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Product

High-temperature wireISO 3808 / EN 5014310 to 40 kV DC-60 to +180 °C

Silicone High-Voltage Ignition Cable10 kV to 40 kV DC / pulse corona-resistant silicone ignition cable for -60 °C to +180 °C

Heavy-wall homogeneous silicone high-voltage ignition cable engineered with Class 5 tinned or nickel-plated copper conductors and void-free VMQ dielectric for industrial gas burners, boilers, turbines, and electrostatic equipment up to 40 kV DC.

Flame-retardant
Ozone, UV & moisture
Oil-resistant
Order designation
HV-Si 1×1.5 / Ø 7.0
Outer Ø ≈
7.00 mm
Wall thickness
2.70 mm
Total weight ≈
58.0 kg/km
Min. bend R (fixed)
42 mm
All sizes (9)
Request a quoteDatasheetWhatsApp
Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum
Ignition voltage
10 to 40 kV DC
5 to 15 kV AC rms continuous
Breakdown V
≥ 35 to 60 kV
High-margin homogeneous VMQ wall
Temperature
-60…+180 °C
Continuous · +220 °C peak zone
Conductor
Sn-Cu / Ni-Cu
1.0 to 2.5 mm² Class 5 stranded
Standard ODs
5, 7, 8, 10 mm
Matches standard igniter boots
Min bend radius
6 × OD fixed
12 × OD flexing installation

Typical values for this cable type, based on ISO 3808 / SAE J2031 / EN 50143 — confirmed in the datasheet and quotation for your order.

Application fit

Is Silicone High-Voltage Ignition Cable right for your machine?

Select Silicone High-Voltage Ignition Cable for direct spark transformers, industrial gas/oil burners, and corona discharge electrodes requiring standard 5 mm, 7 mm, 8 mm, or 10 mm outer diameters.

Furnace, kiln & high-temp zone

Suitable

Delivers 10–40 kV ignition pulses reliably to furnace pilot electrodes and boiler burners in -60 °C to +180 °C ambient.

Switchgear & control cabinet wiring

Suitable

Precision 5.0, 7.0, 8.0, and 10.0 mm outer diameters mate directly with standard threaded HV ignition transformer glands and spark boots.

Fixed installation

Suitable

Corona- and ozone-resistant silicone wall prevents surface tracking and partial discharge degradation in humid combustion air.

Motorised monospiral reel

Not suitable

Unarmoured homogeneous silicone wall is designed for fixed burner leads; use stainless-armoured flare cable on long exposed stacks.

Use Thermo-Trex Flare Stack Cable
Typical machinesIndustrial Gas & Oil BurnersSteam Boilers & Heat RecoveryGas Turbines & CombustorsElectrostatic PrecipitatorsCommercial Ovens & Kilns

Construction

Layer by layer

High-voltage corona-resistant single-core construction: Class 5 tinned or nickel-plated copper conductor and void-free thick-wall VMQ silicone rubber dielectric.

1234
Schematic, not to scale — generated from the layer data
#LayerMaterial & reference
1HV ignition conductorFine-stranded tinned copper or nickel-plated copper (1.0 / 1.5 / 2.5 mm², IEC 60228 Class 5)Low-resistance metallic core delivers full spark energy to industrial burner electrodes
2Void-free conductor interfacePressure-extruded corona-suppressing silicone interfaceEliminates micro-voids at the conductor surface to suppress internal partial discharge
3Heavy-wall HV silicone dielectricHigh-dielectric-strength methyl-vinyl silicone elastomer (VMQ, ≥ 25 kV/mm)Provides 10 kV to 40 kV DC pulse insulation without thermal cracking
4Anti-tracking outer silicone skinOzone-, UV- and arc-track-resistant silicone outer layer (red-brown or black)calibrated 5.0, 7.0, 8.0, or 10.0 mm OD for standard Beru/Kromschröder-type HV boots

HV-Si 5 mm / 7 mm

15 kV to 25 kV DC ignition cable for commercial boilers, ovens, and gas burners

HV-Si 8 mm / 10 mm

30 kV to 40 kV DC heavy-wall silicone cable for high-energy industrial igniters and plasma units

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on ISO 3808 / SAE J2031 / EN 50143. Values for your order are confirmed in the datasheet and quotation.

