High Temperature Cables
High-temperature and chemical-resistant cables for engines, industrial ovens, heating equipment, and process-control wiring — rated from 150°C to 550°C across silicone, PTFE, SRML, fiberglass, and mica-insulated constructions.
Key Attributes
- Insulation Materials: Silicone rubber (SiR), PTFE (Teflon®), FEP, ETFE, SRML (silicone + fiberglass braid), varnished fiberglass, and mica-fiberglass composite — each matched to a specific continuous temperature class from 150°C to 550°C.
- Conductors: Multi-strand bare copper, tinned copper, nickel-plated copper, or solid nickel-clad copper per IEC 60228 Class 5; nickel-plated and nickel-clad variants are required for sustained temperatures above 240°C where tin plating degrades.
- Rated Voltage Range: 300 V / 500 V (appliance and control wiring) to 600 V (power feeders) to 1,000 V (heavy industrial), depending on insulation wall thickness and construction type.
- Chemical Resistance: PTFE, FEP, and ETFE fluoropolymer insulations resist virtually all industrial solvents, acids, alkalis, oils, and fuels; silicone provides broad resistance to ozone and UV; both outperform PVC and XLPE in chemically aggressive process environments.
- Jacket & Braid Options: Bare silicone rubber outer jacket, fiberglass braid (self-extinguishing, abrasion-resistant), stainless steel wire braid for mechanical protection at extreme temperatures, or open-weave ceramic fibre sleeve for >450°C radiant-heat zones.
Primary Industry Applications
- Industrial Ovens & Furnaces: Internal wiring for oven elements, thermocouple leads, and temperature-controller connections where ambient air temperatures continuously exceed 200°C; SRML and varnished fiberglass cables are the standard specification.
- Engine & Exhaust Systems: Sensor leads, ignition wiring, and lambda/oxygen-sensor cables routed within 50 mm of exhaust manifolds, turbocharger housings, and catalytic converters requiring sustained ratings of 200°C to 260°C.
- Industrial Heating Equipment: Element-feed wiring, band-heater connections, and infrared-panel power leads on injection-moulding machines, extrusion lines, and heat-sealing equipment demanding flexible, oil-resistant cables at 150°C to 250°C.
- Chemical & Petrochemical Plants: PTFE and FEP-insulated instrumentation cables for flow transmitters, pressure sensors, and control signals in corrosive atmospheres (acids, solvents, chlorinated compounds) where standard XLPE or PVC insulation degrades within months.
- Aerospace & Defence: Lightweight PTFE and ETFE wires per SAE AS22759 for engine nacelle wiring, afterburner instrumentation, and avionic control runs where weight, temperature rating, and chemical inertness are all simultaneously critical.
Product Overview
High-temperature cables are engineered to maintain dielectric and mechanical integrity in extreme environments where standard PVC or XLPE insulation fails. LCSC's range spans five principal technologies — Silicone Rubber (180°C), PTFE (260°C), and Fiberglass/Mica (450°C–550°C) — to suit applications from appliance wiring to furnace terminals. These cables utilize IEC 60228 Class 5 flexible conductors, featuring nickel plating for temperatures above 250°C to prevent oxidation and plating degradation. Manufactured to IEC 60245 and UL 758 standards, the selection covers cross-sections from 0.5 mm² to 16 mm², ensuring compliance and reliability for both signal and power applications.
Key Features and Advantages
| Feature | Description | Benefit |
|---|---|---|
| Multi-Tier Insulation Range (150°C to 550°C) | Five insulation technologies — SiR, SRML, PTFE, varnished fiberglass, and mica-fiberglass — each rated to a verified continuous temperature class per IEC 60245 and UL 758. | Single-source procurement across all temperature zones in one plant: appliance wiring at 180°C, engine sensors at 260°C, and furnace element feeds at 450°C+, without switching suppliers. |
| Nickel-Plated / Nickel-Clad Copper Conductors | Conductors above 250°C rating use electrodeposited nickel plating or solid nickel-clad copper per IEC 60228, Class 5 multi-strand construction. | Maintains stable, low-resistance terminations above 250°C where tin plating degrades; eliminates the oxidised, high-resistance conductor ends that cause element failures and thermocouple signal drift in furnace installations. |
| PTFE / FEP / ETFE Fluoropolymer Options | Fluoropolymer insulations (PTFE: -70°C to +260°C; FEP: -70°C to +200°C; ETFE: -70°C to +150°C) provide near-universal chemical inertness alongside thermal performance. | Eliminates insulation attack from acids, alkalis, fuels, solvents, and chlorinated process chemicals — the primary cause of premature cable failure in petrochemical and pharmaceutical plant instrumentation. |
| Fiberglass Braid Outer Jacket (SRML Construction) | Self-extinguishing fiberglass braid over silicone rubber insulation per UL 3512 / IEC 60245-3; rated to 200°C with cut-through and abrasion resistance. | Adds mechanical protection to flexible silicone wire in motor-lead and transformer-connection applications where soft silicone rubber alone is vulnerable to contact abrasion from winding edges. |
| Verified Flame Performance (IEC 60332-1) | All cables in this range pass IEC 60332-1 single-cable vertical flame propagation testing. | Required for installation inside enclosed ovens, industrial panels, and engine compartments where a cable fire must self-extinguish rather than propagate to adjacent wiring or insulation. |
| Flexible Multi-Strand Construction | Class 5 (IEC 60228) fine multi-strand conductors maintained across all temperature ratings. | Preserves installation flexibility and resistance to conductor fatigue cracking in vibrating engine-bay environments and oven door hinge-point routings with repeated open/close cycling. |
Insulation Type & Temperature Rating Reference
All ratings are continuous operating temperatures. Intermittent peak ratings are typically 20–30°C above the continuous figure for durations not exceeding 500 hours/year.
