JSS 51034-1992

RAKSHA MANTRALAYA
MINISTRY OF DEFENCE
JOINT SERVICES SPECIFICATION
ON
DETAILED SPECIFICATION FOR WIRE ELECTRICAL, HIGH

TEMPRATURE FLUOROPDYMER INSULATED
JSS 51034: 1992

Reaffirmed 2002
MANAKIKARAN NIDESHALAYA
RAKSHA UTPADAN TATHA POORTI VIBHAG
RAKSHA MANTRALAYA, 'H' BLOCK, NIRMAN BHAWAN PO
NEW DELHI - 110 011
DIRECTORATE OF STANDARDISATION
DEPARTMENT OF PRODUCTION & SUPPLIES
MINISTRY OF DEFENCE, 'H'- BLOCK, NIRMAN BHAWAN PO
NEW DELHI - 110 011
JSS 51034: 1992
Reaffirmed 2002
RAKSHA MANTRALAYA
MINISTRY OF DEFENCE
JOINT SERVICES SPECIFICATION
ON
DETAILED SPECIFICATION FOR WIRE ELECTRICAL, HIGH

TEMPRATURE FLUOROPDYMER INSULATED
MANAKIKARAN NIDESHALAYA
RAKSHA UTPADAN TATHA POORTI VIBHAG
RAKSHA MANTRALAYA, 'H' BLOCK, NIRMAN BHAWAN PO
NEW DELHI - 110 011
DIRECTORATE OF STANDARDISATION
DEPARTMENT OF PRODUCTION & SUPPLIES
MINISTRY OF DEFENCE, 'H'- BLOCK, NIRMAN BHAWAN PO
NEW DELHI - 110 011
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JSS 51034: 1992
Reaffirmed 2002
RECORD OF AMENDMENTS
Amendment Amendment Amended by

Signature
pertains to:
Authority Name & Appointment &
No. Date Sl.No./ Para No./ Column (IN BLOCK Date
No. LETTERS)
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JSS 51034: 1992
Reaffirmed 2002
CONTENTS
S.No. Page
No.
0. FOREWORD 1
1. SCOPE 2
2. RELATED SPECIFICATIONS AND DOCUMENTS 2
3. INFORMATION TO BE SUPPLIED BY THE PURCHASER 3
4. ILLUSTRATIONS AND DRAWINGS 3
5. PATENTS 3
6. DEFINITIONS 4
7. MATERIAL, PROCESS AND FINISHES 5
8. MARKING 8
9. PACKAGING 9
10. QUALIFICATION APPROVAL AND MAINTENANCE OF 9

QUALIFICATION APPROVAL PROCEDURE
11. BATCH ACCEPTANCE PROCEDURE 10
12. TEST PROCEDURE 12
13. TEST DETAILS 12
14. LIST OF PATTERNS 28
15. TECHNICAL NOTES 28
16. LIST OF STANDARDS 29
17. SUGGESTIONS FOR IMPROVEMENT 29
APPENDIX ‘A’ to ‘E’ 60-73
REPLACEMENT GUIDE 74
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JSS 51034: 1992
Reaffirmed 2002
0. FOREWORD
0.1 This specification has been prepared by Electronics Components

Standardisation Organisation on behalf of Electronics Standardisation sub Committee,
on the authority of Standardisation Committee, Ministry of Defence
0.2 This Specifications is approved by the Ministry of Defence and is

mandatory for use by the Defence Services
0.3 This JSS supersedes the JSS 51004:1976, amendment No. 1,1983.
0.4 This JSS would be used for Design, Manufacture, Quality Assurance and
procurement of the Items.
0.5 Quality Assurance Authority for the items covered in this JSS in
Controllerate of Quality Assurance (Electronics) for Army, Navy and Air forced.
Enquires regarding this specifications relating to any contractual conditions should be
addressed to the Quality Assurance Authority named in the tender or contract. Other
technical enquires should be referred to : -
The Officer – in – Charge

LCSO
DRDO Complex,
CV Raman Nagar
Banglore-560006
0.6 Copies oft this specifications can be obtained on payment from : -
The Controller
Controllerate of Quality Assurance
(Electronics)
Jayachamrajendra Naga PO
Banglore-560006
0.7 This specification holds good only for the supply order for which it is
issued.
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JSS 51034: 1992
Reaffirmed 2002
1. SCOPE
1.1 This specification relates to the requirements of Wire Electrical, High

Temperature, Fluoropolymer Insulated for applications in electrical and electronic
equipment used by the Service. Both extruded or spiral wrapped and fused poly Tetra
Fluoro Ethylene (PTFE), and extruded Fluorianted Ethylene Propylene (FEP)
insulated wires, for hook – up and interconnection applications are covered. This
specification also supersedes JSS 51004: 4*76, Amdt 1 1983 – Detailed specifications
for Equipment Wires, PTPE Insulated.
1.2 For the perpose of interpretation or construction in case of any omission,

conflicts, ambiguities or inconsistencies to the extends that the contract consists of
any or all of the following documents, such documents shall rank in the following
order of precedence: -
(a) This specifications, and

(b) Other applicable documents
2. RELATED SPECIFICATIONS AND DOCUMENTS
2.1 Joint Service Specification
JSS 50101: 1985 : Environmental Test Methods for Service

Electronic Components.
JSS 50102: 1985 : Procedure for the Qualification Approval and

Acceptance of Standard Electronic Components
JSS 50102: 1985 : Procedure for Preparation and updating of Joint

Services Specifications on Electrical
Components
2.2 Other specifications
IS 9938: 1981 : Recommended colours for PVC Installation for

LF Wires and Cables Reaffirmed 1991
IS 10673: 1983 : Sampling Plans and Procedures for Inspection by

attributes for Electronics Items. Re-affirmed
1991
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JSS 51034: 1992
Reaffirmed 2002
2.3 Source of Supply
2.3.1 Joint Service Specifications can be had from : -
The Controller
Controllerate Quality Assurance
(Electronics)
PO JC Nagar,
Banglore-560006
2.3.2 IS Specifications can be had from :-
Bureau of India Standards

Manak Bhawan
9, Bahadur shah Zafar Marg
New Delhi- 110002
3. INFORMATION TO BE SUPPLIED BY THE PURCHASER
3.1 When ordering wire electrical, high temperature covered in this

specification it is essential to quote :
(a) Title and number of this specification.

(b) Style reference and colour of insulation.
(c) Defence Stores catalogue Number and
(d) Quantity on order (length).
4. ILLUSTRATIONS AND DRAWINGS
4.1 Purpose- The essential purpose of the illustrations and drawings in this
specification is to ensure mechanical interchangeability.
4.2 Dimensions – Dimensions are in millimeters.
4.3 Drawings- Where drawings are quoted, they are mandatory. Copies of
such drawings are obtainable from the Officer-in-Charge, LCSO.
5. PATENTS
5.1 Patents or Design rights or copy right may subsist in connection with items
defined as standards and issue of this specification which is the subject of such rights.
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Reaffirmed 2002
6. DEFINITIONS
6.0 For the purpose of this specification the definitions contained in JSS
50101:1985, JSS 50102: 1985 and JSS 50111:1985 together with the following shall
apply.
6.1 Style Reference – the Style references used in this specifications are
abbreviations to Identify families of wire Electrical, high temperature of defined
characteristics. These are derived as follow: -
(a) The first letter ‘W’ represents ‘Wire Electrical’

