UL1672 Double Insulated Hookup Wire — 300 V, 105 °C, Double Insulated PVC, 26 AWG to 8 AWG

What UL1672 Double Insulated Hookup Wire Is Built For

UL1672 Double Insulated Hookup Wire is a UL AWM hookup wire rated 300 V and 105 °C, with a double insulated PVC construction over a stranded tinned copper conductor. It is made for internal wiring where a single insulation wall may not provide enough dielectric margin: LED drivers, transformer leads, appliance harnesses, automotive modules, control panels, and power supplies. The double insulation structure places a PVC inner layer directly over the conductor and a PVC jacket over that inner layer, so the wire carries two separate dielectric barriers instead of one. The outer jacket also protects the inner layer during routing, pulling, and termination.

For OEM electrical design engineers, the key selection numbers are the 300 V rating, the 105 °C continuous temperature rating, the -20 °C cold resistance, and the 26 AWG to 8 AWG range. For panel and harness builders, the stranded conductor and PVC jacket are designed to cut, strip, and crimp without the strands fanning out. For maintenance and purchasing engineers, the wire is available in nine standard colors, in full coils or cut lengths, and carries UL, RoHS, REACH, and NP grade certification.

Layer-by-Layer Construction

The conductor is stranded, lead-free tinned copper. Tinning protects the copper from oxidation before and after installation, and the stranded construction keeps the wire flexible enough to route through equipment enclosures. When the wire is cut and stripped, the tinned strands stay together, so the stripped length can enter a terminal or crimp barrel at the published dimension.

The first insulation layer is a PVC compound applied directly over the conductor. This inner layer is the primary dielectric and is formulated for the 105 °C temperature rating. The second layer is a PVC jacket over the inner layer. The jacket adds mechanical protection, contributes to the VW-1 flame rating, and provides the second dielectric barrier that gives the construction its double insulated classification.

The wire is produced with low eccentricity, meaning the insulation wall thickness is held evenly around the conductor. Low eccentricity matters because a thin spot in the wall is where dielectric breakdown is most likely to start. The overall diameter tolerance is ±0.2 mm, and the inner diameter and conductor construction are held to ±0.01 mm. Those tolerances support automated cutting and stripping, where small diameter changes can affect blade depth and strip quality.

Electrical and Environmental Ratings

The table below lists the published construction and supplier-provided safety current for each AWG size. Safety current values are provided by the supplier and are not a standard ampacity rating. Use them as a starting point, then confirm the final current in the actual installation conditions.

The nominal cross-section column is for naming reference only. The conductor construction is the controlling specification. Voltage rating is 300 V. Temperature rating is 105 °C. Cold resistance is -20 °C. Flame rating is VW-1.

Performance Under Heat, Cold, and Flame

The PVC compound is rated for 105 °C continuous operation. That temperature covers internal wiring in LED drivers, transformer leads, appliance harnesses, and power supplies where local heating raises the wire temperature above ambient. The same compound is rated for cold resistance down to -20 °C, so the wire remains workable in unheated cabinets, outdoor luminaires, and cold-weather equipment.

The VW-1 flame rating means the wire resists flame propagation when exposed to a flame source. In an enclosure, that gives the fault current a lower chance of spreading along the wire bundle. The jacket is also formulated to resist abrasion and pulling during installation. It is smooth enough to pull through tight routing paths and does not knot easily, which helps harness builders maintain consistent lead lengths. The PVC jacket is waterproof and resistant to freezing at the rated cold limit. These performance points come from the PVC compound and the double insulation construction, not from a separate jacket additive.

Where UL1672 Wire Is Used

UL1672 double insulated hookup wire is used inside equipment where a UL-recognised lead is required and the working voltage stays within 300 V. Typical installations include LED lighting fixtures and drivers, transformer lead wire, automotive wiring, appliance internal wiring, control panels, security equipment, audio equipment, power supplies, and household electrical appliances.

In an LED fixture, the wire connects the driver board to the LED array, where the 105 °C rating covers the driver heat and the double insulation adds a barrier against the metal housing. In a transformer, the wire is used for primary and secondary leads, where the double insulation reduces dielectric stress at the winding exit. In an appliance harness, it connects the power board to motors, switches, and heating elements, and the VW-1 rating limits flame spread if a fault occurs. In automotive wiring, the tinned copper conductor resists corrosion from moisture and temperature cycling. In control panels, the nine standard colors make it easier to identify circuits at the terminal block. The wire is also used in security cameras, alarm boards, speakers, and lighting systems, where flexible PVC jacket and stranded conductor simplify routing in tight enclosures.

Selection and Installation Notes

Choose the AWG size from the current the circuit will carry and the voltage drop the equipment can tolerate. The 300 V rating is the maximum working voltage for this construction. The 105 °C rating is a continuous temperature limit; soldering, stripping, and termination processes should stay within the PVC compound's limits. The -20 °C cold resistance means the wire can be installed and routed at low temperatures, but the jacket should not be pulled around sharp corners below that limit.

The stranded tinned copper conductor is intended for crimp terminals, soldered connections, and screw terminals. When stripping, set the blade depth for the overall diameter shown in the table. The ±0.2 mm overall diameter tolerance and ±0.01 mm inner diameter tolerance are tight enough for automated processing, but they are not a substitute for a strip-force test on the actual terminal. The double insulation layer should not be stripped back beyond the point required for the termination.

The wire is supplied in 610 m coils for 26 AWG to 18 AWG, 305 m coils for 16 AWG to 10 AWG, and 100 m coils for 8 AWG. Cut lengths of 8 m (25 ft) and 32 m are available for repair and sample quantities. Standard colors are Red, Black, Yellow, Green, Blue, White, Brown, Grey, and Orange. The NP grade PVC compound is a phthalate-free compound and meets RoHS 2.0. Certification includes UL, RoHS, REACH, and NP grade.

Certification, Configurations, and Ordering

The wire carries UL, RoHS, REACH, and NP grade certification. The NP grade compound is a phthalate-free compound and satisfies RoHS 2.0 plus NP 17-item testing. These are the certifications supported for this product. The wire is available in nine standard colors and in the coil lengths listed above.

If your equipment requires a specific AWG, color, coil length, or cut length, include those details in the inquiry form with the expected voltage, current, and operating temperature. For OEM design engineers, the most useful data to confirm are the conductor construction, overall diameter, and safety current in Table 1. For harness builders, the key points are the ±0.2 mm overall diameter tolerance and the stranded tinned copper conductor that stays together during stripping. For maintenance and purchasing engineers, the key points are the UL, RoHS, REACH, and NP grade certification, the nine standard colors, and the availability of both full coils and cut lengths. To confirm that UL1672 double insulated hookup wire fits your device, send the application details through the inquiry form on this page.