Ministry of Defence

Defence Standard 02-517

Issue 2 Publication Date 29th February 2008

REQUIREMENTS FOR CABLE,

ELECTRIC

Part 5

Miscellaneous
DEF STAN 02-517 Part 5 Issue 2

Contents

Foreword ............................................................................................................................................... iv
Introduction.......................................................................................................................................... vii
1 Scope ......................................................................................................................................... 1
2 Warning ..................................................................................................................................... 1
3 Related Documents .................................................................................................................. 1
4 Performance Specification ...................................................................................................... 2
5 National/International Regulations ......................................................................................... 2
6 Military Standards/Requirements ........................................................................................... 3
6.1 Requirements for Materials ..................................................................................................... 3
6.2 Construction ............................................................................................................................. 3
6.2.1 Conductor Stranding................................................................................................................ 3
6.2.2 Conductor Insulation................................................................................................................ 3
6.2.3 Tapes ......................................................................................................................................... 3
6.2.4 Identification of Cores.............................................................................................................. 3
6.2.5 Laying–Up of Cores.................................................................................................................. 4
6.2.6 Screens...................................................................................................................................... 4
6.2.7 Screen Insulation...................................................................................................................... 4
6.2.8 Sheathing .................................................................................................................................. 4
6.2.9 Overall Diameter ....................................................................................................................... 5
6.2.10 Marking ...................................................................................................................................... 5
6.2.11 Additional Markings ................................................................................................................. 5
6.3 Tests .......................................................................................................................................... 5
6.3.1 Scheduled Tests ....................................................................................................................... 5
6.3.2 Electrical Tests ......................................................................................................................... 6
6.3.3 Tests on Cable Components ................................................................................................... 6
6.3.4 Tests on Completed Cables .................................................................................................... 6
6.3.5 Dimensions ............................................................................................................................... 7
6.3.6 Visual Examination................................................................................................................... 7
6.3.7 Additional Tests applicable to Cables having Limited Fire Hazard Sheaths to Def
Stan 61–12 Part 31 ................................................................................................................... 7
6.4 Quality Assurance of Products ............................................................................................... 8
6.4.1 General Requirements ............................................................................................................. 8
6.4.2 Procedure .................................................................................................................................. 8
6.4.3 Tests and Sampling Levels on Completed Cables ............................................................... 8
6.5 Packaging and Labelling ......................................................................................................... 9
6.5.1 General ...................................................................................................................................... 9
6.5.2 Packaging.................................................................................................................................. 9
6.5.3 Supply on Reels........................................................................................................................ 9
6.5.4 Supply on Drums ...................................................................................................................... 9
6.5.5 Supply in Coils – Mineral Insulated Cables only................................................................... 9
6.5.6 Despatch Lengths..................................................................................................................... 9
7 Design Requirements/Guidance ........................................................................................... 10
8 Corporate Knowledge And Experience ................................................................................ 10
Annex A Abbreviations and Definitions ............................................................................................ 11
Annex B Procurement Check List...................................................................................................... 12
Annex C Tables of Dimensions.......................................................................................................... 13
C.1 General .................................................................................................................................... 13
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Tables

Table 1 — Tolerances for Nominal Diameters.....................................................................................5

Table 2 — Test Schedule .......................................................................................................................6
Table C.1 — Multicore Silicone Rubber Insulated, Limited Fire Hazard Sheathed
Compensating Cables, Collectively Screened 1.0 mm2 ......................................................14
Table C.2 — Single Core, Silicone Rubber Insulated Cables, Glass Braided Overall...................15
Table C.3 — Single and Two–Pair, Silicone Rubber Insulated, Pairs Screened, PCP ..................16
Table C.4 — 3–Core Thermocouple Extension Cable, Silicone Rubber Insulated,
LFH Sheathed 4 mm2...............................................................................................................17
Table C.5 — PVC Insulated, Textile Braided Cord 0.2mm2 ..............................................................18
Table C.6 — 30–Quad, Individually Screened, PCP, Sheathed 0.6 mm2 .........................................19
Table C.7 — Single Core PVC Insulated Equipment Wires for Thermocouples 0.6mm2 ..............20
Table C.8 — Single and Multicore, PVC Insulated, Screened and Unscreened, Sheathed and
Unsheathed Special Resistance Wires 0.75 mm2 ................................................................20
Table C.9 — Single Core PVC Insulated Cables (Flexing) 3 mm2 ....................................................21
Table C.10 — 3–Core EPR Insulated, CSP (LFH) Sheathed Flexible Cords ...................................22
Table C.11 — Multicore, EPR Insulated, CSP Sheathed Flexible Cables for Ship–Shore
Connections.............................................................................................................................23
Table C.12 — Multicore, EPR Insulated, CSP Sheathed, Flexible Cable 0.5mm2...........................24
Table C.13 — Core, EPR Insulated, LFH Sheathed, Copper Wire Braided Cable 1.0mm2 ............25
Table C.14 — Multipair, EPR Insulated, LFH Sheathed, Screened and LFH Sheathed 0.5 mm2 ..26
Table C.15 — Mineral Insulated Cables..............................................................................................27
Table C.16 — Twin, EPR Insulated, Screened and Heavy Duty Tough Rubber Sheathed
Underwater Cable 1.5 mm2 .....................................................................................................28
Table C.17 — Single Core, EPR Insulated and LFH Sheathed Cable, Cores Individually
Screened 4.0 mm2....................................................................................................................29
Table C.18 — Multicore EPR Insulated and LFH Sheathed Cable, Cores Individually
Screened ..................................................................................................................................30
Table C.19 — Single Core, EPR Insulated, Heavy Duty Tough Rubber Sheathed 280 mm2 .........31
Table C.20 — Single Core, EPR Insulated, Heavy Duty Tough Rubber Sheathed 280 mm2 .........33
Table C.21 — Numerical Index to NATO Stock Numbers.................................................................34

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Foreword
AMENDMENT RECORD

Amd No Date Text Affected Signature and Date

REVISION NOTE

This standard is raised to Issue 2 to update its content.

HISTORICAL RECORD

This standard supersedes the following:

Def Stan 02–517 Part 5 Issue 1 April 2000

NES 517 Part 5 Issue 1 July 1992

Sponsorship

1. This Defence Standard (Def Stan) is sponsored by the Warship Support Agency (WSA), Ministry of
Defence (MOD).

2. The complete Def Stan 02-517 comprises:

Requirements for Cable, Electric

Part 1: Pressure–Tight Ethylene Propylene Rubber (EPR) or Silicone Rubber Insulated,

Chlorosulphonated Polyethylene (CSP) Limited Fire Hazard (LFH) Sheathed

Part 2: Polyolefin Insulated

Part 3: Co–Axial

Part 4: Fluorinated Material Insulated

Part 5: Miscellaneous

3. If it is found to be unsuitable for any particular requirement the MOD is to be informed in writing of
the circumstances.

4. Any user of this Defence Standard either within MOD or in industry may propose an amendment to
it. Proposals for amendments that are not directly applicable to a particular contract are to be made
to the publishing authority identified on Page 1, and those directly applicable to a particular contract
are to be dealt with using contract procedures.

5. No alteration is to be made to this Defence Standard except by the issue of an authorised

amendment.

6. Unless otherwise stated, reference in this Defence Standard to approval, approved, authorised or
similar terms, means the Ministry of Defence in writing.

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7. Any significant amendments that may be made to this Defence Standard at a later date will be
indicated by a vertical sideline. Deletions will be indicated by 000 appearing at the end of the line
interval.

8. Extracts from British Standards within this Defence Standard have been included with the
permission of the British Standards Institution.

Conditions of Release

General

9. This Defence Standard has been devised solely for the use of the MOD, and its contractors in the
execution of contracts for the MOD. To the extent permitted by law, the Crown 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 Defence Standard is used for any
other purpose.

10. This document is Crown Copyright and the information herein may be subject to Crown or third party
rights. It is not to be released, reproduced or published without written permission of the MOD.

11. The Crown reserves the right to amend or modify the contents of this Defence Standard without
consulting or informing any holder.

MoD Tender or Contract Process

12. This Defence Standard is the property of the Crown. Unless otherwise authorised in writing by the
MOD must be returned on completion of the contract or submission of the tender in connection with
which it is issued.

13. When this Defence Standard is used in connection with a MOD tender or contract, the user is to
ensure that he is in possession of the appropriate version of each document, including related
documents, relevant to each particular tender or contract. Enquiries in this connection may be made
of the Authority named in the tender or contract.

14. When Defence Standards are incorporated into contracts, users are responsible for their correct
application and for complying with contractual and other statutory requirements. Compliance with a
Defence Standard does not of itself confer immunity from legal obligations.