(b) The second letter ‘H’ represents ‘High Temperature application’.
(c) The following number represents the Voltage Ratings, as given in
Table 1.
TABLE 1 – VOLTAGE RATINGS
Code Number Voltage rating AC (rms)
1 250 V
2 600 V
3 1000 V
(d) The subsequent letter represents the dielectric material used for the
wire installation as follows
P- Extruded or Spiral Wrapped and Fused Poly Tetra Fluoro Ethylene (PTFE).
F – Extruded Fluorinated Ethylene Propylene (FEP)
(e) The single digit and letter combination following as hyphen (after the
coding at (a) to (d) above) represents the applicable conductor details
(material and coating) as in Table 2, and together with the preceding
coding constitutes the pattern.
TABLE 2
CONDUCTOR MATERIAL AND COATING
Code CONDUCTOR
Digit and Material Coating
Letter
Combinations)
1A Soft or Annealed Copper Silver
2A High Strength Copper Alloy Silver
(H.S.C.A)
3A Copper clad Steel (C.C.C) Silver
1B Soft or Annealed Copper Nickel

2B High Strength Copper Alloy Nickel
(H.S.C.A)
3B Copper clad Steel (C.C.C) Nickel
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(f) The subsequent digits which follow denote the conductor size code
(examples given in Table 3) which in combination with the pattern defines
the Style reference (see clause 16). The conductor size code consists of a
series of digits (minimum of three upto a maximum of five) the final two
digit being, incidentally the approximate conductor strand size in AWG;
the preceding digits denoting the number of strands in the conductor
covered.
TABLE 3
EXAMPLES OF CONDUCTOR SIZE CODE
Conductor Size code Stranding (NO of strands/ Dia of

each strand (mm))
132 1/0.20
130 1/0.25
128 1/0.32
740 7/0.08
726 7/0.40
1938 19/0.10
1936 19/0.13
1934 19/0.16
10530 105/0.25
13326 133/0.29
13327 133/0.36
Examples of Style References
WH2P-1A 1934 Wire Electrical, High Temperature, 600 V, PTPE Insulated

with silver coated, soft or annealed copper, conductor size
19/0.16 mm.
WH3F-1A 13327 Wire Electrical, High temperature 1000V,FEP Insulated, with

silver coated soft or annealed copper, conductor size 133/0.36
mm.
7. MATERIAL, PROCESS AND FINISHES
7.1 General- Where materials processes and finishes are specified in this
specification they are mandatory. Attention is drawn to the requirements in JSS
50102: 1985 that materials processes and finishes shall not be changed significantly
without prior approval.
7.2 Workmanship, Processes and Finishes – Wire electrical, High

Temperature, shall be manufactured and processed in a careful and workmanlike
manner. The wire shall be free of kinks, abrasions and cracked or peeled surfaces. It
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JSS 51034: 1992
Reaffirmed 2002
shall be free uniform in quality and free from defects which will adversely affect its
serviceability. The insulation shall be from splinters, blisters and non homogeneities
visible to the normal eye (20-20 vision corrected). The colour of the insulated wires
shall be as specified in clause 16. The details of the colour scheme applicable and
colour coding shall be as specified in Appendix ‘A.
7.2.0 Material and constructions - The materials for principle components of the
wire Electrical, high Temperature shall specified in clause 16. when a definite
material is not specified, a material shall be used that will unable the finished wires to
meet the performance requirements for the manufacture of the finished wires shall be
of such quality and form that the finished product conforms to the requirements
specified herein.
7.2.1 Conductor – The conductor shall consists of single stranded or bunched

soft or annealed high conductivity copper wires, coated in accordance with the clause
16 and covered with a uniform concentric layer of insulation, and shall have the same
coating. The stranding shall be in accordance with Table (see pages 37 to 38) after
insulation. The conductor shall be round in shape, uniform in cross section and free
from flaws, scales and other imperfections.
Conductor material- It shall be one of the following in clause 16: -
Type 1 – soft or annealed copper

Type 2 – High strength copper alloy
Type 3 – Copper clad steel
7.2.1.2 Conductor Coating – The conductor coating shall be either silver or nickel,
as specified in clause 16. Silver coatings shall be minimum 1 mm thick. The
individual wires shall be coated before stranding. The addition of metallic coating
after stranding shall not be permitted. Silver plated conductor strands shall pass the
‘Continuity of costing and coating thickness over conductor’s test ( See clause 13.9)
7.2.1.3 Conductor splicing – Splices shall not be made in a standard conductor as

a whole. However, individual strands had solid conductors may be spliced. Splices
shall be made by solid conductors may be spliced. Splices shall be made by electro-
welding or brazing with silver composition solder. Splices shall be of the butt type,
except for 0.32 mm and smaller conductors where the solid conductor strand may be
twisted, in which case they shall have a minimum overlay of 15 mm.
7.2.2 Insulation – A tight fitting continuous coating shall be added over the
conductor and so cured and processed or maintained so as to provide for accurate
centering of the conductor (see clause 7.2.3) and retention of circular cross section.
The insulation shall be free be free from defects and shall have an adequate finish (
see clause 7.1) and capable of being readily stripped from the conductor by standard
methods leaving the conductor clean for soldering or crimping.
7.2.2.1 Insulation aterial – Either spiral wrapped and fuzed, or

extruded/polyTetra/Fluoro Ethylene (PTFE) or extruded Flourinated Ethylene
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JSS 51034: 1992
Reaffirmed 2002
Propylene (FEP) insulation, as specified in clause 16 shall meet the requirements of

this specification.
7.2.2.2 Insulation Colour – Colour of the finished wires shall generally correspond
to the shades defined as per IS:9938
‘Recommended colours for PVC Insulation for LF Wires and cables’.

When insulation surfaces have been coloured with inks or dyes they shall be non-
conductive, permanently fast and shall not change, fade, run or bleed when used in
direct sunlight and within specific temperature rating of the insulation used. The
colour code stripe(s) shall meet the requirements of Stripe Durability’ test (Test No.
13.14) satisfactorily (see clause 7.1 also)
7.2.3 Outer Coverings – Outer coverings applied when specified shall be as

follow:
7.2.3.1 Braid – Braids shall be closely woven of glass yarn or synthetic yarn. The
angle of application and yarn tensions shall be such to avoid twisting, kinking and
damage to the primary insulation when the wires is operated at the rated temperature.
Braids shall be saturated or filled and coated with non-tarnishing, fungus resistant,
heat, flame and moisture resistant lacquers with smooth finish which will prevent
fraying at cut ends under conditions, incident to handling while being installed and
during normal service. The braid and finish shall have sufficient colour stability to
retain circuit identification during operation at rated temperature. Unless the finishing
compounds are coloured for circuit identification they shall be sufficiently transparent
so as not to impair underlying colour coding of the braid. The addition of a braid shall
add to the specific maximum diameter under the braid not more than 0.38 mm for
core diameters upto 3.175 mm, not more than 0.50 mm for cores 3.20 mm to 6.35
mm, and not more than 0.89 mm for cores over 6.35 mm diameter.
a) Polyamide jacket – Polyamide jacket unless circuit identification is

applied to the jacket, shall be sufficiently transparent so as not to impair
any underlying colour coding.
b) Poluvinyl jacket – Polyvinyl jacket material shall be a polyvinyl

chloride or its copolymer with polyvinyl acetate.
c) FEP Fluoropolymer jacket- FEP Fluoropolymer jacket material shall

be Fluorinated Ethylene propylene. Unless circuit identification is applied
to the jacket, it shall be sufficiently transparent so as not to impair any
underlying colour coding.
d) TFE- Fluoropolymer Jacket – TFE Fluoropolymer jacket material

shall be Poly tetra Fluoro Ethylene.
7.2.3.3 Shield – when shield is specifically required, a closely braid of coated

copper strands shall be applied to provide coverage of not less than 90 percent when
determined by the following formula: -
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JSS 51034: 1992
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K=[2R - F2] X 100

Where:
K = Percent coverage
F = Npd/ Sin (a)
A = angle of braid with axis of cable
Tan (a) = 2 R x ( D + 2 d ) X P/C

d= Diameter of individual braid wire(mm)
c= Number of carriers
D= Diameter of cable under shield (mm)
N= Number of wires per carrier
P= Picks per mm.
Before braiding, strands shall conform to the requirements for conductors.