| Insulation Type | Standard | Continuous Rating | Chemical Resistance | Typical Application |
|---|---|---|---|---|
| Silicone Rubber (SiR) | IEC 60245-3 / UL 3512 | -60°C to +180°C | Oil, ozone, UV — good; solvents — limited | Appliance wiring, oven door harnesses, lighting |
| SRML (SiR + Fibreglass Braid) | UL 3512 / IEC 60245-3 | -60°C to +200°C | As SiR; improved abrasion resistance via braid | Motor leads, transformer connections, heating equipment |
| FEP (Fluorinated Ethylene Propylene) | UL 758 / SAE AS22759 | -70°C to +200°C | Excellent — resists most acids, solvents, fuels | Instrumentation cables, plenum-rated signal wiring |
| ETFE (Ethylene Tetrafluoroethylene) | UL 758 / SAE AS22759 | -70°C to +150°C | Excellent — superior abrasion resistance vs PTFE | Aerospace harness, radiation-resistant nuclear plant wire |
| PTFE (Polytetrafluoroethylene) | UL 758 / SAE AS22759 | -70°C to +260°C | Outstanding — inert to virtually all chemicals | Engine sensors, chemical-plant instrumentation, aerospace |
| Varnished Fibreglass (TGGT) | UL 5196 / UL 5251 | Up to +260°C | Fire-resistant; limited to dry environments | Furnace/oven element feeds, kiln wiring |
| Mica-Fibreglass (MG Wire) | IEC 60331 / UL 5128 | Up to +550°C | Fire-resistant circuit integrity to +550°C | Steel-mill instrumentation, glass-furnace controls |
Technical Specifications
| Parameter | Specification Details |
|---|---|
| Conductor Material | Multi-strand bare copper (BC) or tinned copper (TC) to 200°C; nickel-plated copper (NPC) or nickel-clad copper (NCC) for 250°C+ ratings; per IEC 60228 Class 5 |
| Wire Gauge Range | 0.5 mm² to 16.0 mm² (AWG 20 to AWG 6); available as single-core or multi-core constructions |
| Rated Voltage | 300 V / 500 V (appliance & control) · 600 V (power, UL rating) · up to 1,000 V (industrial power feeders, heavy insulation wall) |
| Continuous Temperature Range | SiR / SRML: -60°C to +200°C · FEP / PTFE: -70°C to +260°C · Fiberglass: up to +450°C · Mica-Fibreglass (MG): up to +550°C |
| Insulation Resistance | ≥ 100 MΩ·km at 20°C (per IEC 60245-1); re-verified after thermal ageing at rated temperature for 168 h per IEC 60216 |
| Dielectric Withstand (Hi-Pot) | 2,000 V AC / 5 min (300/500 V-rated cables); 2,500 V AC / 5 min (600 V-rated) — no breakdown (production test per IEC 60245-1) |
| Conductor DC Resistance (max) | ≤ 39.0 mΩ/m (0.5 mm²) · ≤ 19.5 mΩ/m (1.0 mm²) · ≤ 4.95 mΩ/m (4.0 mm²) per IEC 60228 at 20°C |
| Tensile Strength (insulation) | ≥ 5.0 N/mm² (silicone rubber, IEC 60245-1) · ≥ 10.0 N/mm² (PTFE/FEP, IEC 60245-1) |
| Elongation at Break | ≥ 150% (silicone rubber) · ≥ 200% (PTFE/FEP) — per IEC 60811-501 after thermal ageing |
| Flame Performance | IEC 60332-1-2: single-cable vertical flame — passes (all constructions) |
| Compliance Standards | IEC 60245-1/3, IEC 60332-1, UL 758, UL 3512, UL 5128, SAE AS22759 (PTFE/FEP/ETFE), IEC 60228, RoHS, REACH |
Customization & Product Options
We support flexible cable configurations to match specific thermal zone, chemical environment, and installation requirements:
- Insulation Upgrade by Zone: Single harness assemblies with mixed insulation grades — standard XLPE on ambient-temperature trunk runs transitioning to PTFE or SRML at the thermal-zone entry point — reducing cost while meeting temperature requirements throughout.
