Carlisle Interconnect Technologies’ (CarlisleIT) Thermazone™ wires are designed for use in high temperature and severe environment applications such as engine wire, fire detection circuits, fly-by-wire systems and flight critical circuits. Three wire options are offered MIL-DTL-25038/1 (Thermazone I), MIL-DTL-25038/3 (Thermazone IIIK, IIIG) and BMS 13-55 (Boeing Material Spec).

The MIL-DTL-25038/1 (Thermazone I), MIL-DTL-25038/3 (Thermazone IIIK, IIIG) wires are ideal for critical circuit applications where wires must operate in extremely harsh environments, under vibration, and with direct flame exposure. Their heavy-duty, non-asbestos construction offers excellent mechanical performance and abrasion resistance. Thermazone IIIG meets or exceeds Thermazone IIIK’s performance due to the use of an innovative insulation which incorporates a PTFE coated fiberglass fluid barrier. The Thermazone IIIK is compatible with MIL-DTL-38999 connectors.

The BMS 13-55 Boeing Material Spec Firezone wire is intended for operation under short-term emergency conditions including exposure to flames with temperatures up to 1100°C and in areas where exposure to thermal changes and corrosive fluids are normal.

ESW Firezone Cables

A range of high temperature, fire proof and fire resistant single and multi-core cables, incorporating PTFE and Polyimide, specifically designed for use in fire zone areas of the aircraft engine.

BMS 13-55 Firezone Wire

BMS 13-55 is the Boeing specification for Firezone wire. These wires are designed for critical circuit applications where wires must operate in extremely harsh environments, under vibration, and with direct flame exposure.

MIL-W-25038 Wire

These wires are designed for critical circuit applications where wires must operate in extremely harsh environments, under vibration, and with direct flame exposure.

A range of high temperature, fireproof and fire resistant single and multi-core cables, incorporating PTFE and Polyimide, specifically designed for use in fire zone areas of the aircraft engine.


Key Features

  • Cable designs to ESW specifications
  • Resist burning and withstand high temperatures
  • Lightweight and space saving
  • Excellent resistance to hydraulic fuel, petroleum and ester-based oils
  • Distinctive red stripe on jacketed versions

Mechanical/Environmental Performance

Reference* Core Type Shielding Jacket Type
Fire Resistant Cable 600V AWG 16 to 22
ESW-1200-010 Single Core Unshielded Unjacketed
ESW-1201-010 Single Core Unshielded Unjacketed
ESW-1202-012 Single Core Nickel Plated Copper PTFE
ESW-1202-022 Multi Core (2) Nickel Plated Copper PTFE
ESW-1202-032 Multi Core (3) Nickel Plated Copper PTFE
ESW-1202-042 Multi Core (4) Nickel Plated Copper PTFE
ESW-1203-012 Single Core Nickel Plated Copper PTFE
ESW-1203-022 Multi Core (2) Nickel Plated Copper PTFE
ESW-1203-032 Multi Core (3) Nickel Plated Copper PTFE
ESW-1203-042 Multi Core (4) Nickel Plated Copper PTFE
Fire Resistant Thermocouple Cable 600V AWG 10 to 20
ESW-1600-010 Single Core (NiCr) Unshielded Unjacketed
ESW-1601-010 Single Core (Al-Ni) Unshielded Unjacketed
ESW-1602-010 Multi Core (2) Nickel Plated Copper PTFE
Fire Proof Cable ● 600V ● AWG 16 to 22
ESW-1250-010 Single Core Unshielded Unjacketed
ESW-1251-010 Single Core Unshielded Unjacketed
ESW-1252-012 Single Core Nickel Plated Copper PTFE
ESW-1252-022 Multi Core (2) Nickel Plated Copper PTFE
ESW-1252-032 Multi Core (3) Nickel Plated Copper PTFE
ESW-1252-042 Multi Core (4) Nickel Plated Copper PTFE
ESW-1253-012 Single Core Nickel Plated Copper PTFE
ESW-1253-022 Multi Core (2) Nickel Plated Copper PTFE
ESW-1253-032 Multi Core (3) Nickel Plated Copper PTFE
ESW-1253-042 Multi Core (4) Nickel Plated Copper PTFE
ESW-1254-010 Single Core Unshielded Unjacketed
ESW-1254-022 Multi Core (2) Nickel Plated Copper PTFE
ESW-1254-032 Multi Core (3) Nickel Plated Copper PTFE

Approvals

ESW 1200, ESW 1201, ESW 1202, ESW 1203
ESW 1250, ESW 1251, ESW 1252, ESW 1253, ESW 1254
ESW 1600, ESW 1601, ESW 1602

BMS 13-55 is the Boeing specification for Firezone wire. These wires are designed for critical circuit applications where wires must operate in extremely harsh environments, under vibration, and with direct flame exposure.


