61-12 (PART 0) /issue 1 6 November 1992 Wires Cords and Cables Electrical - Metric Units Part 0:general Requirements and Test Methods For Qualification Approval

Ministry of Defence
Defence Standard
61-12(PART 0)
/Issue 1 6 November 1992
WIRES CORDS AND CABLES

ELECTRICAL - METRIC UNITS
PART 0:GENERAL REQUIREMENTS

AND TEST METHODS FOR
QUALIFICATION APPROVAL
GENERIC SPECIFICATION
DEF STAN 61-12 (PART 0)/1
AMENDENTS ISSUED SINCE PUBLICATION
AMD NO DATE OF TEXT AFFECTED SIGNATURE &

ISSUE DATE
Revision Note
Arrangement of Defence Standard 61-12

Part 0 Generic Specification
Part 1 Insulated Flexible Cords and Flexible Cables
Part 2 Cables for Power and Lighting
Part 4 Sub-Miniature Electric Cables
Part 5 Small Multicore Cables
Part 6 PVC, Polyethylene and Silicone Rubber
Insulated Equipment Wires
Part 7 Cords - General Requirements
Part 7
Section 2 Cords - Telecommunications
Part 8 PTFE Insulated Equipment Wires
Part 9 Cables, Radio Frequency
Part 10 PVC Insulated Cables for Road Vehicles
Part 11 Imperial/Metric Cross Reference Index
Part 12 Cables, Telephone
Section 1 External
Section 2 Internal for Switchboard, Distribution and Jumper Wiring
Section 3 For Field Use
Part 13 PVC Insulated Non-Sheathed Cables for Switchgear and
Control Gear Wiring
Part 14 Wires Electrical/Enamel Insulated Round Winding Wires
and Non-Insulated Tinned Copper Wires
Part 16 Wires Electrical
Section 1 Aerial (Antenna) Wires
Section 2 HF Aerial (Antenna) Feeder or Earthing Systems
Part 17 Detonator Firing Circuits
Part 18 Equipment Wires Limited Fire Hazard
Part 19 Single Core Flexible Cables for Welding Circuits
Part 20 Braids, Wire
Part 21 Wires and Cables, Lightweight Extruded Insulation.
135°C Tin Plated and 150°C Silver Plated Conductors
Part 22 Equipment Interconnecting Cables

Part 23 General Requirements - Digital Data Transmission
2
Part 25 Limited Fire Hazard Cables up to 2.5 mm CSA
Part 26 Wires and Cables, Dual Extruded Insulation. Types OVF
and OVFMET Sheath, 140°C Conductor
Part 27 Power Connections to Mobile Equipment
Part 28 Ground Interconnection Type Septosheath- ground, Trailer
Part 29 Extruded ETFE and ETFE Metsheath. 135°C Tin Plated and
150°C Silver Plated Conductors
Part 30 Taped and Extruded PTFE Glass Insulation Types
Uniflexefglas, Uniflexefglasmet 150°C Silver Plated
Conductor
Part 31 Sheaths (Limited Fire Hazard)
Part 33 Airframe Wires and Cables in the Temperature Categories
of 135°C, 150°C, 200°C and 260°C. Sectional
Specification
Part 34 Ribbon Cables 1.27 mm Pitch suitable for Insulation
Section 1 Displacement Connector (IDC) Termination. Sectional
Specification
Part 90 Detail Specifications
Blank Page
WIRES, CORDS AND CABLES, ELECTRICAL

GENERAL REQUIREMENTS AND TEST METHOD
FOR QUALIFICATION APPROVAL GENERIC SPECIFICATION
PREFACE
i This part of the Standard summarizes the test methods and general
requirements for qualification approval for wires, cords and cables,
electrical for Ministry of Defence (MOD) use.
ii This part of the Standard has been prepared because there is no
suitable British or CECC Standard acceptable to the MOD. When a suitable
British or CECC Standard becomes available this Defence Standard will be
amended to implement the British or CECC Standard for MOD use.
iii This Defence Standard has been prepared by the Defence Electrical and
Electronic Standardization Committee (DELSC) working party L2/2.
iv This Standard has been agreed by the authorities concerned with its use
and shall be incorporated whenever relevant in all future designs,
contracts, orders etc and wherever practicable by amendment to those
already in existence. If any difficulty arises which prevents application
of this Defence Standard, the Directorate of Standardization shall be
informed so that a remedy may be sought.
v Any enquiries regarding this Standard in relation to an invitation to
tender or contract in which it is incorporated are to be addressed to the
responsible technical or supervising authority named in the invitation to
tender or contract.
vi This Standard has been devised for the use of the Crown and its
contractors in the execution of contracts for the Crown. The Crown hereby
excludes all liability (other than liability for death or personal injury)
whatsoever and howsoever arising (including but without limitation,
negligence on the part of the Crown its servants or agents) for any loss or
damage however caused where the Standard is used for any other purpose.
1
CONTENTS PAGE
Preface 1
Section One. General

1 Scope 3
2 WARNING 3
3 Related Specifications and Documents 3
4 Patent Rights Registered Designs and Copyrights 5
5 Ordering Information to be Supplied by the Purchaser 5
6 Packaging and Labelling 6
7 Definitions 6
8 Wire and Cable Categorization 7
9 Identification 7
10 Materials and Construction 7
11 Guide to Current Carrying Capacity of Conductors 8
Section Two. Conductors

12 Test Methods 9
Section Three. Wires

13 Test Methods 11
Section Four. Cores

14 Test Methods 26
Section Five. Cables

15 Test Methods 27
Section Six. Sheaths

16 Test Methods 32
Section Seven. Test Requirements and Sampling Plans
17 Test Requirements 41
Section Eight. Qualification Approval Procedures
18 Qualification Approval 46
Annex A List of Test Fluids A-1

Annex B Summary of Def Stan 61-12 Series Test Methods B-1
Annex C Colour Code for Multicore Cables C-1
Annex D British Conductor Parameters D-1
Annex E American Conductor Parameters E-1
2
WIRES, CORDS AND CABLES ELECTRICAL - GENERAL REQUIREMENTS

AND TEST METHODS FOR QUALIFICATION APPROVAL - GENERIC SPECIFICATION
Section One. General

1 Scope
1.1 Defence Standard 61-12 (Part 0) is the generic specification for a
family of2 conductors
2
ranged from a nominal cross sectional area (csa) of
0.035 mm to 630 mm and the associated wires, cords and cables which are
manufactured using selected conductors in the above range.
1.2 The Defence Standard details the tests, test methods, Qualification
Approval Procedures and general requirements for wires, cords and cables.
It applies to all conductors and insulations, including specialized
categories of insulations where additional tests shall apply, eg Limited
Fire Hazard applications.
1.3 Where possible, test requirements have been detailed to reflect the
minimum level of properties which wires and cables for MOD use, shall meet.
Necessary deviations from the test requirements shall be specified under
the particular test heading of those tests called up in the relevant
sectional specification.
1.4 The Sectional Specifications shall select tests from this Standard
relevant to their application. Any additional specialized test or
deviations from those tests listed in this Standard shall also be stated in
the Sectional Specifications.
2 WARNING
2.1 This Standard calls for the use of substances and/or test procedures
that may be injurious to health if adequate precautions are not taken. It
refers only to technical suitability and in no way absolves either the
supplier or the user from statutory and all other legal obligations
relating to health and safety at any stage of manufacture or use.
3 Related Specifications and Documents
3.1 The following documents and publications are referred to in this Part
of the Standard.
ISO 1817/BS 903 Determination of the Effects of Fluids
Part A16 1987
ISO 2574 - 1974(E) Aircraft Electrical Cables Identification
IEC 304 Colour Chart for Insulation and Sheaths of Electric
Cables
BS 3G 100 Part 2 Temperature - Pressure Requirements
Sect 3 Sub-Sect 3.2
1983
BS 148 1984 Specification for Unused Mineral Insulating Oils
for Transformers and Switchgear
BS 507 1985 Ethanol for Industrial Use
BS 573 1987 Plasticizer Esters
BS 2G 230 1991 General Requirements for Aircraft Electrical Cables
BS 2G 231 1990 Conductors for General Purpose Electrical Cables
and Aerospace Applications
BS 1595 Part 1 1986 Propan-2-ol (Isopropyl Alcohol) for Industrial Use
3
3.1 (Contd)
BS 2011 Part 2.1 Damp Heat Steady State
CA 1977
BS 2011 Part 2.1 Mould Growth
J 1989
BS 2011 Part 2.1 Climatic Sequence
Z/ABDM 1983
BS 2782 Part 1 Determination of Flammability by Oxygen Index
Method 141 1986
BS 4487 1969 Inhibited 1.1.1-Trichloroethane (Methylchloroform)
BS 5750 Quality Systems
BS 6360 1991 Conductors in Insulated Cables and Cords
BS 6469 1990 Insulation and Sheaths of Electric Cables
BS 6580 1985 Corrosion Inhibiting Engine Coolant Concentrate
BS 6746 1990 Specification for PVC Insulation and Sheaths of
Electric Cables
BS 6746C 1990 Colour Chart for Insulation and Sheath of Electric
Cables
BS 6899 1991 Rubber insulation and Sheath of Electric Cables
Def Stan 61-12 Sheath Limited Fire Hazard
Part 31/1
Def Stan 00-9/2 General Requirements for Qualification Approval,
Capability Approval and Quality Assurance of
Components for MOD Use
Def Stan 01-5 Fuels, Lubricants and Associated Products
Def Stan 05-91 Quality System Requirements for Design/Development,
Production, Installation and Servicing
Def Stan 05-92 Quality System Requirements for Production and
Installation
Def Stan 91-4/5 Fuel, Naval Distillate
Def Stan 91-22/2 Lubricating Oil, Engine
Def Stan 91-35/1 Hydraulic Fluid, Petroleum, Emulsifying
Def Stan 91-46/1 Damping Fluids
Def Stan 91-48/1 Hydraulic Fluid, Petroleum, Super Clean
NES 641 Determination of the Vertical Flammability of
Electric Cables
NES 711 Determination of the Smoke Index of the Products of
Combustion from Small Samples of Materials
NES 713 Determination of the Toxicity Index of the Products
of Combustion from Small Samples of Materials
NES 715 Determination of the Temperature Index of Small
Specimens of Materials
CPU/AIS Agreed Industry Standard. Packaging of wires,
Cords and Cables Electrical
TS 10123 Insecticidal Aerosol
TS 10281A Cleaning Compound, Foaming for Aircraft Surfaces
DGS 200/1110A See Def Stan 01-5
3.2 Copies of related specifications and documents are obtainable from:
DOCUMENT SOURCE
British Standards (BS) British Standards Institution

IEC Publications (IEC) Sales Office
ISO Publications (ISO) Linford Wood
MILTON KEYNES MK14 6LE
4
3.2 (Contd)
DOCUMENT SOURCE
Defence Standard Publications Directorate of Standardization

(Def Stan) Kentigern House
65 Brown Street
GLASGOW G2 8EX
Naval Engineering Standards (NES) MOD Library

Block E
Foxhill
BATH BA1 5AB
Agreed Industry Standard Defence Packaging Authority

CPU/AIS 300 Building 18
Royal Arsenal West
Woolwich
LONDON
Technical Specification (TS) DRA/QATS (Materials Centre)

Building E135/29
Royal Arsenal East
Woolwich
LONDON SE18 6TD
3.3 Reference in this Standard to any related documents means in any

invitation to tender or contract the edition and all amendments current at
the date of such tender or contract unless a specific edition is indicated.
4 Patent Rights, Registered Designs and Copyrights
4.1 Users of this Standard shall note that these procedures may be claimed
to be subject to patent/copyright/design rights in this or other countries.
5 Ordering Information to be Supplied by the Purchaser
(a) description of product to include:
Conductor - csa, Stranding, Plating

Insulation - Temperature rating, Voltage Rating
Number of cores - Printed or coloured identification
Screened, Sheathed
(b) detail specification number (if applicable);
(c) manufacturer’s/supplier’s part number;
(d) NATO stock number (if codified);
(e) length required.
5
6 Packaging and Labelling

6.1 Packaging and labelling shall be in accordance with the requirements
specified in Agreed Industry Standard CPU/AIS/300, or as stated in the
contract.
7 Definitions
7.1 Standard Atmospheric Conditions. Standard Atmospheric Conditions are:
Temperature: 20°C ± 5°C (In cases of dispute during testing it
shall be 23°C ± 2°C)
Relative Humidity: 50% ± 5%
Air Pressure: 96kPa ± 10kPa
7.2 Strand. A strand is a cylindrical metallic electrical conducting
element of uniform cross section area (csa).
7.3 Plated strand. A strand that is covered with a thin layer of tin,
silver or nickel.
7.4 Conductor. A conductor is a single strand or several strands formed
in concentric layers.
7.5 Conductor size. A number closely related to the csa of the conductor
(UK) or to the American Wire Gauge (awg) (USA).
7.6 Dielectric. An electrically insulating material concentrically formed
round a conductor.
7.7 Insulation. A general term to describe the material that
concentricall y surrounds a wire or cable.
7.8 Wire. A single conductor concentrically surrounded by dielectric.
7.9 Cable. An assembly consisting of conductor, insulation and, where
applicable, screen and jacket.
7.10 Cord. A very flexible wire or cable of fine conductor strands, the
tensile strength of which depends on additional elements such as a thread.
7.11 Core. A single wire in a cable.
7.12 Multi-core cable. A cable consisting of two or more cores and/or
other elements laid together helically.
7.13 Screen. A metallic layer of strands usually in woven form, which
surrounds a wire or cable to reduce electromagnetic interference or
radiation.
7.14 Sheath. A layer of material surrounding a wire or cable added to
improve the resistance of the dielectric to environmental conditions or to
provide a suitable printing surface.
7.15 Armour. A concentric layer of steel strands laid over the insulation
of wire or cable for mechanical protection.
6
7.16 Temperature rating. The temperature rating of a wire or cable is