- Conductor Size & Core Count: Single-core power cables from 0.5 mm² to 16 mm²; multi-core control cables from 2-core to 12-core; twisted-pair and shielded twisted-pair configurations for thermocouple extension and instrumentation signal runs.
- Conductor Plating: Bare copper (to +120°C ambient), tinned copper (to +150°C), nickel-plated copper (to +260°C), or nickel-clad copper (to +450°C) — matched to the application's peak conductor temperature, not just the ambient air temperature.
- Outer Jacket Options: Bare silicone rubber, fiberglass braid (standard or stainless steel wire braid for impact zones), braided stainless-steel overbraid for mechanical protection in vibrating engine-bay routings, or open-weave ceramic fibre sleeve for radiant heat above 450°C.
- Cut Lengths & Reel Formats: Standard 100 m reels (thin-gauge instrumentation wire) and 50 m reels (power cable); custom cut-to-length in increments from 1 m for assembly pre-kitting; bulk metre-mark printing on jacket for length verification.
- Custom Labelling: Laser-printed circuit ID heat-shrink sleeves, colour-coded silicone tape flags, or PTFE-printed identification tags; all label materials rated to the cable's full continuous temperature specification.
Application Scenarios
- Commercial Oven & Range Internal Wiring: SRML cables (-60°C to +200°C, UL 3512) connecting heating elements, thermostat probes, convection fan motors, and door-interlock switches in commercial bakery ovens and industrial cooking equipment running 12–16 hours per day.
- Turbocharger & Exhaust-Proximity Sensor Leads: PTFE-insulated, nickel-plated copper wires (-70°C to +260°C) for lambda (oxygen) sensor, exhaust gas temperature (EGT) sensor, and NOx sensor signal leads routed within 30 mm of turbo housings in diesel and petrol engine applications.
- Injection Moulding Machine Heater Bands: Flexible SiR cables with fiberglass braid (to +200°C) for the power feeds to barrel heater bands and hot-runner manifold controllers on injection moulding machines, where cables must tolerate oil mist, high cyclic temperature, and 20+ years of flexing at the machine door.
- Chemical Reactor Instrumentation: PTFE or FEP-insulated twisted-pair instrumentation cables for pH, flow, and pressure transmitter signals in chemical reactor environments with concentrated acid or solvent atmospheres — the fluoropolymer insulation resists chemical permeation that destroys standard XLPE or PVC cables in weeks.
- Industrial Furnace & Kiln Element Terminals: Varnished fiberglass TGGT cable (to +260°C) and mica-fiberglass MG wire (to +550°C) for the final connection from furnace wall penetration to heating element terminals, where thermocouple wiring and power feeds operate in sustained radiant-heat environments inaccessible to any polymer-insulated cable.
- Aerospace Engine Nacelle Wiring: PTFE and ETFE per SAE AS22759 for engine nacelle harnesses: high temperature rating, lightweight thin-wall insulation, and inertness to jet fuel, hydraulic fluid, and de-icing chemicals — all mandatory requirements that standard automotive wire cannot satisfy.
LCSC Sourcing & Support
LCSC offers flexible B2B support with rapid 3–5 day prototyping and small-batch NPI orders with no minimum order quantity; production scaling to high-volume blanket orders with rolling forecasts. Application engineering support available for insulation class selection, conductor plating specification, and thermal-zone mapping — including review of routing diagrams to identify locations where insulation upgrades are required. 100% production electrical testing on every reel and assembly: conductor continuity, Hi-Pot dielectric withstand (2,000 V AC / 5 min for 300/500 V-rated cables), and insulation resistance verification. Full material traceability per batch: IEC 60245 insulation test reports, IEC 60332-1 flame test certificates, conductor IEC 60228 compliance records, and RoHS/REACH material declarations for plant maintenance and OEM qualification files.
