Silicone Rubber Insulated Cable — IEC 60245 / VDE 0250-502 Silicone Rubber Insulated and Sheathed Multi-Core Flexible Cable Rated 180°C Continuous for Steel Mills, Foundries, Glass Plants, Industrial Ovens, Lighting Fixtures, and High-Temperature Equipment Power and Control Wiring
Fire Resistant, High Temperature & LSZH Cables /Silicone Rubber Cable

Silicone Rubber Insulated Cable — IEC 60245 / VDE 0250-502 Silicone Rubber Insulated and Sheathed Multi-Core Flexible Cable Rated 180°C Continuous for Steel Mills, Foundries, Glass Plants, Industrial Ovens, Lighting Fixtures, and High-Temperature Equipment Power and Control Wiring

Silicone rubber insulated cable: IEC 60245 silicone insulated multi-core flexible cable, 180°C continuous. Class 5 tinned copper 0.5–50 mm². For steel mills, furnaces, ovens, lighting, heating equipment. Halogen-free, flame retardant. Fibreglass braid option. CE, RoHS.

Key Features

IEC 60245 / VDE 0250-502 compliant — the international standards for silicone rubber insulated flexible cables; silicone is an inorganic polymer (Si-O backbone) with thermal stability to 180°C+ continuous, making it the standard insulation for cables operating in proximity to industrial heat sources
Silicone rubber core insulation and outer sheath — a homogeneous silicone-silicone construction where both the core insulation and the outer sheath are peroxide-cured silicone rubber; the all-silicone construction provides consistent thermal performance, flexibility, and halogen-free fire safety throughout the cable cross-section
Class 5 flexible tinned copper conductor — tinning prevents copper oxidation in the 80–150°C ambient environment where the cable operates; bare copper at these temperatures develops a thick oxide scale that increases conductor resistance and terminal contact resistance
Rated 180°C continuous conductor temperature — the cable operates at the conductor temperature where standard PVC (70°C), XLPE (90°C), and EPR (90°C) have all catastrophically failed; silicone's thermal stability allows direct connection to heating elements, lamp holders, and equipment terminals at temperatures that would melt or char organic-insulated cables
Halogen-free — silicone rubber contains no chlorine, bromine, or fluorine; in a fire, silicone decomposes to non-conductive silica ash (SiO₂), carbon dioxide, and water vapor — no corrosive HCl, no toxic halogenated gases, minimal smoke; essential for enclosed high-temperature equipment where a cable fire would fill the enclosure with toxic fumes
Flame retardant to IEC 60332-1-2 — silicone ignites with difficulty (high LOI — Limiting Oxygen Index of 25–35%), burns with a low flame when an external ignition source is present, and self-extinguishes when the source is removed; the combustion residue is non-conductive silica, maintaining some electrical insulation between conductors even during and after a fire
Optional fibreglass outer braid — provides mechanical abrasion protection for the soft silicone sheath, prevents the cable from sticking to hot metal surfaces, and reflects radiant heat (white braid colour) to reduce the cable surface temperature; the braid is saturated with high-temperature silicone varnish for durability
Multi-core 2–12 cores, 0.5–50 mm² — covering control and power circuits in a single cable family; common configurations: 3-core for three-phase heater power, 5-core for three-phase + neutral + earth, 7–12 core for multi-circuit control and instrumentation in high-temperature zones

Applications

Steel mill and foundry equipment cabling — silicone insulated cable for ladle preheaters, tundish heaters, continuous casting sensors, and furnace charging equipment where radiant heat from molten metal raises the cable surface temperature to 150–200°CIndustrial oven and kiln wiring — power and control cable entering the hot zone of paint curing ovens, powder coating ovens, ceramic kilns, and heat treatment furnaces through sealed cable penetrations; the cable operates continuously at the oven internal temperature (150–250°C)Lighting fixture internal and interconnection wiring — silicone cable for high-wattage luminaires, theatre and stage lighting, and sports field floodlights where the cable operates in the enclosed, elevated-temperature environment of the fixture housing at 120–180°CHeating element power connections — flexible silicone cable connecting the power supply to electric resistance heating elements in plastic extruders, injection molding machines, packaging machinery, and industrial process heatersPower generation — generator RTD wiring, turbine casing thermocouple extension cables, and exhaust temperature sensor cabling in gas turbine and diesel generator installationsGlass and ceramics manufacturing — cable for furnace forehearth controls, annealing lehr conveyors, and glass tempering furnace power and instrumentation where ambient temperatures reach 100–180°CCommercial kitchen and bakery equipment — flexible silicone cable for pizza ovens, conveyor toasters, commercial deep fryers, and bakery deck ovens where the cable is routed inside the appliance at temperatures up to 200°C