that temperature at which it can operate continuously. It is the sum of
the ambient temperature and the temperature rise of the wire or cable due
to current flow.
8 Wire and cable categorization
Wires and cables shall be categorized in the individual sectional
specifications.
9 Identification
9.1 Printing shall be durable and non-aggressive and shall be discernible
using normal reading vision.
9.2 Unless otherwise stated in the sectional specification or contract,
wires and cables shall be durably identified on the outer surface in
accordance with ISO 2574 with the addition of the last seven digits of the
NATO Stock Number. The manufacturers code and year of manufacture shall be
as stated in BS 2G 230.
9.3 Cores in cables shall be identified by colour or printing but not
both.
9.4 Colours shall be in accordance with annex C, or as detailed in the
contract and shall be distinguishable as being those detailed in BS 6746C
(IEC 304).
10 Materials and Construction
10.1 Conductors. Conductors shall be made from 100% new materials which
have been subjected to normal essential processing to meet the resistance
and mass requirements of annex D.
10.1.1 Copper conductors (or copper alloy where required) shall be
annealed in accordance with BS 6360 and may be plated with either tin,
silver or pure nickel (not compounds of nickel).
10.1.2 Conductors of other materials shall be specified in the relevant
sectional or detail specification.
10.1.3 Conductors shall have no joints, kinks or other irregularities. No
strand joint shall be within 300 mm of a joint in an adjacent strand.
10.1.4 Strands shall be clean, bright and free from surface irregularities
with no kinks.
10.1.5 A strand can contain one joint in any 50 m and it shall be brazed,
hard soldered, or cold pressure welded.
10.2 Insulations. Dielectric and insulating materials shall be made from
100% new materials.
10.2.1 Sheaths shall be in contact with the underlying material
circumferentially and along the complete length of the wire or cable and
shall be removable without damage to the underlying material or binder
tape.
7
10.3 Fillers. Fillers are used to improve the circumferential roundness

of a cable. They shall not adversely react with other components of the
cable and shall have properties similar to or better than the insulation
and sheathing material.
10.4 Screens. The strands used in the manufacture of screens shall comply
with Clause 10.1.4.
10.4.1 The screen shall be in contact with the underlying insulation
layer, circumferentially and along the complete length of the wire or
cable.
10.4.2 Only one joint in any 10 m length of screen strand is permissible
and the joint shall be brazed or hard soldered. No joint shall be within
300 mm of a joint in an adjacent strand.
10.4.3 The screen filling factor (Kf) is defined as:
m= Number of spindles
n= Number of ends per spindle
d= Diameter of strands in mm
D= Mean diameter of screen (Diameter over insulation + 2.25d)
L= Lay of screen strands in mm
There shall be a minimum of 3 ends per spindle and the minimum Kf = 0.5
11 A Guide to the Current Carrying Capacity of Copper Conductors
11.1 Under consideration
8

12 Test Methods
Test shall be carried out at Standard Atmospheric Conditions unless
otherwise stated.
12.1 Visual inspection of plated strands or braid. A minimum length of
2 m shall be subjected to and meet the requirements of BS 2G 230 Test 4 and
BS 2G 231 clause 3.4.
12.2 Conductor composition. Specimens shall be subjected to the method of
BS 2G 230 Test 3. The number of strands to be measured shall be:
Conductors up to 37 strands - all strands
Conductors with 38 to 200 strands - 50% minimum
Conductors with 201 to 700 strands - 30% minimum
Conductors with 701 or more strands - 10% minimum
12.2.1 Calculate the cross sectional area (csa) using the formula
2
0.7855 d S where d = average diameter of measured strands and S = number of
strands in conductor.
The requirements of annex D of this Standard shall be met.
12.3 Mass per unit length of conductor. Specimens shall be subjected to
BS 2G 231 Test 5.2 The mass shall be as specified in annex D.
12.4 Strand plating continuity. Specimens shall be subjected to and meet
the requirements of BS 2G 230 Test 9.
12.5 Tensile strength and elongation at break. Specimens shall be
subjected to BS 2G 231 Test 5.1 and shall meet the requirements of table A
of this Standard.
12.6 Strand Plating Adherence. Specimen shall be inspected in accordance

with and meet the requirements of BS 2G 230 test 10.
12.7 Strand Plating thickness. The plating shall be measured by a
suitable method. The minimum thickness for silver plating shall be 1µ.
12.8 Conductor Electrical Resistance. Specimens shall be measured in
accordance with BS 2G 230 Test 12 and meet the requirements of table D of
this Standard.
9
Table A
Tensile Strength and Elongation at Break
(Copper and Copper Alloy Conductors)
TENSILE STRENGTH MINIMUM ELONGATION %

2
STRAND DIAMETER N/mm
COPPER mm PRIOR TO AFTER
MIN MAX INSULATING INSULATING
Below 0.14 5.5 5.0

0.14 to 0.21 9.0 7.4
0.22 to 0.51 220 300 14.0 11.4
0.51 to 1.36 18.0 14.7
Above 1.36 22.5 18.5
Copper Alloy Using 7 strands
Below 0.12 350 6.0 6.0
10

13 Test Methods
13.1 Electrical resistance after insulation. Specimens shall be subjected
to the following tests:
13.1.1 Measure the electrical resistance using suitable equipment and
correct to 20°C using the formula R 20 = Rt [1 + α (20-T)]
where:
T = test temperature °C
R t = Resistance at temperature T
R 20 = Resistance at 20°C
α = Temperature coefficient of resistance of the conductor material /°C
In cases of dispute, a four terminal measurement method shall be used.
13.1.2 The requirement shall be stated in the sectional specification.
13.2 Solderability. Specimens shall be subjected to BS 2G 230 Test 14a or
14b. Test 14a shall be the reference method in cases of dispute.
13.2.1 Specimen preparation
2
(a) Conductor of 0.7 mm csa or below: Remove at least 150 mm from the
sample and discard. Cut five specimens of approximately 30 mm and strip
the insulation to expose 15 to 20 mm of conductor.
2
(b) Conductors greater than 0.7 mm csa: Extract a sufficient number of
2
strands to make up a conductor sample with a csa of 0.5 to 0.7 mm .
(c) Screens: Extract a sample of five strands from the screen braid.
13.2.2 Requirements. The wetting times shall be 2.0 seconds maximum for
tin plated copper conductors and 1.0 second maximum for silver plated
copper conductors.
NOTE: Where is is intended to solder wires after long storage, silver
plated wire is recommended.
13.3 Appearance and identification. The surface shall present a smooth
appearance with no ridges or channels and shall be marked in accordance
with clause 9 of this Standard.
13.4 Mass. Specimens shall be subjected to BS 2G 230 test 2 and shall
meet the requirements of the sectional specification.
13.5 Wire diameters. Specimens shall be subjected to BS 2G 230 test 6 and
shall meet the requirements of the sectional specification.
13.6 Conductor strand adhesion. Specimens shall be subjected to and meet
13.7 Insulation thickness and concentricity. Specimens shall be subjected
to and meet the requirements of BS 2G 230 Test 5. The insulation thickness
shall be stated in the Sectional Specification.
11
13.8 Colour. Specimens shall meet the requirements of 9.4 of this

Standard.
13.9 Colour stability. Specimens shall be placed in an air circulating
oven for a period of 24 ± 0.25 hours at the temperature rating of the
cable/core. After removal from the oven and allowing to cool they shall be
uniform and recognizable as the original colour.
13.10 Colour fastness to light. Specimens shall be subjected to and meet
13.11 Insulation resistance. Specimens shall be subjected to BS 2G 230
Test 17. The test solutions, temperature and requirements shall be stated
in the Sectional Specification.
13.12 High voltage immersion. Specimens shall be subjected to and meet
the requirements of BS 2G 236 Test 16a. The test voltage and cable
specimen length shall be stated in the Sectional Specification.
13.13 High voltage dry spark. Specimens shall be subjected to and meet
the requirements of BS 2G 230 Test 16b. The test voltage shall be stated
in the Sectional Specification.
13.14 High voltage dry impulse. Specimens shall be subjected to and meet
the requirements of BS 2G 230 Test 16c. The test voltage shall be stated
in the-Sectional Specification.
13.15 Surface resistance. Specimens shall be subjected to and meet the
requirements of BS 2G 230 Test 18.
13.16 Overload resistance
Specimens shall be subjected to BS 2G 230, Test 31. The sectional
specification shall state temperatures T1 and T2.
13.16.1 Requirement
(a) At the end of 30 min at a temperature T1, there shall be no smoke, no
overheating smell and the colour shall be recognizable as being of the
original.
(b) At the end of 15 min at a temperature T2, there shall be no
spontaneous combustion, splitting of the insulation or baring of the
conductor.
(c) The specimen shall show no indication of separation or embrittlement

of the insulation after being subjected to the room temperature bend test.
The High Voltage Immersion Test is not required.
13.17 Dielectric constant
13.17.1 A specimen of wire conductor size 19/0.15 of length not less than
1 m shall be immersed in a solution as described in BS G230 test 16a. The
length of specimen in the solution shall be carefully measured and
recorded. The capacitance between the conductor of the specimen and the
solution shall be measured using a suitable ac bridge, working frequency
approximately 1 kHz. The dielectric constant of the insulant shall be
calculated using the formula:
12
13.17.1 (Contd)
Where D1 is the overall diameter of the conductor (mm)

D2 is the overall diameter of the insulation (mm)
l is the length immersed (m)
C is the measured capacity (Farads)
-12
is the permittivity of free space (8.85 x 10 )
13.17.2 The dielectric constant shall be as stated in the Sectional
Specification.
13.18 Resistance to wet arc tracking. Specimens shall be subjected to
BS 2G 230 Test 42. The test generator shall be rated at 15 kVA.
Three samples of five looms shall be tested, if one sample fails the test
shall be repeated. If any failures occur on retest the sample shall be
rejected.
13.19 Room temperature bend. Specimens shall be subjected to and meet the
requirements of BS 2G 230 Test 24. The mandrel diameter and tensile force
shall be stated in the Sectional Specification.
13.20 Cold bend. Specimens shall be subjected to and meet the
requirements of BS 2G 230 Test 25. The mandrel diameter, tensile force and
cold chamber temperature shall be stated in the Sectional Specification.
13.21 Adherence of insulation on conductor. Specimens shall be subjected
to and meet the requirements of BS 2G 230 Test 21. The minimum and maximum
adherence forces shall be stated in the Sectional Specification.
13.22 Dynamic cut through. Specimens shall be subjected to BS 2G 230
Test 26. The requirements shall be stated in the Sectional Specification.
13.23 Notch-propagation resistance. Specimens shall be subjected to and
meet the requirements of BS 2G 230 Test 27.
13.24 Scrape abrasion. Specimens shall be subjected to BS 2G 230 Test 30.
The requirements shall be stated in the Sectional Specification.
13.25 Wire to wire abrasion. Specimens shall be subjected to
BS 2G 230 Test 37 . The
2
load shall be 2.5 kg and the test shall be
performed on 0.6 mm csa wire only. The minimum number of cycles shall be
2,500,000.
13.26 Pliability Specimens shall be subjected to BS 2G 230 Test 38a.
The mandrel diameters and maximum recoil distance shall be stated in the
Sectional Specification.
13
13.27 Identification durability. Specimens shall be subjected to and meet

the requirements of BS 2G 230 Test 36. The minimum number of strokes and
the applied force shall be 100 and 2N respectively.
13.28 Flexing endurance. A size 0.35 wire shall be fitted into a machine
schematically shown in figure 1, so that the wire, in contact with two
mandrels of 15 mm diameter, shall be flexed through 180° whilst under a
load of a minimum of 1.0 kg. The wire shall be flexed at 18 ± 2 cycles/min
and one cycle consists of movement from the horizontal up through 90°, down
through 180° and back to the horizontal. The wire shall carry the current
specified in the Sectional Specification, for the duration of the test.
After a specific number of cycles, carry out a High Voltage (Immersion)

test 13.12.
The Sectional Specification shall specify the number of cycles.
Fig 1 Schematic Flexing Endurance Test Rig
13.28.1 Requirement. There shall be no localized heating and the wire

shall meet the requirements of the High Voltage (Immersion) test.
13.29 Accelerated ageing. Specimens shall be subjected to and meet the
requirements of BS 2G 230 Test 19. The air circulating oven shall be set
for 168 hours at a temperature stated in the sectional specification. The
mandrel diameters and the applied force shall be stated in the Sectional
Specification.
13.30 Delamination and shrinkage. Specimens shall be subjected to and
meet the requirements of BS 2G 250 Test 22. The sample shall be subjected
to 3 cycles of 4 hours at the wire rated temperature ± 3°C followed by
one hour at standard atmospheric condition.
There shall be no evidence of delamination, the permitted amount of
shrinkage shall be stated in the Sectional Specification.
13.31 Delamination and insulation blocking. Specimens shall be subjected
to and meet the requirements of BS 2G 230 Test 23. The temperature cycle
shall be 100 hours at the wire rated temperature ± 3°C. The tension and
mandrel diameter shall be stated in the Sectional Specification.
14
13.32 Delamination (tape wrapped insulation). Specimens shall be

subjected to BS 2G 230 Test 32. The wire shall be aged in an air oven 50
hours. The specimens shall be subjected to tension by applying an axial
force of 6.8 N to the movable chuck. The apparatus, with the specimen in
place, shall be brought to temperature and the wire shall be subjected to
the cycles of twisting and untwisting. If no delamination is observed, the
specimen shall be subjected to and meet the requirements of the high
voltage immersion (BS 2G 230 Test 16a). The temperatures shall be stated
in the sectional specification.
13.33 Climatic. Specimens shall be subjected to BS 2011, Part 2.1,
Test Z/ABDM, Procedure 1. Six turns of the sample shall be wound on a
mandrel, the ends shall be sealed and passed to the outside of the test
chamber. The climatic category, low air pressure and mandrel diameter
shall be stated in the section specification.
13.33.1 Requirements
13.33.1.1 Specimens shall meet the requirements of the relevant part of
BS 3G 100, Part 2, Section 3, Subsection 3.2 which shall be stated in the
13.33.1.2 Specimens shall show no signs of deterioration or discoloration
and the identification shall be legible.
13.33.1.3 Specimens shall meet the requirements of 13.11 of this Standard.
13.34 Damp heat steady state
13.34.1 Method. Five turns of a specimen shall be wound round a mandrel,
ensuring the specimen is in contact with the mandrel for all five turns and
mounted in a test chamber meeting the requirements of BS 2011, Part 2.1,
Test Ca. The specimen may be preheated to 90°C to avoid condensation. The
test chamber shall be maintained under temperature and humidity conditions
and for a period to be stated in the sectional specification. The mandrel
diameter shall also be stated in the sectional specification. The specimen
shall be removed from the test chamber and held at standard atmospheric
conditions for one hour minimum.
13.34.2 Requirements. The specimen shall be subjected to and meet the
requirements of the room temperature bend 13.19 of this Standard.
13.35 Resistance to solder heat. Resistance to Solder Heat test shall be
carried out on a 300 mm length of size 0.6 wire. Remove 10 mm of
insulation from each end and bend the wire through 90°, 35 mm from each end
and with a radius of approximately 10 mm to form an elongated U. See
figure 2.
15
Fig 2 Resistance to Solder Heat Test