The metallic coating on the copper strands of shield shall be similar to the metallic
coating of the conductor of the wire to which the shield is applied, unless otherwise
specified. The braided shield shall not increase the maximum diameter of the wire
specified by more than 0.76 mm
7.2.4 Spark Test- spark test in accordance with clauses 13.3 shall be performed
upon 100 percent of the insulated wires supplied under this specification. Insulation
breakdowns resulting from this test and cut out of the finished wire.
8. MARKING
8.1 A label containing the following information shall be security attached to

each reel/ unit pack of the wire: -
a) Nomenclature, i.e, Wire Electrical High Temperature. V FEP

Insulated.
b) Style reference and colour
c) JSS number
d) Defence stores Catalogue Number
e) Manufacturer’s Code & Date and
f) Length in meters, in case a reel/unit pack contains more than one no.
of lengths, length and location of each piece shall be indicated.
Marking done on the Reel shall be located on the flange area, and shall not
become illegible during use.
8.2 When each unit length of the shall be identify by a printing applied to
surface of the visible through the outer surface. The printing identification shall
consists of the following, at intervals of 20 cm to 150 cm, as measured from the
beginning of one complete marking to the beginning of the succeeding complete
marking.
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JSS 51034: 1992
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a) JSS Number and Style Reference

b) Manufacturer’s Code and Date
The printing shall be in a contrasting colour ( black or white is preferable)

and of a permanent type of ink or dye. Printed characters shall be completed and
legible.
9. PACKAGING
9.1 Packaging 9 preservation, identification and packing) shall be in

accordance with the terms of the contract.
9.2 Unless otherwise specified the wires shall be supplied in continuous

lengths of 100 m wound on non-returnable bobbins or reels. Both ends of the wires
shall be available for inspection. For bulk supplies, the nominal lengths of 100 to
300m. except that not more than 20 percent of the total length in any size may be
supplied at random lengths of 20m to 100 m. lengths of less than 50m shall not be
acceptable.
9.3 Both the flanges of such reels shall show the length of each individual
piece in meters as also its position on the reel.
9.4 Bulk supplies shall be packed in a manner which will ensure acceptance by
a common carrier and will afford protection against physical and mechanical damage
during transit from supply source to the first receiving activity for immediate use.
10. QUALIFICATION APPROVAL AND MAINTENANCE OF

QUALIFICATION APPROVAL PROCEDURE
10.0 Qualification approval and Maintenance of Qualification Approval shall be

obtained as described in JSS 50102 and this specification.
10.1 Provision of samples- The manufactures shall submit 100m of the

complete length of finished wire in each of the highest and lowest sizes, separately in
each pattern for which approval is desired. For each pair of samples, one of the
samples shall be in any one of the single colours specified and the other shall be in
multicolour.
10.1.1 Ten metre lengths of representative silver coated strands used in the
construction of each of the finished wire samples, prior to stranding, shall also be
provided.
10.2 Certificate of Constriction- When submitting samples for qualification

approval testing the manufacturer shall certify that 100 percent of the finished wore
passes the Spark Test ( see clauses 7.2.4 and 13.3), Splices Test ( see clauses 7.2.1.3
and 3.4) conductor continuity Test (see clause 13.5) after verification.
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JSS 51034: 1992
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10.3 Grouping of Specimens- The full lengths of sample shall be subjected to

the group ‘0’ test as in Table 4. Specimens shall then be taken from the sample as
required and subjected to the remaining tests.
10.4 Test Incidence- The specimens shall be subjected to the tests specified in
Table 4.
QUALIFICATION APPROVAL TEST

(Clauses 10.1,10.3,10.4)
No. of Specimens Title of Test Testy Number

Visual Examination 13.1.1
Dimensions 13.1.2
Concentricity of Insulation 13.2
FULL LENGTH Spark Test * 13.3
Splices * 13.4
Conductor Continuity 13.5
GROUP ‘1’
Conductor Resistance 13.6
Dielectric Withstanding Voltage 13.7
Insulation Resistance 13.8
GROUP ‘2’
Continuity of Coating and Coating 13.9
Thickness over Conductor
Conductor tensile strength and Elongation 13.10
GROUP ‘3’
Insulation Dielectric Constant and power 13.11
Factor
Insulation Tensile Strength and Elongation 13.12
Surface Resistance 13.13
Stripe durability 13.14
GROUP ‘4’
Cold Bend 13.15
Heat Resistance 13.16
Wrap Back 13.17
Resistance to soldering Heat 13.18
Flammability 13.19
Group ‘5’
Mould Growth 13.20
* Production Test to be based on certification by manufactures
11. BATCH ACCEPTANCE PROCEDURE
11.0 Batch Acceptance shall be performed as described in JSS 50102 and in this
specification.
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JSS 51034: 1992
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11.1 Inspection Batch- An inspection shall be all wires of one specific reference
and colour, produced under essentially the same conditions and offered for inspection
at one time. The batch size shall be the numbers of reel/unit packs of each wire.
11.2 100 percent Acceptance Tests- These tests shall be performed as given in
given in Table 5.
Table 5
100 PERCENT ACCEPTANCE TEST
(Clause 11.2)
Test Number Title of Test

13.1.1 Visual Examination
13.3 Spark Test *
13.4 Splices *
13.5 Conductor Continuity
* Production Test- to be based on certification by manufactures
11.3 Sampling Test – Sampling tests shall consists of group ‘A’ and Group ‘B’
as given in clause 11.3.1 and 11.3.2 respectively. Information on resubmission of
rejected batches is given in IS 10673
11.3.1 Group ‘A’ Tests – These tests shall be performed as given in Table 6.
TABLE 6
Group ‘A’ Tests
(Clauses 11.3.1)
Test Number Title of Test AQL (Percent Inspection Level

Defective)
13.1.2 Dimensions
13.6 Conductor Resistance
13.7 Dielectric withstanding

Voltage *
13.8 Insulation Resistance *
13.9 Continuity of coating &

coating Thickness over
conductor
13.10 Conductor Transit

strength and Elongation
* The Length of the specimens for these tests shall be a minimum of 10m.
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JSS 51034: 1992
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11.3.2 Group ‘B’ Tests – These tests shall be performed as given in Table 7.
TABLE 7
GROUP ‘B’ TESTS
Test Number Title of Test AQL (Percent Inspection Level

Defective)
13.2 Concentricity
13.11 Dielectric Constant and
power factor
13.12 Insulation Tensile
Strength and
Elongation
13.13 Surface Resistance 4 S3
13.15 Cold Bend
13.16 Heat Resistance
13.17 Wrap Back
13.18 Resistance to Soldering
Heat
12. TEST PROCEDURE
12.1 Atmospheric Conditions for Testing- Unless otherwise specified all tests
shall be performed under standard atmosphere conditions defined in section 2 of JSS
50101.
13. TEST DETAILS
Test Title of Test Description Requirements

Number
13.1 General
Examination
13.1.1 Visual The Wire shall be visually The appearances,
Examination examined for its general construction, finish, colour
condition, construction and and marking shall be
finish satisfactory. The wire shall
be uniform in quality and
free of kniks, abrasion and
cracked or peeled surface.
The wire insulation shall
be free from splinters,
blisters and non-
homogeneities
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JSS 51034: 1992
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Number
13.1.2 Dimensions The dimensions shall be
checked as under:
13.1.2.1 Conductor The diameter of the conductor The dimensions shall be
Diameter shall be checked. The conform to these specified
conductor shall be either solid in clause 16 and fall within
or standard as applicable as the limits defined in Table
specified in clause 16. in the 9 at pages 37 to 38 refer
case of Standard conductors,
measurements on the
individual strands shall also be
made
Test Apparatus Micro-meter
caliper graduated to read
0.0025 mm (o.1 mil) and
having flat surface on both
anvil and end of spindle, each
approximately 6mm in
diameter. The surface of the
anvil and spindle shall be
parallel to within 0.0025mm
Test specimens Test
specimens removed from the
finished wire shall be free
from mechanical damage. Any
dirt, grease or other extraneous
materials shall be removed
from the specimen by means
of a soft wiping cloth using
chloroform or any other
suitable solvent. One specimen
each atleast 15 cm in length
removed from each end of the
sample unit of wire shall be
tested.
Test Procedure
The micrometer caliper shall
be applied directly over the
wire so that the anvil and
spindle are just brought in
contact with the specimen in
such a manner that the wire is
not distorted. The criterion of
contact is the initial
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JSS 51034: 1992
Reaffirmed 2002

