TEBAOFLEX 5kV 200°C High-Temperature Silicone Cable is a halogen-free, extra-flexible single-core 5,000 V AC RMS / 10,000 V DC high-voltage lead wire manufactured with fine-stranded IEC 60228 Class 5 tinned copper and a thick void-free VMQ silicone-rubber dielectric wall (1.8-2.8 mm). Tested at 12 kV AC and rated continuously from -60°C to +200°C, it maintains supple 5 × OD bendability inside compact medium-voltage cabinets, Class H dry-type transformers, HV DC power supplies, and industrial heating systems.
1. Application Scope & High-Voltage Silicone Selection Matrix
Standard 300/500 V SiF silicone wires and 3 kV DC electronic hook-up leads lack the radial insulation thickness required for 3.3 kV-5 kV AC motor windings, transformer taps, and 10 kV DC power electronics. TEBAOFLEX bridges that gap across 0.50 mm² to 50 mm² with ozone-immune silicone elastomer that never hardens or cracks under thermal cycling or UV/corona exposure.
- Class H Dry-Type Transformers & Form-Wound MV Motors: Flexible coil-to-terminal jumper leads, VPI-compatible stator tails (verify varnish compatibility), and
3.3 kV / 4.16 kVmotor terminal-box wiring. - High-Voltage DC Power Supplies, Lasers & Test Equipment:
10 kV DCcapacitor-charging leads, CO2/excimer laser power modules, X-ray / medical imaging cabinets, hipot test leads, and electrostatic precipitator rectifiers. - Industrial Induction Furnaces, Plasma & UV Curing Lamps: High-voltage ignition and ballast leads routed through
180°C-200°Cradiant heat zones where PVC, XLPE, and EPR embrittle.
| TEBAOFLEX HV Silicone Series | AC / DC Voltage Rating | Continuous Temp. | Conductor Range | Primary Engineering Duty |
|---|---|---|---|---|
| 5kV 200°C Silicone (This Page) | 5 kV AC / 10 kV DC | -60°C to +200°C | 0.50-50 mm² (20-1/0 AWG) | MV motor/transformer power & 10 kV DC cabinets |
| UL 3644 1kV Silicone | 1,000 V AC | -60°C to +200°C | 24 AWG to 4/0 AWG | 1 kV inverters, traction motors & Class H leads |
| UL 3239 HV Silicone | 3 kV-40 kV DC | -60°C to +200°C | 26 AWG to 10 AWG | UL-recognized electronic CRT, laser & PSU hook-up |
| FZLSi 10kV Ignition | 10 kV HV Pulse / AC | -50°C to +180°C | 1.0-2.5 mm² | Gas burner, boiler & industrial spark ignition |
| UL 3257 10kV AC 250°C | 10 kV AC RMS | -60°C to +250°C | 24 AWG to 10 AWG | UL 250°C high-voltage burner & UV lamp leads |
Unscreened HV Clearance Rule: This single-core cable has no semiconducting layer or grounded metallic shield. Above 3.0 kV AC, avoid clamping the insulation tightly against sharp grounded metal edges; use insulating standoffs, PTFE/silicone grommets, or maintain air clearance to prevent localized air-gap corona discharge.
2. Cable Construction (Single-Core Void-Free HV Silicone Anatomy)
Matching the single-layer stepped studio photograph, the cable uses high-purity tin-plated copper stranding and pressure-extruded, hot-air/CV vulcanized silicone rubber without hygroscopic textile braids:
200°C.1.8 mm to 2.8 mm radial wall) to eliminate micro-voids that trigger internal partial discharge.3. Technical & Dielectric Characteristics
Verified electrical, thermal, and environmental performance parameters for TEBAOFLEX 5 kV 200°C silicone cable:
| Parameter | Engineering Rating | Test / Application Condition |
|---|---|---|
| Nominal AC Voltage Rating | 5,000 V AC RMS (50/60 Hz) | Internal cabinet, coil, and standoff-supported HV equipment wiring |
| Continuous DC Voltage Rating | Up to 10,000 V DC | Non-reversing, low-ripple DC power supplies & capacitor banks |
| Factory Dielectric & Spark Test | 12,000 V AC (50 Hz) | 18 kV spark | Routine high-potential withstand and 100% in-line spark test |
| Volume Dielectric Strength | ≥ 22 kV/mm | High-purity electrical-grade VMQ silicone elastomer (IEC 60243-1) |
| Operating Temperature Range | -60°C to +200°C continuous | Short-term thermal excursion up to +230°C; stays flexible at -60°C |
| Minimum Bending Radius | 5 × OD (fixed) | 8 × OD (flexing) | Low-modulus elastomer avoids terminal lug mechanical strain |
| Halogen-Free & Fire Behaviour | Halogen-free, non-corrosive | IEC 60754-1 / EN 50267-2-1; leaves non-conductive SiO2 ash on burn |