Coat the stripped ends of the wire with a non-activated flux and immerse
both ends into-a solder bath for 10 seconds to a depth of 7 mm within 5
minutes of bending. The solder bath shall be at a temperature of 260°C ±
10°C and surface dross shall be removed prior to the immersion.
13.35.1 Requirement. The insulation shall not split or show signs of
melting and the shrinkage shall not exceed 1 mm at either end.
Delamination on taped insulations shall not exceed 1 mm at either end.
13.36 Thermal endurance. Specimens shall be subjected to and meet the
requirements of BS 2G 230 Test 20. The thermal life and temperature rating
shall be stated in the sectional specification.
13.37 Resistance to fluids. Specimens shall be subjected to and meet the
requirements of BS 2G 230 Test 29. The immersion time, temperature and
fluids shall be selected from annex A of this Standard and stated in the
13.38 Mould growth. Specimens shall be subjected to BS 2011 Part 2.1
Test J. Severity shall be 28 days. Requirements shall be stated in the
13.39 Flammability Specimens shall be subjected to an meet the
requirements of BS 2G 230 Test 28a. The time of flame application shall be
stated in the Sectional Specification.
13.40 Flame propagation. Specimens shall be subjected to and meet the
requirements of BS 2G 230 Test 28b. The time of flame application shall be
stated in the Sectional Specification.
13.41 Critical oxygen index. Specimen shall be subjected to and meet the
requirements of BS 2782 Part 1 Method 141. The ignition time shall be 15 s
and the minimum critical oxygen index shall be stated in the Sectional
Specification.
13.42 Smoke index
13.42.1 Test apparatus
(a) A smoke density chamber approximately 900 mm x 900 x 600 mm deep. Is

to be fitted with:
Electrical heater with adjustable output.
16
13.42.1 (Contd)
Valve controlled openings for Flame Gas, Radiometer Air, Flame Air, Vent
and Inlet Vent.
Chamber temperature sensor.
Photomultiplier micro-photometer with shutter.
Vertical colimated light beam
A mixing fan placed centrally in the top of the chamber.
An auxiliary heater placed centrally to accelerate initial heating.
A 15 jet gas burner, remotely ignited, and designed to take premixed
air/propane gas fuel. Details of the burner are shown in figure 4.
(b) A Specimen Holder which consist of a metal box with internal
dimensions of approximately 76 mm x 76 mm x 30 mm deep and which is open at
one end and with an all round 2 mm lip at the other. The holder shall take
a 1.5 mm diameter wire mesh grid 75 mm x 75 mm, with 12.5 mm x 12.5 mm
apertures which have been spot welded at the intersections. The holder
also contains a heat insulating block 75 mm x 75 mm x 10 mm wrapped in
aluminium foil and a block tensioning spring and locking pin (see
figure 3).
(c) A chart recorder with a full scale deflection (FSD) of 50 mV and a
chart speed of 10 mm/minute.
(d) A timer of minimum 20 minutes duration and an accuracy of ± 1 second.
13.42.2 Specimens. The specimens shall be conditioned at standard

atmospheric conditions for 24 hours prior to the test. Specimens shall
consist of 13 x 75 mm lengths of size 0.6 wire cut from the reel, laid
centrally side by side between the wire grid and the insulating block in
the holder. The holder is placed in the chamber with the wires in a
vertical position. The grid, samples and insulating block shall be held
firmly against the retaining lip by the retaining pin.
13.42.3 Pre-requisites
(a) Determine the ‘Heater Volts’ setting to obtain 2.5 W/cm sq at the
specimen surface using the "Furnace calibration" procedure of the smoke
density chamber.
(b) Calibrate the photomultiplier photometer using a primary standard and
the manufacturers calibration procedure.
13.42.4 Procedure. The chamber shall have reached a steady state
condition and the furnace, photometric system and burner shall have been
calibrated.
(a) Switch on the circulating fan and place the loaded sample holder on
the support rods directly in front of the furnace.
(b) Immediately close the chamber door and simultaneously start the chart
recorder and timing device.
17
13.42.4 (Contd)
(c) After 5 minutes open the propane valve and ignite the gas. As quickly
as possible, increase the propane rate such that the yellow flame covers
approximately 90% of the specimen width. Immediately open the air valve to
produce a blue flame. The air/propane mixture should be adjusted so that
the blue flame touches the specimen over 90% of its width at a height of
approximately 5 mm above its bottom edge.
(d) Continue the test for a further 15 minutes or until a minimum %
transmittance (Tm) is obtained.
(e) If during the test, the indicated Transmittance (T) falls to 10%
select a more sensitive range on the recorder.
(f) At the end of the test period extinguish the burner, wait for any
sample burning to cease, remove the sample from in front of the furnace and
evacuate the chamber.
(g) Continue evacuation of the chamber until a stable maximum %
Transmittance is obtained. Record this value as the clear beam
transmittance (Tc).
NOTE: Testing the other specimen involves repeating the procedure from
13.42.4.
13.42.5 Adjustment of test values
(a) Clouding of the optical windows necessitates an adjustment of the test
figures by calculating Specific Optical Densities Dsc and Dsmax from Tc and
Tmin respectively using the following formula:
Specific Optical Density (Ds = 132 where T = % Transmittance.
Corrected Specific Optical Density (Dsmaxc) = Dsmax - Dsc

(b) Convert Dsmaxc to % Transmittance and plot on the recorder trace
adjacent to the time of Tmin. T = antilog10 (2 - Dsmaxc)
132
(c) If Dsc is 3% or less of Dsmax, no further corrections are required.
(d) If Dsc is greater than 3% of Dsmax, correct the trace as follows:
Where transmittance less than 70% (Ds = 20) has been recorded, correct the
70% transmittance point by: 20 - (20 Dsc) after converting into %
transmittance. Dsmax
18
13.42.5 (Contd)
(e) Construct a curve using the corrected values.
(f) Smoke Index (Ds at Tmin) if transmittance is greater than 70%.
= tmin
= Ds70 + Ds40 + Ds10 + (Ds at Tmin)(x-Tmin)
t70 t40 t10 tmin(x-y)
tmin
if transmittance is less than 70%, where:

Ds70, Ds40, Ds1O and Ds at Tmin = Specific Optical Densities corresponding
to 70%, 40%, 10% transmittance and transmittance greater than 70%
respectively.
t70, t40, t10 and tmin = times in minutes from the start to reach 70%, 40%,
10% transmittance and transmittance greater than 70% respectively.
x = lowest transmittance reference value reached during the test, ie 70%,
40% or 10%.
y = next lower transmittance reference value to x ie 40%, 10% or 0%.
13.42.6 Calculate the mean of 3 results obtained from 3 samples of the
material.
13.42.7 Requirement. The test report shall detail:
(a) The Smoke Index value.
(b) A description of the material.
(c) Any unusual occurrence ie the material melting and dripping.
(d) The following statement: ‘This test result does not assess the fire
hazard of the material or a product made from this material under actual
fire conditions. Consequently the results of this test alone shall not be
quoted in support of claims with respect to the fire hazard of the material
or product under actual fire conditions. The results when used alone,
shall only be used for research and development, quality control and
material specifications.
(e) The requirement for the smoke index value shall be stated in the
19
13.42.7 (Contd)
Specimen Holder
76mm x 76mm x 30mm
Retaining Lip
Foil wrapped heat
insulating block
75mm x 75mm x 10mm
Apertures
12.5mm x 12.5mm Specimen
Stainless Steel
mesh spot welded Retaining pin
at intersections
75mm x 75mm
Fig 3 Schematic Drawing of Specimen Mounting (Smoke Index)
20
Fig 4 Typical Burner Arrangement (Smoke Index)
13.43 Toxicity index (Limited Fire Hazard). Operators shall take all
necessary precautions against exposure to and inhalation of fumes generated
in this test.
13.43.1 Object. To determine the quantity of gases in relation to those
which are fatal to man in 30 minutes, and which may be present in a
material during complete combustion of 100 g in 1 cubic metre of air under
flaming conditions.
The concentrations in ppm of gases considered lethal to man in 30 minutes,
designated Cf:
Carbon Dioxide 100,000 Sulphur Dioxide 400
Carbon Monoxide 4,000 Nitrogen Oxides 250
Hydrogen Sulphide 750 Phenol 250
Ammonia 750 Hydrogen Cyanide 150
Formaldehyde 500 Hydrogen Bromide 150
Hydrogen Chloride 500 Hydrogen Fluoride 100
Acrylonitrile 400 Phosgene 25
3
(a) An airtight test chamber shall be a minimum of 0.7 m and fitted with
a door, a viewing panel and several leak-proof sampling positions. It
shall be lined with an inert material such as polypropylene and a
21
13.43.2 (Contd)
transparent polycarbonate sheet for the viewing panel. There shall be
forced air extraction, which can be sealed off when not required. A 6
blade, minimum 200 mm diameter, axial mixing fan shall be fitted centrally
and horizontally to the roof of the chamber.
(b) A Bunsen burner, 125 mm high and with 11 mm burner bore, modified to
be supplied with both methane and air (5 mm bore inlet tubes have been
found satisfactory). Gas and air flow rates of 10 litres/min and 15 3
litres/min respectively are gross calorific value of approximately 40MJ/m
and the burner flame shall be adjusted to give a height of 100 mm and a
temperature of 1150°C ± 50°C.
(c) A specimen support shall be ‘tennis racket’ shape with a sheet steel
ring 2-4 mm thick with outside diameter 100 mm and internal diameter 75 mm,
criss crossed with heat resistant wire to form a lattice of 10 mm spacing.
(d) Gas sampling shall be by using calorimetric gas reaction tubes
situated within the test chamber, or by any other suitable method which
gives similar rapid sampling and minimum absorption or condensation of the
gases.
(e) A five minute timing device with an accuracy of ± 1 second is
required, and glass wool of filter membrane quality.
13.43.3 Background correction factor. The background correction factor

shall be determined in the followng manner:
(a) Place the burner in the centre of the test chamber floor and adjust
and record the flow rates required to achieve the flame height and
temperature stated previously. Ventilate the chamber on completion.
(b) Place carbon monoxide, carbon dioxide and oxides of nitrogen reaction
tubes in sampling positions, ensuring all others are sealed. Seal the
chamber, ignite the burner and extinguish it after one minute. Run the
mixing fan for 30 seconds. Determine the concentrations of the three
gases. After extracting the residues of the burning, ventilate the chamber
for three minutes.
(c) Repeat (b) with a burning time of two minutes followed by a third time
of three minutes.
(d) Construct a graph with the values for the three gases obtained with
carbon dioxide having a value of 0.03% at zero time.
13.43.4 Test specimens
(a) To avoid unnecessary testing, the gas constituents of the result of

burning the test material should be determined prior to determining the
Toxicity Index.
(b) The test material shall be conditioned at 23°C ± 2°C and 50% ± 5% RH
for 24 hours prior to testing.
22
13.43.4 (Contd)
(c) Cut 9 x 20 mm lengths from wires sized .04, .35 and 2.5, strip the
insulation and measure the mass of the insulation to the nearest mg. The
mass of the specimens which will emit hydrogen fluoride gas should have a
mass of less than 0.1 g to ensure that the gas concentration is within the
measurement range of the calorimetric gas reaction tubes.
13.43.5 Test procedure. Determine the Toxicity Index using the following
procedure:
(a) Set up the test chamber with the burner centrally placed, gas and air
supplies, sampling tubes and specimen support in position, ensuring that
the air extraction system is sealed off.
(b) Place the specimen on the support so that it will be completely
engulfed by the flame, and supporting it on glass wool if it is considered
that the specimen will produce molten droplets before complete combustion
is achieved.
(c) With the air temperature 23°C ± 2°C, seal the chamber ignite the
burner and start the timer. Turn off the burner immediately complete
combustion of the specimen has been achieved and record the time.
(d) Mix the gases for 30 seconds using the mixing fan.
(e) Immediately draw the combustion products through each detection tube
in turn, starting with those which will detect halogen acids if present.
On completion of the analysis, open the chamber and extract the gas
residues with forced ventilation and continue for three minutes. Examine
the specimen and if there is unburnt portions present, the test is
inconclusive and shall be repeated using a new specimen.
(f) Repeat the procedure to obtain nine sets of results.
13.43.6 Toxicity index calculation. Calculate the concentration (C8) of

each gas produced when 100g of the material is
3
burnt and the combustion
products diffused in a volume of air of 1.0 m , using the following
formula:
C 8 = C x 100 x V ppm where C = concentration of gas in the chamber (ppm)
m m = mass of test specimen (g)3
V = volume of test chamber (m )
Subtract the Background Correction Factor for the appropriate gases.
Toxicity Index =
where 1, 2, 3 . . . . n represents each of the gases detected and Cf = the

concentration of gas that is fatal to man after 30 minutes exposure (ppm).
13.43.7 Test requirement. The Toxicity Index per 100 g of material shall
be the average of the nine results and shall not exceed a value to be
stated in the Sectional Specification, when calculated to a length of 1 m of
.35 wire.
3
The Hydrochloric Acid Gas content shall not exceed 10 cm /m where
23
13.43.7 (Contd)
Hydrochloric Acid = C x V and C = concentration of hydrochloric 3 acid gas (ppm)
Gas Content 1 V = Volume of the test chamber (m )
1 = Length of test specimen
The following shall be stated in the test report:

(a) A full description of the material under test to include type, grade
and manufacturer’s reference number.
(b) The following statement: This test result alone does not assess the
fire hazard of the material, or a product made from this material, under
actual fire conditions. Consequently, the results of this test alone are
not to be quoted in support of claims with respect to the fire hazard of
the material or product under actual fire conditions. The results when
used alone are only to be used for research and development, quality
control and material specifications.
13.44 Temperature index (Limited Fire Hazard). Operators shall take the
necessary precautions against exposure to or inhalation of fumes generated
in this test.
13.44.1 Object. To determine the minimum temperature at which the test
specimen will continue to burn for three minutes or for a given distance in
a gas stream of clean dry air or oxygen/nitrogen mix, which ever condition
is satisfied first.
(a) The inner tube of a chimney consisting of two concentric glass tubes,
450 mm high and with internal diameters of 75 mm and 85 mm respectively, is
mounted on a base to which is fed a gas mixture of nitrogen and oxygen.
The gas mixture is diffused through a 80 mm to 100 mm deep bed of glass
beads 3 mm to 5 mm in diameter, or similar non-combustible diffusers. The
inner tube is wound with nichrome wire with the windings graded in the area
occupied by the specimen, from narrow spacing at the top to wider spacing
at the bottom to give a minimum temperature gradient along the length of
the specimen. The gas mixture is pre-heated by a winding of nichrome wire
round a ceramic porous plate which lies between the diffuser and the bottom
on the inner tube. The two heaters shall be finely regulated by a suitable
electrical control. The position of a thermocouple shall be adjustable
with the inner tube to monitor the temperature of the space surrounding the
specimen which shall be maintained at the required temperature ± 2°C. A
wire screen should be fitted to prevent falling fragments depositing on the
base of the tube.
(b) The specimen holder shall hold the specimen vertical in the centre of
the tube. A typical arrangement is shown in BS 2782 Part 1 Method 141.
(c) The gas mixture can be clean, dry air or oxygen/nitrogen of 98%
purity.
(d) An igniter shall be fitted and five minute timer accurate to ± 1 s is
required.
13.44.3 Calibration. The apparatus shall have consistent oxygen
concentration levels within the chimney, to be determined by measuring the
% oxygen content in the chimney, or by making the following checks:
24
13.44.3 (Contd)
(a) There shall be no leaks.
(b) The gas flow meter shall be calibrated every six months.
(c) The chimney atmosphere shall be chemically analysed every six months.
13.44.4 Test specimens. 12 to 15 specimens, 70 mm to 150 mm in length,
shall be cut from a reel of .35 wire and each marked 50 mm from one end.
The specimens shall be conditioned at 23°C ± 2°C and 50% ± 5% RH for
24 hours immediately prior to testing. All material surfaces shall be free
from fuzz, burrs and cutting dust and if undirectional or anisotropic, the
specimens shall be tested in each direction.
13.44.5 Test procedure
(a) Adjust the currents to both heater elements to give the desired
temperature in the chimney and adjust the gas flow to 40 mm/s ± 10 mm/s as
calculated at the temperature of 23°C ± 2°C. Check that the temperature is
constant in the area to be occupied by the specimen. The temperature may
vary by ± 2°C up to 125°C and by ± 3°C above 125°C.
(b) When the temperature is stable, mount the specimen vertically in its
holder with the marked end uppermost. The upper end of the specimen shall
be at least 100 mm from the top of the chimney. Reposition the
thermocouple so that it is touching the specimen 25 mm from the top.
(c) When the temperature has stabilized, remove the thermocouple, ignite
the top of the specimen by applying the flame for 15 seconds, and start the
timer.
13.44.6 Temperature assessment. Initial trials to establish the
approximate value of the temperature at which the specimen will burn for
three minutes or for 50 mm or should be carried out. by taking increments
of 10°C, establish the temperature at which the specimen burns for three
minutes or the flame travels 50 mm. An increment of 10°C below the
established temperature should fail to meet the criteria. Repeat the test
three times at the established temperature and calculate the mean value
in °C.
13.44.7 Test requirements. The Temperature Index shall be a minimum of
250°C.
The Test Report shall include the following:
(a) A full description of the material under test to include type, grade,
density, anisotrophy, composition and manufacturer’s reference/batch number.
(b) Dimensions of the test specimen.
(c) Any disparity such as charring, dripping and bending.
(d) The following statement: "This test result alone does not assess the
fire hazard of the material, or a product made from this material, under
actual fire conditions. Consequently, the result of this test alone shall
not be quoted in support of claims with respect to the fire hazard of the
material or product under actual fire conditions. The results, when used
alone, should only be used for research and development, quality control
and material specifications".
25
Section Four. Cores

14 Test Methods
14.1 Cable core tests. Cables cores shall be tested where applicable in
accordance with 12.1 to 13.44 inclusive of this Standard, as required by
the sectional specification.
26

15 Test Methods
15.1 Mass. Specimens shall be subjected to BS 2G 230 test 2. The
requirement shall be stated in the sectional specification.
15.2 Cable outer diameter. Specimens shall be subjected to BS 2G 230
test 6. The requirements shall be stated in the sectional specification.
15.3 Cable to cable abrasion. Specimens shall be subjected to BS 2G 230
Test 37. The number of cycles shall be specified in the sectional
specification (applicable to 0.6 single core screened cables only).
15.4 High voltage immersion. Specimens shall meet the requirements
of 13.12 of this Standard.
15.5 High voltage dry spark. Specimens shall meet the requirements
15.6 Cold bend. Specimens shall be subjected to BS 6469 section 4.3.3.
The mandrel diameter shall be five times the cable OD and the temperature
-30°C to -34°C unless otherwise stated in the sectional specification. The
specimens shall be free from cracks and screened cables shall meet the
requirements of 13.12 of this Standard.
15.7 Thermal endurance. Specimens shall be subjected to BS 2G 230
test 20. The upper temperature limit shall be the rated temperature of the
cable. The Arrhenius plot shall indicate the insulation has a minimum life
of 50,000 hours.
15.8 Insulation resistance (screen to conductor). Specimens shall be
subjected to and meet the requirements of BS 2G 230 test 17. Alternative
solutions shall be stated in the sectional specification.
15.9 Room temperature bend. Specimens shall be subjected to BS 2G 230
test 24. The mandrel diameter and force shall be stated in the sectional
specification.
15.10 Climatic. Specimens shall meet the requirements of 13.33 of this
Standard.
15.11 Damp heat steady state. Specimens shall meet the requirements
15.12 Flammability. Specimens shall be subjected to NES 641 as detailed
below.
15.12.1 Apparatus. The apparatus is to consist of a vertical stainless
steel tube with ventilation openings, a stainless steel lid, a conical
stainless steel fuel tray of weight 160g ± 20g and a mild steel suspension
bar 135 mm long and 5 mm diameter. The complete equipment with all
dimensions is shown in figure 5.
The apparatus is to be mounted on a non-asbestos heat insulating refractory
fibre sheet of minimum length and width 450 mm and minimum thickness 10 mm.
27
15.12.1 (Contd)
The sheet is to be provided with means of locating the conical fuel tray
centrally under the tube of the apparatus. This may be achieved either by
the insertion of locating pins of the same refractory material into the
sheet, or by routing out cavities of the same dimensions as the conical
fuel tray and feet of the apparatus to a maximum depth of 4 mm ie at least
6 mm thickness of insulating board remains at the cavities.
The stainless steel tube is to be placed centrally over the conical fuel
tray. The specimen suspension bar is to be located in the 2.5 mm radius
notches on the top edge so as to allow the sample to be suspended. The
three in number M6x 1 mm x 60 mm bolts are to be adjusted so as to allow
the specimen to be centralized relative to the axis of the tube. The lid
is to be positioned so as to leave an air gap of 10 mm ± 1 mm.
Prior to the commencement of any testing, all equipment is to be cleared of
residual dirt/soot from previous test. The equipment is to be at a
temperature of 20°C ± 5°C before the commencement of any test.
15.12.2 Fuel. Fuel shall be 96.0% (v/v) Ethanol to BS 507.
15.12.3 Test specimens. The test specimen is to consist of one cable or
of a number of cables twisted together. The twisted cables are to have a
lay length of 275 mm ± 50 mm and are to be bound at each end with one turn
of 0.5 mm diameter copper wire.
NOTE: The lay length is the distance measured in millimetres along the
length of the twisted specimen whereby one cable of the specimen completes
one full revolution of the specimen.
The length of the test specimen is to be 850 mm ± 10 mm in a finished
condition, and three test specimens are to form the test sample.
For cables less than 4 mm OD - 5 lengths of cable shall form the test
specimen. For cables 4 mm or greater but less than 10 mm OD - 3 lengths of
cable shall form the test specimen. For cables 10 mm or greater but less
than 70 mm OD - one length of cable shall form the test specimen.
The test shall be carried out at a temperature of 20°C ± 5°C.
NOTE: Cables with an OD of 70 mm or greater cannot be assessed by this
method.
15.12.4 Positioning of apparatus. The apparatus is to be positioned in a
draught free enclosure of minimum size 25 m3 and is to be a minimum of 1m
from any enclosure wall and not more than 1m from the enclosure base. The
enclosure is to be fitted with a fume extraction system which is to be used
on completion of each test.
15.12.5 Burn time and fuel quantity calculations. Before commencement of
test the burn time and fuel quantity shall be calculated as follows:
t=k+ D
— minutes
6
28
15.12.5 (Contd)
where t = Burn time (minutes)

k = 1 when the cable used to form the test 2specimen has a total
conductor csa of up to and including 2.5 mm
D = circumscribed diameter of the overall test specimen in mm
where k = 2 when the cable used to form2 the test specimen has a total
conductor csa greater than 2.5 mm
The fuel quantity = 10 x t ml.
NOTE: The time taken to burn a 40 ml sample of fuel at 20°C ± 5°C under an
unloaded chimney shall be 300 ± 20 seconds.
15.12.6 Test procedure. Prepare the specimen as in 15.12.3 and secure to
the suspension bar with 0.5 mm copper wire. Insert the test specimen into
the stainless steel tube so that the suspension bar is located in the
2.5 mm radius notches. Adjust the specimen so that it is suspended
vertically along the centre axis of the tube and that the free end
protrudes 50 mm ± 5 mm from the bottom.
Adjust the three in number M6 x 1 mm x 60 mm bolts so that the free end of
the test specimen is held centrally to the tube axis. Position the
apparatus as in 15.12.4 and pour the calculated amount of fuel into the
conical fuel tray. Ignite the fuel and allow to burn until it has all been
consumed. Allow the specimen to continue to burn undisturbed.
When all the burning and glowing of the specimen has ceased, remove it from
the tube. Hold the specimen, horizontally, 300 mm above the floor and
allow to fall freely to strike the floor. Repeat this operation then
carefully remove the cable sheath and examine its inside surface.
The length of cable damage, measured to the nearest 10 mm, is that length
of the inside of the sheath up to the point where no damage is visible.
Repeat the whole procedure for the remaining two specimens, ensuring that
the test equipment is cleaned of all dirt/soot from previous test and that
the ambient starting temperature is 20°C ± 5°C.
NOTE: Marks from the fixing wires, soot and colour changes are not regarded
as damage.
15.12.7 Requirements
15.12.7.1 The results for the three specimens shall be averaged. A
minimum of 250 mm of cable when measured from the suspended end, shall
remain undamaged. Less than 250 mm shall be regarded as a failure.
15.12.7.2 A test report shall be issued which shall consist of:
(a) The statement: The test results relate only to the behaviour of the
test specimens of the product under the conditions of the test. They are
not intended to be used to support claims regarding the potential fire
hazards of the product in use.
29
15.12.7.2 (Contd)
(b) Identification and description of the product tested.
(c) The average undamaged length for the three specimens.
15.12.7.3 Three specimens tested initially, no failures - accept cable.
Two or three failures - reject cable. One failure - retest a further three
specimens - no failures allowed on retest.
30

16 Test Methods
16.1 Sheath insulation thickness. Specimens shall be subjected to BS 6469
clause 2.1 and shall have an average thickness not less than the value
stated in the sectional specification. The thickness at any point shall
not be less than 80% of this value.
16.2 Appearance and identification. The outer surface of the sheath shall
be reasonably smooth and substantially circular. The colour shall be
tested visually with normal reading vision and shall be a match with the
standard colours in BS 6746C (IEC 304).
16.3 Sheath insulation resistance constant
16.3.1 Method 1. Specimens shall be subjected to and meet the
requirements of BS 2G 230 test 17. The measurement shall be made between
the collective screen (untaped) and the solution.
16.3.2 Method 2. Specimens of collectively screened cables of minimum
length 5m, with no tape over screen shall be subjected to the following
test.
16.3.2.1 Immerse the specimens in distilled water for a period of 28 days
at a temperature of 18°C to 25°C with a 250 mm length at each end
protruding from the water. After the immersion period apply a dc voltage
of 500V ± 10% between the screen and the water for one minute. Measure the
insulation resistance.
16.3.2.2 Calculate the sheath insulation resistance constant as follows:
k= LR
M /km where: D = diameter over sheath (mm)
1000 Log D d = diameter over screen (mm)
d L = immersed length of cable (m)
R = insulation resistance of specimen
16.3.2.3 the insulation resistance constant shall be 0.1 km minimum.

