Ministry of Defence

Defence Standard 61-12 (Part 18)

Issue 5 Publication Date 20th January 2006

Wires, Cords and Cables,

Electrical

Part 18:
Equipment Wires Limited Fire
Hazard

Reprinted 26th August 2011 incorporating

Amendment 3
DEF STAN 61-12 Part 18 Issue 5 Amend 3

Contents
Foreword ......................................................................................................................................................v
Introduction..................................................................................................................................................vi
1 Scope ............................................................................................................................................. 1
2 Warning .......................................................................................................................................... 2
3 Related Documents........................................................................................................................ 3
4 Definitions....................................................................................................................................... 3
5 Type Identification and Colours ..................................................................................................... 4
6 Materials......................................................................................................................................... 4
6.1 Conductors..................................................................................................................................... 4
6.2 Insulation. ....................................................................................................................................... 4
6.3 Screens. ......................................................................................................................................... 5
6.4 Sheaths .......................................................................................................................................... 5
7 Construction ................................................................................................................................... 5
7.1 Mass of wires and cables............................................................................................................... 5
7.2 Conductor stranding....................................................................................................................... 5
7.3 Insulation ........................................................................................................................................ 5
7.4 Screens .......................................................................................................................................... 5
7.5 Sheaths .......................................................................................................................................... 6
8 Electrical Tests............................................................................................................................. 10
9 Physical Tests .............................................................................................................................. 11
10 Fire Hazard Tests......................................................................................................................... 14
10.1 Flammability tests. ....................................................................................................................... 14
10.2 Critical oxygen index test. ............................................................................................................ 14
10.3 Smoke index test.......................................................................................................................... 14
10.4 Toxicity index test......................................................................................................................... 15
10.5 Temperature index test. ............................................................................................................... 15
11 Tests............................................................................................................................................. 18
11.1 General......................................................................................................................................... 18
11.2 Jacketed Cables........................................................................................................................... 18
11.3 List of tests and Sample Sizes ..................................................................................................... 18
12 Packaging and Labelling .............................................................................................................. 19
13 Tables........................................................................................................................................... 19
Annex A..................................................................................................................................................... 29
Type Designator Coding Structure............................................................................................................ 29
A.1 Scope ........................................................................................................................................... 29
A.2 Coding Structure for the Type Designator ................................................................................... 29
A.3 Diagram of Coding Structure........................................................................................................ 31
A.4 Examples of Type Designators .................................................................................................... 32
Annex B..................................................................................................................................................... 33
Packaging Of Wires And Cables............................................................................................................... 33
B.1 Packing on reels........................................................................................................................... 33
B.1.4 Length .......................................................................................................................................... 33
B.1.5 Wrapping ...................................................................................................................................... 33
B.1.6 Marking......................................................................................................................................... 33

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Tables

Table 1 — Conductor Size and Guide to Current Ratings ................................................................................. 2

Table 2 —Details of Conductors sizes 30 to 12 .................................................................................................. 7
Table 3 —Details of Conductors cross section areas 4 –10mm ....................................................................... 8
Table 4 —Dimensions of Complete Equipment Wires and Cables................................................................... 8
Table 5 —Mass of Complete Equipment Wires and Cables .............................................................................. 9
Table 6 —List of Test Fluids, Additional Requirements .................................................................................. 10
Table 7 —Tests and Sample Sizes..................................................................................................................... 16
Table 8 —Specific Test Requirements .............................................................................................................. 18
Table 9 —Standard Range Type 1 Unscreened ................................................................................................ 21
Table 10 —Standard Range Type 2 Unscreened .............................................................................................. 22
Table 11 —Standard Range Screened............................................................................................................... 23
Table 12 —Standard Range Screened and Sheathed ...................................................................................... 24
Table 13 —Maintenance Range Type 1 Unscreened........................................................................................ 25
Table 14 —Maintenance Range Type 2 Unscreened........................................................................................ 26
Table 15 —Maintenance Range Screened......................................................................................................... 27
Table 16 —Maintenance Range Screened and Sheathed ................................................................................ 28
Table 17 —Standard Range Type 1 Unscreened 4-10mm ............................................................................... 29
Table 18 —Cable and Wire Type Coding........................................................................................................... 29
Table 19 —Conductor Size ................................................................................................................................. 30
Table 20 Insulation Base Colour.................................................................................................................. 31

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AMENDMENT RECORD

Amd No Date Text Affected Signature and Date

1 30/06/2006 Tables 10, 11 & 12

2 27/01/2010 Clauses 1.6, 3.1, 6.12, 9.1, 9.2.8, 9.4.4.1,

9.4.4.2, 11.3.1.1, 11.3.1.2 & 11.3.1.3

Tables 1, 3, 4, 5 & 7

3 26/08/2011 Various parts of Clauses 3, 5, 9, 10 & 13

Tables 6 7 & 9

REVISION NOTE

This standard is raised to Issue 5 Amendment 3 to incorporate the flammability test updates associated with
the up-issue of BSG230 from 2 to 3.

HISTORICAL RECORD

This standard supersedes the following:

Issue 5 Amendment 1 of this standard incorporates minor amendments and extend the size range to include
cables with conductors up to10mm2 cross sectional area

Issue 4 of this Standard incorporates user comments on the sheath temperature ratings and includes
additional 85°C rated cables as well as extends the range of Type 1 pliable cables to include conductors up to
10mm2.

Issue 3 of this Standard removes the previous INTERIM status and specifies a reduced toxicity level for Table
I items having a toxicity level of not greater than 0.2. Those between 0,2 and up to 1.5 remain in Table II for
maintenance purposes.

Issue 2 of this Standard included amendments and additions to bring the Standard more into line with Service
requirements.

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Foreword
a) This standard provides requirements for and also lists, equipment, wires, having Limited Fire Hazard
(LFH) insulation, for Ministry of Defence Use.

b) This standard has been produced on behalf of the Defence Material Standardization Committee (DMSC)
by Defence Cables & Interconnections Standardization Committee.

c) This standard has been agreed by the authorities concerned with its use and is intended to be used
whenever relevant in all future designs, contracts, orders etc. and whenever practicable by amendment to
those already in existence. If any difficulty arises which prevents application of the Defence Standard, UK
Defence Standardization (DStan) shall be informed so that a remedy may be sought.

d) Any enquiries regarding this standard in relation to an invitation to tender or a 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.

e) Compliance with this Defence Standard shall not in itself relieve any person from any legal obligations
imposed upon them.

f) This standard has been devised solely for the use of the Ministry of Defence (MOD) and its contractors in
the execution of contracts for the MOD. To the extent permitted by law, the MOD hereby excludes all
liability whatsoever and howsoever arising (including, but without limitation, liability resulting from
negligence) for any loss or damage however caused when the standard is used for any other purpose.

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Introduction

This Defence Standard specifies the requirements for, and also lists, equipment wires, having limited fire
hazard (LFH) insulation, for Ministry of Defence use.

This is a performance Standard, actual insulation material is not specified and tests are included to control
materials offered for approval. With the development of new materials and/or constructions it is likely that
additional tests will require to be devised.

Tables 9 to 12 list the standard range of equipment wires and cables having a toxicity level as defined in 10.4

Tables 13 to 16 list the maintenance range of equipment wires and cables. They are manufactured to Issue 2
of this Standard and differ in certain significant features, including a higher toxicity level.

Table 17 lists the 4, 6 and 10mm2 conductors for use in Defence Standard 61-12 (Part 25) large cables

The cables are also designated in two groups types 1 and 2

Type 1 Pliable, with Moderate Dynamic Cut Through Resistance (also used as core wires in Defence
Standard 61-12(Part 25) cables)

Type 2 Less Pliable than Type 1 Wire but having Higher Dynamic Cut Through Resistance

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 DEF STAN 61-12 Part 18 Issue 5 Amend 3

Wires, Cords and Cables, Electrical Part 18: Wires and Cable
Electrical Limited Fire Hazard - Standards for Defence -
Sectional Specification

1 Scope

1.1 This specification describes the construction, identification and testing of wires and cables for the internal
wiring of electronic or other equipment.

1.2 These wires and cables (i.e. screened wires) are also used as the cores of cables.

1.3 The insulation of the wires and the sheathing of cables in this specification present a limited fire hazard
and produce limited levels of noxious fumes, smoke and corrosive products when assessed by the methods of
test in this specification.

1.4 The wires listed in this Standard are required to meet the Relative Thermal Life and Temperature Index
Test of BS 3G 230, Appendix C for 40,000 hours at 120°C, and are suitable for continuous use within the
temperature range -50°C to +120°C.

1.5 Cables Type 1SB, 1SBM120, 2SB and 2SBM listed in this Standard are required to meet the Relative
Thermal Life and Temperature Index Test of BS 3G 230, Appendix C for 40,000 hours at 120°C, and are
suitable for continuous use within the temperature range -50°C to +120°C.

1.6 Cables Type 1SBM85 shall have sheathing material qualified to Def Stan 61-12 (Part 31) and meet the
Relative Thermal Life and Temperature Index Test of BS 3G 230, Appendix C for 40,000hours at 85°C and are
suitable for continuous use within the temperature range -30°C to +85°C.

