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Product

10–150 kV DC unshielded silicone HV wire10 kV – 150 kV DC−60 to +180 °C SiliconeHSW / HSX / HST

HSW / HSX / HST Unshielded Silicone High-Voltage DC Wire10 kV to 150 kV DC void-free silicone (HSW, HSX) & FEP-jacketed silicone (HST) HV lead

Ultra-flexible unshielded high-voltage DC equipment wire in three voltage-graded architectures: homogeneous silicone (HSW, 10–100 kV DC), semiconductive stress-graded silicone (HSX, up to 150 kV DC), and fluoropolymer FEP/PFA-jacketed silicone (HST) for.

Flame-retardant

Ozone, UV & moisture

Oil-resistant

Approved

HSW / HSX / HST Model

Order designation: HSW-30KV-1.5
Rated DC voltage: 30 kV DC
Test voltage: 55 kV DC
Nominal OD: 6.4 mm
Weight: 48 kg/km

All sizes (14)

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Engineering reply in 2 business hoursCut-to-length export drumsEN 10204 3.1 certificate per drum

DC voltage range: 10 to 150 kV DC
Dielectric: 30 kV/mm SiR
Thermal range: −60 to +180 °C
HSW / HSX / HST: 3 Variants
Conductor: 0.5–16 mm²
Bend radius: 5 × OD

Typical values for this cable type, based on IEC 60502 / UL 3239 / VDE 0250 / MIL-DTL-16878 — confirmed in the datasheet and quotation for your order.

Application fit

Is HSW / HSX / HST right for your machine?

Designed for internal and external point-to-point HV DC routing in power supplies, lasers, electrostatic precipitators, ion implanters, and HV test benches.

Switchgear & control cabinet wiring

Suitable

Limp vacuum-extruded silicone rubber bends to 5 × OD inside compact high-voltage multiplier cascades and HV power racks.

Furnace, kiln & high-temp zone

Suitable

Operates continuously from −60 °C cryogenic chambers up to +180 °C (+200 °C peak) thermal environments.

Immersion & wet locations

With conditions

Use the HST variant (extruded FEP/PFA outer skin over silicone) when immersed in transformer oil, SF6 or cleaning solvents.

VFD inverter to AC motor screened feeder

Not suitable

Unshielded HV DC wire has no outer metallic screen; where grounded touch-safety or EMC screening is required, use HSUS / HSL.

Use HSUS / HSL Screened HV

Typical machinesHigh-Voltage DC Power Supplies & MultipliersCO2 / Excimer Lasers & Plasma GeneratorsElectrostatic Painting, Flocking & PrecipitatorsElectron Microscopes (SEM / TEM) & Mass SpectrometersHV Insulation Hipot & Capacitor Charging Units

Construction

Layer by layer

Three series: HSW (tinned copper + homogeneous void-free HV silicone), HSX (tinned copper + extruded semiconductive silicone conductor screen + HV silicone for corona suppression ≥ 40 kV), HST (HSW/HSX core + thin-wall transparent FEP fluoropolymer outer jacket).

Schematic, not to scale — generated from the layer data

#	Layer	Material & reference
1	Fine-stranded tinned copper conductor	Stranded tinned copper (IEC 60228 Class 5 / Class 6, 0.50 mm² / 20 AWG to 16 mm² / 6 AWG)Prevents strand-tip corona inception and ensures solder/crimp reliability
2	Extruded semiconductive stress-smoothing layer (HSX / HST)	Co-extruded semiconductive silicone layer bonded over the stranded conductor (standard on HSX and > 40 kV DC grades)Eliminates microscopic air pockets at the conductor surface so partial discharge cannot initiate
3	Void-free high-dielectric silicone rubber (HSW / HSX / HST)	Multi-pass or pressure-cured high-purity polydimethylsiloxane (SiR) insulation with ≥ 30 kV/mm dielectric strengthWithstands 10 kV DC to 150 kV DC while remaining supple from −60 °C to +180 °C
4	Optional FEP fluoropolymer protective skin (HST series)	0.25–0.40 mm extruded fluorinated ethylene propylene (FEP) outer jacket (on HST series; HSW/HSX have homogeneous outer silicone surface)Provides transformer-oil barrier, low coefficient of friction and mechanical abrasion protection

HSW (Homogeneous Void-Free Silicone, 10–100 kV DC)

Single-monolith high-purity red, white or translucent silicone rubber insulation for dry air and cabinet HV DC interconnects

HSX / HST (Corona-Graded & FEP-Jacketed, 20–150 kV DC)

HSX adds an inner semiconductive conductor stress screen for PD-free service to 150 kV DC; HST adds a chemical/oil-proof FEP outer jacket

Technical data

Ratings & operating limits

Typical values: Typical values for this cable type, based on IEC 60502 / UL 3239 / VDE 0250 / MIL-DTL-16878. Values for your order are confirmed in the datasheet and quotation.

