.)
XL-Dur is a lead wire
insulation utilizing thermoset, chemically cross-linked poly-ethylene.
Because of its excellent physical and electrical properties, XL-Dur is
highly desirable for a wide variety of applications.
CSPE is a chlorosulfonated polyethylene. CSPE insulation has excellent heat resistance, color stability and electrical properties.
Neoprene insulation has good
heat aging characteristics and is an excellent low-cost motor lead
wire. It may be considered for use in hazardous locations and is being
used in explosion-proof motors recognized by UL.
Silicone Rubber (braidless
silicone) lead wire features easy and clean stripping without the
problems associated with glass braid lead wire. It has excellent
physical and mechanical strength properties. Silicone rubber is
recommended for high-temperature applications in motors, lighting
fixtures, clothes dryers, stoves, therapeutic, and electronic devices.
It is recommended that varnish compatibility be checked before
production. Some rigid varnishes may cause cracking when the wire is
Belden Hook-Up and Lead Wire products are manufactured using
these materials and are offered in a variety of sizes and designs to
meet rigid industry and government specifications. Manufactured
in-house, our hook-up and lead wire process begins with copper rod. Our
rubber formulation and plastic mixing facilities give us complete
control of the product from start to finish. As a result, consistent
quality of these products is always assured.
Our hook-up and lead wire products can be used in a wealth of
applications including interconnection circuits, internal wiring of
computer and data processing equipment, appliances, lighting, motor
leads, heating and cooling equipment, harness fabrication and