1.7 These wires and cables have a voltage rating of 600V rms or 800V D.C.

1.8 These wires and cables are suitable for soldered or crimped terminations. They are not designed or
necessarily suitable for solderless wrapped electrical connections.

1.9 Although these wires and cables may be subjected to testing by contamination by one or more of the
fluids listed in Table 6 of this Standard, attention is drawn to 2.2.1 and 2.2.3.

1.10 Stranded conductors shall be used for flexing applications. For fixed applications stranded or solid
conductors may be used.

1.11 The following minimum bend radii shall be used within equipment:

for flexing applications, 10 times the overall diameter of the wire or cable;

for fixed applications, 4 times the overall diameter of the wire or cable.

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2 Warning

2.1 The Ministry of Defence (MOD), like its contractors, is subject to both United Kingdom and European laws
regarding Health and Safety at Work, without exemption. All Defence Standards either directly or indirectly
invoke the use of processes and procedures that could be injurious to health if adequate precautions are not
taken. Defence Standards or their use in no way absolves users from complying with statutory and legal
requirements relating to Health and Safety at Work.

2.2 Particular attention is drawn to the following hazards although the list may not necessarily be exhaustive:

2.2.1 Flammable and/or toxic fumes may be given off from the specimens when subjected to the fire
hazard/flammability tests. Operators are to take appropriate precautions to avoid exposure to the evolved
fumes.

2.2.2 Compliance with 9.2.8 (resistance to fluids test) provides no guarantee that the wires are suitable for
continuous use in the specified fluids.

2.2.3 It should be noted that isopropyl alcohol and aircraft fuel are not specified for Type 2 wires and that
these fluids can adversely affect certain Type 2 wire insulations.

2.2.4 Due to the wide variety of insulation materials which may meet this Standard, particular attention is
drawn to Clause 5 especially with respect to selection of Type and size of wire to be used.

Table 1 — Conductor Size and Guide to Current Ratings

SIZE NUMBER AND NOMINAL MAXIMUM CONTINUOUS
DIAMETER OF STRANDS CURRENT
Nom.csa* IN CONDUCTOR (SEE NOTE BELOW)
mm2 mm amperes
(a) (b) (c) (d)
30 0.05 1/0.25 0.3
26 0.12 1/0.40 0.8
23 0.28 1/0.60 1.8
19 0.63 1/0.90 4.0
30 0.055* 7/0.10 0.3
28 0.079 7/0.12 0.5
26 0.15 19/0.10 0.8
24 0.2 19/0.12 1.3
22 0.35* 19/0.15 2.2
20 0.6* 19/0.20 3.7
18 1.0* 19/0.25 5.8
16 1.5* 19/0.30 7.7
14 2.0 37/0.25 11.4
12 2.5* 37/0.30 15.6
4* 56/0.30 TBD
6* 84/0.30 TBD
10* 80/0.40 TBD
NOTE * As specified for use as cores in 61-12 (Part 25) cables
Current ratings will depend on circumstances but for general guidance the combination of conductor size and current
shown in table 1 will give a temperature rise of about 15°C at an ambient temperature of 70°C.

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3 Related Documents

3.1 Reference is made in this Standard to:

IEC Publication 304 Standard Colours for Insulation of Low Frequency Cables and Wires

BS ISO 1817 Rubber, vulcanized —Determination of the effect of liquids

BS EN 622 Part 2 Requirements for Hardboards

BS EN 29453 Soft Solder Alloys - Chemical Composition and Forms

BS EN 60228 Conductors of insulated cables

BS 3G 230 Specification for General Requirements for Aircraft Electrical Cables

BS 3G 231 Specification for Conductors for General Purpose Aircraft Electrical Cables and
Aerospace Applications

BS 1595 Propan-2-ol (isopropyl alcohol) for industrial use.

Def Stan 61-12 Part 0 Wires, Cords and Cables Electrical. General Requirements and Test Methods for
Qualification Approval

Def Stan 61-12 Part 25 Wires, Cords and Cables Electrical, Wires and Cables Electrical Limited Fire
Hazard, up to Conductor Size 10mm2 Cross Sectional Area
Def Stan 61-12 (Part 31) Wires, Cords and Cables Electrical - Metric Units: Part 31 Sheaths, Limited Fire
Hazard

Def Stan 91-4 Fuel, Naval, Distillate: Dieso F-76

Def Stan 91-35 Hydraulic Fluid, Petroleum:Emulsifying, Anti-wear OX30

3.2 Reference in this Standard to any related document 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.

3.3 In consideration of clause 3.2 above, users shall be fully aware of the issue and amendment status of all
related documents, particularly when forming part of an Invitation to Tender or contract. Responsibility for the
correct application of standards rests with users.

3.4 DStan can advise regarding where related documents are obtained from. Requests for such information
can be made to the DStan Helpdesk. How to contact the helpdesk is shown on the outside rear cover of Def
Stans.

4 Definitions

4.1 For the purpose of this Defence Standard the definitions given in BS3G 230 shall apply together with the
following:

4.1.1 Primary stage. For the purpose of this Defence Standard the primary stage will be taken as being
the `buying in' of the basic materials, which are required to manufacture the complete wires and cables.

4.1.2 Wire, electrical. A single metallic conductor of solid, stranded or tinsel construction designed to
carry current in an electrical circuit. It may be bare or insulated, but does not have a metallic covering, jacket
or shield. Refers to bulk quantities only.

4.1.3 Cable, power, electrical. Two or more insulated conductors (solid, tubular or stranded) contained in
a common covering, or two or more insulated conductors twisted or moulded together without a common
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covering, or one insulated conductor with a metallic covering, shield or outer conductor. The rated working
voltage of the item must be 250V or more and the size of each individual conductor must be size 18 or larger.

4.1.4 Cable, special purpose, electrical. Two or more individually insulated conductors (solid or
stranded) contained in a common covering or two or more individually insulated conductors twisted or moulded
together without a common covering, or one insulated conductor with a metallic covering or shield.

5 Type Identification and Colours

5.1 Because of the differing physical nature of insulation systems which may be used in the construction of
wires and cables to this Standard, the wires and cables have been divided into two categories to indicate their
handle ability for installation purposes. They are as follows:

5.1.1 Type 1

5.1.1.1 Wire Type 1 Unscreened, Pliable, with Moderate Dynamic Cut Through
Resistance

5.1.1.2 Cable Type 1SB Screened Type 1 Wire

5.1.1.3 Cable Type 1SBM 85 Screened and Sheathed Type 1 Wire, 85°C Rated Sheath

5.1.1.4 Cable Type 1SBM 120 Screened and Sheathed Type 1 Wire 120°C Rated Sheath

5.1.2 Type 2

5.1.2.1 Wire Type 2 Unscreened, Less Pliable than Type 1 Wire but having
Higher Dynamic Cut Through Resistance

5.1.2.2 Cable Type 2SB Screened Type 2 Wire

5.1.2.3 Cable Type 2SBM Screened and Sheathed Type 2 Wire

5.2 Test and limits to control dynamic cut through and pliability for the two categories are given in 9.2.6 and
9.2.11.

5.3 Colours. The colours in which the wire and cable shall be supplied are given in tables 9 to 17. The
colours shall be a reasonable match with the colours specified in IEC Publication 304

6 Materials

6.1 Conductors.

6.1.1 Conductors sizes 30-12 of the completed wires and cables shall be of tin coated annealed copper
and shall comply with BS 3G231 as applicable as well as with Table 2 and 9.1 of this Standard. Tensile
strength and elongation at break tests shall be in accordance with BS 3G230, Test 7.

6.1.2 Conductors 4mm cross sectional area and above shall be to BS EN 60228.

6.2 Insulation.

6.2.1 The insulation shall meet all the relevant requirements of this Standard.

6.2.2 The dielectric constant of the insulation shall not be greater than 4 when measured at approximately
1kHz.

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6.3 Screens.

6.3.1 Screens shall consist of a braid of annealed, tin plated, copper strands conforming to BS 3G 231
before braiding and constructed as detailed in 7.4 of this Standard.

6.4 Sheaths

6.4.1 The sheathing material for cable type 1SBM 85 shall be qualified to Def Stan 61-12 (Part 31).

6.4.2 The sheathing material for cable type 1SBM 120 shall meet the requirements of this Standard.

7 Construction

7.1 Mass of wires and cables.

7.1.1 The mass of the complete equipment wires and cables shall not exceed the limits specified in Table
5.

7.2 Conductor stranding

7.2.1 Strands used for conductors shall be clean, bright and free from surface irregularities. The
conductors shall be as specified in Table 2 or 3 of this Standard.

7.2.2 The stranded conductor sizes shall be of concentric construction and shall comply with 6.1 of this
Standard. The lay of the strands within each layer shall be uniform throughout the conductor length.

7.2.3 Joints in single strands shall be brazed or hard soldered and there shall be not more than one such
joint in any 50m of single strand. Joints in single strands shall not be within 300mm of any other joint in the
same layer.

7.2.4 Conductors consisting of single strands shall be not joined.

7.3 Insulation

7.3.1 The conductor shall be uniformly and continuously covered with one or more layers of insulation.

7.3.2 To permit satisfactory termination the insulation shall not be loose, but it shall be possible to remove
the insulation completely without any insulation residue remaining.

