TEBAOFLEX UL 3239 Style 3 kV 200°C Silicone High-Voltage Wire is a flexible single-core, unbraided silicone-rubber insulated equipment lead built around a stranded nickel-coated copper conductor across seven documented sizes from 12 AWG to 24 AWG (with 10 AWG engineered via custom drawing). Designed for protected internal high-voltage routing where standard 600 V hook-up wire lacks dielectric margin, it pairs 3 kV insulation strength with supple 200°C thermal stability.
1. Application Scope & UL 3239 vs. UL 3257 High-Voltage Silicone Comparison
Electrical designers frequently compare UL 3239 against higher-voltage AC ignition and silicone styles when routing internal HV leads inside compact cabinets. Verify whether your circuit carries filtered DC, high-frequency pulses, or 50/60 Hz RMS AC before selecting wall thickness:
- HV DC Power Supplies, Lasers & Analytical Modules: Internal
3 kVbus leads in CO2/fiber laser exciters, X-ray/medical imaging sub-assemblies, electrostatic precipitators, and capacitor banks. - Inverter, Ballast & Power-Conversion Enclosures: Protected high-potential interconnects inside high-ambient industrial rectifiers, induction heaters, and test instruments.
- Industrial Heating & Thermal Process Cabinets: Elevated-temperature equipment zones (up to
200°C) requiring greater dielectric clearance than600 Vor1 kVleads.
Browse our broader high-temperature specialty wire and cable catalog or compare TEBAOFLEX high-voltage silicone series directly:
| TEBAOFLEX HV Silicone Series | Voltage Class | Temp Rating | Primary Waveform & Equipment Duty |
|---|---|---|---|
| UL 3239 Style 3 kV (This Page) | 3 kV (3,000 V) | 200°C | Compact 12–24 AWG HV DC / equipment internal lead wire |
| UL 3257 10 kV AC Silicone Wire | 10 kV AC | 250°C | Heavy-wall AC corona, gas-burner ignition & ozone-generator leads |
| 5 kV 200°C Silicone HV Cable | 5 kV | 200°C | Intermediate 5 kV flexible silicone power & testing lead |
| UL 3644 1 kV Silicone Rubber Wire | 1 kV (1,000 V) | 200°C | 1,000 V motor, inverter & heating-element internal lead wire |
2. Authentic Single-Core Construction (UL 3239 3 kV Reference)
Unlike multi-core industrial power cables or fiberglass-braided furnace wires, baseline UL 3239 uses a clean two-element single-conductor geometry:
12–24 AWG (65/0.254 mm down to 11/0.16 mm) to prevent high-temperature conductor oxidation up to 200°C. Tinned copper or solid-conductor variants are reviewed against your approved production drawing.1.07 mm nominal wall on 12 AWG; 0.60–0.65 mm on 14–24 AWG) with no outer braid or separate sheath, preserving supple routing flexibility and clean HV connector boot sealing.3. Technical Characteristics & Engineering Boundaries
| Selection Parameter | Documented Reference | Verification & Design Note |
|---|---|---|
| Product Model | UL 3239 Style, Single-Core | One metallic conductor + extruded silicone wall (not multi-core) |
| Rated Voltage | 3 kV (3,000 V) | Confirm DC vs. AC RMS/pulsed duty; UL 3239 tiers are classically DC-rated |
| Rated Temperature | 200°C Continuous | Silicone retains flexibility in cold & elevated-heat cabinet zones |
| Documented Gauge Span | 12, 14, 16, 18, 20, 22 & 24 AWG | Overview cites 10–24 AWG; 10 AWG requires a separate confirmed drawing |
| Reference Bend Radius | 10 × Finished Outer Diameter | Protected fixed internal routing away from sharp chassis edges |
10 AWG & High-Voltage AC Engineering Warning: Do not extrapolate a 10 AWG conductor diameter, wall thickness, or finished OD from the 12–24 AWG table; request a dedicated 10 AWG drawing. Additionally, because unbraided silicone is softer than cross-linked XLPE or fluoropolymers and UL 3239 voltage classes are traditionally DC-defined, always confirm AC corona/partial-discharge margin, stand-off bush protection, and creepage distances for your specific machine.