Technical Specifications

Standard IEC 60245-3 (silicone rubber insulated cables); VDE 0250-502 (silicone rubber insulated cables, Germany); GB/T 5013.3 (China national standard, equivalent to IEC 60245 for silicone insulated cables); the standards define the silicone insulation compound requirements, test methods, and performance criteria
Rated Voltage 300/500 V (standard for control and instrumentation); 450/750 V (for power circuits); the voltage rating is maintained at the rated continuous conductor temperature — silicone's dielectric strength does not degrade significantly at temperatures up to its decomposition point (>300°C)
Conductor Material Tinned copper (standard for >150°C applications); nickel-plated copper on request for 200°C+ continuous; bare copper for ≤150°C applications; IEC 60228 Class 5 flexible stranded
Conductor Cross-Sections 0.5, 0.75, 1.0, 1.5, 2.5, 4, 6, 10, 16, 25, 35, 50 mm²
Core Count 2-core; 3-core; 4-core; 5-core; 7-core; 12-core; custom configurations for equipment OEMs
Core Insulation — Silicone Rubber Peroxide-cured methyl-vinyl silicone rubber (VMQ); rated 180°C continuous conductor temperature; Shore A 60–80; the insulation thickness per the voltage class per IEC 60245 — thicker than PVC or XLPE at the same cross-section because silicone's dielectric strength is 15–20 kV/mm (vs 20–30 kV/mm for XLPE)
Core Identification Solid color insulation per HD 308 S2: brown (L1), black (L2), grey (L3), blue (N), green-yellow (PE); numbered black cores on request; the color is integral to the silicone compound — it does not fade or rub off at the rated operating temperature
Core Assembly Concentric stranding of insulated cores with a controlled lay length; fibreglass or polyester yarn filler elements in the core interstices maintain cable circularity; the filler must also be high-temperature rated — standard PP or cotton fillers would melt or char at the cable's operating temperature
Core Binder Tape High-temperature polyester (PET) or polyimide (Kapton) tape wrap over the core assembly; provides mechanical stability and a smooth cylindrical surface for the sheath extrusion
Outer Sheath — Silicone Rubber Same peroxide-cured silicone rubber compound as the core insulation; Shore A 60–70; standard color: red-brown (natural silicone color), black, grey, blue, or white; the sheath provides mechanical protection, additional electrical insulation, and the cable's environmental resistance
Outer Braid — Fibreglass (Optional) Fibreglass yarn braid over the silicone sheath; saturated with high-temperature silicone varnish; white (standard, for radiant heat reflection) or natural; the braid prevents the soft silicone surface from being cut or abraded by contact with hot metal edges and surfaces, and prevents the cable from sticking to hot surfaces
Maximum DC Conductor Resistance at 20°C — Tinned Copper Per IEC 60228 Class 5; 39.0 Ω/km (0.5 mm²) to 0.386 Ω/km (50 mm²)
Insulation Resistance at 20°C — Silicone ≥200 MΩ·km (core-to-core at 500 V DC, 1 min)
Insulation Resistance at 180°C — Silicone ≥0.1 MΩ·km (minimum at rated temperature); the IR decreases by approximately 3 orders of magnitude from 20°C to 180°C — this is the normal temperature behavior of silicone and is accounted for in the insulation thickness design
Test Voltage (AC) — 300/500 V Types 2 000 V AC / 5 min per IEC 60245
Test Voltage (AC) — 450/750 V Types 2 500 V AC / 5 min
Temperature — Continuous (Conductor) 180°C; the silicone insulation maintains its mechanical and electrical properties at this temperature for 10 000+ hours cumulative exposure per the thermal endurance classification per IEC 60216
Temperature — Short-Term Excursion 220°C for limited periods (hours); silicone does not melt — it decomposes to silica at >300°C — but the decomposition rate accelerates significantly above 200°C, progressively reducing the insulation thickness
Temperature — Low-Temperature Flexibility -60°C; silicone remains flexible at temperatures where PVC (-5°C) and XLPE (-20°C) are brittle; the cable can be installed and handled in winter conditions without pre-heating
Minimum Bend Radius — Fixed Routing 5× cable OD (the soft silicone insulation and sheath allow tighter bends than XLPE or PVC cables, but the core assembly filler and binder tape geometry limits the minimum bend radius)
Minimum Bend Radius — Occasional Flexing 8× cable OD
Current Rating — De-Rating at Elevated Ambient The cable's current rating must be de-rated for the elevated ambient temperature. For a cable rated 180°C in a 150°C ambient, the permissible conductor temperature rise from I²R heating is only 30°C (180–150), compared to 140°C in a 40°C ambient (180–40). De-rating factor = √[(180−T_ambient) / (180−40)]. At 150°C ambient: √(30/140) = 0.46 — the cable carries 46% of its 40°C ambient current rating
Flame Retardant IEC 60332-1-2; silicone self-extinguishes; the combustion residue is non-conductive silica ash
Halogen-Free IEC 60754-1: HCl emission <0.5% (silicone contains no halogens — zero HCl by chemistry, not by additive formulation)
Low Smoke IEC 61034-2: silicone produces minimal smoke when burned; the combustion products are primarily SiO₂ powder (white, non-toxic)
Oil Resistance — Silicone Moderate; silicone is swollen by non-polar solvents (gasoline, mineral oil, aromatic hydrocarbons); for applications with oil exposure, specify a fluoropolymer (FEP/PTFE) outer jacket or a fibreglass braid with oil-resistant coating
Weather / UV / Ozone Resistance Excellent; silicone is inherently UV-stable and ozone-resistant; the cable can be used outdoors and in ozone-generating environments (near HV equipment) without degradation
Certifications CE; RoHS; VDE on request; UL on request; ISO 9001 manufactured

Detailed Description

What Is Silicone Rubber Insulated Cable?