7.3.4 The dimensions of the insulated conductor and the thickness and the concentricity of the insulation
shall be measured in accordance with the methods specified in BS 3G 230 Test 5 and shall be within the limits
stated in Table 4 of this Standard.

7.4 Screens

7.4.1 Screens shall be of close fitting braided construction. Wherever the screened cable is cut it shall be
possible to slide back the screen over a distance of 100mm on a 600mm length of cable, the other end of the
cable being clamped.

7.4.2 There shall be no joints in the complete braid. Where breaks in the individual strands occur, the ends
shall be brazed or tucked out of the braid and there shall not be more than one such break in any 300mm
length of cable or in any 10m of individual strand. Where renewal of spindles is necessary, the ends shall be
tucked out of the braid and there shall not be more than one spindle renewal in any 300m length of cable.

7.4.3 The braid construction details shall be as follows:

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7.4.3.1 Diameter of braiding strands, maximum:

0.11 mm for cables of conductor size up to and including 19/0.2mm;
0.13 mm for cables of conductor size of 19/0.25mm and above.

7.4.3.2 Ends per spindle minimum 3.

7.4.3.3 Filling Factor (Kf) , minimum 0.5.

Kf = mnd ( 1+ π 2 D2)½
2πD ( L2 )

where D = mean diameter of braid = diameter over dielectric + 2.25d

d = diameter of braiding strands in millimetres

L = lay of braid in millimetres
m = total number of spindles
n = total number of ends per spindle

7.5 Sheaths

7.5.1 The sheaths shall be annular and free from defects. The overall diameter shall be measured in
accordance with BS 3G 230, Test 6 and shall be within the limits specified in Table 4 of this Standard.

7.5.2 The sheath shall not be loose but it shall be removable without damaging the metal screen.

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Table 2 —Details of Conductors sizes 30 to 12

SIZE NUMBER AND NOMINAL CONDUCTOR MAXIMUM ELECTRICAL

NOMINAL CROSS DIAMETER RESISTANCE AT 20°C Ω/km
DIAMETER OF SECTIONAL
STRANDS IN AREA
CONDUCTOR
MINIMUM MAXIMUM WIRE AND CABLE ALL
TYPES

Mm mm2 mm mm ohms/km

(a) (b) (c) (d) (e) (f)

30 1/0.25 0.05 0.246 0.254 383.5
26 1/0.40 0.12 0.380 0.404 145.6
23 1/0.60 0.28 0.570 0.606 64.0
19 1/0.90 0.63 0.855 0.909 28.5
30 7/0.10 0.055 0.27 0.32 336.0
28 7/0.12 0.079 0.33 0.38 259.0
26 19/0.10 0.15 0.46 0.53 141.5
24 19/0.12 0.20 0.55 0.62 95.6
22 19/0.15 0.35 0.72 0.80 60.0
20 19/0.20 0.6 0.94 1.04 33.2
18 19/0.25 1.0 1.18 1.29 21.1
16 19/0.30 1.5 1.39 1.53 14.5
14 37/0.25 2.0 1.68 1.82 10.9
12 37/0.30 2.5 2.02 2.18 7.6

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Table 3 —Details of Conductors cross section areas 4 –10mm

SIZE NUMBER AND NOMINAL CONDUCTOR DIAMETER MAXIMUM

NOMINAL CROSS ELECTRICAL
DIAMETER OF SECTIONAL RESISTANCE AT 20°C
STRANDS IN AREA
CONDUCTOR
MINIMUM MAXIMUM WIRE AND CABLE ALL
TYPES
mm mm2 mm mm ohms/km
(a) (b) (c) (d) (e) (f)
56/0.30 4 2.30 2.64 5.09
84/0.30 6 2.85 3.27 3.39
80/0.40 10 3.80 4.19 1.95

Table 4 —Dimensions of Complete Equipment Wires and Cables

WIRE 1SB AND 2SB 1SBM 85, 1SBM

1 AND 2
CABLE 120 AND 2SBM
TYPES
SIZE NUMBER AND RADIAL DIAMETER
NOMINAL THICKNESS OF
DIAMETER OF INSULATION OVER OVER SCREEN OVER SHEATH
STRANDS IN INSULATION
CONDUCTOR

NOM. MIN MIN MAX MIN MAX MIN MAX

mm mm mm mm mm mm mm mm mm
(a) (b) (c) (d) (e) (f) (g) (h) (j) (k)
30 1/0.25 0.20 0.15 0.55 0.70 - - - -
26 1/0.40 0.20 0.15 0.70 0.85 - - - -
23 1/0.60 0.20 0.15 0.90 1.05 - - - -
19 1/0.90 0.20 0.15 1.20 1.35 - - - -
30 7/0.10 0.20 0.15 0.60 0.75 - - - -
28 7/0.12 0.20 0.15 0.65 0.80 - - - -
26 19/0.10 0.20 0.15 0.80 0.95 1.20 1.45 1.60 2.00
24 19/0.12 0.20 0.15 0.90 1.05 1.30 1.55 1.70 2.10
22 19/0.15 0.20 0.15 1.05 1.20 1.45 1.70 1.85 2.25
20 19/0.20 0.20 0.15 1.30 1.50 1.70 1.95 2.10 2.50
18 19/0.25 0.20 0.15 1.55 1.75 1.95 2.20 2.35 2.75
16 19/0.30 0.20 0.15 1.80 2.00 2.35 2.60 2.75 3.15
14 37/0.25 0.25 0.20 2.15 2.35 2.50 2.80 2.90 3.35
12 37/0.30 0.25 0.20 2.50 2.70 2.85 3.15 3.25 3.70
4mm2 56/0.30 0.25 0.20 3.10 3.30 - - - -
2
6mm 84/0.30 0.25 0.20 3.75 4.05 - - - -
2
10mm 80/0.40 0.25 0.20 4.75 5.15 - - - -

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NOTE: - indicates that the column heading does not apply.

Table 5 —Mass of Complete Equipment Wires and Cables

WIRE CABLE TYPE NUMBER AND MASS MAXIMUM

NOMINAL DIAMETER kg/100m
OF STRANDS IN
CONDUCTOR
mm
(a) (b) (c)
1/0.25 0.092
WIRE TYPES 1/0.40 0.200
1 AND 2 1/0.60 0.395
1/0.90 0.790
7/0.10 0.110
7/0.12 0.150
19/0.10 0.290
19/0.12 0.345
19/0.15 0.490
19/0.20 0.756
19/0.25 1.04
19/0.30 1.65
37/0.25 2.07
37/0.30 2.71
56/0.30 4.00
84/0.30 6.20
80/0.40 10.10
CABLE TYPES 19/0.10 0.576
1SB AND 2SB 19/0.12 0.720
19/0.15 0.911
19/0.20 1.27
19/0.25 1.77
19/0.30 2.5
37/0.25 3.03
37/0.30 3.81
CABLE TYPES 19/0.10 0.829
1SBM 85, 19/0.12 0.988
1SBM 120 AND 19/0.15 1.20
2SBM 19/0.20 1.60
19/0.25 2.13
19/0.30 2.92
37/0.25 3.48
37/0.30 4.31

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Table 6 —List of Test Fluids

FLUID TEST FLUID TEMPERATURE Notes

°C
(a) (b) (c)
Fuel Oil Dieso 47/20, NATO F-76 20 ± 3
Def Stan 91-4 (or DERV)
ISO 1817 Liquid B 40 ± 3
Aviation fuel Nato F-44 AVCAT/FSII (JP5) 70 ± 3 Avcat used as Avtur is not
normally used on naval
vessels
Hydraulic Oil ISO 1817 Liquid 103 70 ± 3 Covers Skydrol 500 and other
phosphate ester fluids
Nato H 520 (OM18) or H515 70 ± 3
(OM15)
Def Stan 91-35 OX30 50 ± 3
Dimethyl silicone ZX42 70 ± 3 Alternative use ZX43 or ZX44
Oil Detergent mineral oil OMD-113 100 ± 3
ISO 1817 Liquid 101 120 ± 3 Synthetic diester base
Cleaning and BS1595 isopropyl alcohol 50 ± 3
De icing
Kilfrost ABC DTD 900/4907 50 ± 3
4 ± 0.1 % Formaldehyde plus 20 ± 3
1 ± 0.1 % o-Cresol (general
purpose reagent) in water
Water De ionized 50 ± 3
Na Cl 3.5% (sea water) 50 ± 3

8 Electrical Tests

8.1 Electrical tests on wires types 1 and 2. Wires Type 1 and Type 2 shall be subjected to the following
electrical tests.

8.1.1 Dry Spark Test. Def Stan 61-12 (Part 0) clause 13.13 or 13.14. The test voltage shall be 5kV rms.
for test 16b or 8kV peak for test 16c.

8.1.2 Conductor Resistance Test. In accordance with BS 3G 230, test 12. The conductor resistance
shall be tested for compliance with the values stated in Table 2 of this Defence Standard.

8.1.3 High Voltage Immersion Test. Def Stan 61-12 (Part 0) clause 13.12. The test voltage shall be
2.5kV rms. The number of specimens to be tested shall be 3 random samples per wire size.

8.1.4 Insulation Resistance Test. Def Stan 61-12 (Part 0), clause 13.11. The number of specimens to be
tested shall be 3 random samples per wire size. The insulation resistance shall not be less than 0.2 MΩ/km.