Key Features

  • Firezone wires for aircraft engine applications are designed to operate continuously at 260°C
  • Firezone applications are designed to operate for a minimum of 15 minutes at up to 2000°F (1093°C), including in a direct flame
  • Firezone qualification must pass BSS 7324 and M25038 Shake and Bake Test

MS1355-drawing

Shake and Bake Test Description

  • Wire must withstand a flame temperature of 2,000° ± 50°F for 15 minutes
  • After the flame has been stabilized, the wire is vibrated 30 times per second, with the rack having a maximum total excursion (overall movement) of approximately .06 inches (1.52mm)
  • After 15 minutes, the lowest insulation resistance is measured
  • No insulation can flake or fall off during the flame exposure

Firezone Requirements v. Results

Requirements Results
BMS 13-55 10kΩ 500kΩ

Product Construction

Conductor Nickel-plated copper
Insulation Impregnated inorganic fiber and TFE coated glass braid
Jacket Seamless-wrap PTFE tape
Identification Surface printed per BMS 13-55
Colors Color coated per BMS 13-55
Voltage Rating 600V
Temperature Rating -65 to 260°C

Mechanical/Environmental Performance

Boeing P/N P/N AWG Stranding Nominal Conductor Diameter Nominal Insulation Diameter Weight lbs/1000ft (kg/1000M) Maximum Resistance
BMS13-55T01 C01 G12 12-BF1-1925 12 19/25 0.088(2.24) 0.157(3.99) 29.11(19.5) 2.78(9.12)
BMS13-55T01 C01 G14 14-BF1-1927 14 19/27 0.07(1.78) 0.123(3.12) 18.25 (12.3) 4.32 (14.2)
BMS13-55T01 C01 G16 16-BF1-1929 16 19/29 0.055(1.39) 0.108(2.74) 12.71(8.5) 6.86 (22.5)
BMS13-55T01 C01 G18 18-BF1-1930 18 19/30 0.049(1.24) 0.101(2.57) 10.53(7.1) 9.14(30.0)
BMS13-55T01 C01 G20 20-BF1-1932 20 19/32 0.039(.991) 0.093(2.36) 8.01(5.4) 14.57(47.9)
BMS13-55T01 C01 G22 22-BF1-1934 22 19/34 0.031(.787) 0.086(2.18) 6.35(4.3) 23.7(77.7)

These wires are designed for critical circuit applications where wires must operate in extremely harsh environments, under vibration, and with direct flame exposure.


Key Features

  • Firezone wires for aircraft engine applications are designed to operate continuously at 260 °C
  • Firezone applications are designed to operate for a minimum of 15 minutes at up to 2000 °F (1093 °C), including in a direct flame
  • Firezone qualification must pass BSS 7324 and M25038 Shake and Bake Test

Shake and Bake Test Description:

  • Wire must withstand a flame temperature of 2,000° ± 50°F for 15 minutes
  • After the flame has been stabilized, the wire is vibrated 30 times per second, with the rack having a maximum total excursion (overall movement) of approximately .06 inches (1.52 mm)
  • After 15 minutes, the lowest insulation resistance is measured
  • No insulation can flake or fall off during the flame exposure

M25038 Construction Drawing

Firezone Requirements v. Results

Requirements Results
MIL-W-25038 50 Ω 10 kΩ

Product Construction

MIL-W-25038/1 Construction Details
Jacket PTFE-coated fiberglass braid and finisher
Insulation Composite inorganic dielectric
Conductor 27% nickel-coated copper ranging from 22 – 4/0 AWG

 

MIL-W-25038/3 Construction Details
Jacket Fused high-performance PTFE tape (also available with Seamless Wrap PTFE tape)
Insulation
Thermazone IIIK Outer: PTFE/polyimide tape fluid barrier

Inner: Inorganic dielectric

Thermazone IIIG Outer: PTFE-coated fiberglass fluid barrier

Inner: Inorganic dielectric

Conductor 12-18 AWG: 27% nickel-coated copper

20-22 AWG: 27% nickel-coated high-strength copper alloy

Mechanical Environmental Performance

Voltage Rating 600 V
Temperature Rating -55 to 260 °C
AWG 22-12
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