Categories of Naval Defence Standard

15. The Category of this Naval Defence Standard has been determined using the following criteria:

a) Category 1. If not applied may have a Critical affect on the following:

Safety of the vessel, its complement or third parties.
Operational performance of the vessel, its systems or equipment.

b) Category 2. If not applied may have a Significant affect on the following:

Safety of the vessel, its complement or third parties.
Operational performance of the vessel, its systems or equipment.
Through life costs and support.

c) Category 3. If not applied may have a Minor affect on the following:

MOD best practice and fleet commonality.
Corporate experience and knowledge.
Current support practice.

Related Documents

16. In the tender and procurement processes the related documents in each Section and Annex A can
be obtained as follows:
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a) British Standards British Standards Institution,

389 Chiswick High Road,

London, W4 4AL

b) Defence Standards Defence Procurement Agency

An Executive Agency of the MoD

UK Defence Standardization,

Kentigern House

65 Brown Street,

Glasgow, G2 8EX

c) Other documents Tender or Contract Sponsor to advise.

17. All applications to Ministry Establishments for related documents are to quote the relevant MOD
Invitation to Tender or Contract Number and date, together with the sponsoring Directorate and the
Tender or Contract Sponsor.

18. Prime Contractors are responsible for supplying their subcontractors with relevant documentation,
including specifications, standards and drawings.

Health and Safety

Warning

19. This Defence Standard may call for the use of processes, substances and procedures that may be
injurious to health if adequate precautions are not taken. It refers only too technical suitability and in
no way absolves either the supplier or any user from statutory obligations relating to health and
safety at any stage of manufacture or use. Where attention is drawn to hazards, those quoted may
not necessarily be exhaustive.

20. This Defence Standard has been written and is to be used taking into account the policy stipulated in
JSP430: MOD Ship Safety Management System Handbook.

Additional Information

(There is no relevant information)

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Introduction

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REQUIREMENTS FOR CABLE, ELECTRIC

- Part 5
Miscellaneous

1 Scope
a) This Defence Standard (Def Stan) 02–517 Part 5, covers the manufacture and testing requirements
of miscellaneous cable types not covered in Def Stan 02–517 Parts 1 to 4, where usage is specific
to HM Surface Ships, Submarines and Shore/Underwater applications.

b) The voltage rating of the cables is as specified in the Tables of Dimensions contained in Annex C
and the frequency of supply is up to and including 400 Hz.

c) Cables shall be required to withstand the conditions of reeving, temporary support and glanding into
equipment and through bulkheads, which are accepted practices in the Shipbuilding and Ship
refitting industry.

2 Warning
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.

3 Related Documents
a) The following Related Documents are referred to in this Standard.

BS EN ISO 9000, Quality management systems. Fundamentals and vocabulary.

BS EN 10257–1, Zinc or zinc alloy coated non–alloy steel wire for armouring either power cables or
telecommunication cables. Land cables.

BS EN 10257–2, Zinc or zinc alloy coated non–alloy steel wire for armouring either power cables or
telecommunication cables. Submarine cables.

BS EN 10264–1, Steel wire and wire products. Steel wire for ropes. General requirements.

BS EN 10264–2, Steel wire and wire products. Steel wire for ropes. Cold drawn non alloy steel wire for
ropes for general applications.

BS EN 10264–3, Steel wire and wire products. Steel wire for ropes. Round and shaped non alloyed
steel wire for high duty applications.

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BS EN 50267–1, Common Test Methods for cables Under Fire Conditions. Tests on Gases Evolved
During Combustion of Materials from Cables. Apparatus.

BS EN 60584–1, Thermocouples. Reference tables.

BS EN 60702–1, Mineral insulated cables and their terminations with a rated voltage not exceeding 750
V. Cables.

BS EN 60811–1–4, Insulating and sheathing materials of electric cables. Common test methods.
General application. Tests at low temperature.

BS 115, Metallic Resistance Materials for Electrical Purposes.

BS 2782–0, Methods of Testing Plastics.

BS 5099, Spark Testing of Electric Cables.

BS 6360, Specification for Conductors in Insulated Cables and Cords.

BS 6500, Specification for Insulated Flexible Cords and Cables.

BS 7655–1, Specification for Insulating and Sheathing Materials for Cables. Cross–Linked Elastomeric
Insulating Compounds.

BS 7655–2, Specification for Insulating and Sheathing Materials for Cables. Cross–Linked Elastomeric
Sheathing Compounds.

BS 7655–3, Specification for Insulating and Sheathing Materials for Cables. PVC Insulating Compounds.

BS 7655–4, Specification for Insulating and Sheathing Materials for Cables. PVC Sheathing
Compounds.

Def Stan 02–527, Requirements for Cables, Electric, Fire Survival, High Temperature Zones and Limited
Fire Hazard Sheathed.

Def Stan 61–12, Wires, Cords and Cables, Electrical–metric Units:

Part 18: Equipment Wires, Limited Fire Hazard;
Part 31: Sheaths, Limited Fire Hazard.

Def Stan 81–41, Packaging of Defence Materiel:

Part 1: Introduction to Defence Packaging.

JSP 430, Ship Safety Management System Handbook:

Volume 1: Policy and Guidance on MOD Ship and Equipment Safety Management.

4 Performance Specification
No relevant information included.

5 National/International Regulations
No relevant information included.

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6 Military Standards/Requirements
Related Documents: BS EN ISO 9000; BS EN 60811–1–4; BS 5099; BS 6360; Def Stan 61–12 Part 31;
Def Stan 81–41 Part 1; see also Section 3.

6.1 Requirements for Materials

a) All materials shall be in accordance with the requirements of Annex C.

6.2 Construction

6.2.1 Conductor Stranding

a) The number and nominal diameter of the individual wires to be used to form a conductor shall be in
in accordance with the requirements of Annex C.

b) In non–flexible cables the lay length of all wires in each layer shall be uniform throughout the length
of the conductor and the direction of lay of any layer of wires shall be the reverse direction to that of
wires in the adjacent layer.

6.2.2 Conductor Insulation

a) The insulation material shall be in accordance with Annex C, and shall be applied evenly around the
conductor by suitable means.

6.2.3 Tapes

a) Tapes shall be applied helically with approximately 20 per cent overlap unless otherwise specified.
The width of tape and angle of lay shall be such as to minimize wrinkles and creases when the cable
is bent.

6.2.4 Identification of Cores

a) Cores shall be identified by colour or by number as specified in Annex C. Colour identification shall
be by colouring the whole or outer surface of the insulation or by continuous coloured stripe along
the insulation. The colour shall have no deleterious effect on any component of the cable and shall
be practically fast to manufacturing processes and to light.

b) In cases where details are not specified in Annex C the following requirements apply:

1) Coloured cores shall be in the order red, blue, green, yellow, white, black, brown, violet, orange,
pink, turquoise, grey;

2) Multicore cables having numbered identification shall have cores numbered sequentially starting
with No. 1 in the centre. If the centre contains two or more cores they shall be numbered 1, 2,
etc. If a filler centre is specified the number shall start in the first layer. The numbering of the
cores in the subsequent layers shall follow in sequence from previous layer, or centre and
continue consecutively in the same direction throughout;

3) In cables with twisted pairs the individual cores of each pair shall be numbered as follows:

i) 1 pair, cores numbered 1 and 2;

ii) 2 pairs, cores numbered 1 and 2 in the first pair and 3 and 4 in the second pair;

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iii) For cables with a greater number of pairs the numbering shall be similarly extended,
starting from the centre pair, first layer, and proceeding in advancing order in the same
direction in each layer and in sequence from the preceding layer or centre.

6.2.5 Laying–Up of Cores

a) The cores shall be laid up helically in the formation stated in Annex C. The lay of the cores in each
layer shall be about 20 times the pitch circle diameter for non–flexing cables and about 12 times the
pitch circle diameter for flexing cables.

b) To achieve a compact and circular cable and to provide for effective glanding, centres and the
interstices between the cores may be filled as deemed necessary by the manufacturer with fibrous
or suitable elastomeric material. The composition of the filler used shall have no deleterious effect
on the components or performance of the cable.

c) For twisted pairs and quads the cores shall be twisted together with a maximum lay of 200 mm. The
lay lengths of the pairs and quads are chosen and related to reduce inductive effect and cross talk to
a minimum. The direction of lay of any pair or quad shall be the same as the direction of lay of that
pair or quad in the cable.

6.2.6 Screens

a) Where required the braided wire screen of material and size quoted in Annex C shall be applied
over the insulated core or laid–up assembly of cores. The braided screen shall be a snug fit. Joints
in the braidwire shall be woven in or twisted so that the wire ends turn outwards. There shall be no
joints in the completed braid.

b) The number of spindles, ends and length of lay shall be such as to provide a braid with a filling factor
of not less than 0.6 or as specified in Annex C. The filling factor of the braid is defined as:

mnd ⎡ π2D2⎤
2πD ⎢⎣
1+ 2 ⎥½
L ⎦

Where D = mean diameter of braid (mm)

d = diameter of braiding wire (mm)
L = length of lay of braiding wire (mm)
m = total number of spindles
n = total number of ends per spindle

6.2.7 Screen Insulation

a) Adequate screen insulation is required to maintain isolation of screens when the cable is subjected
to the rigours of installation and other normal handling hazards. Extruded or tape–wrapped material
may be used. If tape–wrapped, the tape shall be applied helically with not less than 25 per cent
overlap. The width of tape and angle of lay shall be such as to minimize wrinkles and creases when
the cable is bent.