Number
development of frictional
resistance to movement of the
wire between the micrometer
caliper scale and the value
recorded. Two measurements
of the diameter at position
approximately 90o apart on the
specimens are required. Three
sets of measurements at point
equally spaced along the
length of the specimen shall be
made
Test Results –The average
diameter of the conductor
sample unit shall be the
average of the results obtained
from the specimen tested. The
minimum diameter of the
conductor sample unit shall be
the smallest of all values
averaged in determining the
average diameter, as above.
These diameter values shall be
recorded to the nearest 0.025
mm (1mil).
13.1.2.2 Overall The diameter of the finished The dimensions shall be
diameter wire shall be measured with a within the limits specified
micrometer caliper with the in clause 16
some defined characteristics as
in clause 13.1.2.1. Each
sample unit of the wire shall
be measured at three places,
one measurement near each
end of the unit and one
measurement near the mid
point. Two measurements of
diameter at positions
approximately 90o apart at
each of the above three points
shall be made.
13.2 Concentricity The concentricity of insulating The concentricity of wire
shall be measured on a cross insulating shall be 70
wire at 10 X magnification. percent minimum.
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JSS 51034: 1992
Reaffirmed 2002

Number
If the wire Construction
includes additional layers (e.g
Jacket or insulation coating)
outside the primary insulation
separate determination shall be
made for the primary
insulation and finished wire.
The cross section of the wire.
Both the minimum thickness
and maximum thickness of the
primary insulation or total
insulation wall, as applicable
shall be located for the same
cross section and measured.
The percentage concentricity
is 100 times the ratio of the
minimum measurement to the
corresponding maximum
measurement. Three different
cross sections shall be
measured in each sample unit.
13.3 Spark Test The test shall be conducted on There shall be no
a complete length of wire in breakdown
the manner specified below:
a) Test Electrode: The
electrode shall make an
intimate contact with the
surface of the insulated wire
and shall preferably consist of
a fine link or bead chain.
b) Running Speed: The speed
of the wire through the
electrode shall be such that the
insulation is subjected to the
specified Test Voltage (see
clause 16) applied between the
conductor and every point is in
contact with the electrode for
not less than 0.1 second/ both
ends of the wire conductor
shall be grounded.
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JSS 51034: 1992
Reaffirmed 2002

Number
c) Fault Indicator: A suitable
fault indicating device for
detection of insulation flaws
shall be provided. The detector
shall be arranged so as to
maintain its indication even
after the fault has passed out of
the electrodes.
NOTE- Production Test-
Compliance to be certified by
the manufacturer (see clause
10.2)
13.4 Splices Full length of the wire shall be The Stipulation of clause
examined for conformity to the 7.2.1.3 shall be met.
requirements for conductor
splicing (see clause 7.2.1.3)
NOTE: - Production test-
Compliance for insulated
wires to be certified by the
manufacturer. (see clause
10.2).
13.5 Conductor The complete length of wire There shall be no
Continuity shall be tested for conductor discontinuity
continuity with an ohmmeter
or other suitable testing
device.
13.6 Conductor The Electrical resistance shall The value shall be between
Resistance be measured on the complete the limits specified in
length of wire. The resistance Table 9.
measuring device shall be
capable of measuring
accurately within 0.5 percent
of the value of determined.
The measured value corrected
proportionately to the length
and expressed in
ohms/kilometer shall be
referred to the standard
temperature of the 20oC. for
copper conductors the
resistance shall be corrected to
the standard temperature by
multiplying the measured
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JSS 51034: 1992
Reaffirmed 2002

Number
value by the factor R2, where
R = ____1__________
1 + 0.00393(t-20)
‘t’ being the temperature in

degrees Celsius at which the
measurement is made.
NOTE – To correct the value
proportionately to the length,
the measured resistance shall
be multiplied by the factor 1, L
being the length of the wire in
kilometers.
13.7 Dielectric The test voltage shall be ac as The insulated wire shall
withstanding the waveform being withstand the specific test
voltage approximately sinusoidal and voltage and there shall be
the frequency shall be 40 and no evidence or flash over.
60 Hz and the voltage to be
taken into consideration shall
be expressed as an ras value.
Test Specimens – The
specimens shall be a 10 meter
minimum length of insulated
wire, with the ends prepared
for the electronic connection
(2 cm insulation being
removed from each end),
selected from each sample
unit.
Test Procedures- The test
specimen of the insulated wire
shall be immersed, in a water
bath ( 5 percent by weight
solution of sodium chloride in
water) at 20oC + 5 deg C, with
atleast 4 cm of insulted wire at
each end of the specimen
extending above the water, for
a minimum period of 1 hour.
The insulated wire shall then
be tested between the two
conductors joined together and
17
JSS 51034: 1992
Reaffirmed 2002

Number
an electrode in contact with
the water by an application of
the test voltage specified at 60
Hz, as follows:
Application of Test Voltage-
the test voltage shall be
uniformly increased from zero
to the specific peak voltage
(see clause 16) in 30 seconds
and maintained at that voltage
continuously for a period of 1
minute + 5 seconds and
uniformly reduced to zero in
30 seconds.
Following the test, the
specimen shall be examined.
13.8 Insulation This test shall be conducted The insulation resistance
Resistance immediately after the dielectric shall be not less than the
withstanding voltage test(see resistance value specified
clause 13.7). the test voltage in clause 16 expressed in
shall be 500 + 50 vdc with the Meg ohms/km/
conductor maintained at high
potential. The period of
immersion in the water bath
will be the same ( 1 hour
minimum) as specified in
clause 13.7. the insulation
resistance shall be measured
after an electrification of 1
minute + 5 second
- 0 seconds
At a temperature of 20oC + 5
deg C. in case of dispute on
value of resistance the
measurement shall be repeated
at 20oC + deg C
The minimum requirement of
Insulation Resistance Value X,
in Meg Ohms/km, shall be
calculated as follows:
X = X.Leg (D/d)at
10
18
JSS 51034: 1992
Reaffirmed 2002

Number
20oC 9 in Megaohms/km)
where K = 15290
D = maximum average
diameter of finished wire in
mm.
d= conductor of diameter in
mm.
13.9 Continuity of Test procedures as given in As in clause 7.2.1.2
coating and appendices B & C shall be
coating followed
thickness over
conductor
13.10 Conductor These tests shall be carried out The conductor tensile
tensile strength on specimen of coated strength and elongation
and Elongation conductors removed from the values shall be within the
finished wire. Five specimens limits specified in table 9.
from each sample unit shall be NOTE – Conductor tensile
tested. The test procedure strength values will be
specified in appendix ‘D’ shall presenting treated as ‘ for
be followed information only’
13.11 Insulation The specimen shall be of
Dielectric sufficient length so that the
Constant & measured capacitance is not
Power Factor less than 100 pice-farads. The
external surface shall be
grounded by application of
sprayed metal or by immersion
in mercury except when the
wire is shielded in which case
the shield shall be the ground
electrode.
The power factor and the
capacitance shall be either the
bridge method or the resonant
circuit substitution method at
room temperature and at a
frequency of 1 MHz. the
method shall permit
determination of the power
factor with an accuracy of
plus or minus 5 percent of the
measurement value. The power
factor shall be measured
19
JSS 51034: 1992
Reaffirmed 2002

