The document discusses Thermal Wire's armored multi-conductor cables for high energy ignition and thermocouples. The cables consist of individual conductors assembled into a core and protected by a flexible, sealed armor and jacket. This eliminates the need for separate installation of wires through conduit. The armor options include continuously welded and corrugated aluminum or stainless steel. Jacketing materials range from 200°C to 300°C and seal the armor. The cables are tested to various industry standards and come in various conductor, voltage, and temperature configurations. Thermal Wire provides a factory-assembled solution that reduces costs compared to individual wiring methods.

1. ARMORED HEI and
THERMOCOUPLE CABLES
(High Energy Ignition)

2. Why the need ?
 Historically , the single conductor cables, whether they be thermocouple
duplex wire or single conductor HEI wire were purchased separately. Then
these single wires were generally then fed through conduit. This process is
cumbersome, expensive when it comes to cable management and lay inside
the conduit. Often, glass braided cables or Teflon® insulated cables could be
damaged during this process. Thermal Wire has solved this process by
supplying an armored cable, sealed from the elements. Furthermore, this
system provides a factory assembled, armored and jacketed cable. HEI
composite hybrid cables are available. They may be armored with stainless
steel or aluminum, continuously welded and corrugated (CCW), galvanized
steel interlock or aluminum interlocked armor, as well as with served wire
armor (SWA). Three jacketing types are available: 200°C, 250°C, or 300°C.
This overall jacket seals and encapsulates the armor for interlock, non-CCW)
and provides excellent chemical resistance (except for very strong bases).
Sound cable design considerations, and the use of high quality state of the art
insulating materials, coupled with solid American craftsmanship enhance the
cable performance. Non conductive jacket typically not needed for CCW
armor.
 The electrical wire delivering the charge to this system and the thermocouple
wire play a vital role and work in harmony with each other to ensure circuit
integrity. As with all systems, the electrical wire needs to be carefully
considered. Many design notes include: Voltage rating, oil and moisture
resistance, Standards Agency Requirements, armor requirements, routing
considerations, UV resistance etc. lengths of cable, finished OD, weight etc.

3. Multi-Conductor High Energy
Ignition Cable Armored
450°C 10KVAC 25KVDC
 This cable eliminates the need to run cable in pipe. A factory assembled cable consisting of HEI (high energy
ignition) single conductorsrated10KVAC/25KVDC 450°C. The HEI conductors consist of Thermal Wire CST 450
ignition cables which are cabled together to form a round core. Then, a CCW (continuously corrugated and
welded aluminum or stainless steel), or interlocked galvanized steel, aluminum interlock, or SWA (served
wire armor) is applied to protect the core. CCW armor is completely sealed and yet flexible at the same
time. As an option for non CCW armor, a non conductive jacketing materials is extruded to seal the armored
core from the outside environment. Jacketing materials range from 200°C FEP, 250°C PFA, and 300°C ECA
3000. The core HEI conductors are temperature rated to 450°C. The Fluoropolymer extrusion over the armor
is considered “sacrificial” and does not derate the credentials of the core HEI wires.
 Passes Flame test IEEE 1202 (383)
 Designed to Pass UL 4 Tightness of armor to conductors
 Passes Flame test IEC 60332-1-2 & IEC 60332-1-3
 Passes Flame test CSA C22.2 No 2556 FV-2/VW-1 (sec. 9.4)
 Specify fluoropolymer armor jacketing material. 200°C (392°F) FEP, 250°C (482°F) PFA or 300°C (572°F)
TWC
PN:
AWG mm2 # Conductors Finished OD
inch
Finished
OD mm
Weight
Lbs/1MFT
Weight
KG/KM
450-
3C16
MTS-A
16 1.5 3 0.952” 24.18 615 935
450-
4C16
MTS-A
16 1.5 4 0.968” 24.18 780 1,250
450-
3C14
MTS-A
14 2.08 3 0.952” 24.18 700 1,100