Product Comparison
* High Temperature Range (This Product) vs Standard XLPE Automotive Wire vs Standard PVC Building Wire
| Attribute | High-Temp Cables — This Product ★ | Standard XLPE Automotive Wire | Standard PVC Building Wire |
|---|---|---|---|
| Continuous Temp Rating | 150°C to 550°C (insulation-dependent) | 90°C to 125°C (GXL/SXL) | 70°C (PVC) / 90°C (THHN) |
| Conductor Plating | Nickel-plated / nickel-clad Cu for >250°C | Bare or tinned copper (BC/TC) | Bare copper (BC) only |
| Chemical Resistance | PTFE/FEP: outstanding — resists virtually all industrial chemicals | Oil and coolant per ISO 6722 | Oil and moisture — limited |
| Flame Performance | IEC 60332-1: passes (all constructions) | IEC 60332-1: passes (GXL/SXL) | IEC 60332-1: passes for LSZH; fails for standard PVC |
| Insulation Materials | SiR, SRML, PTFE, FEP, ETFE, Fibreglass, Mica-Fibreglass | GXL / TXL / SXL XLPE | PVC / THHN / LSZH |
| Rated Voltage | 300 V to 1,000 V | 12 V / 24 V DC (automotive) | 300 V / 600 V / 1,000 V |
| Peak Temp Rating | Up to +550°C (MG wire, IEC 60331) | +150°C (SXL, ISO 6722 Class D) | ≤ 90°C (LSZH); ≤ 70°C (PVC) |
| Application Scope | Ovens, furnaces, engines, chemical plants, aerospace | Engine bay, vehicle wiring looms | Building wiring, dry indoor panels |
| Key Standard | IEC 60245, UL 758, UL 3512, UL 5128, SAE AS22759 | ISO 6722, SAE J1128 | IEC 60227, NEC THHN, BS 6231 |
FAQ
1. How do I select the correct insulation type for my operating temperature?
Start from the maximum continuous ambient temperature at the cable routing location — not the process temperature. Add 10–15°C headroom above the measured peak ambient to allow for hot spots and seasonal variation. For temperatures up to 180°C, silicone rubber (SiR / SRML per IEC 60245-3) is the most cost-effective and flexible choice. From 180°C to 260°C, PTFE is the standard specification, providing both the temperature rating and broad chemical resistance. Above 260°C, varnished fiberglass (TGGT, to 260°C) or mica-fiberglass MG wire (to 550°C) are required. Never select an insulation exactly at its rated limit — the continuous temperature rating represents the maximum, not the design target.
2. When should nickel-plated conductors be specified instead of tinned copper?
Tin-plated copper is strictly limited to 150°C due to copper-tin intermetallic diffusion and a low melting point of 232°C, which risks catastrophic terminal melting in high-heat applications. For cables rated 200°C to 260°C, nickel-plated copper (NPC) must be specified to maintain stable contact resistance. For extreme environments exceeding 350°C (e.g., Mica-fiberglass MG wire), nickel-clad copper (NCC) or pure nickel is required to prevent conductor oxidation and termination failure.
3. What is the difference between IEC 60332-1 flame-tested cable and fire-resistance-rated cable to IEC 60331?
These are two different requirements that are frequently confused. IEC 60332-1 tests whether a cable self-extinguishes after ignition — it measures flame propagation, not circuit survival during a fire. All cables in this range pass IEC 60332-1. IEC 60331 tests fire-resistance: the ability of a cable to continue carrying current for a defined period (30 or 90 minutes) while exposed to a sustained 750°C flame. Mica-fiberglass MG wire passes IEC 60331 because the mica tape maintains dielectric integrity even as the braid and outer layers char. PTFE and silicone cables pass IEC 60332-1 (they self-extinguish) but are not fire-resistance-rated to IEC 60331. For emergency circuit wiring (fire alarms, sprinkler controls, emergency lighting) in buildings, IEC 60331-compliant mica cable is the mandatory specification.
4. Can PTFE-insulated cable be used in food-processing and pharmaceutical environments?
Yes. PTFE (polytetrafluoroethylene) is FDA-listed and meets EU food-contact material regulations (EU 10/2011) — it is chemically inert to all cleaning agents, disinfectants, steam, and the process chemicals used in food and pharmaceutical production. PTFE-insulated cables are the standard specification for sensor leads, heater connections, and control wiring inside autoclaves, CIP (clean-in-place) systems, and freeze-driers, where repeated steam sterilisation at 134°C and caustic chemical wash-downs eliminate all polymer alternatives. FEP offers similar chemical inertness with slightly improved flexibility versus PTFE at low installation temperatures.
5. Can LCSC supply custom multi-core high-temperature cables, and what core counts are available?
Yes. LCSC supplies multi-core high-temperature cables in 2-core through 12-core constructions, with single-core sizes from 0.5 mm² to 16 mm² per core. For thermocouple extension cable, twisted-pair cores with overall foil shield and drain wire are available in silicone-rubber and PTFE insulation to match all standard thermocouple types (K, J, T, E, N). For multi-axis machine and kiln control wiring, numbered multi-core cables in SRML or PTFE construction are supplied on 100 m reels or as custom cut lengths to your assembly schedule. Contact our technical team with the required core count, conductor size, rated temperature, voltage rating, and chemical exposure conditions for a matched specification.