Number
directly. The dielectric
constant shall be calculated
from the capacitance
measurement and from the
formula given below:
K = 41.4 C log (D/d)
10
Where
K = Dielectric constant
C= Capacitance of specimen in
microfarads per 1000m.
D= Average outside diameter
over dielectric
d= Average diameter of
conductor.
13.12 Insulation These tests shall be made on The insulation tensile
Tensile strength 125mm insulation specimens strength and elongation
and Elongation prepared by cutting specimens values shall not be less
of finished insulated wire that than the minimum values
length and removing the specified in clause 16.
conductor without damage to
the insulation. Five specimens
from each sample unit shall be
tested. The test procedure
specified in appendix ‘E’ shall
be followed and the results
averaged to determine
compliance. The speed of
traverse of the jaws shall be 50
mm/minute minimum and
500mm/ minute maximum and
the initial separationof the
gauge marks for elongation
shall be 25.4 + 0.076 mm. the
tensile strength which shall be
calculated on the original cross
sectional area of the specimen
( based on the diameter of the
conductor in mm and the
thickness of insulation) and the
elongation at break shall be
recorded for each piece.
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JSS 51034: 1992
Reaffirmed 2002

Number
13.13 Surface The specimens shall consists The surface resistance
Resistance of 150 mm length of finished value shall not be less than
wire provided with either two the value specified in
6 mm ring type metal foil clause 16. clause
electrodes or for a small wires, (13.13.1) need not be
several turns of fine tin coated carried out if the initial
wire wrapped snugly around value is grater than 40
the axis of the specimen and Mega ohm mm.
bound with take off leads for
electrical testing of the surface
between the electrodes. The
two electrodes shall be spaced
25 mm apart between nearest
edges and shall be
approximately located near the
middle of the test specimen.
Conditioning- the specimens

shall be conditioned for 96
hours at 25oC + 5 deg C at 95
percent relative humidity. The
surface resistance shall be
calculated while the specimen
is still in the conditioning
chamber with a d.c. potential
of 200 to 500 volts, by noting
the potential and leakage
current after one minute
electrification.
Surface Resistance = V X D
(in mega ohm mm ) I X 25
Where = d.c potential in volts
D = Measured overall diameter
of the wire in mm, and
I = Leakage current in
microamperes
13.13.1 Final
Measurement
13.13.1.1 Dielectric After the initial measurement There shall be no evidence
strength of resistance, a 2500V ras 50 of distress such as areing,
Hz potential shall be applied smoking or burning, flash
for one minute between the over or dielectric failures.
21
JSS 51034: 1992
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Number
electrodes
13.13.1.2 Surface After a discharge interval of 15 The value shall not have
Resistance to 20 minutes, following the changed more than 50
above test, the surface percent from the initial
resistance shall be re-measured value.
13.14 Stripe Durability of the coloured The colour code stripes
Durability stripe shall be evaluated using shall with stand a
a repeated scrape abrasion minimum of 125 cycles
tester. In this instrument a (250 strokes)
short specimen of coloured
marking to be tested is firmly
clamped in a horizontal
position with its upper
longitudinal surface area freely
exposed. A 0.64mm diameter
steel mandrel, usually a needle
is then repeatedly subbed over
the insulation surface at the
stripe so that the longitudinal
axis of mandrel and specimen
are at right angles to each
other, and the point of
tangency between the two is
very small.
A specified weight affixed to a
jig above mandrel controls the
thrust exported to the
insulation surface. By
employing a motor driven
reciprocating can mechanism
and counter, the machine
permits an accurately
measured number of abrasion
strokes all equivalent in thrust
magnitude to be delivered in a
conveniently short time. A test
specimen of previously un-
tested wire sample shall be
mounted on the specimen
clamp. 500 g (total weight)
shall be applied through the
rubbing needle to the
insulation surface for wires
with non conductor sizes
22
JSS 51034: 1992
Reaffirmed 2002

Number
0.51mm and larger and 250 g
for wires with non conductor
sizes 0.10 mm and smaller.
The counter shall be set at zero
and the drive motor started.
This test shall be run for a
minimum of 125 cycles ( 250
strokes)
NOTE -1 This test does not
apply to constructions which
have clear jackets or braids
over the colour coded primary
insulation
NOTE – 2 the needle shall be
changed every 25000 cycles
(50000 strokes).
13.15 Cold Bend Specimens of the completed No readily visible
wire each having a length of derangement shall result
300mm plus the length from this conditioning and
required for wrapping on the bending. The specimen
mandrel with 25mm insulation shall withstand for one
stripped down at each end of minute the dielectric test as
the conductor, shall be specified for primary
conditioned in a chamber insulation of the applicable
maintained at -65oC + 1 deg C type. Additionally in the
for 4 hours with one end case of shielded wire with
attached to the mandrel. After a sheath over the shield the
conditioning and while still in sheath shall with – stand
the chamber at he above for 1 minute, a potential of
specified temperature the 200 volts from sheath to
specimens shall be tested by water
bending over a mandrel of the
size specified in the Table 8,
without opening the chamber,
specimens for which a 75 mm
or larger mandrel is specified
shall be subjected to a 180
degree in the opposite
direction over the mandrel. For
specimens for which a mandrel
smaller than 75mm in a
diameter is specified the
mandrel shall be rotated at the
approximate rate of 15
23
JSS 51034: 1992
Reaffirmed 2002

Number
revolutions per minute so as to
wind atleast three turns of
wore on the mandrel and
rewrapped in the opposite
direction in a similar manner,
Weight shall be attached to the
free end of the specimens to
keep the wire taut during the
bending operation so that close
turns of the specimens upon
the mandrel will be obtained.
The coiled specimens shall be
removed from the mandrel
without straightening and
brought to the room
temperature and visually
examined. The coiled or bent
sections of the wires shall then
be immersed, except for
approximately 50mm at each
end, in tap water at room
temperature for 1 hour.
TABLE – 8 COLD BEND

TEST MANDREL SIZES
Wire Sizes Diameter of
Mandrel
(max)
Wires with (mm)
conductor
size nominal
dia(mm)
0.20 through 1.52 25
1.83 2.36 50
2.82 through
5.41 75
13.16 Heat Resistance Specimens of finished

insulated wire, each having a
length of 300 mm plus the
24
JSS 51034: 1992
Reaffirmed 2002

Number
length required for winding on
the mandrel shall be subjected
to a temperature of 200oC (for
wires with PTFE insulation or
230oC(for wires with FEP
insulation) as applicable (see
clause 16) for a period of 96
hours +1hour
-0hour.
The specimens shall than be No readily visible
removed from the conditioning derangement shall result
chamber and allowed to return from this heating and
to room temperature. coiling. There shall be no
Following the oven ageing, cracking or delamination of
specimens shall be wound the insulation. Slight
tightly around discolouration shall be
mandrel(approximately but not considered normal and
less than three times of the acceptable.
overall diameter of the wire) Server discolouration or
for five close turns and colour change is sufficient
removed s as helical coil. The cause for rejection. The
coiled specimen shall be wire shall withstand the
immersed (except for dielectric withstanding
approximately 50mm at each voltage test.
end) for one hour in tap water
at room temperature and shall
then withstand for one minute
the dielectric withstanding
voltage test (see clause 13.7)
13.17 Wrap Back (For The centre portion of a 300mm The specimen shall show
wires with minimum length specimen of no evidence of cracks and
PTEF insulation finished PRFE insulated wire the wire shall withstand the
only) shall be tightly would back on Dielectric withstanding
itself for a total of four close voltage test.
turns (see Fig. 1). The
specimen shall then be placed
in an oven and heated for two
hours at 307oC + 5deg C. At
the end of this period the
specimen shall be visually
examined without
magnification and than
subjected to the dielectric
withstanding voltage test (see
25
JSS 51034: 1992
Reaffirmed 2002