| Ozone, Corona & UV Immunity | Ozone-inert (EN 60811-403) | Resists ozone cracking near HV terminals and UV lamp housings |
4. Specification & SKU Schedule (0.50 mm² to 50 mm²)
Standard single-core 5 kV AC / 10 kV DC constructions. Free-air current ratings are referenced at 30°C ambient for a single wire in open air at 200°C maximum conductor temperature (derate for bundled cabinet ducts or > 40°C enclosures):
| Part No. / SKU | Cross-Section (Approx. AWG) | Class 5 Tinned Cu Stranding | Nominal Silicone Wall (mm) | Nominal Outer OD (mm) | Max. DC Resistance at 20°C (Ω/km) | Free-Air Ampacity (A) | Weight (kg/km) |
|---|---|---|---|---|---|---|
5KV-SIL-0.5 | 0.50 mm² (~20 AWG) | 16 / 0.20 mm | 1.8 | 4.5 | 40.1 | 15 A | 24 |
5KV-SIL-0.75 | 0.75 mm² (~18 AWG) | 24 / 0.20 mm | 1.8 | 4.8 | 26.7 | 19 A | 28 |
5KV-SIL-1.0 | 1.0 mm² (~17 AWG) | 32 / 0.20 mm | 1.8 | 5.0 | 20.0 | 23 A | 32 |
5KV-SIL-1.5 | 1.5 mm² (~16 AWG) | 30 / 0.25 mm | 2.0 | 5.6 | 13.7 | 30 A | 42 |
5KV-SIL-2.5 | 2.5 mm² (~14 AWG) | 50 / 0.25 mm | 2.0 | 6.1 | 8.21 | 41 A | 55 |
5KV-SIL-4.0 | 4.0 mm² (~12 AWG) | 56 / 0.30 mm | 2.0 | 6.7 | 5.09 | 55 A | 73 |
5KV-SIL-6.0 | 6.0 mm² (~10 AWG) | 84 / 0.30 mm | 2.2 | 7.7 | 3.39 | 70 A | 102 |
5KV-SIL-10 | 10 mm² (~8 AWG) | 80 / 0.40 mm | 2.2 | 8.9 | 1.95 | 98 A | 150 |
5KV-SIL-16 | 16 mm² (~6 AWG) | 126 / 0.40 mm | 2.4 | 10.6 | 1.24 | 132 A | 222 |
5KV-SIL-25 | 25 mm² (~4 AWG) | 196 / 0.40 mm | 2.5 | 12.4 | 0.795 | 176 A | 328 |
5KV-SIL-35 | 35 mm² (~2 AWG) | 276 / 0.40 mm | 2.6 | 14.0 | 0.565 | 218 A | 440 |
5KV-SIL-50 | 50 mm² (~1/0 AWG) | 396 / 0.40 mm | 2.8 | 16.2 | 0.393 | 276 A | 615 |
Custom heavy cross-sections up to 120 mm², higher 10 kV AC / 20 kV DC radial silicone walls, and outer fiberglass-braid mechanical armouring are manufactured to order. Browse our complete High-Temp & Specialty Cables catalog for fluoropolymer and braided Class H motor leads.
5. Frequently Asked Questions (5kV High-Temperature Silicone Wire)
Can a 5 kV AC silicone cable be operated at higher voltage in continuous DC circuits?
Yes. Because steady-state DC voltage eliminates 50/60 Hz capacitive charging currents and alternating partial-discharge stress inside the elastomer wall, this 5 kV AC RMS silicone wire supports up to 10 kV DC in non-reversing, low-ripple high-voltage DC power supplies, capacitor banks, laser exciters, and electrostatic precipitators.
Does this unscreened 5 kV silicone lead wire require standoff clearance from grounded metal cabinet walls?
Yes. Because this flexible single-core lead wire does not incorporate semiconducting layers or a grounded metallic copper screen, clamping it directly against sharp grounded sheet metal above 3.0-3.5 kV AC concentrates electric stress in the surrounding air gap and can initiate surface corona. Route leads on insulating standoffs or sleeves inside MV cubicles, even though VMQ silicone inherently resists ozone cracking far better than PVC or EPDM.
Why is tinned copper mandatory on 200°C silicone high-voltage cables instead of bare copper?
At continuous temperatures between 150°C and 200°C, oxygen diffusing through permeable silicone elastomer rapidly blackens bare copper strands, raising termination contact resistance. Electroplated tin forms a protective barrier on every Class 5 strand, preventing copper oxidation during vulcanization and 200°C service while preserving easy crimping and soldering.
Can this unscreened 5 kV silicone wire be buried underground as a primary airfield or substation distribution cable?
No. Unscreened single-core silicone wire is engineered strictly for internal equipment, transformer coil leads, switchgear cubicles, test benches, and protected HV enclosures. For underground direct-buried or ducted medium-voltage distribution, specify a radial-field screened cable such as RG7H1OZR Armoured HEPR Medium-Voltage Cable.
Specify 5kV 200°C High-Voltage Silicone Lead Wire
Send your AC or DC operating voltage, pulse/ripple waveform, conductor cross-section (0.50-50 mm²), insulation colour, and coil/reel length for engineering review and quotation.
