Application & Operating Conditions
UL 3135 ultra-flexible silicone rubber wire provides 600 V AC internal power and control interconnections across -60°C to +200°C for Class H electric motors, industrial heating equipment, EV/ESS battery modules, and power inverters. High-count tinned copper stranding paired with a 0.78 mm elastomer wall resists vibration fatigue and high-temperature embrittlement.
Class H Motors, Transformers & Drives
600 V AC phase and thermal-protector lead-out wiring for Class H (180°C) motors, VFD power stages, dry-type transformers, and high-frequency inductors exposed to continuous 200°C heat.
Commercial Heating, Baking & Food Equipment
Odorless, non-toxic thermoset silicone rubber withstands continuous radiant heat inside commercial ovens, heat-sealing jaws, industrial dryers, and Semiconductor chamber heaters without outgassing plasticizers.
Battery Packs, Test Leads & Robotics
Fine-stranded tinned copper constructions (such as 12 AWG 65/30 and 16 AWG 50/33) route effortlessly around tight busbar corners in lithium battery BMS harnesses and test fixtures.
High-Voltage & Heavy-Abrasion Alternatives: UL 3135 is rated up to 600 V AC with an unbraided smooth silicone surface. For external mechanical abrasion against metal housings specify UL 3122 Braided Silicone Wire; for 3 kV to 50 kV DC ignition or corona circuits specify UL 3239 High-Voltage Silicone Wire.
Wire Construction (UL AWM Style 3135)
Built to UL 758 AWM Style 3135 specifications, this 600V single-conductor appliance wire combines multi-filament tinned copper stranding (such as 65/30, 41/30, 50/33, and 41/34) with a 0.78 mm (30 mil) single-layer thermoset silicone rubber extrusion, delivering superior dielectric margin and effortless routing flexibility.
| Layer / Component | Material & UL 758 / UL 1581 Engineering Specification |
|---|---|
| 1. Conductor | Fine-stranded annealed tinned copper (silver-white tin coating prevents copper oxidation at +200°C continuous operating temperatures and guarantees clean crimp and solder joints), 26 AWG to 12 AWG. |
| 2. Insulation Material | High-tear-strength thermoset Silicone Rubber (SiR), single-layer smooth extrusion (no fiberglass braid), halogen-free, odorless, non-toxic, and immune to solder-iron melt-back. |
| 3. Wall Thickness | 0.78 mm (0.031 in / 30 mil minimum average) heavy 600 V insulation wall for high dielectric safety across power electronics and heating circuits. |
| 4. Standard Color Code | 10 stocked colors: Black, Red, White, Green, Yellow, Blue, Brown, Grey, Violet, and Orange (plus Green/Yellow ground wire upon request). |
| 5. Surface Marking | UL AWM STYLE 3135 200°C 600V FT2 TEBAOFLEX CABLE printed in high-contrast heat-cured ink along the silicone jacket. |
UL 3135 Cross-Section: Heavy 0.78 mm (30 mil) single-layer 600V silicone rubber wall extruded over high-count fine-stranded silver-white tinned copper.
Technical Characteristics
Tested to UL 1581 at 2,000 V AC dielectric withstand and 6,000 V AC inline spark voltage, UL 3135 maintains stable volume resistivity from -60°C cryogenic cold rooms up to +200°C industrial ovens, while resisting ozone, corona discharge, UV radiation, and moisture absorption.
| Parameter | UL 758 / UL 1581 Rated Value |
|---|---|
| Reference Standard | UL 758 Appliance Wiring Material (AWM Style 3135) & UL 1581 |
| Nominal Operating Voltage | 600 V AC RMS |
| Dielectric Withstand & Spark Test | 2,000 V AC (1 min dielectric test) / 6,000 V AC inline spark test |
| Continuous Temperature Rating | -60°C to +200°C (UL 200°C thermal class; cold bend verified at -40°C / -60°C) |
| Flame Retardancy | UL 1581 Horizontal Flame Test (FT2) |
| Minimum Bending Radius | 4 × Overall Diameter (fixed installation) / 6 × OD (flexible harness routing) |
| Thermal & Solder Resistance | Thermoset elastomer will not melt, shrink back, or harden under 200°C continuous heat or brief solder contact |
| Environmental Compliance | EU RoHS 2 & REACH SVHC compliant, zero halogens, zero heavy-metal plasticizers |
UL 3135 Dimensional, Resistance & Weight Schedule (26–12 AWG)
The engineering table below details all 8 standard UL 3135 fine-stranded tinned copper gauges from 12 AWG (3.31 mm²) to 26 AWG (0.13 mm²). Both North American imperial units (Ω/1,000 ft, lbs/1,000 ft) and metric equivalents (Ω/km, kg/km) are provided for direct OEM harness design.