Number
clause 13.7)
Fig. 1 Test specimen for Wrap Back Test
13.18 Resistance to Specimens of finished wire, The insulation shall not

soldering Heat each 150mm in length shall be flare away from the
prepared for soldering heat test conductor, open up over
by removing 12mm of the end the bent portion nor shrink
of the insulation, the back more than the value
specimens shall be given 90 as specified in clause 16
degree bend over mandrels of for the applicable wire.
their own diameters. These
ends shall be immersed for 5
seconds to within 3mm of the
insulation in a pot of moten
60-40(tin-lead) solder
maintained at a temperature of
approximately 320oC. There
shall be no flux used in
preparing the wire for
soldering
13.19 Flammability Five specimens of wire shall After the source of the
be cut consecutively from the flame has been removed,
same coil and shall be freely the wire shall cease to burn
exposed in an atmosphere of within 10 seconds and the
75 percent relative humidity at total length burned or
a temperature of 20oC + 5 deg charred shall not exceed
C for a period of 16 hours 75mm
before testing
Each specimen of wire shall
then be supported to an angle
of 45 deg in a draught free
chamber. The hottest point of a
vertical 75mm non-luminous
26
JSS 51034: 1992
Reaffirmed 2002

Number
flame from a 9.5mm bunsen
burner with a blue cone 25mm
high, shall be arranged to
impinge on the central portion
of the specimen for 15
seconds.
NOTE 1 – Satisfactory
operation of the flame may be
confirmed by inserting a bare
copper wire 0.71 + 0.025mm
diameter having a free length
of not less than 100mm in the
flame in the position to be
occupied by the specimen. The
flame is satisfactory for the test
if the wire melts in not more
than 6 seconds and not less
than 4 seconds.
NOTE 2 – Care shall be
exercised in making this test as
toxic fumes are given off from
the wire.
13.20 Mould Growth As in JSS 50101 Test Number As in JSS 50101 test
(for information 14. three test specimen (each Number 14
only) 65cm + 15mm long) shall be
used
27
JSS 51034: 1992
Reaffirmed 2002
14. LIST OF PATTERNS
14.1 Preferred Pattern Page No.
WHIP -1A Wire Electrical, High Temperature 250V, 30

PTPE Insulated
WH2P-1A Wire Electrical, High Temperature 600V, 39

PTFE Insulated
WH3P-1A Wire Electrical, High Temperature 1000V, 43

PTFE Insulated
WH1F-1A Wire Electrical, High Temperature 250V, 47

FEP Insulated
WH2F-1A Wire Electrical, High Temperature 600V, 51

FEP Insulated
WH3F1A Wire Electrical, High Temperature 1000V, 55

FEP Insulated
15. TECHNICAL NOTES
15.1 Intended Use- The PTFE and FEP insulated single core wire covered by
this specification is intended for high temperature applications, is suitable for use in
internal wiring of the electrical and electronic equipment and switch boards. PTFE
insulation has good resistance to hot soldering irons except in the case of wire styles
under pattern WHIP-1A where the limitations mentioned under clause 15.2 apply.
FEP insulation does not resist hot soldering irons.
15.2 Thin wall Insulation- Wires having thin wall insulation of 0.18mm
thickness and less are intended for limited low voltage applications. They are
relatively fragile and easily damaged, and should not be used where mechanical stress
or abrasive environment exists. These wires are not suitable in circuits requiring the
highest degree of reliability. In order to appear consistent, the temperature rating is
the same as that assigned to wires with Thicker walls of the same dielectric material.
However, care must be taken during installation and using hot soldering iron, to avoid
damage to the dielectric and to leave no residual physical strain on the dielectric wall,
as plastic flow could result in failures.
15.3 Solid Conductors- the use of solid conductor wires requires caution. Usage
should be limited to lengths of less than 15 to 25 cm, and is not recommended where
flexing is likely to occur or the wire subjected to different vibratory modes along its
length, i.e., between different chassis.
28
JSS 51034: 1992
Reaffirmed 2002
15.4 Current Carrying Capability of Wires- the power dissented in a wire, when
carrying, is I2R. This produce a rise in conductor temperature, which will be added to
the ambient temperature at which the chassis is operating. In covered wire or wires in
sleeving the temperature rise will depend on the thermal resistance of the covering, its
position in the chassis, the amount of free air circulating and whether it is part of a
cable form. This is extremely difficult to calculate and the safety factor to be allowed
is often arbitrary Given an allowable temperature rise over ambient operating
conditions, the conductor must be chosen to have sufficient cross sectional area to
carry the required current.
15.5 Voltage drop- Voltage drop should also be considered in selecting

conductor sizes. In heater circuits where large numbers of values are used, or in
aircraft wiring installations where long runs are necessary, the effect of the voltage
drop can be important. It is difficult to calculate because temperature can efficient of
the wire have to be taken into account in addition to the ambient and operational
temperatures. For instance the resistance of copper is approximately 20 percent higher
at 75oC than it is at 20oC, introducing a considerable error if the voltage drop were to
be calculated on a basis of constant resistance. Where voltage drop is excessive a
larger diameter wire is generally used, although this increases weight and cost.
15.6 Operating Temperature- The total allowable rise due to the passage of
current added to the maximum ambient temperature of the chassis gives the required
operating temperature of the covered wire. The practical limit is always determined
by the covering and not by the wire.
15.7 Voltage Rating- The voltage rating specified (see clause 16) is the
maximum recommended rms voltage at sea level between conductor and ground for
continuous operation. The corresponding allowable direct current potential is
approximately 40 percent greater.
15.8 Maximum Temperature Rating- The temperature rating at sea; eve; is the
maximum recommended hot spot for continuous operation.
15.9 Multicore Cables- Although this specification does not cover multicore,
will manufactured in conformity with this specification are suitable for use as
component parts in making up cables as needed. It must however be noted that the
components before cable assembly and do not cover the performance requirement of
multicore cable constructions to assure compatibility with the required operating
conditions are beyond the preview of this specification.
16. LIST OF STANDARDS
16.0 This list gives details of Wire Electrical, High Temperature, which have
been selected as standards for use in service electronic equipment.
29
JSS 51034: 1992
Reaffirmed 2002
16.1 Pattern WH1P-1A: Wire Electrical, High Temperature, 250V, PTFE

Insulated
16.1.1 Temperature severity : T 65/200 */
*/ Based on the maximum permissible continuous operating temperature

of the conductor and Cold Test(see clause 13.15) conditioning
Temperature.
16.1.2 Voltage rating : 250 V rms
16.1.3 Spark Test : 2.5KV rms.
16.1.4 Conductor material : Type 1A, Silver plated soft or

Annealed copper (See Table 2
And Table 3)
Conductor Resistance : See table 9

Conductor Tensile Strength : See table 9
Conductor Elongation : See table 9
16.1.5 Dielectric Withstanding Voltage : 1.5 KV rms.
30
JSS 51034: 1992
Reaffirmed 2002
TABLE -9 CONDUCTOR REQUIREMENTS

(Type 1A silver plated soft or annealed Copper)
Conductor Stranding Area of Diameter Diameter of conductor (mm) Conductor Conductor Elongation
Size code (No. of Conductor 2 of Strands Min Max Nom 1 (as resistance 140 (strand) (min)
Strands)/ Dia (mm) (mm) in clause per 1000m at Tensile %
(mem) of 16 with 20oC (Test No Strength
each strand 1) values 13.6) (max) (max)
(mm) rounded 2/ohm (n/m2)
upto
second
decimal
1 2 3 4 5 6 7 8 9 10
CONDUCTOR STYLES
1/0.20 0.0324 0.202 0.190 0.229 0.20 557.7 303X106 9.0
1/0.25 0.0507 0.254 0.241 0.279 0.25 356.4 296X106 13.5