6.2.8 Sheathing

a) The core or assembly of cores shall be covered with the specified sheathing material to an average
thickness as specified in Annex C. The thickness at any point shall not be less than 80 per cent of
the nominal value. The surface of the sheath shall be reasonably smooth and substantially circular
so as not to degrade cable glanding.

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6.2.9 Overall Diameter

a) The overall diameter of the cable is not to depart from the values specified in Annex C. Where a
nominal diameter only is specified then the tolerances given in Table 1 apply.

Table 1 — Tolerances for Nominal Diameters

Overall diameter of cable Tolerances

Above mm Up to and Including mm Minus mm Plus mm

- 5 0.4 0.6
5 10 0.5 0.7
10 15 0.6 0.8
15 20 0.7 0.9
20 30 0.9 1.1
30 40 1.1 1.3
40 50 1.3 1.5
50 60 1.5 1.7
60 70 1.7 1.9
70 80 1.9 2.1

6.2.10 Marking

a) Except where otherwise stated in the Table of Dimensions in Annex C, the following information
shall be printed on the cable surface:

1) Manufacturer’s name: may be abbreviated;

2) Year of manufacture: may be abbreviated to the last 2 digits if necessary;

3) Def Stan 02–517;

4) Last 7 digits of the NATO Stock Number (NSN).

This information shall be repeated at intervals not exceeding 1 metre along the cable and shall be printed
in a durable, legible manner in a contrasting colour.

6.2.11 Additional Markings

a) Any additional markings called for in the contract or order shall be provided.

6.3 Tests

6.3.1 Scheduled Tests

a) Two types of tests are specified as follows and the tests appropriate to each type are listed in
Table 2.

1) Production Quality Tests: These shall be made on each batch of 20 km of cable, or at least
once on each month’s production, whichever is the lower. Two samples of cable shall be
selected from the production batch, one sample being of the smallest size produced.

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2) Production Routine Tests: These shall be made on every uninterrupted manufactured length
of cable produced.

6.3.2 Electrical Tests

a) Electrical tests shall be carried out in accordance with Clauses 6.3.3.1 to 6.3.4.6. The frequency of
tests shall be in accordance with Table 2.

Table 2 — Test Schedule

Description of Test Clause Production Production

Quality Routine
Tests on Cable Components
Spark Test on Core 6.3.3.1a. 9
Tests on Completed Cable
Spark Test on Sheath 6.3.4.1a. 9
Voltage Withstand 6.3.4.2a. 9
Insulation Resistance 6.3.4.3a. 9
Inner Conductor Resistance 6.3.4.4a. 9
Screen Voltage Withstand 6.3.4.5a. 9
Screen Insulation Resistance 6.3.4.6a. 9
Dimensions 6.3.5a. 9
Visual Examination 6.3.6a. 9
Cold Bend 6.3.7.1a. 9
Tensile Strength & Elongation at Break 6.3.7.2a. 9
Tear Resistance 6.3.7.3a. 9
Accelerated Ageing 6.3.7.4a. 9
Heat Shock 6.3.7.5a. 9
Hot Set Test 6.3.7.6a. 9

6.3.3 Tests on Cable Components

6.3.3.1 Spark Test on Core

a) All insulated cores shall be spark tested in accordance with the requirements of BS 5099.

6.3.4 Tests on Completed Cables

a) All completed cables shall be tested dry at the Contractor’s Works except that single core sheathed
cables shall be tested in water in which the period of immersion shall be not less than 12 hours.

6.3.4.1 Spark Test on Sheath

a) Where specified in the appropriate Table of Dimensions in Annex C, cable sheaths shall be spark
tested in accordance with the requirements of BS 5099. The rms value of the test voltage shall be
as stated in the Table of Dimensions, Annex C.

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6.3.4.2 Voltage Withstand Test

a) The voltage withstand test shall be carried out at ambient temperature with alternating voltage of
sine wave form at any frequency between 40 Hz and 60 Hz. The voltage shall be increased
gradually and maintained steady at the test voltage and time stated in the appropriate Table of
Dimensions in Annex C, between each conductor and either water, screen or other cores which
shall be earthed as applicable. Cores may be connected in groups to reduce the number of tests.

6.3.4.3 Insulation Resistance Test

a) The insulation resistance test between cores and between screens are to be carried out immediately
after the completion of the voltage withstand test. The measurement shall be made at 500 V dc ±10
per cent after 1 minute electrification. The apparent change in insulation resistance during
electrification shall be steady. The results shall be corrected to megohms for a 1 km length at 20°C
using the appropriate correction constants and shall not be less than 1000 Mohm between cores
and 2 Mohm between screens. The cable shall comply with the requirements as specified in the
appropriate Tables of Dimensions in Annex C.

6.3.4.4 Inner Conductor Resistance

a) The conductor resistance of each inner conductor shall be measured at room temperature and
corrected to 90°C by the constants specified in BS 6360, where appropriate. The corrected
resistance is not to exceed the value stated in the appropriate Tables of Dimensions in Annex C.

6.3.4.5 Screen Voltage Withstand

a) To be carried out in accordance with Clause 6.3.4.2a. as applicable and as stated in the appropriate
Table of Dimensions in Annex C.

6.3.4.6 Screen Insulation Resistance

a) To be measured in accordance with Clause 6.3.4.3a. as applicable and as stated in the appropriate
Table of Dimensions in Annex C.

6.3.5 Dimensions

a) The dimensions of the cable shall be measured for compliance with the relevant information
contained in the appropriate Table of Dimensions in Annex C.

6.3.6 Visual Examination

a) Samples from completed cables shall be subjected to a visual examination to ensure that the cable
is in full compliance with the constructional requirements specified.

6.3.7 Additional Tests applicable to Cables having Limited Fire Hazard Sheaths to Def Stan 61–
12 Part 31

6.3.7.1 Cold Bend

a) The method of test shall be in accordance with the requirements of BS EN 60811–1–4.The diameter
of the mandrel shall be five times the cable OD. The temperature shall be -30°C to -34°C. After the
test no cracks shall be apparent in the sheathing.

6.3.7.2 Tensile Strength and Elongation at Break

a) Sheath samples shall be tested in accordance with and meet the requirements of Def Stan 61–12
Part 31.
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6.3.7.3 Tear Resistance

a) Sheath test samples shall be constructed and tested in accordance with and meet the requirements
of Def Stan 61–12 Part 31.

NOTE This test is applicable to cables of 8 mm OD and above.

6.3.7.4 Accelerated Ageing

a) Samples for tensile strength at break, elongation at break and tear shall be aged for seven days at
110°C ±2°C in accordance with the method detailed in Def Stan 61–12 Part 31.

b) The results obtained shall not vary by more than 10 per cent for tensile strength at break or more
than 20 per cent for elongation at break and tear, when compared with results obtained after seven
days ageing period in Def Stan 61–12 Part 31, as quoted in material approval test report.

6.3.7.5 Heat Shock

a) Samples of cable sheaths shall be tested in accordance with the requirements of Def Stan 61–12
Part 31, except that the temperature of 150°C ±2°C shall be maintained for four hours. No cracks
shall occur in the test sample.

6.3.7.6 Hot Set Test

a) To confirm that the sheath has been adequately cross–linked, the hot set test in accordance with the
requirements of BS EN 60811–1–4, shall be performed. The test temperature shall be 200°C ± 5°C
and the stress on the sample 0.2 N/mm2. The maximum elongation shall be not greater than 175
per cent and the maximum permanent set no greater than 25 per cent.

6.4 Quality Assurance of Products

6.4.1 General Requirements

a) The manufacturer shall be included in the register of the Department of Trade and Industry (DTI)
United Kingdom Register of Quality Assessed Companies and assessed by a UK accredited
certification body to BS EN ISO 9000 series.

6.4.2 Procedure

a) The manufacturer shall ensure Quality of Conformance to the specified requirements by the
following methods:

1) Inspection of materials and cable in the course of manufacture to ensure that the requirements
of this Standard are met and the necessary standard of workmanship and process control is
being maintained;

2) Subjection of cable and representative samples to the specified tests.