Silicone rubber insulated cable is a multi-core flexible cable in which both the core insulation and the outer sheath are made of silicone rubber — an inorganic polymer with a silicon-oxygen (Si-O) molecular backbone that provides thermal stability to 180°C+ continuous, far beyond the capability of any organic cable insulation. It is the standard cable for the hot zones of industrial plants: the cable that connects the ladle preheater to its power supply, the cable that enters the ceramic kiln through the hot-face penetration, the cable inside the sports field floodlight housing at 180°C.

The critical difference between silicone rubber insulation and organic insulations (PVC, XLPE, EPR) is thermal stability at the molecular level. Organic polymers have carbon-carbon (C-C) backbones that begin to break down (pyrolyze) at 200–300°C, losing mechanical strength and electrical insulation. Silicone's Si-O backbone is fundamentally more thermally stable — the Si-O bond energy (452 kJ/mol) is significantly higher than the C-C bond energy (348 kJ/mol) — giving silicone its continuous temperature rating of 180°C with excursions to 220°C+ without catastrophic failure.

Silicone vs Other High-Temperature Insulation Materials

Silicone is the most flexible, most cost-effective high-temperature cable insulation. But it is not the only option:

PropertySilicone RubberPTFE/FEPMica/Glass TapeMI Cable (Cu/MgO)
Max continuous temp180°C (200°C hi-temp)200°C (260°C short)250–450°C250°C (continuous) / 1 083°C fire
FlexibilityExcellent — softest HT insulation at all temperaturesModerate — stiffer than siliconePoor — semi-rigidNone — rigid
Dielectric strength15–20 kV/mm18–22 kV/mmDepends on mica tape thicknessMgO is rated by IR, not kV/mm
Chemical resistanceModerate — attacked by non-polar solvents; excellent water/ozone resistanceExcellent — inert to nearly all chemicalsGoodExcellent (metal sheath)
CostReference1.5–3×3–5×3–10×
Best forGeneral industrial high-temp flexible cableThin-wall, chemical-exposed, aerospaceHighest temp flexible wire, heating element leadsFireproof, radiation, extreme temperature

For the majority of industrial high-temperature applications — steel mills, foundries, glass plants, commercial cooking equipment, industrial ovens — silicone rubber is the correct insulation material. It provides the best balance of temperature rating, flexibility, ease of termination, and cost.

Why Choose Yichi Silicone Rubber Insulated Cables

  • IEC 60245 / VDE 0250-502 compliant silicone compound — 180°C continuous verified by type testing: The silicone insulation compound is peroxide-cured VMQ (methyl-vinyl silicone rubber), selected and qualified for the full IEC 60245 test schedule including thermal endurance per IEC 60216. The 180°C continuous rating is verified by Arrhenius-modeled accelerated ageing, not claimed from the material data sheet
  • Tinned copper conductor as standard — correct for >150°C duty: Tinned copper is specified because bare copper oxidizes rapidly at the cable's operating ambient temperature, increasing conductor resistance and creating high-resistance terminal connections that lead to localized heating. The tinning is continuous and verified on every production batch
  • All-silicone construction — insulation + sheath: Both layers are silicone rubber — no mixed-material interfaces that could delaminate due to differential thermal expansion at elevated temperature. The silicone-silicone interface is chemically compatible and the bond between the two layers is maintained at the rated continuous temperature
  • Multi-core 2–12 configurations for high-temperature control and power: Single-cable solutions for equipment that requires multiple circuits in the hot zone — a 7-core silicone cable can carry power, control, and sensor signals through a single sealed cable penetration into an industrial oven, eliminating multiple separate penetrations
  • Fibreglass braid option for mechanical and thermal protection: The braid protects the soft silicone sheath from abrasion against hot metal edges, prevents the cable from sticking to hot surfaces (a common problem with silicone — it has a high coefficient of friction against metal when hot), and the white braid colour reflects radiant heat, reducing the cable's surface temperature

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Product: Silicone Rubber Insulated Cable — IEC 60245 / VDE 0250-502 Silicone Rubber Insulated and Sheathed Multi-Core Flexible Cable Rated 180°C Continuous for Steel Mills, Foundries, Glass Plants, Industrial Ovens, Lighting Fixtures, and High-Temperature Equipment Power and Control Wiring

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