1/0.32 0.0806 0.320 0.305 0.330 0.31 224.4 296 X106 13.5
126 1/0.40 0.1282 0.404 0.381 0.432 0.40 140.9 296 X106 13.5
124 1/0.51 0.2047 0.511 0.483 0.559 0.51 88.4 290 X106 15
122 1/0.64 0.3243 0.644 0.6274 0.6604 0.64 56.1 290 X106 20
120 1/0.81 0.5168 0.812 0.787 0.838 0.81 34.7 276 X106 20
118 1/1.02 0.8209 1.024 0.991 1.041 1.02 21.8 276 X106 20
116 1/1.29 1.3073 1.29 1.270 1.321 1.29 13.9
114 1/1.63 2.0825 1.63 1.600 1.651 1.63 8.5
STANDARD CONDUCTOR STYLE
740 5) 7/0.08 0.0340 0.787 0.2235 0.2790 0.25 570.9 325 X106 5.5
738 5) 7/0.10 0.0568 0.102 0.2790 0.3300 0.31 332.3 325 X106 5.5
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JSS 51034: 1992
Reaffirmed 2002
Size code (No. of Conductor 2 of Strands Min Max Nom 1 (as resistance 140 (strand) (min)
Strands)/ Dia (mm) (mm) in clause per 1000m at Tensile %
(mem) of 16 with 20oC (Test No Strength
each strand 1) values 13.6) (max) (max)
(mm) rounded 2/ohm (n/m2)
upto
second
decimal
1 2 3 4 5 6 7 8 9 10
736 5) 7/0.13 0.0887 0.127 0.356 0.406 0.38 210.5 325 X106 5.5
734 7/0.16 0.1409 0.160 0.457 0.508 0.48 133.7 303 X106 9.0
19/0.10 0.1540 0.101 0.457 0.559 0.51 126.7 335 X106 5.5
7/0.20 0.2270 0.202 0.584 0.635 0.61 83.2 303 X106 9.0
19/0.13 0.2487 0.127 0.584 0.686 0.64 80.2 325 X106 5.5
7/0.25 03547 0.254 0.711 0.787 0.76 52.5 296 X106 13.5
1934 5) 19/0.16 0.3820 0.160 0.737 0.838 0.81 49.8 303 X106 9.8
5) See notes at the end of the Table.
32
JSS 51034: 1992
Reaffirmed 2002
TABLE 9 – CONDUCTOR REQUIREMENT (Contd.)

(Type 1A Silver Plated Soft or Annealed Copper)
Size code (No. of Conductor 2 of Strands resistance 140 (strand) (min)
Min Max Nom 1 (as
Strands)/ Dia (mm) (mm) per 1000m at Tensile %
in clause
(mem) of 20oC (Test No Strength
16 with
each strand 1) 13.6) (max) (max)
values
(mm) 2/ohm (n/m2)
rounded
upto
second
decimal
1 2 3 4 5 6 7 8 9 10
STANDARD CONDUCTOR STYLES (Contd)
728 7/0.32 0.5630 0.320 0.914 0.991 0.97 33.0 296 x106 13.5
1932 5) 19/0.20 0.6162 0.202 0.940 1.041 0.02 30.3 303x106 9.0
726 7/0.40 0.8969 0.404 1.194 1.270 1.22 20.7 296x106 13.5
1930 5) 19/0.25 0.9627 0.254 1.168 1.321 1.27 19.1 296x106 13.5
1929 5) 19/0.29 1.2293 0.286 1.346 1.499 1.45 14.9 296x106 13.5
2630 26/0.25 1.3174 0.254 1.448 1.575 1.52 14.2 296x106 13.5
1927 5) 19/0.36 1.9412 0.361 1.651 1.854 1.83 9.5 296x106 13.5
4130 41/0.25 2.0774 0.254 1.829 2.057 1.93 9.0 296x106 13.5
1925 19/0.45 3.0848 0.456 2.159 2.362 2.31 6.0 296x106 13.5
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JSS 51034: 1992
Reaffirmed 2002
3728 37/0.32 2.9763 0.320 2.134 2.311 2.26 5.3 296x106 13.5
6530 65/0.25 3.29.3 0.254 2.362 2.515 2.36 5.7 296x106 13.5
3726 37/0.40 4.7397 0.404 2.692 2.921 2.82 3.9 296x106 13.5
10530 105/0.25 5.3204 0.254 2.997 3.302 3.05 3.5 296x106 13.5
13329 5) 133/0.29 8.6054 0.286 4.013 4.394 4.29 2.2 296x106 13.5
13327 5) 133/0.36 13.5889 0.361 5.029 5.512 5.41 1.4 296x106 13.5
1) Nominal Values are for information only, Nominal values are not requirement.
2) Applies to measurement done on the conductor of the finished wire.
3) Requirements apply to strand taken from the conductor of the finished wire.
4) Tensile strength values ‘for information only’
5) Preferred stranding for associated size.
34
JSS 51034: 1992
Reaffirmed 2002
16.1.6 Insulating Resistance (X) will be calculated as
X = k log (D/d) Mega ohms/km (min) at 20oC

Where
K = 15290
D= maximum average diameter of finished wire
d = Conductor diameter
16.1.7 Insulating Material : Extruded or Spiral Wrapped and fused

Poly Tetra Fluoro Ethylene (PTFE)
Concentricity of Insulation : 70 percent (min).
Insulation Dielectric : 2.2 (max)

constant
Insulation Power factor : 0.005 (max) or 0.5 percent
Insulation Tensile Strength : 21 x 106 N/m2 (min)
Insulation Elongation : 150 percent (min)
Surface Resistance : 0.2 Mega ohms mm (min)
Insulation Colour : As in Table 11
16.1.8 Cold Bend : 4 hours atb + deg C
16.1.9 Heat Resistance : 96 hours at 290oC

Insulation shrinkage
3.17 mm max
16.1.10 Wrap Back : As Applicable
16.1.11 Resistance to soldering Heat : Insulation shrinkage

3.17 mm max
16.1.12 Outline Drawings and Dimensions
Extruded or Spiral Wrapped and Fused PTFE Insulation
Fig. 2 – Outline Drawings for Pattern WH1P – 1A

36
JSS 51034: 1992
Reaffirmed 2002
NOTE 1: All dimensions are in millimeter. See Table 10 for dimensions
NOTE 2: Conductor will be either solid or stranded as specified.

Conductor dimensional limits, etc., have been defined in Table 9 on pages
37 to 38.
16.1.13 List of standards : As in Table 10 supplemented

By the range as applicable in
Table 11 for each style
Reference covered.
Conductor Finished Wire

Style Reference Stranding (No Diameter Diameter over Insulation
of Strands/ (Nominal) Minimum Maximum
Diameter of
each strands)
SOLID
CONDUCTOR
STYLES
WH1P-1A 130 1/0.25 0.25 0.51 0.61
WH1P-1A 128 1/0.32 0.32 0.58 0.69
WH1P-1A 126 1/0.40 0.40 0.66 0.76
WH1P-1A 124 1/0.51 0.51 0.76 0.86
WH1P-1A 122 1/0.64 0.64 0.89 1.02
WH1P-1A 120 1/0.81 0.81 1.07 1.17
STANDARD
CONDUCTOR
STYLES
WH1P-1A 740 7/0.08 0.25 0.51 0.61
WH1P-1A 738 7/0.10 0.31 0.56 0.66
WH1P-1A 736 7/0.13 0.38 0.64 0.74
WH1P-1A 734 7/0.16 0.48 0.74 0.84
WH1P-1A 1938 19/0.10 0.51 0.74 0.84
WH1P-1A 732 7/0.20 0.61 0.86 0.97
WH1P-1A 1936 19/0.13 0.64 0.86 0.97
WH1P-1A 730 7/0.25 0.76 1.02 1.12
WH1P-1A 1934 19/0.16 0.81 1.02 1.12
WH1P-1A 728 7/0.32 0.97 1.22 1.32
WH1P-1A 1932 19/0.20 1.02 1.22 1.32
16.1.14. Range – As in Table 11 Being insulated wires the Defence Stores code
Letters Numbers vary in accordance with the different colours and dated under each
size (style reference)
37
JSS 51034: 1992
Reaffirmed 2002
Table 11 RANGE
(Clause 16.1.13 and 16.1.14 See clause 7.1 also)
Colour/style Colour if Insulation WH1P-1A 130 Defence Stores