6.4.3 Tests and Sampling Levels on Completed Cables

a) All cable shall be subjected to the Production Routine tests specified in Clause 6.3.

b) On satisfactory completion of Production Routine tests random samples shall be taken during cutting
for despatch and subjected to Production Quality Tests.

c) The Quality Assurance Authority may at intervals select samples of cable for Quality Audit or check
testing in their own laboratory. Samples shall be selected by the supervising representative of the

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Quality Assurance Authority at the completion of acceptance tests. The cost of all samples shall be
met by the manufacturer.

6.5 Packaging and Labelling

6.5.1 General

a) Packaging and labelling shall be in accordance with the requirements of Def Stan 81–41 Part 1.

6.5.2 Packaging

a) Unless otherwise stated in the order or contract, the cable shall be supplied in coils, on reels or
drums in the lengths stated in the appropriate Table of Dimensions in Annex C.

6.5.3 Supply on Reels

a) Reels shall be non–returnable and suitable for the cable. Cables 15 mm or less overall diameter
and not exceeding a mass of 25 kg may be supplied on non–returnable reels. The barrel diameter
shall be not less than 20 times the maximum specified diameter of the cable.

b) A weatherproof label shall be attached to the reel, permanently and clearly marked with details as
quoted in the contract and is to include the following information:
1) Tare weight in kg;
2) NATO Stock Number of cable;
3) Length of cable in metres;
4) Date of cable sheath manufacture (month and year);
5) Contract number and date;
6) Name of cable manufacturer.

c) Cable ends shall be adequately sealed and a suitable protective wrapping is to be used around the
outside of the cable after winding on reels with sufficient overlap to retard the ingress of liquids.

6.5.4 Supply on Drums

a) Drums shall be supplied by the manufacturer, in accordance with the manufacturers standard
commercial specification. The information detailed in Clause 6.5.3b. shall be permanently and
clearly marked on the flange of each drum, either by stencilling with white paint or by stamping the
details on a suitable alloy marker plate nailed to the drum. The alloy plate shall have a minimum
thickness of 3 mm.

6.5.5 Supply in Coils – Mineral Insulated Cables only

a) The coils shall be closely and neatly wound to an internal diameter not less than 20 times the
diameter of the cable and shall be wrapped in hessian or other suitable material. A label shall be
attached to each coil having the information referred to in Clause 6.5.3b.

6.5.6 Despatch Lengths

a) Unless otherwise specified in an order or contract, standard lengths are shown in the Tables of
Dimensions in Annex C. A tolerance of ±5 per cent shall be acceptable.

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DEF STAN 02-517 Part 5 Issue 2

7 Design Requirements/Guidance
No relevant information included.

8 Corporate Knowledge And Experience

No relevant information included.

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 DEF STAN 02-517 Part 5 Issue 2

Annex A
Abbreviations and Definitions

For the purpose of this Standard the following abbreviations apply:

BS British Standard
BS EN British Standard European
CSP Chlorosulphonated Polyethylene
DEF STAN Defence Standard
EMF Electromotive Force
EPR Ethylene Propylene Rubber
IPT Integrated Project Team
ISO International Standard Orgaization
LFH Limited Fire Hazard
MLS2 Marine Electical Systems 2
MOD Ministry of Defence
NATO North Atlantic Treaty Organisation
NES Naval Engineering Standard
NSN NATO Stock Number
OD Outside Diameter
PCP Polychloroprene
PVC Polyvinyl Chloride
rms Root Mean Square
WSA Warship Support Agency

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DEF STAN 02-517 Part 5 Issue 2

Annex B
Procurement Check List

No relevant information included.

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 DEF STAN 02-517 Part 5 Issue 2

Annex C
Tables of Dimensions

C.1 General
a) Current rating

Except where otherwise specified, the current ratings quoted in the following Tables are for one core
only carrying current. When more than one core carries current the following reduction factors shall
apply:

2 cores equally loaded may carry 80% of single core rating;

3 cores equally loaded may carry 70% of single core rating;
4 cores equally loaded may carry 70% of single core rating;
7 cores equally loaded may carry 60% of single core rating;
14 cores equally loaded may carry 50% of single core rating;
18 cores equally loaded may carry 45% of single core rating;
30 cores equally loaded may carry 40% of single core rating.

The current ratings shown in the following Tables are based on an ambient temperature of 40°C.

b) De–rating Factor for Higher Cooling–Air Temperatures:

Temperature °C 40 45 50

De–rating factor 1.00 0.82 0.72

c) The voltage rating of the cables given in the Tables of Dimensions is the rms value. On direct
current circuits the cables may be used with voltage rating equal to the peak value of the alternating
voltage rating shown in these Tables.

d) A numeric Index of NATO Stock Numbers is shown at Table C.21.

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DEF STAN 02-517 Part 5 Issue 2

Table C.1 — Multicore Silicone Rubber Insulated, Limited Fire Hazard Sheathed Compensating Cables, Collectively Screened 1.0 mm2
Conductor Stranding 7/0.40 mm (See Table C.1)
Conductor Diameter 1.20 mm
Minimum Insulation Resistance per km at 20°C at 500 V 100 megohms
Test Voltage 1500 V rms
Voltage Rating 440 V

EMF with 0°C reference cold

Diameter No of Diameter Gas Flame Test Maximum junction and 100°C hot
Insulation Sheath
NSN No of over glass Cores of taped ScreenWire Overall Conductor junction
Conductor Radial Radial
6145–99 Cores braid and per Laid–up Size Diameter Resistance per
Thickness Thickness Test Minimum
Lacquer Layer Cores km at 20°C Min Mean Max
Voltage Breakdown
mm mm mm mm mm mm mm V V ohm mV mV mV
7/0.40 Plain
7 0.5 2.60 21.6
–521– Copper
14 F.4.10 11.79 0.20 1.3 16.0 440 440 4.235 4.277 4.319
6969 7/0.40
7 0.5 2.60 584
Constantan

NOTE 1 The constantan shall be composed of approximately 44% Nickel and 56% Copper.

NOTE 2 The thermal emf values shall be measured on each pair of completed cables and the values shall be in accordance with the requirements of those in the table and BS EN 60584–1.

NOTE 3 The insulation shall be Type E silicone rubber, glass braid and lacquer in accordance with the requirements of Def Stan 02–527.

NOTE 4 Core identification is to be by numbers.

NOTE 5 The screen wire shall be tinned copper wire in accordance with the requirements of BS 6360. Filling factor is not to be less than 0.5.

NOTE 6 The sheath shall be Limited Fire Hazard sheath in accordance with the requirements of Def Stan 61–12 Part 31.

NOTE 7 The standard despatch length is 100 m per drum.

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 DEF STAN 02-517 Part 5 Issue 2

Table C.2 — Single Core, Silicone Rubber Insulated Cables, Glass Braided Overall

Conductor Rating
Diameter Maximum
Nominal Overall Conductor
NSN 6145–99 Strand Diameter Voltage Current
Area Maximum Resistance per
mm mm mm km at 20°C ohm V A
mm

-521–7005 1.0 1/1.13 1.13 3.8 17.9 440 16

-521–7006 1.5 1/1.38 1.38 4.3 12.0 440 21
-521–7007 2.5 1/1.78 1.78 5.0 7.21 440 29
-521–7008 4.0 7/0.85 2.55 5.6 4.60 440 38
-521–7009 16.0 7/1.70 5.10 9.6 1.14 440 90
-521–7010 0.75 24/0.20 1.14 3.6 25.4 440 6
-521–7011 1.0 32/0.20 1.32 3.8 19.1 440 10
-521–7012 1.5 30.0.25 1.60 4.3 13.0 440 15
-521–7013 2.5 50/0.25 2.00 5.0 7.82 440 20

NOTE 1 The conductors shall be tinned, annealed copper wire in accordance with the requirements of BS 6360.

NOTE 2 The insulation shall be silicone insulation in accordance with the requirements of BS 7655-1,Type E1 2,
covered with a glass fibre braid impregnated with a suitable lacquer.

NOTE 3 The cores shall be coloured black.

NOTE 4 Identification of manufacturer, year of manufacture threads and external marking in accordance with
Clauses 6.2.10 and 6.2.11 shall not be required.

NOTE 5 The nominal length on drum is 100 m.

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DEF STAN 02-517 Part 5 Issue 2

Table C.3 — Single and Two–Pair, Silicone Rubber Insulated, Pairs Screened, PCP
Conductor Stranding 7/0.44 mm
Conductor Diameter 1.32 mm
Maximum Conductor Resistance per km at 20°C 18.2 ohms
Minimum Insulation Resistance per km at 20°C at 500 V 100 megohms
Test Voltage 1500 V rms

Insulation Diameter Diameter Braid Screen Dimeter Overall

Diameter Diameter Diameter Radial
NSN No of over over Laid– Length Voltage
Radial over ptp over Laid–up over Proofed Thickness of
6145-99- Pairs Diameter Varnished up Taped Size Diameter Minimum Maximum on Drum Rating
Thickness Tape Pairs Tape Sheath
Glass Braid Pair
mm mm mm mm mm mm mm mm mm mm mm mm M V
525-2051 1 1.4 9.14 9.64 250 440
0.5 2.32 2.72 5.49 0.15 6.24 6.34 12.68 12.98
525-2052 2 1.5 15.98 17.48 250 440

NOTE 1 The conductors shall be tinned copper wire in accordance with BS 6360.