16.4 Tear resistance
16.4.1 Preparation of samples. Strip a length of sheathing from the cable
sufficient for five test specimens detailed in figure 6.
16.4.2 Remove all irregularities and corrugations by cutting and/or
grinding ensuring that the final thickness is between 0.6 mm and 2.0 mm
inclusive.
16.4.3 Cut out five specimens with the dimensions as detailed in figure 6.
16.4.4 Make a longitudinal cut starting 3.8 mm from the wider end and
splitting the remaining length into equal widths.
32
All dimensions are in millimetres
Fig 6 Test Specimen for Tear Resistance Test
16.4.5 Test Method

16.4.6 The test shall be conducted in an ambient temperature of 20° ± 5°C
and the specimen under test shall have been at that temperature for the
previous 3 hours.
16.4.7 Measure the thickness of the specimen where the split terminates2 to
an accuracy of 0.01 mm applying a maximum contact pressure of 0.07 N/mm .
16.4.8 Clamp the split ends in a tensile testing machine and separate the
jaws at a rate of 500 mm/min ± 50 mm/min. Record the maximum force
registered in tearing the insulation.
16.4.9 Requirement
16.4.10 The Tear Maximum force in Newtons
Resistance = N/mm
Specimen thickness mm
Classify the results from five specimens and take the mean of the three
middle readings.
16.4.11 The minimum Tear Resistance shall be detailed in the sectional
specification.
16.5 Tensile strength and elongation at break
16.5.1 Preparation of samples. Dumb-bells to the dimensions in figure 7
shall be cut longitudinally from a sheath insulation, the OD of which is
5 mm and above. Dumb-bells to the dimensions in figure 8 shall be cut
longitudinally from a sheath insulation the OD of which is less than 5 mm.
For very small cables, tubular test pieces prepared in accordance with
BS 6469 shall be used.
33
Fig 7 Standard Dumb-bell Test Piece
Dimensions in mm
Fig 8 Small Dumb-bell Test Piece

16.5.2 The thickness of the gauge length after removal of corrugations
shall lie between 0.6 mm and 2.0 mm and the thicknesses measured at the two
ends and the middle of the gauge length shall not vary by more than 9.5%.
16.5.3 The width of the gauge length shall be measured in accordance with
BS 903 Part A16 to an accuracy of 0.05 mm. The cross sectional area of
tubular specimens shall be calculated in accordance with BS 6469.
16.5.4 Test method. Using five specimens insert a specimen in a tensile
test machine in standard atmospheric conditions having had the specimen at
that temperature for the previous 3 hours. Separate the jaws at a rate of
250 mm/min ± 50 mm/min.
16.5.5 Record the force required to break the gauge length and the length
of the gauge length at break for the five specimens. Repeat the test until
five valid results are available.
16.5.6 Calculate the tensile strength at break using:
Force at Break (N)
Tensile Strength at Break = 2
Unstretched csa of Gauge Length (mm )
Calculate the elongation at break using:

Change of Gauge Length at Break (mm)
% Elongation at Break = x 100
Original Gauge Length (mm)
Classify the results from five specimens and take the mean of the three
middle readings.
34
16.5.7 Requirement. The minimum Tensile Strength at Break and the minimum
Elongation at Break shall be as detailed in the sectional specification.
16.6 Accelerated ageing
16.6.1 The accelerated ageing test is to be carried out on dumb-bell
samples in accordance with the Thermal Ageing Method of BS 6469 (Ageing in
Air Oven). The samples shall be aged for 7, 14 and 28 days and 110 ± 2°C.
The properties of tensile strength, elongation at break and tear resistance
shall be measured after each ageing period. The difference in the values
of the above properties at the end of the 14 day period and the end of the
28 day period shall not exceed 20%. The elongation at break after the
28 day ageing period shall be equal to or greater than 150%.
16.7 Thermal endurance
16.7.1 Sufficient dumb-bell samples of sheath from the same cable shall be
heat aged for 7, 14 and 28 days at the temperature specified in the
16.7.2 After each ageing the dumb-bell sample is to be tested for tensile
strength and elongation at break and the results obtained shall be as
specified in the sectional specification.
16.8 Sheath compatibility
16.8.1 Seven pieces of 0.5m lengths of cable - three of standard
Chlorosulphonated Polyethylene (CSP) as supplied to BS 6899 type RS4 with
sheathing material to Def Stan 61-12 (Part 31) shall be laid together in a
1-6 formation and bound together with an open spiral whipping. The centre
and alternative samples shall be sheathed with the new material. The bound
samples together with 3 separate 0.5 metre length control samples of each
CSP and sheathing to Def Stan 61-12 (Part 31) shall be placed in an oven at
120°C ± 2°C for 7 days. These samples shall then be removed and allowed to
cool.
(a) After ageing, three samples of sheaths from each of the cables shall
be subjected to tensile strength at break and elongation at break tests.
(b) The tensile strength at break and elongation at break of the sheaths
in the bound sample shall be tested.
(c) The above compatibility tests are to be repeated using Chlorinated

Polyethylene (CPE) to BS 6899 at 120°C, Polychloroprene (PC) to BS 6899 at
100°C and Polyvinyl Chloride (PVC) BS 6746 at 82°C in lieu of CSP.
16.8.2 The tensile strength and elongation at break values of sheaths from
cables in the bound sample are to show no significant change to those from
control cables.
16.9 Hot set. Specimens shall be subjected to BS 6469 test 3.3. The
temperature, applied force and requirements shall be stated in the
16.10 Heat shock. Specimens shall be subjected to and meet the
requirements of BS 6469 test 4.4.3. The temperature and duration of test
35
16.11 Pressure test at high temperature. Specimens shall be subjected to

BS 6469 test 4.2.3. The temperature and indentation requirements shall be
stated in the sectional specification.
16.12 Ozone resistance test. Specimens shall be subjected to and meet the
requirements of BS 6469 test 3.2. Ozone concentration shall be 80 to
100 ppm and the duration of test 120 hours ± 2 hours.
16.13 Elongation at low temperature. Specimens shall be subjected to and
meet the requirements of BS 6469 test 4.3.5. The test temperature shall be
-30°C to -34°C unless otherwise stated in the sectional specification.
16.14 Resistance to fluids. Specimens shall be subjected to test for
resistance to fluids selected from annex A of this Standard. The
temperature and immersion times shall be stated in the sectional
specification.
NOTE: Compliance with this test provides no guarantee that the sheath is
suitable for continuous use in the listed fluids.
16.14.1 Dumb-bell test pieces, 75 mm long, in accordance with figure 6 are
to be immersed in each of the selected fluids. At the end of the immersion
period the samples are to be removed from the fluid and subjected to volume
swell, tensile strength and elongation at break tests. The requirements
16.14.2 Volumetric and gravimetric methods of determination of change in
volume
16.14.2.1 Apparatus. The apparatus to be used is determined by the
temperature of immersion and the volatility of the test liquid. For tests
at temperatures appreciably below the boiling point of the test liquid a
stoppered glass bottle or tube is to be used, of such dimensions that the
test pieces remain completely immersed in the specified volume of test
liquid and are freely exposed on all surfaces without restraint. For tests
at temperatures near the boiling point of the test liquid, the bottle or
tube is to be fitted with a reflux condenser or other suitable means of
minimizing evaporation of the test liquid.
16.14.2.2 Test piece. The test piece is to be a uniform thickness within
the range of 1.45 mm to 1.55 mm. Test pieces are to be cut from the cable
sheath in the direction of the axis. They are to be dumb-bell samples in
accordance with figure 6. They are to be prepared by buffing or cutting to
the required thickness.
16.14.2.3 Procedure. Use three test pieces per listed fluid. Weigh each
test piece in air to the nearest milligram (mass ml), and then reweigh each
test piece in distilled water at the standard laboratory temperature
(mass m2) (see NOTE 1), taking care to ensure that all air bubbles are 3
removed (see NOTE 2). If the density of the material is less than 1 g/cm
it will be necessary to use a sinker when weighing in water to ensure that
the test pieces are completely immersed. If a sinker is used, the mass of
the sinker
5
alone in distilled water is to be determined separately
(mass m ). Blot the test pieces dry with filter paper or a textile fabric
that does not deposit lint.
16.14.2.4 Place the test pieces, suitably separated, in a glass container
with a volume of the test liquid, (previously unused), that is at least
36
16.14.2.4 (Contd)
15 times the combined volume of the test pieces and sufficient to keep them
totally immersed. If the conditions of test do not necessitate the use of
a reflux condenser, the container is to be stoppered. The container is to
be kept at the test temperature and the test pieces are to be shielded from
light during the set.
16.14.2.5 Only test pieces of the same material are to be placed in any
one container. If the density of the material is less than that of the
liquid, means are to be provided for holding the test pieces completely
below the surface of the liquid.
16.14.2.6 At the end of the period of immersion, bring the test pieces, if
necessary, to the standard laboratory temperature, preferably by quickly
transferring them to a fresh portion of the test liquid at this temperature
for a period of not less than 10 minutes and not more than 30 minutes.
Surplus test liquid is to be removed from the surfaces of each test piece
(see NOTE 3).
16.14.2.7 Immediately determine the mass of each test piece in air
(mass m3) to the nearest milligram, and then weigh them in distilled water
(mass m4) at the standard laboratory temperature. If the test liquid is
appreciably volatile at room temperature, an evaporation curve is to be
plotted. The test pieces are to be freely suspended on the balance arm. A
plot of mass versus the square root of time will give a straight line.
This is to be extrapolated to zero time which is to be taken as the time at
which the test piece is removed from the liquid or is free of surplus
liquid. The mass of the test piece is to be determined at 20 or 30s
intervals for not more than 2 minutes: this is easily possible with an
automatic balance. The test piece is to be returned immediately to the
test liquid for 30 to 60 minutes before carrying out the weighing in
distilled water. Alternatively, a weighing bottle method may be used in
which the time for transfer of the test piece shall not exceed 30s after
removal from the liquid.
16.14.2.8 The weighings in distilled water (m2 and m4) and of the sinker
(m5) may be omitted if change in mass only is to be determined.
16.14.2.9 If the test is being continued, replace the test pieces
immediately in the test liquid and return to the thermostatically
controlled oven or bath.
16.14.2.10 Expression of results. Calculate the percentage change in
volume V100 and/or percentage change in mass m100 by means of the formulae:
(m3 - m4 + m5) – (m1 - m2 + m5)
V 100 = x 100
( m1 - m2 + m5 )
m 3 - m1
m 100 = x 100
m1
where:
m1 is the initial mass of the test piece in air;
37
16.14.2.10 (Contd)
m2 is the initial apparent mass of the test piece (plus the sinker if used)
in water;
m3 is the mass of the test piece in air after immersion;
m4 is the apparent mass of the test piece (plus the sinker if used) in
water after immersion;
m5 is the apparent mass of the sinker in water.
Take as the result the average of the values obtained for the last 3 test
pieces.
NOTE 1: The above procedure may not be suitable if the test liquid (other
than water) is readily miscible with water or reacts with it. For such a
liquid, if it is not too viscous or volatile at room temperature, the
masses m2, m4 and m5 may be determined in the test liquid instead of water
and these values used in the formula for calculating the percentage change
in volume; masses m4 and m5 should, in this case, be determined in a fresh
portion of the immersion liquid. If this is not practicable, the same
procedure is to be used as for the water displacement method, except that
the final weighing in water is omitted and the percentage change in volume
is calculated from the formula:
m 3 - m1
V 100 = x 100
p(m 1 - m2 + m5)
where p is the density of the test liquid at the standard laboratory
temperature; this formula may be only approximate if the test liquid is a
mixture because the density of the absorbed liquid may differ from that of
the bulk. Also, the density of any matter extracted from the material may
differ from that of the test liquid.
NOTE 2: Formation of bubbles may be avoided by adding a trace of a
surface-active material, for example detergent, to the water.
NOTE 3: The method of removing the surplus liquid from the surface of the
test piece will vary with the nature of the liquid. When mobile volatile
liquids, such as iso–octane and toluene, are used, remove and quickly wipe
the test piece with a filter paper or piece of textile fabric which does
not deposit lint. Some difficulty may be experienced in completely
removing viscous non-volatile oils by this method and it may be necessary
to dip the test piece quickly in a suitable volatile liquid, such as
methanol or petroleum ether, and again quickly wipe with filter paper or a
piece of textile fabric which does not deposit lint.
16.14.3 Physical properties after immersion
16.14.3.1 Test pieces. The test pieces shall be those specified for
volume swell.
16.14.3.2 Procedure. In the case of dumb-bells, gauge length is to be
applied on the swoll en test piece. Carry out the tensile test at the
standard laboratory temperature within 30 minutes of final removal from the
immersion liquid.
38
16.14.3.3 Expression of results. Calculate the tensile strength per unit

area using the original cross-sectional area of the test pieces before
immersion. Report the result as the change expressed as a percentage of
the value on the original results.
16.14.3.4 Calculate the elongation at break as a percentage of the gauge
length for dumb-bell test pieces after immersion. Report the change
expressed as a percentage of the value on the original results.
16.15 Mould growth. Specimens shall meet the requirements of 13.38 of
this Standard.
16.16 Resistance to ultra violet. Under consideration.
16.17 Critical oxygen index. Specimens shall be subjected to BS 2782
Part 1 Method 141. The ignition time shall be 15 seconds. The sample
thickness and minimum critical oxygen index shall be stated in the
16.18 Temperature index. Specimens shall be subjected to test detailed in
NES 715. The test specimen dimensions and minimum temperature index shall
be stated in the sectional specification.
16.19 Toxity index. Specimens shall be subjected to test detailed in

NES 713. The maximum value of toxicity index expressed in terms of 100g of
material shall be stated in the sectional specification.
16.20 Smoke index. Specimens shall be subjected to the requirements of
13.42 of this Standard as amended below:
16.20.1 Each sample is to consist of a sufficient number of 75 mm long
strips cut from the cable sheath to completely cover the face area of the
sample holder. The cable sheath is to be within the range 1.45 to 1.55 mm
in thickness. To prevent excessive buckling and distortion of the sample
during test, a wire mesh, manufactured from 1.5 mm diameter stainless steel
wire with a spacing of 12.5 mm and a square mesh configuration, is to be
fabricated by placing the sample holder (with wire mesh) test face down
onto a flat surface and positioning each 75 mm length in the holder in a
parallel arrangement so that when the holder is in the test position the
strips are vertical. An insulating block 10 mm thick completely wrapped in
aluminium foil is to be placed on top of the strips followed by a tension
spring and locking pin. See figure 9.
16.20.2 Stainless steel grid. This grid shall consist of nominally
12.5 mm square aperture made from 1.5 mm diameter stainless steel wire,
spot welded at all intersections. The dimension of each grid is such that
it will just fit into a smoke sample holder.
16.20.3 The maximum value of smoke index shall be specified in the
16.21 Halogen gas contents. Specimens shall be tested for potential acid
gas evolution by using the ‘Lassaigne Test’ (Sodium Fusion Test). A 0.25g
± O.1g sample, approximately 25 mm length, of sheathing material, stripped
from the test sample and cut into small pieces shall be subjected to the
above test. The test shall show a negative result (not detectable) for
fluorine, chlorine, bromine and iodine.
NOTE: This test can be dangerous if carried out by an inexperienced
operator.
39
Fig 9 Front View of Smoke Test Sample Holder,