4. Multi-Conductor HEI Cable Armored
250°C 10KVAC 25KVDC
 A factory assembled cable consisting of HEI single conductors up to a maximum voltage rating 10KVAC 25KVDC 250°C
ignition cables and then they are cabled to form a round core. Then, a CCW (continuously corrugated and welded
aluminum) or interlocked galvanized steel, aluminum interlock, or SWA (served wire armor) is applied which protects
the core. CCW armor is completely sealed and yet flexible at the same time. As an option, a non conductive jacketing
materials is extruded to seal the armored core from the outside environment. Jacketing materials range from 200°C
FEP, 250°C PFA, and 300°C ECA 3000. The core HEI conductors are temperature rated to 250°C. The Fluoropolymer
extrusion over the armor is considered “sacrificial” and does not derate the credentials of the core HEI wires
 Single insulated conductors UL Recognized 250C 10KVAC/25kvdc
 Single insulated conductors pass CSA FT-2 Flame Test
 Designed to Pass UL 4 Tightness of armor to conductors

 Specify fluoropolymer armor jacketing material. 200°C (392°F) FEP, 250°C (482°F) PFA or 300°C (572°F)
TWC
PN:
AWG mm2 # Conductors Finished OD
inch
Finished
OD mm
Weight
Lbs/1MFT
Weight
KG/KM
250-
3C16H
VSR-A
16 1.5 3 0.952” 24.18 615 915
250-
4C16H
VSR-A
16 1.5 4 0.972” 24.18 780 1,160
250-
3C14H
VSR-A
14 2.08 3 0.982” 24.18 700 1,050
250-
4C14H
VSR-A
14 2.08 4 1.10” 24.18 890 1,325

5. Type K and KX Shielded Pairs
Thermocouple Armored
250°C
 This cable eliminates the need to run cable in pipe. A factory assembled cable consisting of 250C rated
twisted, shielded pairs of K or KX thermocouple alloys. Then, a CLX (continuously corrugated and welded
aluminum or stainless steel) or interlocked galvanized steel, aluminum interlock, or SWA (served wire
armor) is applied which protects the core. CLX armor is completely sealed and yet flexible at the same time.
As an option for non CLX armored cables, a non conductive jacketing materials is extruded to seal the
armored core from the outside environment. Jacketing materials range from 200°C FEP, 250°C PFA, and
300°C ECA 3000. The core thermocouple conductors are temperature rated to 250°C. The Fluoropolymer
extrusion over the armor is considered “sacrificial” and does not derate the credentials of the core HEI wires
Wire Size Number of Pairs Outer Diameter
Inches mm
Weight
Lbs/MFT
Weight
KG/KM
16 AWG (1.29mm) 2 .645 16.42 185 275
16 AWG (1.29mm) 4 .705 17.92 288 945
16 AWG (1.29mm) 8 .844 13.8 415 617
16 AWG (1.29mm) 12 .949 24.09 485 722
16 AWG (1.29mm) 16 1.30 26.29 551 820
16 AWG (1.29mm) 20 1.115 29.41 612 910
16 AWG (1.29mm) 24 1.197 30.39 698 1038
16 AWG (1.29mm) 36 1.007 25.6 995 1480
18 AWG (1.02mm) 2 .603 7.7 168 250

6. Our Multi-conductor Armored HEI cable and thermocouple cables are a
factory assembled cable in flexible conduit that is jacketed from the
elements and offers a chemical resistant barrier to 300C!
 Conduit cost are reduced
and cost savings are
increased!
 Reduced
labor cost
 Reduced
transportation cost
 Cable ready to “plug
and play”. No need to
fish wires through pipe.
 Flexible armor is sealed
with external Teflon® jacket

10. We provide the right cable
for the right job!
Questions? Contact us today!
Locations in 4 states!
Phone: (239) 430-WIRE
Website: www.thermalwire.com

11. Phone: (239) 430-WIRE
Website: www.thermalwire.com
We provide the
right cable for the
right job!
Questions? Contact us today!
Locations in 4 states!
Naples, FL
Tulsa, OK
Houston ,TX
Nashville, TN
Coming in Spring 2017