8.1.5 Surface Resistance Test. Def Stan 61-12 (Part 0), clause 13.15. Two specimens per wire size
shall be tested.

8.1.6 Dielectric Constant Test. Def Stan 61-12 (Part 0), clause 13.17. The dielectric constant shall not
exceed the value given in 6.2.2.
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 DEF STAN 61-12 Part 18 Issue 5 Amend 3

8.2 Electrical tests on cables, types 1SB and 2SB. In addition to the tests detailed in 9.1, which take place
before screening, the screened cable shall also be subjected to the following electrical test after screening.

8.2.1 Voltage test on screened cable. In accordance with BS 3G 230, test 16d, the test voltage shall be
2.5kV rms. between the conductor and the screen.

8.3 Electrical tests on cables, types 1SBM and 2SBM. In addition to the tests in 9.1 and 9.2 the completed
screened and sheathed cable shall be subjected to the following electrical test after sheathing.

8.3.1 Dry Spark Test. Def Stan 61-12 (Part 0), clause 13.13, the test voltage shall be 1kV rms.

8.3.2 High voltage immersion test on sheath. Def Stan 61-12 (Part 0), clause 13.12, the test voltage shall
be 500V rms. The number of specimens shall be 3 per wire size.

9 Physical Tests

9.1 Mechanical test on conductor and screen braid.- Strands taken from the conductors of the completed
wire, prior to screening if applicable and strands to be used for the construction of the screen braid of all
cables shall be subjected to BS 3G 230 test 7 and shall meet the following requirements of:

a. All strands from screens and conductors shall satisfy BS 3G231.Tables 4 and 6 which shall be
considered to be extended to include conductor strands from 0.45mm to 0.9mm diameter, with the
limits remaining as stated. (see also 6.1.1 and 6.3 of this Standard).

b. All conductor and screen strands shall satisfy the requirements of BS 3G231, Clauses 4.1 and 4.4

9.1.1 Solderability (conductor and screen). Def Stan 61-12 (Part 0), clause 13.2. The wetting time shall
not exceed 1 second. The solder bath temperatures shall be 235°C ± 3°C and the solder shall be to BS
EN29453 1994 grade KP with a non activated flux.

9.2 Physical tests on completed wires. Wires Types 1 and 2 and cable/cores prior to screening,
shall be subjected to the following physical tests.

9.2.1 Insulation thickness and concentricity. Def Stan 61-12 (Part 0), clause 13.7. The requirements
shall be as Table 4 of this Standard.

9.2.2 Strand adhesion test (stranded conductors). Def Stan 61-12 (Part 0), clause 13.6.

9.2.3 Insulation shrinkage test. Def Stan 61-12 (Part 0), clause 13.30, the retractions of the insulation
shall not exceed 3 mm.

9.2.4 Insulation blocking. Def Stan 61-12 (Part 0), clause 13.31. Three samples of wire of conductor size
19/0.15 shall be tested. The mandrel diameter shall be 10mm, the tension 5N.

9.2.5 Bend Tests

9.2.5.1 Room temperature bend test. Def Stan 61-12 (Part 0), clause 13.19. A mandrel of a diameter
8 times the maximum specified diameter of the wire shall be used. The tensile force shall be as specified in
Table 8, for each wire size. One specimen per wire size shall be tested. The test voltage shall be 2.5kV rms.
On completion of test, the insulation shall exhibit neither crazing nor cracking.

9.2.5.2 Cold bend test. Def Stan 61-12 (Part 0), clause 13.20. A mandrel of a diameter which is 20
times the maximum specified diameter of the wire shall be used. The tensile force shall be as specified in
Table 8 for each wire size. The temperature of the chamber shall be -50°C± 2°C and the time shall be 6hours.
The test voltage shall be 2.5kV rms. One specimen per wire size shall be tested.

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DEF STAN 61-12 Part 18 Issue 5 Amend 3

9.2.6 Dynamic cut-through test. Def Stan 61-12 (Part 0), clause 13.22. Three specimens per wire size
shall be tested. The specimens shall be tested at a temperature of 120°C ± 5°C and the rate of loading shall
be 6000g/min at the sample. The minimum force required to achieve cut through to the conductor shall be as
specified in Table 8.

9.2.7 Notch propagation test. Def Stan 61-12 (Part 0), clause 13.23. Three samples of wire of conductor
size 19/0.15 shall be tested. The voltage shall be 2.5kV rms.

9.2.8 Resistance to fluids test. Three samples of wire of conductor size 19/0.15 shall be tested in
accordance with Def Stan 61-12 Part 0 clause 13.37. Test fluids and temperatures shall be as specified in
Table 6 of this Standard. Type 1 wires shall be subjected to all the fluids listed. Type 2 wires shall be
subjected to all the fluids listed with the exception of isopropyl alcohol and aircraft fuel. The duration of
immersion shall be 7 days for all fluids. The test voltage shall be 2.5kV rms.

9.2.9 Scrape abrasion test. Def Stan 61-12 (Part 0), clause 13.24. Three samples of wire shall each be
subjected to 4 scrapes at 120°C ±5°C, the blade shall be loaded with a force as specified in Table 8 and the
average number of cycles for each samples shall not be less than 500 cycles (1000 strokes) for both Types 1
and 2 wire.

9.2.10 Delamination test. (Tape wrapped insulation only) One sample shall be tested in accordance with
Def Stan 61-12 (Part 0), clause 13.32. The ageing temperature shall be 135°C±3°C and the test temperature
the wire rated temperature.

9.2.11 Pliability test. Three samples shall be tested in accordance with Def Stan 61-12 (Part 0), clause
13.26, except that the sample is to be straightened by hand. Samples of 19/0.15 conductor size shall be
tested. The diameter of the mandrel shall be 5mm and the force gradually applied, as specified, sufficient to
bend the wire downwards through 89°.

9.2.11.1 The specimen shall remain in this position for 5 minutes and the force recorded.

9.2.11.2 After this time the force shall be removed and the specimen allowed to return towards its original
position. At a time 5 minutes after removal of the force the recoil angle shall be recorded.

9.2.11.3 The mean force required to bend the wire through 89° and the recoil angle shall not exceed:

9.2.11.4 7N and 45° for Type 1 wire

9.2.11.5 12N and 60° for Type 2 wire

9.2.11.6 In addition it is undesirable to have maximum force and recoil angle at the same time, Type 1 wires
shall have a figure of less than 250 for the product of the force in Newtons and the angle in degrees.

9.2.12 Thermal endurance test. Def Stan 61-12 (Part 0), clause 13.36. A minimum of ten specimens shall
be used for each temperature. The upper temperature limit in this test relates to the maximum continuous
temperature due to current flow. For design demonstration purposes, samples of wire of conductor size
19/0.15 or 19/0.2 shall be tested. The wire shall be wrapped on a mandrel of 13 mm diameter with a weight of
400g for wire size 19/0.15, 700g for wire size 19/0.2.

9.2.12.1 Accelerated ageing. Def Stan 61-12 (Part 0), clause 13.29. The mandrel diameters and tensile
force to be applied to each end of the sample shall be as specified in Table 8 of this Standard.

For Qualification Tests the accelerated ageing test shall be carried out at 160oC.

To determine the test temperature for the Production Quality test requirements, a line is to be drawn through
the 120°C - 40,000 hours point parallel to the Arrhenius plot. The temperature at which this line passes
through 168 hours life is to be the minimum test temperature.

9.2.13 Colour fastness tests

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 DEF STAN 61-12 Part 18 Issue 5 Amend 3

9.2.13.1 Colour fastness to water test. A sample of wire, approximately 100 mm long, from which the
conductor has been removed shall be cut into small pieces. It shall be immersed in approximately 10 times its
own volume of distilled water contained in a covered vessel, for a period of 48 hours at a temperature of
70°C±1°C. At the end of this period the water shall be examined and shall be free from colour.

9.2.13.2 Bleeding of colour test. A test sample shall consist of a bundle of wires, 300mm long, made up
of twisted pairs laid together and bound with glass fibre string or tape at 50 mm intervals so that the pairs
cannot move in relation to each other. Each coloured wire is to be paired with a white wire with a lay of eight
times the diameter of the wire. The test samples shall be stored in an air oven at 120°C ± 3°C for 72 hours.
At the end of this period the sample shall be stripped down and the individual sample wires and control wires
shall be examined for transfer of colour. There shall be no appreciable colour staining and no significant
change in individual colours.

9.2.14 Colour durability test

9.2.14.1 Application. This test is applicable to surface coloured wires only.

9.2.14.2 Test apparatus. A scrape abrasion test rig as described in BS 3G 230, test 30 shall be used.

9.2.14.3 Test procedure. A specimen of wire shall be mounted in the tester and the counter set to zero.
Testing shall be carried out at a temperature of 120°C±5°C using a force of 2N. The test shall be discontinued
as soon as a continuous line is scored through the colour. To achieve a pass 100 cycles shall have been
made before a continuous line is scored through the colour.