Electrical

Nominal pulse / DC voltage
10 kV, 15 kV, 25 kV, 30 kV, 40 kV DC
Continuous AC rms rating
5 kV to 15 kV AC rms (50/60 Hz)
Dielectric breakdown voltage
≥ 35 kV (5 mm) to ≥ 65 kV DC (10 mm)
Dielectric strength
≥ 25 kV/mm per IEC 60243-1
Conductor DC resistance
19.5 Ω/km (1.0 mm²) · 13.3 Ω/km (1.5 mm²)

Thermal

Continuous operating temp.
-60 °C to +180 °C
Short-term peak temperature
+220 °C (up to +250 °C with Ni-Cu core)
Thermal shock test
-50 °C to +200 °C without cracking

Mechanical

Conductor stranding
IEC 60228 Class 5 (19 to 48 strands)
Calibrated outer diameters
5.0 mm · 7.0 mm · 8.0 mm · 10.0 mm (±0.2 mm)
Min. bending radius (fixed)
6 × overall cable diameter

Resistance

Corona & ozone resistance
No cracking under ISO 3808 ozone test
Flame retardance
IEC 60332-1-2 self-extinguishing
Halogen-free verification
IEC 60754-1/2 halogen-free silicone

Reference standards

Ignition cable standard
ISO 3808 Class E/F & EN 50143 ref.
Conductor standard
IEC 60228 Class 5 tinned or Ni-Cu
RoHS & REACH
RoHS 3 & REACH compliant

Identification

Sheath colours
Red-brown (oxide red), black, white, yellow
Surface marking
TEBAOFLEX HV-SI IGNITION [OD mm] [kV] +180°C
Customs tariff (HS)
8544.30 / 8544.49

Sizes

9 standard configurations (Silicone High-Voltage Ignition Cable)

Engineering dimensions, conductor stranding, mass and electrical ratings for Silicone High-Voltage Ignition Cable per ISO 3808 / SAE J2031 / EN 50143.

Dimensions & weights
Order designationCross-section / sizeConductor buildWall ≈
mm		Outer Ø ≈
mm		Metal
kg/km		Weight ≈
kg/km		Min. bend R
fixed mm		Enquiry
Standard Silicone High-Voltage Ignition Cable configurations
HV-Si 1×1.0 / Ø 5.01.0 mm² (18 AWG)32×0.20 mm Sn-Cu1.805.009.631.030
HV-Si 1×1.5 / Ø 5.21.5 mm² (16 AWG)30×0.25 mm Sn-Cu1.805.2014.436.031
HV-Si 1×1.0 / Ø 7.01.0 mm² (18 AWG)32×0.20 mm Sn-Cu2.807.009.654.042
HV-Si 1×1.5 / Ø 7.01.5 mm² (16 AWG)30×0.25 mm Sn-Cu2.707.0014.458.042
HV-Si 1×2.5 / Ø 7.22.5 mm² (14 AWG)50×0.25 mm Sn-Cu2.507.2024.068.043
HV-Si 1×1.5 / Ø 8.01.5 mm² (16 AWG)30×0.25 mm Ni-Cu3.208.0014.474.048
HV-Si 1×2.5 / Ø 8.22.5 mm² (14 AWG)50×0.25 mm Ni-Cu3.008.2024.084.049
HV-Si 1×1.5 / Ø 10.01.5 mm² (16 AWG)30×0.25 mm Ni-Cu4.2010.0014.4112.060
HV-Si 1×2.5 / Ø 10.22.5 mm² (14 AWG)50×0.25 mm Ni-Cu4.0010.2024.0122.061
  • Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
  • Outer diameters and weights are nominal engineering values for Silicone High-Voltage Ignition Cable subject to standard manufacturing tolerances per ISO 3808 / SAE J2031 / EN 50143.