NOTE 2 The insulation shall be Type E silicone rubber, glass braid and lacquer in accordance with the requirements of Def Stan 02–527.

NOTE 3 The interstices in each pair shall be filled with compound which may be cellular to form a circular section.

NOTE 4 The braid screen is to be tinned copper wire BS 6360, minimum filling factor 0.6.

NOTE 5 In the two–pair cable the interstices between pairs are to be filled with compound which may be cellular to form a circular section.

NOTE 6 Sheath material shall be of HOFR, Heavy Duty, PCP in accordance with the requirements of BS 7655–2, Type EM 2.

NOTE 7 A sample of cable 3 m in length is to be subjected to hydraulic test by applying an external water pressure of 2.4 MN/m2 (24 bar) continuously for 24 hours. At the end of this period
the sheath shall be stripped off and examined. There is to be sign of water having percolated through the sheath.

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 DEF STAN 02-517 Part 5 Issue 2

Table C.4 — 3–Core Thermocouple Extension Cable, Silicone Rubber Insulated,

LFH Sheathed 4 mm2
Conductor Stranding 7/0.85 mm
Conductor Diameter 2.55 mm
Core Diameter 3.75 mm
Minimum Insulation Resistance per km at 20°C at 500 V 100 megohms
Maximum Conductor Resistance per km at 20°C See Notes
Test Voltage 1500 V rms

Dia Diameter
Insulation Dia over Radial
NSN No of over Overall Length Voltage
laid–up Thickness
6145–99– Cores Radial Glass on Drum Ratings
Dia Cores of Sheath Min Max
Thickness Braid
mm mm mm mm mm mm mm m V
525–2044 3 0.6 3.75 4.15 9.9 1.2 12.3 13.7 100 440

NOTE 1 Conductors shall be one each of Nickel–Chromium, Nickel–Aluminium and plain copper.

NOTE 2 Conductor materials and temperature/emf characteristics for the Nickel–chromium – Nickel–aluminium
pair shall comply with the following table. Conductor resistances are not to exceed 197.5 ohm/km for Nickel–
Chromium, 81.5 ohm/km for Nickel–Aluminium and4.61 ohm/km for plain copper.

Material Pairs of EMF with 0°C reference Cold Junction and Hot Junction
Cable 100°C
Minimum mV Mean mV Maximum mV
T1 Nickel–Chromium )
) 4.01 4.10 4.19
T2 Nickel–Aluminium )

NOTE 3 The insulation shall be Type E silicone rubber, glass braid and lacquer in accordance with the
requirements of Def Stan 02–527.

NOTE 4 Core identification shall be Nickel–Chromium – red, Nickel–Aluminium – natural, copper – black.

NOTE 5 The laid–up cores shall be taped with a 0.025 mm thick ptp tape or a 0.15 mm proofed textile tape
applied with 20% overlap. The length of lay shall be approximately 16 times the pitch diameter.

NOTE 6 Temperature/emf characteristics shall be measured as a routine acceptance test.

NOTE 7 The sheath shall be Limited Fire Hazard Sheath in accordance with the requirements of Def Stan 61–12
Part 31.

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DEF STAN 02-517 Part 5 Issue 2

Table C.5 — PVC Insulated, Textile Braided Cord 0.2mm2

Conductor Stranding 25/0.1 mm
Conductor Diameter 0.6 mm
Core Diameter 1.2 mm
Minimum Insulation Resistance per km at 20°C at 500 V 20 megohms
Maximum Conductor Resistance per km at 20°C 108 ohms
Test Voltage 1000 V rms

Diameter Diameter over Rating

over laid Length
NSN No of textile braid
up pairs on Drum Voltage Current
6145–99– Pairs (maximum)
m V A
mm mm
522–7861 5 5.5 6.8 100 250 3

NOTE 1 The conductors shall be tinned, annealed copper wire to BS 6360.

NOTE 2 The insulation shall be PVC in accordance with the requirements of BS 7655–3, Type TI 1.

NOTE 3 The pairs are to be coloured as follows:

Number a–wire b–wire

1 white blue
2 white orange
3 white green
4 white brown
5 white grey

NOTE 4 The pairs shall be laid up around a strain cord approx 0.9 mm diameter.

NOTE 5 The specified radial thickness of insulation (0.30 mm) is a nominal figure and the minimum at a point is
0.25 mm.

NOTE 6 The braid shall be nylon, colour black.

NOTE 7 The completed cable shall be capable of passing freely through a gauge of length150 mm and bore
7.1 mm.

NOTE 8 External marking in accordance with Clause 6.2.10a. is not required.

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 DEF STAN 02-517 Part 5 Issue 2

Table C.6 — 30–Quad, Individually Screened, PCP, Sheathed 0.6 mm2

Conductor Stranding 19/0.20mm
Conductor Diameter 1.02mm
Core Diameter 1.42mm
Maximum Conductor Resistance per km at 20°C 33.1 ohms
Test Voltage 1500V rms
Galvanized
Diam Diameter
Screen Screen Insulation Inner Sheath Steel Wire Final Sheath Rating
Diameter No of over Overall
Braid
NSN No of over taped Quads Taped
6145-99- Quads Quads Diam per Laid up
Diam Radial Radial Wire Radial
over Diam Layer Quads Diam Diam Diam Min Max Voltage Current
of Wire Thickness Thickness Size Thickness
Screen
mm mm mm mm mm mm mm mm mm mm mm mm mm mm V A
F.4.
522-7892 30 3.58 0.12 4.10 0.5 5.10 32.80 1.7 36.2 0.45 38.2 1.7 41.6 39.9 42.3 440 -
10.16

NOTE 1 Insulated cores shall be in accordance with the requirements of Def Stan 61–12 Part 18.
NOTE 2 The screen wire braid shall be tinned copper wire.
NOTE 3 The insulation resistance between screens shall not be less than 2 megohms per km.
NOTE 4 The screen insulation, inner sheath and final sheath shall be in accordance with the requirements of Def Stan 61–12 Part 31.
NOTE 5 Identification:
Individual cores of each quad shall be coloured consecutively Red, Blue, Green, Yellow;
Quads shall be coloured as follows (where two colours are specified, the main base colour is shown first);
Centre: Blue, Grey, WHITE/violet, Turquoise;
First layer: Green, Black, Brown, RED/green, RED/black, BLUE/black, BLUE/green, GREY/blue, GREY/green, GREY/brown;
Second layer: Red, White, Violet, Orange, Pink, RED/blue, WHITE/red, RED/brown, WHITE/blue, ORANGE/blue, WHITE/green, GREEN/black, ORANGE/green, WHITE/brown,
BROWN/black, VIOLET/black;
Both core and quad colours shall be clockwise looking at one end of the cable;
The cable shall be marked with a 12 mm wide longitudinal yellow stripe along the outer sheath.
NOTE 6 The galvanized steel wire braid shall be in accordance with the requirements of BS EN 10257–1.
NOTE 7 Standard despatch length shall be 300 m.

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DEF STAN 02-517 Part 5 Issue 2

Table C.7 — Single Core PVC Insulated Equipment Wires for Thermocouples 0.6mm2
Diameter Minimum EMF with 0°C Reference Cold Junction
Overall Conductor Length and Hot Junction 100°C
NSN 6145- Conductor Resistance on
Colour Pairs of
99- Material Min Max per km at Drum Minimum Mean Maximum
Cables
20°C
mm mm ohms m mV mV mV
522- 7893 Plain Copper White 31.3 )
2.1 2.4 100 ) 4.235 4.277 4.319
522- 7894 Constantan Blue 918 )
T1 Nickel-
522- 7895 Brown 1314 )
Chromium
2.1 2.4 100 ) 4.01 4.10 4.19
T2 Nickel- )
522- 7896 Blue 544
Aluminium

NOTE 1 PVC insulation shall be in accordance with the requirements of BS 7655–3.

NOTE 2 Thermal emf values shall be measured on each pair of completed cables.

Table C.8 — Single and Multicore, PVC Insulated, Screened and Unscreened, Sheathed and
Unsheathed Special Resistance Wires 0.75 mm2
Conductor Stranding 24/0.20 mm
Conductor Diameter 1.14 mm
Maximum Conductor Resistance per km at 20°C 146 ohms
Minimum Insulation Resistance per km at 20°C at 500 V 50 megohms
Voltage Test 1500 V rms

Insulation Braid Screen

Ribbon Length
Sheath Radial Diameter Voltage
NSN No of Radial Wire Dimensions on
Dia Dia Thickness Maximum Rating
6145–99– Cores Thickness Size Maximum Drum
mm mm mm mm V
mm mm mm m

525–2035 1 0.6 2.4 - - - 2.8 - 100 440

531–2958 1 0.6 2.4 0.1 3.1 0.5 4.1 - 100 440
525–2036 15 0.6 2.4 - - - 2.8 2.8 x 42 50 440

NOTE 1 The conductor material shall be in accordance with the requirements of BS 115 as far as it is applicable
and shall have a temperature coefficient of resistance not greater than 0.0005 per °C.

