Silicone temperature probes are a reliable and versatile solution wherever the temperature regularly exceeds 100 °C but remains within a range of up to approximately 180 °C. This is their main “sweet spot” and a key advantage over classic PVC‑cable probes.
Flexible and heat‑resistant up to 180 °C
The silicone connection cable maintains its flexibility and insulating properties even at elevated temperatures where PVC cables already start to age and harden. Typical PVC cables are suitable only up to around 105 °C, while silicone safely extends the measuring range up to about 180 °C. Thanks to this, silicone probes are an excellent match for heating, ventilation and many industrial processes that require robust but flexible temperature sensing.
Silicone also withstands frequent thermal cycling, which is common in real systems that heat up and cool down repeatedly. This improves the long‑term stability of the probe and reduces the need for maintenance and replacements.
Key benefits of silicone cables in temperature probes
Silicone‑insulated cables offer several key advantages that make them ideal for demanding temperature measurement tasks:
Higher temperature rating – suitable for continuous operation at elevated temperatures up to around 180 °C, where standard PVC cables are no longer reliable.
Long‑term flexibility – remain flexible over a wide temperature range, which simplifies routing, bending and installation in tight spaces and around pipework.
Better resistance to thermal cycling – withstand frequent heating and cooling without becoming brittle, which increases probe service life and reduces failures.
Reliable operation in demanding environments – provide stable electrical insulation and mechanical robustness in HVAC, industrial and process applications with heat, vibration or mechanical stress.
Typical applications of silicone probes
Silicone temperature probes are designed for reliable temperature measurement in gases and liquids in building services and process engineering. They are widely used in HVAC ducts, where the supply or exhaust air can reach higher temperatures, yet the cable needs to remain flexible for routing and installation.
They are also common in boilers, buffer tanks and pipework in heating systems, often combined with immersion sleeves or threaded pockets. In industrial environments, silicone probes are integrated into dryers and process machines, where elevated temperature and mechanical stress go hand in hand. Laboratory and test benches benefit as well, since silicone probes can handle long‑term exposure to higher temperatures without losing measurement accuracy.
Construction and common variants
A typical silicone temperature probe consists of a sensor tip (usually a stainless steel or brass sleeve) and a silicone connection cable, often supplied in a standard length such as 2 m. The measuring tip diameter is usually small (for example Ø6 mm) to ensure fast response and easy installation into sleeves, ducts or small openings.
Depending on the application, silicone probes can be supplied as immersion probes for use in pipes and tanks, duct probes for air measurement or surface probes that are strapped or clamped onto pipes. Each variant uses the same core idea: a robust metal probe body combined with a flexible silicone cable that withstands temperature and mechanical stress.
Sensing elements inside silicone probes
Inside the probe tip, there is a selected temperature sensor element, chosen according to the control system and accuracy requirements. Very common are resistance temperature detectors such as PT100 and PT1000, which offer a stable and well‑known characteristic. These can also be supplied in higher accuracy classes like 1/3 DIN where precise regulation is required.
For many HVAC and OEM applications, Ni1000 or Ni1000TK5000 elements are used, as well as NTC thermistors with various nominal resistances. In more digital solutions, silicone probes can house semiconductor or digital sensors such as LM235Z or DS18B20. This allows the same mechanical design to be combined with different electrical outputs, depending on the project.
Passive, active and Modbus versions
Silicone temperature probes are available as passive sensors, where the raw resistance (or in some cases voltage) is read directly by the controller. This is the simplest and most common variant in classical HVAC installations. For longer cable runs and more standardized interfacing, active probes convert temperature into a 0–10 V or 4–20 mA signal.
In modern building automation and industrial control, digital communication plays an important role. Silicone‑cable temperature probes are therefore also offered with Modbus RTU over RS485, turning the probe into a field device that communicates measurement values directly in digital form. This reduces wiring complexity and allows straightforward integration into BMS or SCADA systems.
When to choose a silicone probe up to 180 °C
A silicone‑cable probe is the optimal choice whenever the expected temperatures exceed 100 °C but do not reach extremely high‑temperature ranges where special cables are required. In a typical portfolio, PVC is used for lower ranges, silicone up to about 180 °C, while special high‑temperature silicone and glass‑fibre cables cover even higher limits. For the vast majority of heating, ventilation and building applications, the standard silicone range up to 180 °C covers all common operating conditions. This offers an attractive balance between cost, mechanical robustness and thermal capability, without the drawbacks that come with the most extreme high‑temperature materials.
The following overview of common cable materials and their typical maximum operating temperatures shows where standard silicone up to 180 °C fits compared to other options:
| Image | Cable Material | Maximum Temperature | Thermocouples available |
|---|---|---|---|
 | PVC Cable | up to 105°C | PT100, PT100 1/3DIN, PT 1000, PT1000 1/3DIN, NI1000, NI1000TK5000, NTC 5k / 10k / 20k / Precon / KTY81-210, NTC 1,8 kOhm, LM235Z, DS18B20 |
 | Silicone Cable | up to 180°C | PT100, PT100 1/3DIN, PT 1000, PT1000 1/3DIN, NI1000, NI1000TK5000, NTC 5k / 10k / 20k / Precon / KTY81-210, NTC 1,8 kOhm, LM235Z, DS18B20 |
 | High-temperature Silicone | up to 260°C | PT100, PT100 1/3DIN, PT 1000, PT1000 1/3DIN, NI1000, NI1000TK5000, NTC 5k / 10k / 20k / Precon / KTY81-210, NTC 1,8 kOhm, LM235Z, DS18B20 |
 | Glass Wool Cable | up to 400°C | PT100, PT100 1/3DIN, PT 1000, PT1000 1/3DIN, NI1000, NI1000TK5000, NTC 5k / 10k / 20k / Precon / KTY81-210, NTC 1,8 kOhm, LM235Z, DS18B20 |
For most HVAC and building services applications, silicone cables therefore provide the best compromise between thermal performance and overall cost, without the complexity of more extreme high‑temperature solutions.
Why Choose Andivi?
Andivi offers a comprehensive range of temperature probes, including versions with silicone cables rated up to 180 °C for demanding industrial and HVAC applications. The portfolio covers passive probes, active temperature sensors with 0–10 V or 4–20 mA outputs, and Modbus RTU temperature sensors for seamless integration into modern automation and building management systems. Customers can choose from different sensor elements, cable types, lengths, diameters and mounting accessories to match specific technical requirements.
For project support, product selection or custom designs, customers can easily get in touch with Andivi’s expert team via the online contact form.