UL AWM Style 3135 — 26 AWG to 12 AWG Fine-Stranded Tinned Copper Schedule (600V / 200°C)
| AWG Size | Nom. Area (mm²) | Stranding (No./AWG) | Cond. Dia. (mm) | Nom. Wall (mm / in) | Nom. OD (mm) | Max. DC Res. @ 20°C (Ω/kft | Ω/km) | Approx. Weight (lbs/kft | kg/km) |
|---|---|---|---|---|---|---|---|
| 12 AWG | 3.31 | 65/30 | 2.39 | 0.78 / 0.031 | 3.95 | 1.72 / 5.64 | 27.05 / 40.3 |
| 14 AWG | 2.08 | 41/30 | 1.90 | 0.78 / 0.031 | 3.46 | 2.73 / 8.96 | 18.58 / 27.6 |
| 16 AWG | 1.31 | 50/33 | 1.50 | 0.78 / 0.031 | 3.06 | 4.45 / 14.60 | 13.52 / 20.1 |
| 18 AWG | 0.82 | 41/34 | 1.18 | 0.78 / 0.031 | 2.74 | 7.06 / 23.16 | 9.41 / 14.0 |
| 20 AWG | 0.52 | 19/33 | 0.95 | 0.78 / 0.031 | 2.51 | 11.20 / 36.75 | 7.16 / 10.7 |
| 22 AWG | 0.32 | 17/34 | 0.76 | 0.78 / 0.031 | 2.32 | 18.10 / 59.38 | 5.55 / 8.3 |
| 24 AWG | 0.20 | 7/32 | 0.60 | 0.78 / 0.031 | 2.15 | 28.70 / 94.16 | 4.46 / 6.6 |
| 26 AWG | 0.13 | 7/34 | 0.48 | 0.78 / 0.031 | 2.05 | 45.80 / 150.26 | 3.73 / 5.6 |
UL 200°C & 600V Silicone Wire Comparison Matrix
Compare UL 3135 against related TEBAOFLEX UL 758 silicone rubber hook-up and high-voltage lead wires below to match conductor gauge range, nominal elastomer wall thickness, operating voltage class (300V, 600V, or 3kV–50kV), and external abrasion protection to your equipment enclosure.
| UL AWM Style | Rated Temp / Voltage, Wall Structure & Recommended OEM Application |
|---|---|
| UL 3135 (This Page) | 200°C / 600V AC | Heavy 0.78 mm (30 mil) braid-free silicone wall over fine-stranded tinned copper (26–12 AWG) for flexible 600V power leads, motors, heaters, and battery packs. |
| UL 3512 Silicone Wire | 200°C / 600V AC | Extended heavy-gauge silicone hook-up series (up to 10–2 AWG / thicker wall above 8 AWG) for higher-current 600V industrial furnace and motor feeders. |
| UL 3132 Silicone Wire | 150°C / 300V AC | Compact 0.40 mm (16 mil) braid-free silicone wall (30–16 AWG, 1.10–2.30 mm OD) for low-voltage sensors, LED drivers, and tight PCB headers. |
| UL 3122 Braided Silicone | 200°C / 300V AC | Silicone insulation + fiberglass outer braid for abrasion protection in commercial ovens, kilns, and heating appliances. |
| UL 3239 HV Silicone | 200°C / 3kV–50kV DC | Extra-thick high-dielectric silicone wall for high-voltage power supplies, laser tubes, X-ray modules, and ignition leads. |
Frequently Asked Questions (FAQ)
Find direct OEM engineering answers covering UL 3135 fine-stranded conductor flexibility, dielectric and thermal differences versus UL 3512 silicone wire and UL 1015 105°C PVC hook-up wire, custom 0.08 mm filament stranding, and factory spool or pre-cut lead delivery schedules.
How does UL 3135 differ from UL 1015 600V PVC hook-up wire?
While both carry a 600 V AC rating and ~0.78 mm (30 mil) nominal insulation wall, UL 1015 PVC wire is limited to +105°C, stiffens below -10°C, and melts on contact with soldering irons. UL 3135 thermoset silicone rubber operates continuously from -60°C to +200°C, remains ultra-limp in tight enclosures, and will not melt or release corrosive halogens.
What is the difference between UL 3135 and UL 3512 200°C 600V silicone wire?
UL 3135 specifically targets fine-stranded flexible appliance leads across 26 AWG to 12 AWG with a 0.78 mm (30 mil) extruded silicone wall, whereas UL 3512 spans broader industrial hook-up gauges (including heavier power conductors from 10 AWG upwards with stepped wall thicknesses).
Can UL 3135 be ordered with 0.08 mm ultra-fine tinned copper strands?
Yes. Alongside standard UL fine stranding (65/30 on 12 AWG, 41/30 on 14 AWG, 50/33 on 16 AWG, 41/34 on 18 AWG), TEBAOFLEX produces custom 0.08 mm filament tinned copper bundles for battery test leads, moving stages, and compact power modules.
What reel lengths, colors, and lead times are available for OEM orders?
All 10 standard colors (Black, Red, White, Green, Yellow, Blue, Brown, Grey, Violet, Orange) are supplied on 305 m (1,000 ft) or 610 m (2,000 ft) spools, with custom cut-and-stripped leads and 7–12 working day production turnaround.
Need UL 3135 200°C 600V Silicone Wire Spools or Custom Fine Stranding?
Share your required AWG size (26–12 AWG), stranding count, color breakdown, and target delivery schedule to receive factory pricing, sample reels, and UL AWM 3135 datasheet support.
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