NOTE 2 The insulation shall be PVC compound in accordance with the requirements of BS 7655–3 and the
sheathing shall be PVC compound in accordance with the requirements of BS 7655–4.

NOTE 3 The insulation of the single cores shall be coloured red and the sheath of the screened cable coloured
black. The multicore cable shall be formed from insulated conductors banded together in a parallel ribbon and
coloured in the order yellow, black, blue, red, violet, yellow, black, blue, red, violet, yellow, black, blue, red and violet.

NOTE 4 The screen wire shall be tinned copper wire in accordance with the requirements of BS 6360 and the
filling factor shall not be less than 0.6.

NOTE 5 Manufacturer’s identification tape, year of manufacture threads and external marking in accordance with
Clause 6.2.10a. shall not be required.

NOTE 6 Cables shall be supplied on non–returnable reels which are to be marked ‘Special Resistance Cable’.

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 DEF STAN 02-517 Part 5 Issue 2

Table C.9 — Single Core PVC Insulated Cables (Flexing) 3 mm2

Conductor Stranding 100.20 mm
Conductor Diameter 2.4 mm
Maximum Conductor Resistance per km at 20°C 5.4 ohms
Minimum Insulation Resistance per km at 20°C at 500 V 4 megohms
Voltage Test 1000 V rms

Insulation Rating
Overall
Length on
NSN Radial Diameter
No of Cores Diameter Drum Voltage Current
6145–99– Thickness Maximum
mm m V A
mm mm

529–9206 1 0.45 3.3 4.0 100 440 16

537–8757 1 0.45 3.3 4.0 100 440 16

NOTE 1 The conductors shall be tinned copper wires to BS 6360.

NOTE 2 The insulation shall be PVC compound in accordance with the requirements of BS 7655–3, Type TI 1.
The minimum thickness of insulation shall not be less than 0.4 mm.

NOTE 3 Identification:
a. Cable NSN 6145–99–529–9206. The insulation compound shall be coloured PINK.
b. Cable NSN 6145–99–537–8757. The insulation compound shall be coloured RED.

NOTE 4 Manufacturer’s identification tape, year of manufacture thread and external marking in accordance with
Clause 6.2.10a. shall not be required.

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DEF STAN 02-517 Part 5 Issue 2

Table C.10 — 3–Core EPR Insulated, CSP (LFH) Sheathed Flexible Cords
Conductor Insulation Sheath Minimum Rating
Maximum
Diameter Insulation
NSN No of Voltage Conductor Length
Nominal Radial over Laid– Radial Diameter Resistance per
6145-99- Cores Strand Diameter Diameter Test Resistance per on Drum Voltage Current
Area Thickness up Cores Thickness Overall km 20°C at
km at 20°C
500V
Sq mm mm mm mm mm mm mm mm V megohms ohms m V A
521-8346 3 0.5 16/0.20 0.93 0.6 2.13 4.60 0.8 6.6 1500 900 40.1 100 440 12
521-8349 3 1.5 30/0.25 1.60 0.8 3.20 6.91 1.0 9.3 1500 800 13.7 100 440 23
521-8351 3 4.0 56/0.30 2.60 1.0 4.60 9.94 1.2 12.8 1500 600 5.09 500 440 43

NOTE 1 The conductors shall be tinned copper wire in accordance with the requirements of BS 6360.

NOTE 2 The insulation shall be Ethylene Propylene Rubber (EPR) in accordance with the requirements of BS 7655–1, Type EI 7. Cores shall be coloured: brown, blue, green/yellow.

NOTE 3 The sheath shall be in accordance with the requirements of Def Stan 61–12 Part 31.

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 DEF STAN 02-517 Part 5 Issue 2

Table C.11 — Multicore, EPR Insulated, CSP Sheathed Flexible Cables for Ship–Shore Connections
Conductor Insulation Sheath Minimum
Maximum
Diameter Insulation
Voltage Conductor Length on
NSN No of Nominal Radial over Laid–up Radial Diameter Resistance per
Strand Diameter Diameter Test Resistance per Drum
6145-99- Cores Area Thickness Cores Thickness Overall km 20°C at
km at 20°C
500V
Sq mm mm mm mm mm mm mm mm V megohms ohms m
521-8532 3 95 475/0.50 14.5 1.8 18.1 39.10 4.0 49.9 3000 200 0.21 250
521-8533 3 150 756/0.50 18 2.0 22.0 47.52 4.3 59.3 3000 190 0.132 250
521-8534 3 240 1221/0.50 23.0 2.4 27.8 60.05 4.8 73.2 3000 160 0.0817 250

NOTE 1 The conductors shall be tinned annealed copper wire in accordance with the requirements of BS 6360.

NOTE 2 The insulation shall be cross–linked electronic compound in accordance with the requirements of BS 7655–1, Type GP 4. Cores shall be numbered.

NOTE 3 The sheath shall be CSP HOFR 85°C in accordance with the requirements of BS 7655–2, Type SW 2.

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DEF STAN 02-517 Part 5 Issue 2

Table C.12 — Multicore, EPR Insulated, CSP Sheathed, Flexible Cable 0.5mm2
Conductor Stranding 16/0.20mm
Conductor Diameter 0.93mm
Core Diameter 2.16mm
Minimum Insulation Resistance per km at 20°C at 500 Volts 500 megohms
Maximum Conductor Resistance per km at 20°C 40.1 ohms
Test Voltage 1500V rms

No of Sheath Rating
Diameter Maximum
Cores Length on
NSN No of over Laid– Radial Diameter Overall
per Drum Voltage Current
6145-99 Cores up Cores Thickness (nominal) Diameter
Layer
mm mm mm mm m V A
527-4630 19 F.7.12 12.60 1.20 14.00 14.55 100 440 6

NOTE 1 The conductors shall be tinned annealed copper wire in accordance with the requirements of BS 6360.

NOTE 2 The insulation shall be EPR in accordance with the requirements of BS 7655–1, Type EI 7.

NOTE 3 The inner layer consisting of 1 brown, 1 blue and 5 black cores shall be laid up 8 x PD with a left–hand
lay around a glass centre cord. The outer layer of 1 brown, 1 blue and 10 black cores shall also to be laid up at
8 x PD and with a left–hand lay.

NOTE 4 The sheath shall be CSP in accordance with the requirements of BS 7655–2, Type RS 4.

NOTE 5 A sample of cable shall be subjected to the flexing test in accordance with the requirements ofBS 6500,
Appendix D1. Each pulley shall have a diameter of 150 mm and 2 kg weights are to be applied to each pulley. The
cable shall maintain lay formation with no kinking or cores out of lay after 20,000 cycles.

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 DEF STAN 02-517 Part 5 Issue 2

Table C.13 — Core, EPR Insulated, LFH Sheathed, Copper Wire Braided Cable 1.0mm2
Conductor Stranding See NOTE 1
Conductor Diameter 1.11mm
Core Diameter 2.85mm
Maximum Conductor Resistance per km at 20°C 75 ohms
Minimum Insulation Resistance per km at 20°C at 500 Volts 96 megohms
Test Voltage 1500V rms

Diameter Sheath Braid

Length
over Diameter Voltage
NSN No of Laid–up Radial Diameter on
Size Overall Rating
6145- 99- Cores Thickness Thickness Drum
Cores Maximum
mm mm mm mm mm m V
531- 4072 2 5.70 1.1 9.20 0.20 10.20 100 440
NOTE 1 The conductor shall consist of a 0.5 mm copper centre wire surrounded by eight 0.305 mm tinned steel
wires. The copper conductor shall be tinned copper wire in accordance with the requirements of BS 6360. The
tinned steel wires shall have a minimum tensile strength before stranding of 1550/1700 MN/m2 (155/170 hbars) and
be capable of withstanding 30 twists in 37.5 mm when tested as defined in BS EN 10264–1, BS EN 10264–2 and BS
EN 10264–3.

NOTE 2 The insulation shall be EPR in accordance with the requirements of BS 7655–1, Type EI 7.

NOTE 3 Cores shall be coloured red and black.

NOTE 4 The length of lay shall be approximately 10 times the pitch circle diameter.

NOTE 5 The sheath shall be LFH sheath in accordance with the requirements of Def Stan 61–12,Part 31.