9.2.15 Resistance to solder heat test. Def Stan 61-12 (Part 0), clause 13.35.

9.2.16 Flexure endurance test. Def Stan 61-12 (Part 0), clause 13.28. Three samples of wire of 19/0.15
conductor size shall be tested, at temperature of 20°C ±3°C using 15mm diameter mandrels. The mass shall
be 0.6 kg for Type 1 wire and 1 kg for Type 2 wire;

9.2.16.1 The insulation shall withstand the voltage test of 8.1.3;

9.2.16.2 The wire shall be capable of passing its full rated current given in Table 1, for 1000 cycles without
any evidence of localized overheating.

9.3 Test applicable to 1SBM 85 completed cables

9.3.1 Cold bend. Def Stan 61-12 (Part 0), clause 15.6.

9.3.2 Thermal endurance. Def Stan 61-12 (Part 0), clause 13.36 after ageing for 28 days at a temperature
of 110°C±2°C the cable is to be subjected to the requirements of Def Stan 61-12 (Part 0), clause 16.7. The
mandrel shall be 10 times the cable OD and the mass sufficient to ensure that the sample remains in intimate
contact with the mandrel.

9.3.3 Sheath compatibility. Deleted

9.4 Test applicable to 1SBM 120 and 2SBM 120 completed cables

9.4.1 Cold bend. Def Stan 61-12 (Part 0), clause 15.6.

9.4.2 Thermal endurance. As 9.3.2 of this Standard.

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DEF STAN 61-12 Part 18 Issue 5 Amend 3

10 Fire Hazard Tests

10.1 Flammability tests.

10.1.1 Insulated Wire - Def Stan 61-12 (Part 0), clauses 13.39 and 13.40.

Procedure 1. Five specimens per insulation type shall be tested and the flame shall be applied for 5
seconds. The burning shall cease within 15 seconds and the char/burn length shall not exceed 75mm.

Procedure 2. Five specimens per insulation type shall be tested and the flame shall be applied for 12
seconds. The burning shall cease within 15 seconds and the char/burn length shall not exceed 90mm.
The breaking of cable specimens of sizes 24 and smaller shall not be considered a failure provided
the specimens comply with the aforementioned requirements

10.1.2 1SBM 85 Completed cables – Def Stan 61-12 (Part 25) clause 11.6.3

10.1.3 1SBM 120 & 2SBM 120 Sheathed Cables - Def Stan 61-12 (Part 0), clauses 13.39 and 13.40.

Procedure 1. Five specimens per insulation type shall be tested and the flame shall be applied for 5
seconds. The burning shall cease within 15 seconds and the char/burn length shall not exceed 75mm.

Procedure 2. Five specimens per insulation type shall be tested and the flame shall be applied for 12
seconds. The burning shall cease within 15 seconds and the char/burn length shall not exceed 90mm.

10.2 Critical oxygen index test.

10.2.1 Insulated Wire

Def Stan 61-12 (Part 0), clause 13.41. A sample of wire size 22 shall be tested to ISO 4589-2 except that the
test piece shall be 70 to 150mm length cut from the sample wire and the ignition time shall be 15 seconds. The
Critical Oxygen Index shall be not less than 29.

10.2.2 Sheathing material for 850C Sheathed Cables

Def Stan 61-12 Part31 clause 9.5

10.2.3 .1SBM 120 & 2SBM 120 Sheathed Cables –

Def Stan 61-12 (Part 0), clause 13.41. The critical oxygen index shall not be less than 29.

10.3 Smoke index test.

10.3.1 Insulated Wire Insulation

Def Stan 61-12 (Part 0), clause 13.42. Three test runs shall be performed. The smoke index is to be stated in
terms of 1m of size 22 wire and the average of the 3 runs is not to exceed 12 (20 maximum for maintenance
range).

10.3.2 Sheathing material for 850C Sheathed Cables

Def Stan 61-12 Part31 clause 9.9

10.3.3 Sheathing material for 1200C Sheathed Cables

Def Stan 61-12 (Part 0), clause 13.42. Three test runs shall be performed. The smoke index is to be stated in
terms of 1m of cable. The average of three runs is not to exceed 12 (20 for maintenance range).
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 DEF STAN 61-12 Part 18 Issue 5 Amend 3

10.4 Toxicity index test.

10.4.1 Insulated Wire

Def Stan 61-12 (Part 0), clause 13.43. The toxicity index (the average value of the 9 samples) on a 100g
insulation basis shall not exceed 0.2 when calculated to a 1m length of size 22 wire. The hydrochloric acid
gas content shall not be greater than 10 cm3/m

10.4.2 . Sheathing material for 850C Sheathed Cables

Def Stan 61-12 Part31 clause 9.7

10.4.3 Sheathing material for 1200C Sheathed Cables

Def Stan 61-12 (Part 0), clause 13.43 The toxicity index (the average value of the 9 samples) on a 100g
sheathing material shall not exceed 0.2 when calculated to the volume of sheath on a 1m length of size 22
cable single core sheathed cable. The hydrochloric acid gas content shall not be greater than 10 cm3/m.

10.5 Temperature index test.

10.5.1 Insulated Wire -

Def Stan 61-12 (Part 0), clause 13.44. The temperature index value shall not be less than 250°C.

10.5.2 Sheathing material for 850C Sheathed Cables

Def Stan 61-12 Part31 clause 9.6

10.5.3 1200C Sheathed Cables –

Def Stan 61-12 (Part 0), clause 13.44. The temperature index value shall not be less than 250°C.

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DEF STAN 61-12 Part 18 Issue 5 Amend 3

Table 7 —Tests and Sample Sizes

DESCRIPTION OF TEST CLAUSE A B C D DEF STAN 61-12

NUMBER (PART 0) CLAUSE
NO OR BS 3G 230 TEST NO
Tests applicable for single wires without screens or jackets
Dry spark or dry impulse 8.1.1 X1 X X X 13.13
1
Conductor resistance 8.1.2 X X X X BS 3G 230 Test 12
High voltage immersion 8.1.3 X1 X - - 13.12
1
Insulation resistance 8.1.4 X X - - 13.11
Surface resistance 8.1.5 X - - - 13.15
Dielectric constant 8.1.6 X - - - 13.17
Voltage test, screened 8.2.1 X X X X BS 3G 230 Test 16d
cable
Dry spark test on sheath 8.3.1 X1 X X X 13.13
High voltage immersion, 8.3.2 X X - - 13.12
on sheath
Mechanical, conductor 9.1 X X - - BS 3G 230 Test 7
and screen braid
Solderability 9.1.1 X X 13.2
Insulation thickness and 9.2.1 X1 X X - 13.7
concentricity
Strand adhesion 9.2.2 X X - - 13.6
1
Insulation shrinkage 9.2.3 X X - - 13.30
Insulation blocking 9.2.4 X - - - 13.31
Room temperature bend 9.2.5.1 X X - - 13.19
Cold bend 9.2.5.2 X X 13.20
Dynamic cut through 9.2.6 X X - - 13.22
Notch propagation 9.2.7 X X - - 13.23
Resistance to fluids 9.2.8 X - - - 13.37
Scrape abrasion 9.2.9 X X - - 13.24
Delamination (tape 9.2.10 X X - - 13.32
wrapped insulation)
Pliability 9.2.11 X - - - 13.26
Thermal endurance 9.2.12 X - - - 13.36
1
Accelerated ageing 9.2.12.1 X X 13.29
Colour fastness to water 9.2.13.1 X2 - - - --
Bleeding of colour 9.2.13.2 X2 - - -
2
Colour durability 9.2.14 X - - - -

1 If cables of 4mm csa and above are to be supplied the this test is to be carried out on a sample of the largest
size cable in Table 16 for which manufacture is proposed
2 All colours to be tested

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 DEF STAN 61-12 Part 18 Issue 5 Amend 3

DESCRIPTION OF TEST CLAUSE A B C D DEF STAN 61-12

NUMBER (PART 0) CLAUSE
NO OR BS 3G 230 TEST NO
Tests for all cables
Resistance to solder heat 9.2.15 X X - - 13.35
Flexure endurance 9.2.16 X - - - 13.28
Flammability Procedure 1 10.1.1 X X - - 13.39
Procedure 2 10.1.2 X X 13.40
Critical oxygen index 10.2 X - - - 13.41
Smoke index 10.3 X - - - 13.42
Toxicity index 10.4 X - - - 13.43
Temperature index test 10.5 X - - - 13.44
Tests for SBM 85 Cables
Cold bend 9.3.1 X X
Thermal Endurance 9.3.2 X X 16.7
Flammability 10.1.2 X X - -

Tests for SBM 120 Cables

Cold Bend 9.2.5.1 X X - - 15.6
9.2.5.2
Thermal Endurance 9.2.12 X - - - 13.36

Accelerated ageing 9.2.12.1 X1 X - - 13.29

Flammability 10.1.1 X X - - 13.39 and 13.40
10.1.2
Critical Oxygen Index 10.2 X - - - 13.41
Smoke Index 10.3 X - - - 13.42
Toxicity Index 10.4 X - - - 13.43
Temperature Index 10.5 X - - - 13.44
Resistance to Fluids 9.2.8 X - - - 13.37

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DEF STAN 61-12 Part 18 Issue 5 Amend 3