Showing Vertically Mounted Sheath Samples
40

17 Test Requirements
17.1 Qualification approval test. Specimens representative of the size
and category of wires of cables submitted for approval shall be submitted
to test stated in the sectional specification, using the layout of table B
of this Standard.
17.2 Quality conformance test. Quality conformance test, number of
specimens and sample frequency shall be stated in the sectional
specification, using the layout of table B of this Standard.
17.3 Production test. Production test and number of specimens shall be
stated in the sectional specification, using the layout of table B of this
Standard.
17.4 Test samples. The manufacturer/supplier shall select test specimens
which represent the size range in a category of wires or cables
manufactured using the same materials and process.
17.5 Test failures
17.5.1 Failure against any qualification approval test shall preclude the
granting of QA certification.
17.5.2 Failure of any specimen against a quality conformance test shall
result in a further four specimens from the same production run being
tested. No further failures are acceptable.
17.5.3 Failure of any specimen against a production test shall result in
the quality conformance test sequence being initiated.
17.6 Sectional specification. The sectional specification shall contain
as a minimum:
(a) scope of the sectional specification;
(b) related documents;
(c) primary stage of manufacture if different from 18.2 of this Standard;
(d) test requirements and sampling plans for qualification approval test,
quality conformance test and production test using the layout of table B of
this Standard;
(e) any test method or requirement not included in this Standard;
(f) the minimum contents for a detail specification, where that detail
specification does not form part of the sectional, and shall include:
(1) cable description;
(2) NATO stock numbers;

(3) any additional requirements.
41
17.7 Test sampling plans. The sectional specification shall state the
requirements using the layout of table B of this Standard.
Table B
NUMBER OF SPECIMENS IN TESTS
TEST CLAUSE
NO QUALIFICATION QUALITY
APPROVAL CONFORMANCE PRODUCTION
TEST TEST TEST

Visual Inspection 12.1
Conductor Composition 12.2
Mass 12.3
Strand Plating Continuity 12.4
Tensile Strength and Elongation 12.5
at Break
Strand Plating Adherence 12.6
Strand Plating Thickness 12.7
Conductor Electrical Resistance 12.8
Electrical Resistance after 13.1

Insulation
Solderability 13.2
Appearance and Identification 13.3
Mass 13.4
Wire Outer Diameters 13.5
Conductor Strand Adhesion 13.6
Insulation Thickness and 13.7
Concentricity
Colour 13.8
Colour Stability 13.9
Colour Fastness to Light 13.10
Insulation Resistance 13.11

High Voltage (Immersion) 13.12
High Voltage (Dry spark) 13.13
High Voltage (Dry impulse) 13.14
Surface Resistance 13.15
Overload Resistance 13.16
Dielectric Constant 13.17
Resistance to Wet Arc Tracking 13.18
Room Temperature Bend 13.19
Cold Bend 13.20
Adherence of Insulation to 13.21
Conductor
Dynamic Cut-through 13.22
Notch Propagation Resistance 13.23
Scrape Abrasion 13.24
Wire to Wire Abrasion 13.25
Pliability 13.26
42
Table B - Continued

TEST CLAUSE
TEST TEST TEST
Section three. Wires (Contd)

Identification Durability 13.27
Flexing Endurance 13.28
Accelerated Ageing 13.29
Delamination and shrinkage 13.30
Delamination and Insulation 13.31
Blocking
Delamination (Tape Wrapped 13.32
Insulation
Climatic Sequence 13.33
Damp Heat - Steady State 13.34
Resistance to Solder Heat 13.35
Thermal Endurance 13.36
Resistance to Fluids 13.37
Mould Growth 13.38
Flammability 13.39
Flame Propagation 13.40
Critical Oxygen Index 13.41
Smoke Index 13.42
Toxicity Index 13.43
Temperature Index 13.44
Section Four. Cores

Visual Inspection (Conductor) 12.1
Mass (Conductor) 12.3
at Break
Insulation
Solderability 13.2
(Core)
Mass (Core) 13.4
Core Outer Diameter 13.5
Concentricity
Colour 13.8
43
Table B - Continued

TEST CLAUSE
NO QUALITY
QUALIFICATION CONFORMANCE PRODUCTION
APPROVAL TEST TEST
Section Four. Cores (Contd)

High Voltage (Dry Spark) 13.13
High Voltage (Dry Impulse) 13.14
Resistance to Wet Ark Tracking 13.18
Cold Bend 13.20
Conductor
Dynamic Cut Through 13.22
Pliability 13.26
Delamination and Shrinkage 13.30
Blocking
Insulation)
Damp Heat Steady State 13.34
Mould Growth 13.38
Flammability 13.39
Smoke Index 13.42
44
Table B - Concluded

TEST CLAUSE
NO QUALITY
APPROVAL TEST TEST

Mass 15.1
Cable outer diameter 15.2
Cable to Cable Abrasion 15.3
High Voltage Immersion 15.4
High Voltage Dry Spark 15.5
Cold Bend 15.6
Insulation resistance (sceen 15.8
to conductor)
Room temperature bend 15.9
Flammability 15.12

Concentricity
Sheath Insulation Resistance 16.3
Constant
Tear Resistance 16.4
at Break
Sheath Compatibility 16.8
Hot Set 16.9
Heat Shock 16.10
Pressure Test at High 16.11
Temperature
Ozone Resistance Test 16.12
Elongation at Low Temperatures 16.13
Mould Growth 16.15
Resistance to Ultra Violet 16.16
Smoke Index 16.20
Halogen Content 16.21
45

18 Qualification Approval Procedures
18.1 Definitions. The definitions in clauses 3 and 4 of Def Stan 00-9/2
shall apply with the exception of 4.8, 4.9 and 4.14, when reference should
be made to the definitions in 18.2, 18.3 and 18.4 respectively of this
Standard.
18.2 Primary stage of manufacture. The primary stage of manufacture is
defined as the inspection stage or process subsequent to inspection of the
un-insulated conductor prior to processing. The stage or subsequent
process shall be carried out under the direct surveillance of the approved
Quality manager. where this and subsequent stages of processing are
carried out by a sub-contractor, qualification approval may be granted
provided that the SQAA is satisfied that the equivalent disciplines apply.
18.3 Qualification Approval. The process applied to demonstrate that a
manufacturer is capable of producing electrical wires, cords or cables
meeting the requirements of the generic and sectional specification.
18.4 Qualification Approval Authority (QAA). The Approval Authority for
product approvals to this Standard is the Electric Wires and Cables
Subcommittee (L2) of the Defence Electrical and Electronic Standardization
Committee (DELSC).
18.5 Supervising Quality Assurance Authority (SQAA). The Supervising
Quality Assurance Authority is the Quality Assurance Technical Support
(Components) Division of the Defence Research Agency (DRA QATS(Comp)).
18.6 General Requirements for Qualification Approval. With the exception
of the amendments detailed below, the requirements and procedures contained
in Def Stan 00-9/2, Section C shall apply.
18.7 Requirements for Qualification Approval. Clauses 9.1(2), 9.1(6) and
9.1(7) of Def Stan 00-9/2 do not apply. Reference should be made to
18.8, 18.9 and 18.16 of this standard respectively.
18.8 A manufacturer’s quality management system shall meet the
requirements of either:
(a) Defence Standard 05-91 or 05-92 with an appropriate scope, or

(b) BS 5750, Part 1 or 2 with an appropriate scope.
In assessing compliance with these requirements, the SQAA will take into
account any current approvals held by the applicant.
18.9 Application for Qualification Approval. Applications shall be made
and will be processed in accordance with 9.2 of Def Stan 00–9/2, except
that reference to the DSAR should be amended to the Secretary, DELSC L2.
Applications should be addressed to:
The Secretary
DELSC Electric Wires and Cables Subcommittee (L2)
The Directorate of Standardization
Kentigern House
65 Brown Street
GLASGOW G2 8EX
46
18.10 Notice of testing. Clause 9.3 of Def Stan 00-9/2 shall apply. The
manufacturer shall provide the SQAA with test schedule information to allow
planning of the surveillance of the QA test programme.
18.11 Qualification Approval tests. Clause 9.4 and 9.4.1 to 9.4.5 of Def
Stan 00-9/2 do not apply. The test requirements for Qualification Approval
are detailed in the appropriate wire or cable specification. Test samples
shall be representative of normal or intended production, and the range of
sizes to be produced.
18.12 Qualification Approval testing. Clause 10 of Def Stan 00-9/2.
18.13 Qualification Approval test report. Reports shall be prepared and
submitted in accordance with clause 11 of Def Stan 00-9/2, with the
following amendments:
(a) 11.2(4), 11.4 and 11.5 do not apply;
(b) test reports shall be signed by the manufacturer’s designated

representative, signifying that the report is an accurate record of the QA
test results;
(c) one copy of the test report shall be submitted to the SQAA.
18.14 Qualification Approval certificate. Clause 12 of Def Stan 00-9/2
does not apply.
After acceptance of the Qualification Approval test report, the SQAA will
recommend the granting, by the QAA, of Qualification Approval and the issue
of a Qualification Approval certificate. Certificates will be signed and
issued by the Secretary of DELSC L2, on behalf of that subcommittee,
provided the specified requirements have been met. The Secretary will send
copies of the certificate to the DSAR for his records and for entry of the
Qualification Approval onto the QPL (Def Stan 59-59).
18.15 Modifications likely to affect Qualification Approval
18.15.1 Modifications to the approved product. Clause 13.1 of Def
Stan 00-9/2 does not apply.
The manufacturer will prescribe his procedures for dealing with
modifications to approved products and deciding their significance with
respect to the continued validity of the approval. The manufacturer will
maintain separate records of all modifications for each of his qualified
products. These records will be made available to the SQAA on request. If
the manufacturer considers that a modification to the product will affect,
or is likely to affect the validity of the approval, he will consult the
SQAA regarding the extent of re-testing necessary. Failure to notify the
SQAA of significant modifications shall subsequently result in withdrawal
of the approval.
18.15.2 Change of place of manufacture. Clause 13.2 of Def Stan 00-9/2
shall apply.
18.16 Maintenance of Qualification Approval. Clause 14 of Def Stan 00-9/2
shall not apply.
47
18.16 (Contd)
Quality conformance tests are defined in the appropriate product

specification. The manufacturer will prescribe his procedures for
maintaining his product approvals. These should include his defined
criteria for judging the significance of production breaks and his method
for recording and reviewing this and all other information relevant to the
maintenance of the approval. This information will be made available to
the SQAA on request.
Maintenance of Qualification Approval is assured for product which has not
undergone any significant modification, and has been continuously and
successful submitted to the quality conformance tests, provided that
there is no significant break in production. In some circumstances.
re-approval or additional testing to confirm the approval may be required.
18.17 Withdrawal of Qualification Approval. Clause 15 of Def Stan 00-9/2
will apply, but notice of intent to cease production shall be provided to
the QAA.
18.18 Routine surveillance and product audit. As well as monitoring the
initial approval exercise, the SQAA will make periodic visits to the
manufacturer’s premises to ensure that the manufacturer’s prescribed
procedures for discharging his continuing responsibilities (Maintenance of
the approval) under the Qualification Approval are carried out. In
addition, the SQAA may, at intervals, select samples of qualified product
for quality audit. Samples, selected by the SQAA, shall be provided free
of charge by the manufacturer. Sample size will be restricted to that
normally required for QA tests.
18.19 Rules for detail specification preparation
18.19.1 A manufacturer wishing to write a detail specification in
accordance with a sectional part of Def Stan 61-12 shall:
(a) Apply to the QAA for a detail specification number and NATO stock
numbers (if appropriate). A specification number shall only be allocated
when the application has the support of an MOD project or the Master
Specification Officer (MSO) cables.
(b) Prepare the draft detail specification to meet the requirements of the
relevant sectional and generic specification and submit it to the SQAA for
approval.
(c) Gain SQAA approval for the detail specification before commencing the
approval exercise. The specification will be raised to issue 1 when
qualification approval has been granted.
(d) The detail specification shall be the property of the MOD and shall be
published by the Directorate of Standardization.
(e) The manufacturer shall supply one copy of the detail specification to
the Directorate of Standardization within three months of approval being
granted.
48
ANNEX C
Colour Code for Cores in Multi-cored Cables
Core Base Second Core Base Second Core Base Second

Number Colour Colour Number Colour Colour Number Colour Colour
1 Red - 19 Grey Pink 37 Yellow Violet

2 Blue - 20 Red Blue 38 Yellow Orange
3 Yellow - 21 Red Yellow 39 Yellow Brown
4 Green - 22 Red Green 40 Yellow Pink
5 Black - 23 Red Black 41 Green Black
6 Violet - 24 Red Violet 42 Green Violet
7 Orange - 25 Red Orange 43 Green Orange
8 Brown - 26 Red Brown 44 Green Brown
9 Pink - 27 Red Pink 45 Green Pink
10 Grey - 28 Blue Yellow 46 Black Violet
11 Grey Red 29 Blue Green 47 Black Orange
12 Grey Blue 30 Blue Black 48 Black Brown
13 Grey Yellow 31 Blue Violet 49 Black Pink
14 Grey Green 32 Blue Orange 50 Violet Orange
15 Grey Black 33 Blue Brown 51 Violet Brown
16 Grey Violet 34 Blue Pink 52 Violet Pink
17 Grey Orange 35 Yellow Green 53 Orange Brown
18 Grey Brown 36 Yellow Black 54 Orange Pink
55 Brown Pink
The second colour shall form a helical stripe with a lay length of
approximately 12 times the core diameter and with a maximum width of 25% of
the circumference of the core.
C-1
Blank Page
ANNEX D
British Conductor Parameters in Stranded Completed Wires
British Conductor Parameters in Single Strand Wires
D-1
Blank Page
ANNEX E
USA Conductor Parameters in Stranded Completed Wires
E-1
ANNEX E (Concluded)
USA Conductor Parameters in Single Strand Wires
E-2
Blank Page
C Crown Copyright 1992 This Standard may be fully reproduced

except for sale purposes. The
Published by and obtainable from: following conditions must be observed:
Ministry of Defence 1 The Royal Coat of Arms and the
Directorate of Standardization publishing imprint are to be
Kentigern House omitted.
65 Brown Street 2 The following statement is to be
GLASGOW G2 8EX inserted on the cover:
‘Crown Copyright. Reprinted by
Tel No: 041-224 2531/2532 (name of organization) with the
Fax No: 041 224 2503 permission of Her Majesty’s
Stationery Office.’
Requests for commercial reproduction
should be addressed to MOD Stan 1,
Kentigern House, 65 Brown Street,
Glasgow G2 8EX
The following Defence Standard file reference relates to the work on this
Standard - D/D Stan 372/07/32.
Contract Requirements
When Defence Standards are incorporated into contracts users are
responsible for their correct application and for complying with contract
requirements.
Revision of Defence Standards
Defence Standards are revised when necessary by the issue either of
amendments or of revised editions. It is important that users of Defence
Standards should ascertain that they are in possession of the latest
amendments or editions. Information on all Defence Standards is contained
In Def Stan 00-00 (Part 3) Section 4, Index of Standards for Defence
Procurement - Defence Standards Index published annually and supplemented
periodically by Standards in Defence News. Any person who, when making use
of a Defence Standard encounters an inaccuracy or ambiguity is requested to
notify the Directorate of Standardization without delay in order that the
matter may be investigated and appropriate action taken.
90/70001
DEF STAN 61-12(PART 0)/1
WIRES , CORDS AND CABLES ELECTRICAL