Electrical

Rated DC working voltage: 10, 15, 20, 25, 30, 40, 50, 60, 75, 100, 125 & 150 kV DC
Rated AC voltage (50/60 Hz): 4 kV to 60 kV AC rms
Factory DC routine test voltage: 1.5 × to 2.0 × rated U_DC for 5 min
Dielectric breakdown strength: ≥ 30 kV/mm (IEC 60243)
Volume resistivity (20 °C): ≥ 2 × 10¹⁵ Ω·cm
Relative permittivity (εr): 2.8 (silicone) · tan δ ≤ 2 × 10⁻³ at 50 Hz

Thermal

Continuous operating temperature: −60 °C to +180 °C (HSW/HSX/HST)
Short-term peak temperature: +200 °C

Mechanical

Conductor cross-sections: 0.50 mm², 0.75 mm², 1.0 mm², 1.5 mm², 2.5 mm², 4.0 mm² to 16 mm²
Min. bend radius: 5 × OD (HSW/HSX) · 6 × OD (HST)
Shore A hardness: 60 ± 5 Shore A (silicone)

Resistance

Ozone & corona resistance: Inherent Si–O backbone immunity to ozone & UV
Oil & solvent resistance: HST (FEP jacket) fully resistant to mineral transformer oil
Flame & halogen: IEC 60332-1-2 / UL VW-1 · Halogen-free (HSW/HSX)

Reference standards

Applicable specifications: UL 3239 (up to 60 kV DC) · VDE 0250 · MIL-DTL-16878 Type F/FF
High-voltage test method: IEC 60060-1 / IEC 60243-1

Identification

Standard insulation colours: Oxide Red (RAL 3013), White, Translucent or Black
Surface marking: TEBAOFLEX HSW/HSX/HST [kV DC] -60/+180C
Customs tariff (HS): 8544.49 / 8544.60

Sizes

14 standard HSW, HSX & HST unshielded silicone HV DC wire configurations (10–150 kV DC)

Nominal conductor cross-section, DC working voltage, AC rms rating, DC routine test voltage, nominal OD and linear weight.

Voltage ratings, dimensions & test voltages
Order designation	Architecture	Conductor mm² (AWG)	Rated U_DC kV DC	Rated U_AC kV rms	Test Voltage kV DC	Nominal OD mm	Weight kg/km
HSW Series — Homogeneous Void-Free Silicone HV DC Wire (10 kV to 75 kV DC)
HSW-10KV-1.0	HSW Homogeneous SiR	1.0 (18 AWG)	10	4	20	3.6	20
HSW-15KV-1.0	HSW Homogeneous SiR	1.0 (18 AWG)	15	6	30	4.2	24
HSW-20KV-1.5	HSW Homogeneous SiR	1.5 (16 AWG)	20	8	40	5.0	34
HSW-30KV-1.5	HSW Homogeneous SiR	1.5 (16 AWG)	30	12	55	6.4	48
HSW-40KV-1.5	HSW Homogeneous SiR	1.5 (16 AWG)	40	16	70	7.6	64
HSW-50KV-2.5	HSW Homogeneous SiR	2.5 (14 AWG)	50	20	85	9.0	92
HSW-60KV-2.5	HSW Homogeneous SiR	2.5 (14 AWG)	60	25	100	10.5	118
HSW-75KV-2.5	HSW Homogeneous SiR	2.5 (14 AWG)	75	30	120	12.2	155
HSX (Semicon Stress-Graded) & HST (FEP-Jacketed) HV DC Wire (30 kV to 150 kV DC)
HSX-50KV-1.5-SC	HSX Semicon + SiR	1.5 (16 AWG)	50	22	90	9.2	90
HSX-75KV-2.5-SC	HSX Semicon + SiR	2.5 (14 AWG)	75	32	125	12.5	162
HSX-100KV-2.5-SC	HSX Semicon + SiR	2.5 (14 AWG)	100	40	160	15.6	245
HSX-150KV-4.0-SC	HSX Semicon + SiR	4.0 (12 AWG)	150	60	225	21.5	455
HST-30KV-1.5-FEP	HST SiR + FEP Skin	1.5 (16 AWG)	30	12	55	7.0	58
HST-60KV-2.5-FEP	HST SiR + FEP Skin	2.5 (14 AWG)	60	25	100	11.2	138