Table 8 —Specific Test Requirements

ACCELERATED ACCELERATED COLD SCRAPE DYNAMIC CUT

AGEING AND AGEING MAX BEND ABRASION THROUGH FORCE
SIZE
ROOM TEMP MANDREL DIA FORCE FORCE
BEND FORCE
(mm) (N) (N) (N)
(N)
TYPE 1 TYPE 2 TYPE 1 TYPE 2
30 0.5 2.0 10.0 2.0 1.0 3.0 25.0
28 1.0 3.5 10.0 4.0 1.0 3.0 30.0
26 1.6 5.0 10.0 5.0 1.0 4.0 30.0
24 2.5 7.0 10.0 20.0 1.2 5.0 40.0
23 3.0 10.0 13.0 20.0 1.2 5.0 40.0
22 4.0 10.0 13.0 20.0 1.5 6.0 70.0
20 7.0 20.0 13.0 20.0 1.5 6.0 100.0
19 8.0 20.0 20.0 20.0 1.5 7.0 100.0
18 10.0 20.0 20.0 30.0 1.6 7.0 120.0
16 10.0 20.0 20.0 30.0 2.0 8.0 120.0
14 10.0 20.0 25.0 30.0 2.5 10.0 120.0
12 10.0 20.0 30.0 30.0 3.0 12.0 120.0
4mm 10.0 10 X outside 30.0 3.0 12.0
6mm 15.0 N/A diameter 30.0 3.0 12.0 N/A
10mm 20.0 40.0 3.0 12.0

11 Tests

11.1 General.

It is required that all types of insulation and sheathing to this Standard shall be mutually compatible and also
be compatible with other types of insulation and sheath in general use.

11.2 Jacketed Cables

When the sheathing material of jacketed cables conforms to Def Stan 61-12 (Part 31) tests of completed
cables are confined to:

Those required too test for any change in the ageing characteristics of component materials in a complete
cable.

Those required to confirm the performance of a complete cable.

11.3 List of tests and Sample Sizes

All specimens shall meet the requirements of this Standard and the manufacturers shall satisfy BS 3G 230
Clause 7.1 Evidence of certification by an acceptable third party assessment body shall be supplied to the
purchaser on request.

11.3.1 If conformance to this standard is claimed the manufacturer shall have, as a minimum, carried out the
tests listed in Table 7 column (a).

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 DEF STAN 61-12 Part 18 Issue 5 Amend 3

11.3.1.1 For the cables in Tables 9 and 16 - The tests shall be performed on separate specimens of
representative samples of size 22 (19/0.15) except for testing to clauses 9.2.13 when either size 22 or 20 shall
be tested and 10.4 when sizes 301, 22 and 122 shall be tested.
Notes
1. These sizes need not be tested if approval for cables smaller than size26 is to be claimed.

2. These sizes need not be tested if approval for cables larger than size14 is to be claimed.

11.3.1.2 For cables in Table 17 - Shall have demonstrated the insulation system on a Table 9 Type 1,
cable in accordance with clause 11.3.1. In addition samples of the largest cable for which a manufacture
intends to supply shall have been subjected to the tests listed in Table 7 column (a) note 1.

11.3.1.3 Tests listed in Table 7 column (b) shall be carried out in accordance with BS 3G 230 Clause 7.1
(b). A sample of each cable sizes or design that has not been previously manufactured shall have successfully
been subjected to the tests in column (b) before delivery

11.3.1.4 Tests listed in Table 7 column (c) shall be carried out in accordance with BS 3G 230 Clause 7.1
(c).

11.3.1.5 Tests listed in Table 7 column (d) shall be carried out in accordance with BS 3G 230 Clause 7.1
(d).

12 Packaging and Labelling

Packaging and labelling shall be in accordance with the requirements specified in Annex B

13 Tables

Notes on Tables

The definitions of Tables 9 to 17 - items respectively are as follows:

Tables 9 to 12 and 17 Standard items to be used whenever practicable.

Tables 13 to 16. Non-standard items for which there is no replacement. A non-standard item is to be
provisioned only for the maintenance of existing equipment.

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This page is intentionally blank
 Table 9 —Standard Range Type 1 Unscreened
Equipment wires Electrical – Type 1 Limited Fire Hazard – Unscreened (Maximum Toxicity Index 0.2)

Page line Conductor NATO STOCK NUMBER 6145-99-

No. Size
RED BLUE GREEN YELLOW BLACK WHITE BROWN VIOLET ORANGE GREY PINK YELLOW
Green

(a) (b) ( c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m)

1 1/0.25 891-9431 891-9432 891-9433 891-9434 891-9435 891-9436 891-9437 891-9438 891-9439 891-9440 891-9441 891-9442
2 1/0.40 891-9443 891-9444 891-9445 891-9446 891-9447 891-9448 891-9449 891-9450 891-9451 891-9452 891-9453 891-9454
3 1/0.60 891-9455 891-9456 891-9457 891-9458 891-9459 891-9460 891-9461 891-9462 891-9463 891-9464 891-9465 891-9466
Unclassified

4 1/0.90 891-9467 891-9468 891-9469 891-9470 891-9471 891-9472 891-9473 891-9474 891-9475 891-9476 891-9477 891-9478
5 7/0.10 891-9479 891-9480 891-9481 891-9482 891-9483 891-9484 891-9485 891-9486 891-9487 891-9488 891-9489 891-9490
6 7/0.12 891-9491 891-9492 891-9493 891-9494 891-9495 891-9496 891-9497 891-9498 891-9499 891-9500 891-9501 891-9502
7 19/0.10 891-9503 891-9504 891-9505 891-9506 891-9507 891-9508 891-9509 891-9510 891-9511 891-9512 891-9513 891-9514
8 19/0.12 891-9515 891-9516 891-9517 891-9518 891-9519 891-9520 891-9521 891-9522 891-9523 891-9524 891-9525 891-9526
9 19/0.15 891-9527 891-9528 891-9529 891-9530 891-9531 891-9532 891-9533 891-9534 891-9535 891-9536 891-9537 891-9538
10 19/0.20 891-9539 891-9540 891-9541 891-9542 891-9543 891-9544 891-9545 891-9546 891-9547 891-9548 891-9549 891-9550
11 19/0.25 891-9551 891-9552 891-9553 891-9554 891-9555 891-9556 891-9557 891-9558 891-9559 891-9560 891-9561 891-9562
12 19/0.30 891-9563 891-9564 891-9565 891-9566 891-9567 891-9568 891-9569 891-9570 891-9571 891-9572 891-9573 891-9574
13 37/0.25 891-9575 891-9576 891-9577 891-9578 891-9579 891-9580 891-9581 891-9582 891-9583 891-9584 891-9585 891-9586
14 37/0.30 891-9587 891-9588 891-9589 891-9590 891-9591 891-9592 891-9593 891-9594 891-9595 891-9596 891-9597 891-9598

DEF STAN 61-12 Part 18 Issue 5

20
 DEF STAN 61-12 Part 18 Issue 5
21

Table 10 —Standard Range Type 2 Unscreened

Equipment wires Electrical – Type 2 Limited Fire Hazard – Unscreened (Maximum Toxicity Index 0.2)

Page line Conductor NATO STOCK NUMBER 6145-99-

No. Size
RED BLUE GREEN YELLOW BLACK WHITE BROWN VIOLET ORANGE GREY PINK YELLOW
Green

(a) (b) ( c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m)

1 1/0.25 891-9599 891-9600 891-9601 891-9602 891-9603 891-9604 891-9605 891-9606 891-9607 891-9608 891-9609 891-9610
2 1/0.40 891-9611 891-9612 891-9613 891-9614 891-9615 891-9616 891-9617 891-9618 891-9619 891-9620 891-9621 891-9622
3 1/0.60 891-9623 891-9624 891-9625 891-9626 891-9627 891-9628 891-9629 891-9630 891-9631 891-9632 891-9633 891-9634
Unclassified

4 1/0.90 891-9635 891-9636 891-9637 891-9638 891-9639 891-9640 891-9641 891-9642 891-9643 891-9644 891-9645 891-9646
5 7/0.10 891-9647 891-9648 891-9649 891-9650 891-9651 891-9652 891-9653 891-9654 891-9655 891-9656 891-9657 891-9658
6 7/0.12 891-9659 891-9660 891-9661 891-9662 891-9663 891-9664 891-9665 891-9666 891-9667 891-9668 891-9669 891-9670
7 19/0.10 891-9671 891-9672 891-9673 891-9674 891-9675 891-9676 891-9677 891-9678 891-9679 891-9680 891-9681 891-9682
8 19/0.12 891-9683 891-9684 891-9685 891-9686 891-9687 891-9688 891-9689 891-9690 891-9691 891-9692 891-9693 891-9694
9 19/0.15 891-9695 891-9696 891-9697 891-9698 891-9699 891-9700 891-9701 891-9702 891-9703 891-9704 891-9705 891-9706
10 19/0.20 891-9707 891-9708 891-9709 891-9710 891-9711 891-9712 891-9713 891-9714 891-9715 891-9716 891-9717 891-9718
11 19/0.25 891-9719 891-9720 891-9721 891-9722 891-9723 891-9724 891-9725 891-9726 891-9727 891-9728 891-9729 891-9730
12 19/0.30 891-9731 891-9732 891-9733 891-9734 891-9735 891-9736 891-9737 891-9738 891-9739 891-9740 891-9741 891-9742
13 37/0.25 891-9743 891-9744 891-9745 891-9746 891-9747 891-9748 891-9749 891-9750 891-9751 891-9752 891-9753 891-9754
14 37/0.30 891-9755 891-9756 891-9757 891-9758 891-9759 891-9760 891-9761 891-9762 891-9763 891-9764 891-9765 891-9766
 Table 11 —Standard Range Screened