GENERAL REQUIREMENTS AND TEST METHODS
FOR QUALIFICATION APPROVAL
AMENDMENT 1 (Additional text)
1. Remove pages 39 to 48 inclusive.
2. Insert new pages 39 to 50 inclusive.
3. Make a note of this amendment on the Amendment Record.
D/D Stan 372/07/32
3 September 1993
Ministry of Defence
Directorate of Standardization
Kentigern House
65 Brown Street
GLASGOW
G2 8EX
16.14.3.3 Expression of results. Calculate the tensile strength per unit

area using the original cross–sectional area of the test pieces before
immersion. Report the result as the change expressed as a percentage of
the value on the original results.
16.14.3.4 Calculate the elongation at break as a percentage of the gauge
length for dumb-bell test pieces after immersion. Report the change
expressed as a percentage of the value on the original results.
16.15 Mould growth. Specimens shall meet the requirements of 13.38 of
this Standard.
16.16 Resistance to ultra violet.
16.16.1 Apparatus
16.16.1.1 Test Chamber. (See Fig 1). Constructed of corrosion resistant
materials enclosing eight fluorescent UV lamps, a heated water pan, test
specimen racks, and provisions for controlling and indicating operating
times and temperatures.
16.16.1.2 Lamps. Rapid start, medium hi-pin fluorescent UV lamps with a
length of 1200 mm, and a nominal rating of 40 W when operated from a
ballast providing a controlled current of 430 mA at 102V.
Unless otherwise specified in the sectional/detail specification the lamps
shall be UV-B lamps with a peak emission at 313 nm and a spectral energy
distribution as shown in Fig 2.
The lamps shall be mounted in two banks of four lamps each as shown in
Fig 1. The lamps in each bank shall be mounted parallel in a flat plane on
70 mm centres.
16.16.1.3 Specimen mounting. The test specimens shall be mounted in
stationary racks with the plane of the test surface parallel to the plane
of the lamps at a distance of 50 mm from the nearest surface of the lamps
as shown in Fig 1.
16.16.1.4 Test specimens. These shall be exposed within an area 210 mm in
height by 900 mm wide on each side of the apparatus located as shown in
Fig 1.
Fig 1 Fig 2
39
16.16.1.5 Condensation Mechanism. Water vapour shall be generated by

heating a water pan extending under the entire sample area and containing a
minimum water depth of 25 mm. Specimen racks and the test specimens
themselves shall constitute the side walls of the chamber. The back side
of the specimens shall be exposed to cooling effects of ambient room air.
The resulting heat transfer causes water to condense on the test surface.
16.16.1.6 Specimens. Specimens shall be arranged so that condensate runs
off the test surface by gravity and is replaced by fresh condensate in a
continuous process. Vents along the bottom of the test chamber shall be
provided to permit an exchange of ambient air and water vapour to prevent
oxygen depletion of the condensate.
16.16.1.7 Water supply. An automatic control to regulate the level in the
water pan shall be provided. Distilled, deionized, or tap water are
equally acceptable for purposes of the test, since the condensation process
itself distils water onto the test surface.
16.16.1.8 Cycle timer. A continusouly operating cycle time meter, for
programming the selected cycle of UV periods and condensation periods shall
be provided to record total time of operation and total time of UV
exposure.
16.16.1.9 Specimen temperature measurement. Specimen temperature shall be
measured by a thermometer with a remote sensor attached to a black
aluminium panel 75 by 100 by 2.5 mm thick. The thermometer shall be
accurate to ± 1°C through a range from 30° to 80°C. The indicator dial
shall be located outside the test chamber.
The black aluminium panel with the thermometer sensor shall be positioned
in the centre of the exposure area so that the sensor is subject to the
same conditions as the specimens.
16.16.1.10 Specimen temperature control. During UV exposure, the selected
equilibrium temperature shall be maintained within ± 3°C by supplying
heated air to the test chamber.
During condensation exposure, the selected equilibrium temperature shall be
maintained within ± 3°C by heating the water in the water pan.
The UV and condensation temperature control shall be independent of each
other.
Doors shall be located on the room air side of the specimen racks to act as
insulation during the UV exposure and to minimize drafts. Such doors shall
not interfere with the room air cooling of the specimen during the
condensation exposure.
16.16.2 Preparation of test pieces. For cables of 5 mm overall diameter
or greater, prepare five standard dumb-bell test pieces as shown in
figure 7, or if the cable is less than 5 mm overall diameter, five small
dumb-bell test pieces as shown in figure 8 from the cable sheath. The
dumb-bell test pieces are to be taken along the direction fo the cable
axis. If the sheathing is greater than 2.0 mm thick or has ridges on the
inside caused by the cores, the sheathing is to be prepared by grinding or
cutting (cutting is the preferred method) so as to provide an even
thickness between 0.6 mm and 2.0 mm. If the cable is of such a small size
that it is not possible to prepare dumb-bell test pieces, prepare five
tubular test pieces in accordance with BS 6469.
40
16.16.2 (Contd)
Calculate the cross sectional area by measurement of the thickness and
width in three places along the gauge length of the dumb-bell. Take the
median value for the thickness and width to calculate the cross sectional
area. If any one measurement varies from the median by more than 5%, the
test piece is to be rejected. The measuring apparatus shall be a
micrometer or similar instrument (calibrated in millimetres to two decimal
places), having a contact pressure not exceeding 0.078 N/mm.
If the cable is less than 2.5 mm overall diameter tubular test piece are to
be used. Calculate the cross sectional area by the method detailed in
BS 6469.
The test specimens are to be mounted in holders such that the sheaths outer
surface will be exposed to the test environment. To provide rigidity,
flexible specimens may be attached to a backing panel made of aluminium or
other none-corrosive heat conductive material.
16.16.3 Preconditioning. Preconditioning shall be stated in the detail
specification if required.
16.16.4 Procedure. Mount the test specimens in the specimen racks with
the test surfaces facing the lamp. When the test specimens do not
completely fill the racks, fill the empty spaces with blank panels to
maintain the test conditions within the chamber.
Programme the selected test conditions as specified in the sectional/detail
specification. Operate continuously, repeating the cycle except for
servicing the test equipment and for inspection of specimens for the period
specified in the sectional/detail specification.
Carry out the tensile strength and elongation at break test 16.5.
16.16.5 Information required by sectional/detail specification.
(a) Test Cycle periods
(b) Ultra violet lamp type
(c) Test period
(d) Test Temperatures if not :
UV period : 55 ± 3°C
Humidity period : 40 ± 3°C
(e) Humidity
(f) Minimum tensile strength requirement
(g) Elongation requirement
16.17 Critical oxygen index. Specimens shall be subjected to BS 2782
Part 1 Method 141. The ignition time shall be 15 seconds. The sample
thickness and minimum critical oxygen index shall be stated in the
16.18 Temperature index. Specimens shall be subjected to test detailed in
NES 715. The test specimen dimensions and minimum temperature index shall
be stated in the sectional specification.
16.19 Toxicity index. Specimens shall be subjected to test detailed in
NES 713. The maximum value of toxicity index expressed in terms of 100g of
material shall be stated in the sectional specification.
41
16.20 Smoke index. Specimens shall be subjected to the requirements

of 13.42 of this Standard as amended below:
16.20.1 Each sample is to consist of a sufficient number of 75 mm long
strips cut from the cable sheath to completely cover the face area of the
sample holder. The cable sheath is to be within the range 1.45 to 1.55 mm
in thickness. To prevent excessive buckling and distortion of the sample
during test, a wire mesh, manufactured from 1.5 mm diameter stainless steel
wire with a spacing of 12.5 mm and a square mesh configuration, is to be
fabricated by placing the sample holder (with wire mesh) test face down
onto a flat surface and positioning each 75 mm length in the holder in a
parallel arrangement so that when the holder is in the test position the
strips are vertical. An insulating block 10 mm thick completely wrapped in
aluminium foil is to be placed on top of the strips followed by a tension
spring and locking pin. See figure 9.
16.20.2 Stainless steel grid. This grid shall consist of nominally
12.5 mm square aperture made from 1.5 mm diameter stainless steel wire,
spot welded at all intersections. The dimension of each grid is such that
it will just fit into a smoke sample holder.
16.20.3 The maximum value of smoke index shall be specified in the
16.21 Halogen gas contents. Specimens shall be tested for potential acid
gas evolution by using the ‘Lassaigne Test’ (Sodium Fusion Test). A 0.25g
± O.1g sample, approximately 25 mm length, of sheathing material, stripped
from the test sample and cut into small pieces shall be subjected to the
above test. The test shall show a negative result (not detectable) for
fluorine, chlorine, bromine and iodine.
NOTE: This test can be dangerous if carried out by an inexperienced
operator.
Specimen Holder
76mm x 76mm x 30mm
Retaining Lip
Foil wrapped heat

insulating block
75mm x 75mm x 10mm
Apertures
12.5mm x 12.5mm
Specimen sheath material
Stainless Steel
mesh spot welded
at intersections Retaining pin
75mm x 75mm
Fig 9 Front View of Smoke Test Sample Holder, Showing

Vertically Mounted Sheath Samples
42
DEF STAN 61-12 (PART 0)/l

17 Test Requirements
17.1 Qualification approval test. Specimens representative of the size
and category of wires of cables submitted for approval shall be submitted
to test stated in the sectional specification, using the layout of table B
of this Standard.
17.2 Quality conformance test. Quality conformance test, number of
specimens and sample frequency shall be stated in the sectional
specification, using the layout of table B of this Standard.
17.3 Production test. Production test and number of specimens shall be
stated in the sectional specification, using the layout of table B of this
Standard.
17.4 Test samples. The manufacturer/supplier shall select test specimens
which represent the size range in a category of wires or cables
manufactured using the same materials and process.
17.5 Test failures
17.5.1 Failure against any qualification approval test shall preclude the
granting of QA certification.
17.5.2 Failure of any specimen against a quality conformance test shall
result in a further four specimens from the same production run being
tested. No further failures are acceptable.
17.5.3 Failure of any specimen against a production test shall result in
the quality conformance test sequence being initiated.
17.6 Sectional specification. The sectional specification shall contain
as a minimum:
(a) scope of the sectional specification;
(b) related documents;
(c) primary stage of manufacture if different from 18.2 of this Standard;
(d) test requirements and sampling plans for qualification approval test,
quality conformance test and production test using the layout of table B of
this Standard;
(e) any test method or requirement not included in this Standard;
(f) the minimum contents for a detail specification, where that detail
specification does not form part of the sectional, and shall include:
(1) cable description;
(2) NATO stock numbers;
(3) any additional requirements.
43
17.7 Test sampling plans. The sectional specification shall state the
requirements using the layout of table B of this Standard.
Table B
TEST CLAUSE
TEST TEST TEST
Section TWO. Conductors
Visual Inspection 12.1

Mass 12.3
12.4
Strand Plating Continuity
at Break
Strand Plating Adherence 12.6
Strand Plating Thickness 12.7
Conductor Electrical Resistance 12.8

Insulation
Solderability 13.2
Mass 13.4
Wire Outer Diameters 13.5
Concentricity
Colour 13.8

High Voltage (Dry spark) 13.13
High Voltage (Dry impulse) 13.14
13.16
Dielectric Constant
Resistance to Wet Arc Tracking 13.18
Cold Bend 13.20
Conductor
Dynamic Cut-through 13.22
13.24
Wire to Wire Abrasion
Pliability 13.26
44
Table B - Continued

CLAUSE
TEST QUALIFICATION QUALITY
NO
TEST TEST TEST
Section three. Wires (Contd)

Delamination and shrinkage 13.30
Blocking 13.32
Delamination (Tape Wrapped
Insulation
Damp Heat - Steady State 13.34
Mould Growth 13.38
Flammability 13.39
Smoke Index 13.42
Section Four. Cores
Visual Inspection (Conductor) 12.1

Mass (Conductor) 12.3
at Break
Insulation
Solderability 13.2
(Core) 13.4
Mass (Core) 13.5
Core Outer Diameter
13.7
Insulation Thickness and
Concentricity
Colour 13.8
45
Table B - Continued

TEST CLAUSE
NO QUALITY
APROVAL TEST TEST
Section Four. Cores (Contd)

High Voltage (Dry Spark) 13.13
High Voltage (Dry Impulse) 13.14
Resistance to Wet Ark Tracking 13.18
Cold Bend 13.20
Conductor
Dynamic Cut Through 13.22
Pliability 13.26
Delamination and Shrinkage 13.30
Blocking
Insulation)
Mould Growth 13.38
Flammability 13.39
Smoke Index 13.42
46
Table B - Concluded

TEST CLAUSE
NO QUALITY
APPROVAL TEST TEST
Mass 15.1
Cable outer diameter 15.2
Cable to Cable Abrasion 15.3
High Voltage Immersion 15.4
High Voltage Dry Spark 15.5
Cold Bend 15.6
Insulation resistance (sceen 15.8
to conductor)
Room temperature bend 15.9
Flammability 15.12

Concentricity
Sheath Insulation Resistance 16.3
Constant
Tear Resistance 16.4
at Break
Sheath Compatibility 16.8
Hot Set 16.9
Heat Shock 16.10
Pressure Test at High 16.11
Temperature
Ozone Resistance Test 16.12
Elongation at Low Temperatures 16.13
Mould Growth 16.15
Resistance to Ultra Violet 16.16
Smoke Index 16.20
Halogen Content 16.21
47
18 Qualification Approval Procedures

18.1 Definitions. The definitions in clauses 3 and 4 of Def Stan 00-9/2
shall apply with the exception of 4.8, 4.9 and 4.14, when reference should
be made to the definitions in 18.2, 18.3 and 18.4 respectively of this
Standard.
18.2 Primary stage of manufacture. The primary stage of manufacture is
defined as the inspection stage or process subsequent to inspection of the
un-insulated conductor prior to processing. The stage or subsequent
process shall be carried out under the direct surveillance of the approved
Quality manager. where this and subsequent stages of processing are
carried out by a sub-contractor, qualification approval may be granted
provided that the SQAA is satisfied that the equivalent disciplines apply.
18.3 Qualification Approval. The process applied to demonstrate that a
manufacturer is capable of producing electrical wires, cords or cables
meeting the requirements of the generic and sectional specification.
18.4 Qualification Approval Authority (QAA). The Approval Authority for
product approvals to this Standard is the Electric Wires and Cables
Subcommittee (L2) of the Defence Electrical and Electronic Standardization
Committee (DELSC).
18.5 Supervising Quality Assurance Authority (SQAA). The Supervising
Quality Assurance Authority is the Quality Assurance Technical Support
(Components) Division of the Defence Research Agency (DRA QATS(Comp)).
18.6 General Requirements for Qualification Approval. With the exception
of the amendments detailed below, the requirements and procedures contained
in Def Stan 00-9/2, Section C shall apply.
. 18.7 Requirements for Qualification Approval. Clauses 9.1(2), 9.1(6) and

9.1(7) of Def Stan 00-9/2 do not apply. Reference should be made to
18.8, 18.9 and 18.16 of this Standard respectively.
18.8 A manufacturer's quality management system shall meet the
requirements of either:
(a) Defence Standard 05-91 or 05-92 with an appropriate scope, or
(b) BS 5750, Part 1 or 2 with an appropriate scope.