Typical values for this cable type; dimensions and weights for your order are confirmed in the quotation.
Warning: Unshielded HV wires do not confine the radial electric field; maintain adequate air clearance from grounded chassis walls or run inside insulating oil/gas.

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.

ConductorClass 5 stranding
Spark test100 % in-line
Lay-upCores, earth, fillers
SheathingInner, braid / screen, outer
Electrical testsAC voltage, resistance
DimensionsOD, wall thickness
Inspection documents & dispatchDrum & dispatch

Testing & inspection	Test value / reference	Frequency
Routine tests
100 % dry spark & water-bath DC high-voltage proof test	20 kV DC to 225 kV DC hold for 5 min per voltage rating without breakdown	Every production length
Sample tests
Partial discharge (corona extinction) test on HSX series	PD ≤ 5 pC at 1.2 × rated AC rms voltage	Production lot
Thermal ageing (+180 °C / 168 h) & −60 °C cold-mandrel bend	Zero dielectric cracking and ≥ 30 kV/mm post-ageing breakdown	Type approval

Inspection certificate

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

Product approvals

UL 758 Style 3239 (up to 60 kV DC, 150/180 °C) CompliantMIL-DTL-16878 Type F/FF & IEC 60243 Dielectric Verified

Company certificates

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

Marking & supply

Ordering & delivery

Sheath marking

TEBAOFLEX HSW/HSX/HST HIGH VOLTAGE SILICONE [kV DC] -60/+180C

Delivery form: 100 m / 250 m spools or custom HV potted assemblies
Conductor options: 0.25 mm² to 25 mm² tinned, silver-plated or nickel-plated copper
Quality certificate: Individual DC high-voltage test certificate supplied with every spool
Lead time: 2–3 weeks ex-works

Technical documents

Downloads

PDFHSW / HSX / HST Unshielded Silicone High-Voltage DC Wire – technical datasheet14 sizes · construction, technical data, approvals XLSXHSW / HSX / HST spec data (Excel)All 14 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.

What is the difference between HSW, HSX, and HST high-voltage silicone wires?

HSW uses a single homogeneous extrusion of void-free high-purity silicone rubber over the tinned copper conductor (10–100 kV DC). HSX adds a co-extruded semiconductive silicone stress-smoothing layer directly over the stranded conductor to eliminate air voids and suppress partial discharge up to 150 kV DC. HST adds a thin outer skin of FEP fluoropolymer over the silicone core for transformer-oil, chemical, and abrasion resistance.

Can unshielded HSW / HSX wire be routed directly against a grounded metal chassis?

Only at low DC voltages (≤ 10–15 kV DC). Because an unshielded wire has no outer semiconductive layer or grounded metallic braid, touching a grounded metal edge concentrates the electric field across the tiny air wedge between the jacket and metal, causing external surface corona. For grounded bulkhead pass-throughs or touch-safe routing above 15 kV DC, use screened HSUS / HSL cable.

Why is HSW / HSX inapplicable inside mineral transformer oil unless specified as HST?

Standard polydimethylsiloxane (silicone rubber) absorbs low-viscosity mineral transformer oil and swells over time. The HST variant extrudes a seamless fluoropolymer (FEP/PFA) barrier jacket over the silicone dielectric, retaining silicone flexibility while providing complete immunity to mineral and ester oils.

Why are DC voltage ratings roughly 2.5× higher than 50/60 Hz AC rms ratings on HV wires?

Under DC stress, minimal capacitive charging current flows through the dielectric bulk. Under AC stress, alternating displacement currents continuously charge the insulation capacitance and trigger internal/surface partial discharges at peaks 1.414× the rms voltage, requiring lower AC rms working stresses.

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HSW / HSX / HST Unshielded Silicone High-Voltage DC Wire

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