4. Complete 12–24 AWG Conductor & Insulation Dimension Table
The seven rows below reproduce the exact strand counts, nominal conductor diameters, silicone insulation wall thicknesses, and finished outer diameters from the supplied 3 kV reference specification (all part designations use clean standard codes):
| Part Designation | AWG Size | Stranding (Count / Ø mm) | Conductor Ø (mm) | Silicone Wall (mm) | Finished OD (mm) |
|---|---|---|---|---|---|
| UL3239-3KV-12AWG | 12 AWG | 65 / 0.254 | 2.37 | 1.07 | 4.50 ± 0.1 |
| UL3239-3KV-14AWG | 14 AWG | 41 / 0.254 | 1.88 | 0.60 | 3.05 ± 0.1 |
| UL3239-3KV-16AWG | 16 AWG | 26 / 0.254 | 1.50 | 0.65 | 2.80 ± 0.1 |
| UL3239-3KV-18AWG | 18 AWG | 34 / 0.18 | 1.21 | 0.65 | 2.50 ± 0.1 |
| UL3239-3KV-20AWG | 20 AWG | 21 / 0.18 | 0.95 | 0.65 | 2.25 ± 0.1 |
| UL3239-3KV-22AWG | 22 AWG | 17 / 0.16 | 0.76 | 0.65 | 2.05 ± 0.1 |
| UL3239-3KV-24AWG | 24 AWG | 11 / 0.16 | 0.62 | 0.65 | 1.90 ± 0.1 |
| UL3239-3KV-10AWG | 10 AWG (Custom) | Not listed in baseline dimension table; request a confirmed TEBAOFLEX 10 AWG production drawing before ordering. | |||
5. Frequently Asked Engineering Questions & Custom RFQ
What is the difference between UL 3239 and UL 3257 high-voltage silicone cables?
UL 3239 is primarily specified as a compact 150°C–200°C high-voltage DC electronic/equipment lead family (such as the 3 kV tier on this page, with higher voltage tiers available via heavier silicone walls), using unbraided extruded silicone for HV power supplies, laser modules, and protected internal cabinets. UL 3257 is a heavy-wall high-voltage AC ignition and corona-exposed silicone wire rated up to 10 kV AC and 250°C for gas burners, ozone generators, and continuous AC corona stress.
Is UL 3239 3 kV wire a single-core lead or a multi-core power cable?
It is a single-core insulated equipment lead consisting of one stranded metallic conductor surrounded directly by extruded high-voltage silicone rubber insulation, with no separate outer sheath, metallic screen, or fiberglass braid in the baseline reference construction.
Are 10 AWG dimensions included in the standard 3 kV UL 3239 table?
While the style family overview spans 10–24 AWG, the supplied reference table documents verified dimensions for seven stranded sizes from 12 AWG (4.50 ± 0.1 mm OD) through 24 AWG (1.90 ± 0.1 mm OD). Never extrapolate a 10 AWG wall or OD; request a dedicated 10 AWG production drawing from TEBAOFLEX.
Can a 3 kV DC UL 3239 wire be used directly on a 3 kV RMS AC circuit?
Not without waveform and dielectric verification. Under UL 758, UL 3239 voltage tiers are classically defined in kV DC, whereas high-frequency or 50/60 Hz AC circuits impose continuous capacitive charging current and partial-discharge (corona) stress at much lower RMS voltages. Always state whether your 3 kV circuit is filtered DC, pulsed DC, or RMS AC during technical review.
Can conductor plating, insulation colour, and pre-cut harness lengths be customized?
Yes. TEBAOFLEX reviews nickel-plated vs. tinned copper conductors, stranded vs. solid builds, custom silicone colours (Red, White, Black, Blue, High-Voltage Orange), surface marking, and spool or cut-lead packaging against an approved drawing prior to quotation.
What technical data should buyers submit to quote UL 3239 3 kV silicone wire?
Provide the target AWG size (12–24 AWG or custom 10 AWG request), operating voltage and waveform (DC, pulsed, or AC RMS), continuous enclosure temperature, minimum clearance/bend radius, termination lug or HV connector type, colour, and total reel or cut-lead quantity.
Send Your UL 3239 3 kV Silicone High-Voltage Wire Requirements
Share your AWG gauge (12–24 AWG or custom 10 AWG drawing request), DC/AC voltage waveform, conductor plating, silicone colour, and reel or cut-lead quantity. TEBAOFLEX engineers reply within 24 hours with a confirmed drawing and factory quotation.