In assessing compliance with these requirements, the SQAA will take into
account any current approvals held by the applicant.
18.9 Application for Qualification Approval. Applications shall be made
and will be processed in accordance with 9.2 of Def Stan 00-9/2, except
that reference to the DSAR should be amended to the Secretary, DELSC L2.
Applications should be addressed to:
The Secretary
DELSC Electric Wires and Cables Subcommittee (L2)
The Directorate of Standardization
Kentigern House
65 Brown Street
GLASGOW G2 8EX
48
18.10 Notice of testing. Clause 9.3 of Def Stan 00-9/2 shall apply. The
manufacturer shall provide the SQAA with test schedule information to allow
planning of the surveillance of the QA test programme.
18.11 Qualification Approval tests. Clause 9.4 and 9.4.1 to 9.4.5 of Def
Stan 00-9/2 do not apply. The test requirements for Qualification Approval
are detailed in the appropriate wire or cable specification. Test samples
shall be representative of normal or intended production, and the range of
sizes to be produced.
18.12 Qualification Approval testing. Clause 10 of Def Stan 00-9/2.
18.13 Qualification Approval test report. Reports shall be prepared and
submitted in accordance with clause 11 of Def Stan 00-9/2, with the
following amendments:
(a) 11.2(4), 11.4 and 11.5 do not apply;
(b) test reports shall be signed by the manufacturer’s designated
representative, signifying that the report is an accurate record of the QA
test results;
(c) one copy of the test report shall be submitted to the SQAA.
18.14 Qualification Approval certificate. Clause 12 of Def Stan 00-9/2
does not apply.
After acceptance of the Qualification Approval test report, the SQAA will
recommend the granting, by the QAA, of Qualification Approval and the issue
of a Qualification Approval certificate. Certificates will be signed and
issued by the Secretary of DELSC L2, on behalf of that subcommittee,
provided the specified requirements have been met. The Secretary will send
copies of the certificate to the DSAR for his records and for entry of the
Qualification Approval onto the QPL (Def Stan 59-59).
18.15 Modifications likely to affect Qualification Approval
18.15.1 Modifications to the approved product. Clause 13.1 of Def
Stan 00-9/2 does not apply.
The manufacturer will prescribe his procedures for dealing with
modifications to approved products and deciding their significance with
respect to the continued validity of the approval. The manufacturer will
maintain separate records of all modifications for each of his qualified
products. These records will be made available to the SQAA on request. If
the manufacturer considers that a modification to the product will affect,
or is likely to affect the validity of the approval, he will consult the
SQAA regarding the extent of re-testing necessary. Failure to notify the
SQAA of significant modifications shall subsequently result in withdrawal
of the approval.
18.15.2 Change of place of manufacture. Clause 13.2 of Def Stan 00-9/2
shall apply.
18.16 Maintenance of Qualification Approval. Clause 14 of Def Stan 00-9/2
shall not apply.
49
18.16 (Contd)
Quality conformance tests are defined in the appropriate product

specification. The manufacturer will prescribe his procedures for
maintaining his product approvals. These should include his defined
criteria for judging the significance of production breaks and his method
for recording and reviewing this and all other information relevant to the
maintenance of the approval. This information will be made available to
the SQAA on request.
Maintenance of Qualification Approval is assured for product which has not
undergone any significant modification, and has been continuously and
successfully submitted to the quality conformance tests, provided that
there is no significant break in production. In some circumstances,
re–approval or additional testing to confirm the approval may be required.
18.17 Withdrawal of Qualification Approval. Clause 15 of Def Stan 00-9/2
will apply, but notice of intent to cease production shall be provided to
the QAA.
18.18 Routine surveillance and product audit. As well as monitoring the
initial approval exercise, the SQAA will make periodic visits to the
manufacturer’s premises to ensure that the manufacturer’s prescribed
procedures for discharging his continuing responsibilities (Maintenance of
the approval) under the Qualification Approval are carried out. In
addition, the SQAA may, at intervals, select samples of qualified product
for quality audit. Samples, selected by the SQAA, shall be provided free
of charge by the manufacturer. Sample size will be restricted to that
normally required for QA tests.
18.19 Rules for detail specification preparation
18.19.1 A manufacturer wishing to write a detail specification in
accordance with a sectional part of Def Stan 61-12 shall:
(a) Apply to the QAA for a detail specification number and NATO stock
numbers (if appropriate). A specification number shall only be allocated
when the application has the support of an MOD project or the Master
Specification Officer (MSO) cables.
(b) Prepare the draft detail specification to meet the requirements of the
relevant sectional and generic specification and submit it to the SQAA for
approval.
(c) Gain SQAA approval for the detail specification before commencing the
approval exercise. The specification will be raised to issue 1 when
qualification approval has been granted.
(d) The detail specification shall be the property of the MOD and shall be
published by the Directorate of Standardization.
(e) The manufacturer shall supply one copy of the detail specification to
the Directorate of Standardization within three months of approval being
granted.
50
WIRES, CORDS AND CABLES ELECTRICAL
GENERAL REQUIREMENTS AND TEST

METHODS FOR QUALIFICATION APPROVAL
AMENDMENT 2
1. Page 9 Clause 12.8

Delete: table D
Insert: Annex D
2. Page 13 Clause 13.26 Line 2

After ‘The mandrel diameters’
Insert: , ageing temperature, humidity
3. Page 15 Clause 13.33.1.1
Delete: in toto
4. Page 15 Clause 13.33.1.3
Delete: 13.11
Insert: 13.12
5. Annex A Page A-2
Delete: Row Group G Reference Numbers 15 & 16 in toto
Amend: Groups H to M inclusive to read G to L
Amend: Reference Numbers 17 to 21 inclusive to read 15 to 19
D/D STAN/372/07/32 18 February 1994

Ministry of Defence
Kentigern House
65 Brown Street
GLASGOW G2 8EX
DEF STAN 61-12(PART 0)/1
WIRES, CORDS AND CABLES ELECTRICAL
GENERAL REQUIREMENTS AND TEST METHODS
AMENDMENT 3
1 Page 25 New Clause 13.45
Add new clause 13.45 below :
13.45 User Applied Cable Marks. Where cables are intended to be marked
by the user their ability to withstand the proposed marking method shall
be assessed.
13.45.1 Specimens. The specimens of cable shall be marked along their

length with representative strings of alphanumeric characters using the
marking technique stated in the sectional specification.
13.45.2 Visual Examination. The marking shall be examined to ensure

legibility without the aid of magnification and shall be clear and
uniform from a distance of 0.3 metres to 0.4 metres with normal reading
vision when illuminated by a 100 W clear tungsten filament light source
positioned 450 mm to 500 mm from the specimen.
13.45.3 After completion of the visual examination separate specimens

shall be subjected to the following tests.
13.45.3.1 Adherence of Marking. Specimens shall be subjected to the

Identification Durability test, Clause 13.27 of this standard. The
applied force shall be 1.5 N.
13.45.3.2 Resistance to Fluids. Specimens shall be immersed for 20 hours

in the fluids stated in the sectional specification at the specified
temperatures. After removal from the fluid, the specimens shall be
allowed to drain and if necessary, dried by dabbing with a lint free
cloth. The Adherence of Marking test shall be commenced within 45
minutes +/- 15 minutes.
13.45.3.3 Heat Aqeinq. Specimens shall be subjected to the Accelerated

Ageing test Clause 13.29 of this standard.
13.45.3.4 Resistance to Damp Heat Steady State. Specimens shall be

subjected to the Damp Heat Steady State test clause 13.34 of this
standard. The test mark shall be wrapped around the mandrel so that it
faces out. The Sectional Specification may omit this test if the marking
is non aggressive.
2 Make a note of this amendment on the Amendment Record.
10 December 1996
Ministry of Defence
65 Brown Street
Glasgow G2 8EX
D/D STAN/372/07/32
Procurement Executive, Ministry of Defence
Room 1138, Kentigern House, 65 Brown Street, GLASGOW, G2 8EX
Telephone: 0141-224 2595 (Direct Dialling) Fax: 0141-224 2503
0141-248 7890 (Switchboard)
Internet e-mail address: t.leaver@dstan.mod.uk
Your Reference :
Our Reference : D/DStan/11/2
Date : 9 November 1998
Removal of Product Qualification Approval
IMPORTANT ANNOUNCEMENT
1. This Standard contains a Product Qualification Approval (PQA) scheme. iMOD policy requires that all
PQA schemes are removed from Defence Standards called up in contracts placed after 1st January 1998.
2. Users of this Standard are to contact the Project Manager (PM), Equipment Support Manager (ESM) or
Technical Service Authority (TSA) named in the contract or order, to identify whether there is a continuing need
for an approvals scheme.
ii
3. Product Conformity Certification (PCC) is a risk based process that replaces PQA. Once a risk has been
identified PCC can be included as a contract clause. In exceptional circumstances agreement can be sought from
AD/Stan for PCC to be included in a Defence Standard.
4. At the next revision of this Standard the PQA scheme will be removed.
T R Leaver
Head of Standards Programme Management
Tel: 0141 224 2595 FAX: 0141 224 2503
i
Defence Council Instruction (General) 197/97; Quality Temporary Memorandum 5/98; Chief of
Defence Procurement Instruction CDPI/TECH/250 (draft)
ii
PCC is certification that a product meets its specification. When PC is required by the contract, the
contractor is responsible for obtaining the necessary PCC. Certification shall be provided from a
NAMAS accredited laboratory when appropriate. PCC shall apply where a Risk Assessment has been
identified by the PM; ESM or TSA.

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61-12 (PART 0) /issue 1 6 November 1992 Wires Cords and Cables Electrical - Metric Units Part 0:general Requirements and Test Methods For Qualification Approval

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Ministry of Defence

WIRES CORDS AND CABLES

PART 0:GENERAL REQUIREMENTS

AMENDENTS ISSUED SINCE PUBLICATION

AMD NO DATE OF TEXT AFFECTED SIGNATURE &

Arrangement of Defence Standard 61-12

Part 22 Equipment Interconnecting Cables

WIRES, CORDS AND CABLES, ELECTRICAL

Section One. General

Section Two. Conductors

Section Three. Wires

Section Four. Cores

Section Five. Cables

Section Six. Sheaths

Section Seven. Test Requirements and Sampling Plans

Section Eight. Qualification Approval Procedures

Annex A List of Test Fluids A-1

WIRES, CORDS AND CABLES ELECTRICAL - GENERAL REQUIREMENTS

Section One. General

3.2 Copies of related specifications and documents are obtainable from:

British Standards (BS) British Standards Institution

Defence Standard Publications Directorate of Standardization

Naval Engineering Standards (NES) MOD Library

Agreed Industry Standard Defence Packaging Authority

Technical Specification (TS) DRA/QATS (Materials Centre)

3.3 Reference in this Standard to any related documents means in any

Conductor - csa, Stranding, Plating

6 Packaging and Labelling

7.16 Temperature rating. The temperature rating of a wire or cable is

10.3 Fillers. Fillers are used to improve the circumferential roundness

11.1 Under consideration

Section Two. Conductors

12.6 Strand Plating Adherence. Specimen shall be inspected in accordance

TENSILE STRENGTH MINIMUM ELONGATION %

Below 0.14 5.5 5.0

Below 0.12 350 6.0 6.0

Section Three. Wires

13.8 Colour. Specimens shall meet the requirements of 9.4 of this

(c) The specimen shall show no indication of separation or embrittlement

Where D1 is the overall diameter of the conductor (mm)

13.27 Identification durability. Specimens shall be subjected to and meet

After a specific number of cycles, carry out a High Voltage (Immersion)

The Sectional Specification shall specify the number of cycles.

Fig 1 Schematic Flexing Endurance Test Rig

13.28.1 Requirement. There shall be no localized heating and the wire

13.32 Delamination (tape wrapped insulation). Specimens shall be

Fig 2 Resistance to Solder Heat Test

(a) A smoke density chamber approximately 900 mm x 900 x 600 mm deep. Is

13.42.2 Specimens. The specimens shall be conditioned at standard

Specific Optical Density (Ds = 132 where T = % Transmittance.

Corrected Specific Optical Density (Dsmaxc) = Dsmax - Dsc

if transmittance is less than 70%, where:

Fig 3 Schematic Drawing of Specimen Mounting (Smoke Index)

Fig 4 Typical Burner Arrangement (Smoke Index)

13.43.3 Background correction factor. The background correction factor

(a) To avoid unnecessary testing, the gas constituents of the result of

13.43.6 Toxicity index calculation. Calculate the concentration (C8) of

where 1, 2, 3 . . . . n represents each of the gases detected and Cf = the

The following shall be stated in the test report:

Section Four. Cores

Section Five. Cables

where t = Burn time (minutes)

Section Six. Sheaths