NATO STOCK NUMBER 6145-99-

PAGE CONDUCTOR ITEM TYPE TYPE 1SB TYPE 2SB
LINE SIZE
NUMBER PINK WHITE PINK WHITE
INSULATION INSULATION INSULATION INSULATION
(a) (b) ( c) (d) (e) (f)

1 19/0.10 CABLE 891-9799 891-9800 891-9801 891-9802

2 19/0.12 SPECIAL 891-9803 891-9804 891-9805 891-9806
3 19/0.15 PURPOSE 891-9807 891-9808 891-9809 891-9810
4 19/0.20 ELECTRICAL 891-9811 891-9812 891-9813 891-9814
Unclassified

5 19/0.25 CABLE 891-9815 891-9816 891-9817 891-9818

6 19/0.30 POWER 891-9819 891-9820 891-9821 891-9822
7 37/0.25 ELECTRICAL 891-9823 891-9824 891-9825 891-9826
8 37/0.30 891-9827 891-9828 891-9829 891-9830

NOTE The NATO stock numbers in columns (c), (d), (e) and (f) are only applicable where the insulation is coloured pink or white as applicable
and the sheath is coloured black

DEF STAN 61-12 Part 18 Issue 5

22
23

DEF STAN 61-12 Part 18 Issue 5

Table 12 —Standard Range Screened and Sheathed

NATO STOCK NUMBER 6145-99-

PAGE CONDUCTOR ITEM TYPE o
LINE SIZE TYPE 1SBM 85 C TYPE 1SBM 120oC TYPE 2SBM
NUMBER PINK WHITE PINK WHITE PINK WHITE
INSULATION INSULATION INSULATION INSULATION INSULATION INSULATION
(a) (b) ( c) (d) (e) (f) (g) (h)
1 19/0.10 CABLE 053-5000 053-5008 891-9767 891-9768 891-9769 891-9770
2 19/0.12 SPECIAL 053-5001 053-5009 891-9771 891-9772 891-9773 891-9774
3 19/0.15 PURPOSE 053-5002 053-5010 891-9775 891-9776 891-9777 891-9778
4 19/0.20 ELECTRICAL 053-5003 053-5011 891-9779 891-9780 891-9781 891-9782
5 19/0.25 CABLE 053-5004 053-5012 891-9783 891-9784 891-9785 891-9786
Unclassified

6 19/0.30 POWER 053-5005 053-5013 891-9787 891-9788 891-9789 891-9790

7 37/0.25 ELECTRICAL 053-5006 053-5014 891-9791 891-9792 891-9793 891-9794
8 37/0.30 053-5007 053-5015 891-9795 891-9796 891-9797 891-9798

NOTE the NATO stock numbers in columns (c), (d), (e) (f), (g) and (h) are only applicable where the insulation is coloured pink or white as applicable
and the sheath is coloured black
 Table 13 —Maintenance Range Type 1 Unscreened
Equipment wires Electrical – Type 1 Limited Fire Hazard – Unscreened (Toxicity Index 0.2 to 1.5)

Page Conductor NATO STOCK NUMBER 6145-99-

line Size
No. RED BLUE GREEN YELLOW BLACK WHITE BROWN VIOLET ORANGE GREY PINK YELLOW
Green 3
(a) (b) ( c) (d) (e) (f) (g) (h) (j) (k) (l) (m) (n)
1 1/0.25 771-6206 771-6207 771-6208 771-6209 771-6210 771-6211 771-6212 771-6213 771-6214 771-6515 771-6216 729-3026
2 1/0.40 017-5422 017-5431 017-5440 017-5449 017-5458 017-5508 017-5517 017-5526 017-5535 017-5545 017-5554 017-5671
3 1/0.60 017-5423 017-5432 017-5441 017-5450 017-5459 017-5509 017-5518 017-5527 017-5536 017-5546 017-5555 017-5672
4 1/0.90 017-5424 017-5433 017-5442 017-5451 017-5460 017-5510 017-5519 017-5528 017-5537 017-5547 017-5556 017-5673
5 7/0.10 771-6217 771-6218 771-6219 771-6220 771-6221 771-6222 771-6223 771-6224 771-6225 771-6226 771-6227 729-3041
Unclassified

6 7/0.12 728-6125 771-6228 771-6229 771-6230 771-6231 771-6232 771-6233 771-6234 771-6235 771-6236 771-6237 729-3042
7 19/0.10 771-6238 771-6239 771-6240 771-6241 771-6242 771-6243 771-6244 771-6245 771-6246 771-6247 771-6248 729-3043
8 19/0.12 017-5425 017-5434 017-5443 017-5452 017-5502 017-5511 017-5520 017-5529 017-5538 017-5548 017-5557 729-3025
9 19/0.15 017-5426 017-5435 017-5444 017-5453 017-5503 017-5512 017-5521 017-5530 017-5539 017-5549 017-5558 017-5675
10 19/0.20 017-5427 017-5436 017-5445 017-5454 017-5504 017-5513 017-5522 017-5531 017-5540 017-5550 017-5559 017-5676
11 19/0.25 771-6249 771-6250 771-6251 771-6252 771-6253 771-6254 771-6255 771-6256 771-6257 771-6258 771-6259 729-3044
12 19/0.30 017-5428 017-5437 017-5446 017-5455 017-5505 017-5514 017-5523 017-5532 017-5541 017-551 017-5560 017-5677
13 37/0.25 771-6260 771-6261 771-6262 771-6263 771-6264 771-6265 771-6266 771-6267 771-6268 771-6269 771-6270 729-3039

DEF STAN 61-12 Part 18 Issue 5

14 37/0.30 771-6271 771-6272 771-6273 771-6274 771-6275 771-6276 771-6277 771-6278 771-6279 771-6280 771-6281 729-3040
24

3 Base colour is indicated by capital letters

25

DEF STAN 61-12 Part 18 Issue 5

Table 14 —Maintenance Range Type 2 Unscreened
Equipment wires Electrical – Type 2 Limited Fire Hazard – Unscreened (Toxicity Index 0.2 to 1.5)

Page line Conductor NATO STOCK NUMBER 6145-99-

No. Size
RED BLUE GREEN YELLOW BLACK WHITE BROWN VIOLET ORANGE GREY PINK YELLOW
Green
(a) (b) ( c) (d) (e) (f) (g) (h) (j) (k) (l) (m) (n)
1 1/0.25 771-6282 771-6283 771-6284 771-6285 771-6286 771-6287 771-6288 771-6289 771-6290 771-6291 771-6292 722-3157
2 1/0.40 771-6293 771-6294 771-6295 771-6296 771-6297 771-6298 771-6299 771-6300 771-6301 771-6302 771-6303 729-3046
3 1/0.60 771-6304 771-6305 771-6306 771-6307 771-6308 771-6309 771-6310 771-6311 771-6312 771-6313 771-6314 729-3027
4 1/0.90 771-6315 771-6316 771-6317 771-6318 771-6319 771-6320 771-6321 771-6322 771-6323 771-6324 771-6325 729-3028
5 7/0.10 771-6326 771-6327 771-6328 771-6329 771-6330 771-6331 771-6332 771-6333 771-6334 771-6335 771-6336 729-3029
6 7/0.12 771-6337 771-6338 771-6339 771-6340 771-6341 771-6342 771-6343 771-6344 771-6345 771-6346 771-6347 729-3030
Unclassified

7 19/0.10 771-6348 771-6349 771-6350 771-6351 771-6352 771-6353 771-6354 771-6355 771-6356 771-6357 771-6358 729-3031
8 19/0.12 771-6359 771-6360 771-6361 771-6362 771-6363 771-6364 771-6365 771-6366 771-6367 771-6368 771-6369 729-3032
9 19/0.15 771-6370 771-6371 771-6372 771-6373 771-6374 771-6375 771-6376 771-6377 771-6378 771-6379 771-6380 729-3033
10 19/0.20 771-6381 771-6382 771-6383 728-3147 728-3148 728-3149 728-3150 728-3151 728-3152 728-3153 728-3154 729-3034
11 19/0.25 728-3155 728-3156 728-3157 728-3158 728-3159 728-3160 728-3161 728-3162 728-3163 728-3164 728-3165 729-3035
12 19/0.30 728-3166 728-3167 728-3168 728-3169 728-3170 728-3171 728-3172 728-3173 728-3174 728-3175 728-3176 729-3036
13 37/0.25 728-3177 728-3178 728-3179 728-3180 728-3181 728-3182 728-3183 728-3184 728-3185 728-3186 728-3187 729-3037
14 37/0.30 728-3188 728-3189 728-3190 728-3191 728-3192 728-3193 728-3194 728-3195 728-3196 728-3197 728-3198 729-3038
 Table 15 —Maintenance Range Screened
Cables Special Purpose, Electrical and cables, Power, Electrical - Type 1SB and 2SB Limited Fire Hazard Insulation,
Screened (Toxicity Index 0.2 to 1.5)