NOTE 6 The braid shall be tinned copper wire in accordance with the requirements of BS 6360 and shall have a
filling factor of not less than 0.7.

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DEF STAN 02-517 Part 5 Issue 2

Table C.14 — Multipair, EPR Insulated, LFH Sheathed, Screened and LFH Sheathed 0.5 mm2

Conductor Stranding 7/0.30 mm

Conductor Diameter 0.90 mm
Core Diameter 2.5 mm
Maximum Conductor Resistance per km at 20°C 41.5 ohms
Minimum Insulation Resistance per km at 20°C at 500 V 900 megohms
Voltage Test 1500 V rms

Diameter Inner Sheath Braid Outer Sheath

No of over taped Length Voltage
NSN No of Pairs Laid–up Radial Radial on Drum Rating
6145-99- Pairs per Diam Size Diam Diam
Pairs Thickness Thickness
Layer
mm mm mm mm mm mm mm m V
531-4569 6 F.6 13.0 1.3 16.0 0.25 17.5 1.3 20.0 500 250

NOTE 1 The conductors shall be tinned annealed copper wire in accordance with the requirements of BS 6360.

NOTE 2 The insulation shall be Ethylene Propylene Rubber (EPR) in accordance with the requirements of BS EN
7655–1, Type EI 7.

NOTE 3 Two cores shall be twisted together to form a pair. The lay length of each pair shall not exceed 200 mm
and the lay length of individual pairs shall be chosen and related and laid up in a manner to reduce inductive effect
and cross talk to a minimum.

NOTE 4 The pairs shall be laid up with a lay of approximately 16 times their pitch circle diameter and taped with
ptp tape. Over the taped laid–up pairs an inner sheath shall be applied, followed by a tinned copper wire braid
having a filling factor of not less than 0.7. A final sheath shall then to be applied. Both sheaths shall be Limited Fire
Hazard Sheath in accordance with the requirements of Def Stan 61–12 Part 31.

NOTE 5 The pairs shall be identified by means of numbers printed on the insulation. The first pair shall be
numbered 1 and 2.

NOTE 6 The mutual capacitance of a pair shall not exceed 0.065 microfarads per km and the inductance per loop
kilometre shall not to exceed 0.82 millihenrys.

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 DEF STAN 02-517 Part 5 Issue 2

Table C.15 — Mineral Insulated Cables

1 2 3
NSN Description Nominal Coil
6145–99– Length m
522-7905 Thermocouple cable for Temperature Indicators 100
Conductor diameter (nom) 0.76 mm
Nominal area 0.45 sq mm
Insulation thickness (nom) 0.33 mm
Sheath thickness (nom) 0.28 mm
Overall diameter (nom) 3.1 mm ±.05 mm
Approximate weight 41 kg/km
Conductor loop resistance per m at 0°C (nom) 1.13 ohm
One conductor plain copper, the other conductor constantan
Sheath–Cupro–nickel
522-7906 2 core – 1.5 sq mm (1/1.38 mm) Shall be in accordance with the 500 or as ordered
requirements of BS EN 60702–1 1000 V class
522-7907 2 core – 1.0 sq mm (1/1.13 mm) Shall be in accordance with the 500 or as ordered
requirements of BS EN 60702–1 600 V class

NOTE 1 Testing shall be in accordance with the requirements of BS EN 60702–1.

NOTE 2 Cable NSN 6145–99–522–7905 temperature/emf characteristic is to comply with the following voltages
with 0°C reference cold junction and 100°C hot junction.
Minimum 4.235 mV
Mean 4.277 mV
Maximum 4.319 mV

NOTE 3 Manufacturer and year of manufacture identification threads and external marking in accordance with
Clause 6.2.10a. are not required.

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DEF STAN 02-517 Part 5 Issue 2

Table C.16 — Twin, EPR Insulated, Screened and Heavy Duty Tough Rubber Sheathed Underwater Cable 1.5 mm2
Conductor Stranding 7/0.53 mm
Conductor Diameter 1.59 mm
Core Diameter 5.59 mm
Minimum Insulation Resistance per km at 20°C at 500 V 2000 megohms
Maximum Conductor Resistance per km at 20°C 12.2 ohms
Test Voltage 1500 V rms

Belting Screen Inner Sheath Outer Sheath Overall Diameter Rating

Diameter
Length
NSN No of Over Laid– Radial Diam of Radial Radial
Diameter Diameter Minimum Maximum on Drum Voltage Current
6145-99- Cores up Cores Thickness Wire Thickness Thickness
mm mm mm mm m V A
mm mm mm mm mm

527-9005 2 11.18 0.8 12.78 0.2 2.0 17.8 2.0 21.8 24.0 1000 440 5

NOTE 1 The conductors shall be tinned copper wire in accordance with the requirements of BS 6360.

NOTE 2 The insulation shall be EPR in accordance with the requirements of BS 7655–1, Type EI 7.

NOTE 3 The cores shall be coloured Red and Black.

NOTE 4 The cores shall be laid up with a lay length of 15 times to 20 times their pitch circle diameter. The laid–up cores shall be filled and belted with rubber compound. Over the belting
shall be applied a braid screen of tinned copper wires in accordance with the requirements of BS 6360 having a filling factor of not less than 0.6. The screen shall not be embedded in the rubber
belting and to assist in this respect a textile of ptp tape may be applied under and over the screen.

NOTE 5 The cable shall be sheathed with two separate tough rubber coverings. The tough rubber sheath shall be in accordance with the requirements for BS 7655–2, Type RS 2. It is
essential that the outer sheath is readily separable from the inner sheath. The outer sheath shall have a smooth finish.

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 DEF STAN 02-517 Part 5 Issue 2

Table C.17 — Single Core, EPR Insulated and LFH Sheathed Cable, Cores Individually Screened 4.0 mm2
Conductor Stranding 126/0.2 mm
Conductor Diameter 2.7 mm
Minimum Insulation Resistance per km at 20°C at 500 V 1600 megohms
Maximum Conductor Resistance per km at 20°C 4.72 ohms
Test Voltage 12000 V rms

Diameter Insulation Sheath Rating

Diameter Diameter
over Diameter Length on
NSN No of Radial Over Over Radial
Semi–con Diameter Overall Drum Voltage Current
6145-99- Cores Thickness Semi–Con Semi–con Thickness
Tape mm Maximum m V A
mm Tape mm Tape mm mm
mm mm
537-8754 1 3.2 5.3 13.8 14.3 15.3 1.4 19.4 100 3300 43

NOTE 1 The conductors shall be tinned copper wire in accordance with the requirements of BS 6360.

NOTE 2 The insulation shall be Ethylene Propylene Rubber (EPR) in accordance with the requirements of BS 7655–1, Type EI 7.

NOTE 3 Over the conductor shall be applied a woven fabric semi–conducting tape of radial thickness 0.25 mm followed by a layer of EPR insulation and a further woven fabric semi–
conducting tape. The core shall then be braided with 0.2 mm tinned copper wires and sheathed with LFH sheath in accordance with the requirements of Def Stan 61–12 Part 31. The filling factor
of the braid shall not be less than 0.45.

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DEF STAN 02-517 Part 5 Issue 2

Table C.18 — Multicore EPR Insulated and LFH Sheathed Cable, Cores Individually Screened
Conductor Insulation Sheath Minimum Maximum Rating
Diameter Diameter
Diameter Insulation Conductor
NSN No of Over Over Voltage
Nom Radial Over Laid– Radial Diam Overall Resistance Resistance
6145-99- Cores Strand Diam Diam Screened Screened & Test Voltage Current
Area Thickness up Cores Thickness Maximum per km at per km at
Cores Taped Cores
20°C at 500V 20°C
2
mm mm mm mm mm mm mm mm mm mm V megohms ohms V A
3 1.0 32/0.2 1.32 2.5 6.32 7.07 7.4 8000 1600 20.0 2500 17
531-3018 6 16.0 1.4 20.1
3 0.5 16/0.2 0.93 0.8 2.53 3.28 3.58 1500 900 40.1 440 12

NOTE 1 The conductors shall be tinned copper wires in accordance with the requirements of BS 6360.

NOTE 2 The insulation shall be EPR in accordance with the requirements of BS 7655–1, Type EI 7.

NOTE 3 The cable shall consist of six cores, three large cores coloured red, blue and green and three smaller cores coloured likewise.

NOTE 4 Each core shall be braided with 0.15 mm tinned copper wire taped with two ptp tapes each 0.025 mm thick and each applied with 50 per cent overlap. The tapes shall be applied in
opposite directions. The filling factor of the braid shall not be less than 0.45.

NOTE 5 The three large cores shall be laid up with a lay of approximately 12 times this pitch diameter. One small core shall be inserted in each outer interstice. The small red core between
the red and blue larger cores, the small blue core between the blue and green large cores and the small green core in the other interstices. Finally the assembly shall be sheathed with LFH
sheath in accordance with the requirements of Def Stan 61–12 Part 31.