Quality & approvals

Testing & inspection

Routine tests on every production length, sample and type tests per batch — documented on an EN 10204 3.1 inspection certificate.

  1. ConductorClass 5 stranding
  2. Spark test100 % in-line
  3. Lay-upCores, earth, fillers
  4. SheathingInner, braid / screen, outer
  5. Electrical testsAC voltage, resistance
  6. DimensionsOD, wall thickness
  7. Inspection documents & dispatchDrum & dispatch
Testing & inspectionTest value / referenceFrequency
Routine tests
Dielectric spark / high-voltage withstand test100 % in-line spark and AC/DC dielectric withstand per ISO 3808 / SAE J2031 / EN 50143Every manufactured length
Conductor DC resistance & continuity checkWithin maximum 20 °C resistance limit specified for Silicone High-Voltage Ignition CableEvery spool or drum length
Sample tests
Thermal ageing & dimensional verificationWall thickness, concentricity and post-ageing elongation per ISO 3808 / SAE J2031 / EN 50143Per production batch
Flame, outgassing or high-temperature enduranceQualified to ISO 3808 / SAE J2031 / EN 50143 thermal and environmental performance criteriaType qualification

Inspection certificate

Issued with every drum, listing the routine test results for that length.

Product approvals

ISO 3808 / SAE J2031 / EN 50143CE (2014/35/EU) & RoHS 3 (2015/863/EU) CompliantREACH SVHC & Halogen/Asbestos Compliance Verified

Company certificates

ISO 9001ISO 14001ISO 45001VDE marks approvalUL / cULCE · LVD / EMC

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX HV-SI 1×1.5 Ø 7.0 MM 25 KV DC -60/+180 °C
Delivery form
Precision spools, coils or export wooden drums
Standard lengths
50 m · 100 m · 500 m · 1000 m (or cut harnesses)
MOQ
100 m (stock sizes) · 300–500 m (custom build)
Lead time
2–4 weeks ex-works
Incoterms
EXW, FOB, CIF, DAP

Technical documents

Downloads

PDFSilicone High-Voltage Ignition Cable – technical datasheet9 sizes · construction, technical data, approvalsXLSXSilicone High-Voltage Ignition Cable spec data (Excel)All 9 sizes with dimensions and data, for your BOM or quotation
Revision
2026-10-20
Updated
2026-10-20

FAQ

Questions engineers ask first

Not covered here? Send your drawing — an engineer replies within 2 business hours.

Why are industrial silicone ignition cables sized by outer diameter (5 mm, 7 mm, 8 mm, 10 mm)?
Industrial burner ignition transformers, ceramic feedthrough insulators, and spark electrode boots use standardised compression glands sized for 5.0 mm, 7.0 mm, 8.0 mm, or 10.0 mm cable OD. Matching both the kV rating and the exact outer diameter guarantees a corona-tight seal.
What is the difference between this metallic-core ignition cable and a wire-wound EMI suppression ignition cable?
This cable uses a low-resistance metallic copper conductor (13.3–19.5 Ω/km) to deliver maximum spark energy for industrial gas/oil burners and flame-ionisation rods. Where electronic engine ECUs or sensitive instrumentation require RFI noise damping, choose our Wire-Wound Suppression Ignition Cable (0.5–5.6 kΩ/m).
Can this cable be used for flame-ionisation rectification sensing rods as well as spark ignition?
Yes. Because the homogeneous silicone rubber wall has high volume resistivity and negligible surface leakage up to +180 °C, it accurately transmits microampere flame-ionisation rectification signals without leakage attenuation.
How should high-voltage ignition cables be routed near steel burner housings?
Maintain at least 15–25 mm air clearance from grounded metal frames or run the cable inside ceramic/PTFE standoffs to minimize capacitive spark energy loss and prevent corona discharge at sharp metal edges.

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Silicone High-Voltage Ignition Cable

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