NATO STOCK NUMBER 6145-99-

PAGE CONDUCTOR ITEM TYPE
LINE SIZE TYPE 1SB TYPE 2SB
NUMBER WHITE
PINK WHITE PINK
INSULATION INSULATION INSULATION INSULATION
(a) (b) ( c) (d) (e) (f)
1 19/0.10 CABLE 770-8895 771-6176 771-6175 771-6177
2 19/0.12 SPECIAL 771-6178 771-6180 771-6179 771-6181
3 19/0.15 PURPOSE 771-6182 771-6184 771-6183 771-6185
4 19/0.20 ELECTRICAL 771-6186 771-6188 771-6187 771-6189
Unclassified

5 19/0.25 CABLE 771-6190 771-6192 771-6191 771-6193

6 19/0.30 POWER 771-6194 771-6196 771-6195 771-6197
7 37/0.25 ELECTRICAL 771-6198 771-6200 771-6199 771-6201
8 37/0.30 771-6202 771-6204 771-6203 771-6205

DEF STAN 61-12 Part 18 Issue 5

26
 DEF STAN 61-12 Part 18 Issue 5
Table 16 —Maintenance Range Screened and Sheathed
27

Cables Special Purpose, Electrical and cables, Power, Electrical - Type 1SBM and 2SBM Limited Fire Hazard Insulation,
Screened and Sheathed (Toxicity Index 0.2 to 1.5)

NATO STOCK NUMBER 6145-99-

PAGE CONDUCTOR ITEM TYPE
LINE SIZE TYPE 1SBM TYPE 2SBM
NUMBER PINK WHITE PINK WHITE
INSULATION INSULATION INSULATION INSULATION
(a) (b) ( c) (d) (e) (f)
1 19/0.10 CABLE 728-3199 728-3200 728-3201 728-3203
2 19/0.12 SPECIAL 017-5788 728-3201 728-3204 728-3205
3 19/0.15 PURPOSE 017-5789 728-3222 728-6126 728-3206
4 19/0.20 ELECTRICAL 017-5790 728-3223 728-3207 728-6127
5 19/0.25 CABLE 728-3208 728-3209 728-3210 728-3211
6 19/0.30 POWER 017-5791 728-3224 728-3212 728-3213
7 37/0.25 ELECTRICAL 728-3214 728-3215 728-3216 728-3217
Unclassified

8 37/0.30 728-3218 728-3219 728-3220 728-3221

NOTE the nato stock numbers in columns (c), (d), (e) and (f) are only applicable where the insulation is coloured pink or white as applicable
 Table 17 —Standard Range Type 1 Unscreened 4-10mm
Equipment wires Electrical – Type 1 Limited Fire Hazard – Unscreened (Maximum Toxicity Index 0.2)

Page Conductor NATO STOCK NUMBER 6145-99-595-

line Size RED BLUE GREEN YELLOW BLACK WHITE BROWN VIOLET ORANGE GREY PINK YELLOW
No. mm2 Green
(a) (b) ( c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m)
4 4 2296 2297 2298 2299 2300 2301 2302 2303 2304 2305 2306 2307
2 6 2308 2309 2310 2311 2312 2313 2314 2315 2316 2317 2318 2319
3 10 2320 2321 2322 2323 2324 2325 2326 2327 2328 2329 2330 2331
Unclassified

DEF STAN 61-12 Part 18 Issue 5

28
This page is intentionally blank
 DEF STAN 61-12 Part 18 Issue 5 Amend 3

Annex A

Type Designator Coding Structure

A.1 Scope

A.1.1 This annex gives instructions for creating a designator which, when associated with this particular
Defence Standard Number, will uniquely identify a specific item manufactured to the Standard's requirements.

A.1.2 Whilst the primary purpose of such a designator is NATO Stock Number (NSN) assignment, it may
also be used by anyone else requiring a similar designator facility.

A.2 Coding Structure for the Type Designator

A.2.1 This consists of 3 or more elements separated from each other by oblique strokes.

A.2.2 The first element is the relevant cable or wire type code from the following table:

Table 18 —Cable and Wire Type Coding

TYPE DESCRIPTION CODE

Type 1 No Screen or Sheath 1

Type 1SB Screen only 1SB

Type 1SBM 85 Screen and 85°C Rated Sheath 1SBM 85

Type 1SBM 120 Screen and 120°C Rated Sheath 1SBM 120

Type 2 No Screen or Sheath 2

Type 2SB Screen only 2SB

Type 2SBM Screen and Sheath 2SBM

Unclassified
29
DEF STAN 61-12 Part 18 Issue 5 Amend 3

A.2.3 The second is the relevant conductor size code letter from the following table:

Table 19 —Conductor Size

SIZE NUMBER AND NOMINAL CODE

NOMINAL DIAMETER CROSS LETTER
OF STRANDS IN SECTIONAL
CONDUCTOR
mm mm²
(a) (b) (c) (d)
30 1/0.25 0.05 A
26 1/0.40 0.12 D
23 1/0.60 0.28 G
19 1/0.90 0.63 K
30 7/0.10 0.055 B
28 7/0.12 0.079 C
26 19/0.10 0.15 E
24 19/0.12 0.20 F
22 19/0.15 0.33 H
20 19/0.20 0.59 J
18 19/0.25 0.93 L
16 19/0.30 1.34 M
14 37/0.25 1.82 N
12 37/0.30 2.50 P
37/0.37 4.0 R
37/0.46 6.0 S
61/0.46 10.0 T

Unclassified
30
 DEF STAN 61-12 Part 18 Issue 5 Amend 3

A.2.4 The third element is the relevant insulation base colour code letters from the following table:

Table 20 Insulation Base Colour

COLOUR LETTER CODE

RED RE
BLUE BU
GREEN GR
YELLOW YE
BLACK BL
WHITE WH
BROWN BR
VIOLET VL
ORANGE RG
GREY GY
PINK PK

A.2.5 Bicolours. When a bicolour wire requires to be coded, codes for each individual colour are used
separated by an oblique stroke (see example below).

A.3 Diagram of Coding Structure

1st element 2nd element 3rd element Subsequent element

(if required)

1S E YE GR ISSUE NO 4

│ │ │ │ │
│ │ │ │ └───Issue No
│ │ │ │
│ │ │ └────────────────Bicolour
│ │ │
│ │ │ Insulation
│ │ └────────────────────────base colour
│ │
│ │ Conductor
│ └──────────────────────────────────size
│
│ Wire or Cable
────────────────────────────────────────────── Type

31
DEF STAN 61-12 Part 18 Issue 5 Amend 3

A.4 Examples of Type Designators

A.4.1 ISBM 85/P/WH/3: This is a screened and sheathed Type 1 cable having a conductor of 37 strands,
each of 0.30 mm diameter and insulation base colour white to Issue 3, suitable for continuous use in the
temperature range -50°C to +85°C.

A.4.2 2/D/VL/3: This is a non-screened, non sheathed Type 2 wire, having a single solid conductor with a
diameter of 0.40 mm and insulation base colour violet to Issue 3.

A.4.3 1SB/E/YE/GR/3: This is a screened Type 1 cable having a conductor of 19 strands each of 0.10 mm,
with insulation base colour yellow and secondary colour green to Issue 3.

NOTE In all cases the type designator shall be preceded by Def Stan 61-12 (Part 18).

Unclassified
32
 DEF STAN 61-12 Part 18 Issue 5 Amend 3

Annex B

Packaging Of Wires And Cables

B.1 Packing on reels

B.1.1 Sealing

Each length of the wire or cable shall have the ends sealed to prevent the ingress of moisture.

B.1.2 Reels

The wire or cable shall be wound on a reel the barrel diameter of which shall be not less than 12 times the
overall specified diameter of the completed wire or cable.

B.1.3 Wires.

Reels shall be non-returnable, constructed from plywood or standard hardboard complying with the
requirements of BS EN 622 Part 2. Strong plastic reels may be used only when stipulated in the contract.
B.1.4 Length

Unless stated otherwise in the contract or order each reel shall preferably carry 100 metres ± 1% in one length
without joints. The manufacturer may however supply up to 10% of a type in random lengths provided that
each reel contains 100 metres and consists of not more than four lengths, the length of each being not less
than 20 metres.
B.1.5 Wrapping

B.1.5.1 The peripheral surface of the wire as wound on the reel shall be wrapped with PVC or Polyethylene
sheeting to prevent ingress of fluids to the wire or cable carried. There shall be a minimum overlap on the
width between reel flanges of 50 mm. If strip bandage wrapping is utilised the strip edges shall overlap by at
least 25 mm.

B.1.5.2 The wrapping shall be secured in position using a pressure-sensitive adhesive waterproof tape.

B.1.6 Marking

As a minimum each reel shall be marked with the following information :-

NATO Stock Number

Item name and description including the colour of the completed wire or cable
Defence Standard Number
Number of cores and size of conductor
Length/s in metres
Date of manufacture (month and year)
Contract number
Name of manufacturer shall also be stated.
All labels shall be firmly affixed to the outside flanges of drums or reels.

33
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Information on all Defence Standards is contained in Def Stan 00-00 Standards for Defence Part 3
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