NOTE 6 The standard length of cable on a drum is 100 m.

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 DEF STAN 02-517 Part 5 Issue 2

Table C.19 — Single Core, EPR Insulated, Heavy Duty Tough Rubber Sheathed 280 mm2
Conductor Stranding 1769/0.45 mm
Conductor Diameter 26.0 mm
Minimum Insulation Resistance per km at 20°C at 500 V 50 megohms
Maximum Conductor Resistance per km at 20°C 0.08 ohms
Test Voltage 500 V rms

Insulation Inner Sheath Canvas Reinforcement Outer Sheath Rating

Radial Radial Radial Radial Length
Diameter Diameter Diameter Diameter on Drum
NSN 6145-99- Thickness Thickness Thickness Thickness Voltage Current
min max min max min max min max
mm mm mm mm mm mm mm mm m V A
522-7900 0.60 27.4 1.25 30.2 0.60 31.4 1.6 35.0 500 250 275

NOTE 1 The conductor shall be tinned cadmium copper. Cadmium copper of 1 per cent or less nominal cadmium shall have a tensile strength before stranding within the range 780 MN/m2 to
850 MN/m2 and a maximum elongation of 4 per cent. For termination purposes any conductor over26 mm in diameter shall be capable of being compressed by binding to a diameter of 26 mm.
NOTE 2 The wires shall be bunched in groups of 29 wires and the bunches subsequently stranded in the formation listed in NOTE 3. The wires in the individual bunches shall be laid up in the
same direction as the lay of the bunches in each layer. The lay length of the wires in the outer layer of a bunch shall be 65 mm ± 10 per cent when measured in the completed cable.
NOTE 3 Direction of lay:
Centre 1 bunch right–hand;
First layer 6 bunches left–hand (each bunch in layer left–hand);
Second layer 12 bunches right–hand (each bunch in layer right–hand);
Third layer 18 bunches left–hand (each bunch in layer left–hand);
Fourth layer 24 bunches right–hand (each bunch in layer right–hand).
The lay length of the bunches in the fourth layer shall be 380 mm ±10 per cent. In other layers the manufacturer shall aim for a ratio of lay length to pitch circle diameter similar to the
fourth layer but shall meet the requirement of NOTE 9.
NOTE 4 The insulation shall be EPR in accordance with the requirements of BS 7655–1, Type EI 7.
NOTE 5 Identification of the manufacture and year of manufacture tape, or threads shall be applied between the conductors and insulation. A tape shall not exceed 3 mm wide ? 0.05 mm
thick. No other tape is allowable between the conductor and the insulation.
NOTE 6 The inner sheath shall be general purpose grade rubber in accordance with the requirements of BS 7655–2, Type EM I but with a minimum tensile strength of 10 N/mm2.
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DEF STAN 02-517 Part 5 Issue 2

NOTE 7 The outer sheath shall be black, heavy duty tough rubber in accordance with the requirements of BS 7655–2, Type RS 2, and shall have a smooth finish. It is preferable that
vulcanization shall be carried out by the CV process. As a secondary method of vulcanization the cable sheath may be taped and cured or cured under lead. The textile tape shall be finely
woven and applied helically with a nominal overlap of 50 per cent. Pattern of the tape weave showing on the cable sheath is acceptable but the indentations caused by the tape edge shall not be
greater than 0.25 mm deep and not greater than 12 mm wide. The tape shall be removed after vulcanization. Identification shall be by means of an indelible external longitudinal marking of a red
stripe.
NOTE 8 Each length of cable shall be indelibly identified by vulcanizing into the sheath surface yellow numerals approx 20 mm high and positioned approx 4 metres from each end. For each
manufacturer the numerals shall commence at 1 for the first length and run consecutively and the same number shall appear on both ends of the cable. The number shall appear on each
respective drum label (one number per drum).
NOTE 9 It shall not be possible to separate the insulation from the inner sheath or the inner or outer sheaths from the canvas reinforcement. Notwithstanding NOTES 1 and 2, the core shall
be deemed acceptable if it passes the following test:
a. The sheaths and insulation shall be removed over a length of 75 mm distant at least 300 mm from the end of the cable. A measuring tape shall be applied circumferentially around
the conductor with negligible tension, not at any position on the braided section, to indicate a diameter greater than 29.5 mm.

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 DEF STAN 02-517 Part 5 Issue 2

Table C.20 — Single Core, EPR Insulated, Heavy Duty Tough Rubber Sheathed 280 mm2
Conductor Stranding 1769/0.45 mm
Conductor Diameter 25.00 mm
Minimum Insulation Resistance per km at 20°C at 500 V 60 megohms
Maximum Conductor Resistance per km at 20°C 0.067 ohms
Test Voltage 3000 V rms

Insulation Sheath Rating

Radial Length on
NSN Radial
Diameter Thickness Diameter Drum Voltage Current
6145–99 Thickness m
mm Maximum Overall mm V A
mm
mm
As
539–4282 3.0 31.0 3.0 38.0 660 300
ordered

NOTE 1 The conductor shall be tinned copper wire in accordance with the requirements of BS 6360.

NOTE 2 The wires shall be laid up in the form of a rope strand with unidirectional left–hand lay.

NOTE 3 The insulation shall be EPR in accordance with the requirements of BS 7655–1, Type EI 7.

NOTE 4 Each length of cable shall be indelibly identified by vulcanizing into the sheath surface yellow numerals
approximately 20 mm high and positioned approximately 4 metres from each end. For each manufacturer the
numerals shall commence at 1 for the first length and run consecutively and the same number shall appear on both
ends of each length. The number shall appear on each respective drum label (one number per drum).

NOTE 5 After vulcanization it shall not be possible to separate the insulation from the sheath.

NOTE 6 The sheath shall be heavy duty tough rubber in accordance with the requirements of BS 7655–2,
Type RS 2.

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DEF STAN 02-517 Part 5 Issue 2

Table C.21 — Numerical Index to NATO Stock Numbers

NSN 6145–99– Table No NSN 6145–99– Table No

521–6969 Table C.1 522–7896 Table C.7
521–7005 Table C.2 522–7900 Table C.19
521–7006 Table C.2 522–7905 Table C.15
521–7007 Table C.2 522–7906 Table C.15
521–7008 Table C.2 522–7907 Table C.15
521–7009 Table C.2 525–2035 Table C.8
521–7010 Table C.2 525–2036 Table C.8
521–7011 Table C.2 525–2044 Table C.4
521–7012 Table C.2 525–2051 Table C.3
521–7013 Table C.2 525–2052 Table C.3
521–8346 Table C.10 527–4630 Table C.12
521–8349 Table C.10 527–9005 Table C.16
521–8351 Table C.10 529–9206 Table C.9
521–8532 Table C.11 531–2958 Table C.8
521–8533 Table C.11 531–3018 Table C.18
521–8534 Table C.11 531–4072 Table C.13
522–7861 Table C.5 531–4569 Table C.14
522–7892 Table C.6 537–8754 Table C.17
522–7893 Table C.7 537–8757 Table C.9
522–7894 Table C.7 539–4282 Table C.20
522–7895 Table C.7

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 DEF STAN 02-517 Part 5 Issue 2
ALPHABETIC INDEX

(Note: Page numbers are given)

spark test, 7

A voltage test, 7

Accelerated ageing, 8 End sealing, 9

B F

Braids, 4 Filling factor, 4

C I

Cable drums and reels, 9, 10 Identification

Cold bend, 8 cores, 3
Colour coding, 3
Conductor manufacturer, 5
insulation, 3

resistance test, 7
L
stranding, 3
Laying up of cores, 4
Cores
identification, 3
M
laying up, 4
Manufacturer’s abbreviation, 5
tests, 7 Marking, 5

P
D
Packaging and labelling, 9, 10
Despatch lengths, 10 Production quality, 6
Diameter overall, 5 Production routine, 6
Dimensions
test, 7
Q
tolerances, 5
Qualification assurance of products, 9
Quality assurance of products, 8

E
S
Electrical screens, 4
Electrical tests Sampling levels, 9
conductor resistance, 7 Screen
filling factor, 4
insulation resistance, 7
insulation, 4
screen insulation resistance, 7
joints, 4
screen voltage test, 7
Sheathing, 4
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DEF STAN 02-517 Part 5 Issue 2
Spark test, 7 heat shock, 8

hot set, 8
T
production quality, 6
Tapes, 3
Tear resistance, 8 production routine, 6
Tensile strength and elongation at break, 8
Test schedule, 6 tear resistance, 8
Tests
accelerated ageing, 8 tensile strength and elongation at break, 8

cable components, 7 visual examination, 8

cold bend, 8 Tolerances, 5

completed cables, 7, 8
V
dimensions, 7
Visual examination, 8
electrical, 6, 7

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 ©Crown Copyright 2008

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