Code/ Reference Catalogue Number 6145
Number/ –
0 Black
1 Brown
2 Red
3 Orange
4 Yellow No. of styles under
16.2.13 (Table 10)-17
5 Green
6 Blue
7 Violet Total No. of DS Cat Nos.
to be included :
17 x 19 – 323
8 Grey 19 Nos.
9 White
90 White/Black
91 White/Brown
92 White/Red
93 White/Orange
94 White/Yellow
95 White/Green
96 White/Blue
97 White/Violet
98 White/Grey
Total Ds Cat Nos. = 323
Under Pattern Nos.
WH1P-1A
Note 1 – See Appendix ‘A’ for colour coding.
38
JSS 51034: 1992
Reaffirmed 2002
16.2 Pattern WH2P-1A: Wire Electrical, High Temperature, 600 V,PTFE

Insulated.
16.2.1 Temperature severity : T 65/200 *
* Based on the maximum permissible continuous operating temperature of

the conductor and Bend Test (see clause 13.15) conditioning Temperature.
16.2.2 Voltage rating : 600 V rms.
16.2.3 Spark Test : 3.4 KV rms.
16.2.4 Conductor material : Type 1A, silver plated soft

annealed copper (see table 2
(6.1e) and table 9 on page 37 to
38).
Conductor Resistance : See Table 9
Conductor Tensile : See Table 9

Strength
Conductor Elongation : See Table 9
16.2.5 Dielectric Withstanding : 2.0 kV rms.

Voltage
2/
16.2.6 Insulation Resistance : X Megaohms/km(min)

2/ Values of X Shall be calculated as follows
X= k log (D/d) at 20oC where
10
K = 15290
D – Maximum average diameter of finished wire.
d – conductor diameter
16.2.7 Insulation material : Extruded or Spiral wrapped and

fused Poly Tetra Fluoro Ethylene
(PTFE)
Concentricity of : 70 percent ( min)

Insulation

constant
39
JSS 51034: 1992
Reaffirmed 2002
Insulation Power Factor : 0.005 (max) or 0.5 percent
Insulation Tensile : 21 x 10 N/m (min)

Strength
Surface Resistance : 0.2 Mega ohm mm (min)
Insulation colour : As in Table 13
16.2.8 Cold Bend : 4 hours at -65oC

+ 1 deg C
16.2.9 Heat Resistance : 96 hours at 290oC Insulation

Shrinkage 3.17 mm max.
16.2.10 Wrap Back : Applicable
16.2.11 Resistance to Soldering Heat : Insulation shrinkage 3.17 mm

max
16.2.12 Outline Drawing and Dimensions: -

37 to 38.
16.2.13 List of standards : As in Table 12 supplemented by

the range as applicable in Table 13
for each style reference covered.
40
JSS 51034: 1992
Reaffirmed 2002

Diameter of
each strands)
1 2 3 4 5
SOLID CONDUCTOR STYLES
WH2P-1A 132 1/0.20 0.20 0.64 0.86
WH2P-1A 130 1/0.25 0.25 0.67 0.86
WH2P-1A 128 1/0.32 0.32 0.74 0.94
WH2P-1A 126 1/0.40 0.40 0.81 1.02
WH2P-1A 124 1/0.51 0.51 0.91 1.12
WH2P-1A 122 1/0.64 0.645 1.04 1.27
WH2P-1A 120 1/0.81 0.81 1.22 1.42
WH2P-1A 118 1/1.02 1.02 1.42 1.68
WH2P-1A 116 1/1.29 1.29 1.70 2.06
STRANDED CONDUCTOR STYLES
WH2P-1A 740 7/0.08 0.25 0.66 0.86
WH2P-1A 738 7/0.10 0.31 0.71 0.91
WH2P-1A 736 7/0.13 0.38 0.79 0.99
WH2P-1A 734 7/0.16 0.48 0.89 1.09
WH2P-1A 1938 19/0.10 0.51 0.89 1.09
WH2P-1A 732 7/0.20 0.61 1.02 1.22
WH2P-1A 1936 19/0.13 0.64 1.02 1.22
WH2P-1A 730 7/0.25 0.76 1.17 1.37
WH2P-1A 1934 19/0.16 0.81 1.17 1.37
WH2P-1A 728 7/0.32 0.97 1.37 1.58
WH2P-1A 1932 19/0.20 1.02 1.37 1.58
WH2P-1A 726 7/0.4 1.22 1.63 1.88
WH2P-1A 1930 19/0.25 1.27 1.63 1.88
WH2P-1A 1929 19/0.29 1.45 1.85 2.21
WH2P-1A 1927 19/0.36 1.83 2.24 2.59
WH2P-1A 1925 19/0.45 2.31 2.72 3.07
WH2P-1A 3728 37/0.32 2.26 2.67 3.02
WH2P-1A 3726 37/0.40 2.82 3.23 3.58
41
JSS 51034: 1992
Reaffirmed 2002
16.2.14 Range- As in Table 13 Being insulated wires the Defence Stores code
size (style reference) covered under Table 12.
Table 13 RANGE
Colour/style Colour if Insulation WH1P-1A 132 Defence Stores Catalogue

Code/ Number 6145 –
Reference
Number/
0 Black
1 Brown
2 Red
3 Orange
4 Yellow No. of styles under 16.3.13
(Table 12)-27
5 Green
6 Blue
7 Violet Total No. of DS Cat Nos. to
be included :
27 x 19 – 513
8 Grey 19 Nos.
9 White
90 White/Black
91 White/Brown
92 White/Red
93 White/Orange
94 White/Yellow
95 White/Green
96 White/Blue
97 White/Violet
98 White/Grey
Under Pattern Nos.
WH2P-1A

Note 2 – DS Cat Nos will be included later.
42
JSS 51034: 1992
Reaffirmed 2002
16.3 Pattern WH3P-1A: Wire Electrical, High Temperature, 1000 V,PTFE

Insulated.

the conductor and Bend Test (see clause 13.15) conditioning
Temperature.

6.1e) and table 5

Strength

Voltage
2/

10
16.3.7 Insulation material : Extruded or Spiral wrapped and

fused Poly Tetra Fluoro Ethylene
(PTFE)

Insulation

constant
Insulation Tensile : 21 x 106 N/m2 (min)
Strength
43
JSS 51034: 1992
Reaffirmed 2002

+ 1 deg C

16.3.10 Wrap Back : Applicable

max

37 to 38.

the range as applicable in Table
15 for each style reference
covered.
44
JSS 51034: 1992
Reaffirmed 2002
TABLE 14 DIMENSIONS

Diameter of
each strands)
1 2 3 4 5
SOLID CONDUCTOR
STYLES
WH3P-1A 132 1/0.20 0.20 0.86 1.07
WH3P-1A 130 1/0.25 0.25 0.91 1.12
WH3P-1A 128 1/0.32 0.32 0.99 1.19
WH3P-1A 126 1/0.40 0.40 1.07 1.27
WH3P-1A 124 1/0.51 0.51 1.17 1.37
WH3P-1A 122 1/0.64 0.645 1.30 1.52
WH3P-1A 120 1/0.81 0.81 1.47 1.68
WH3P-1A 118 1/1.02 1.02 1.68 1.93
WH3P-1A 116 1/1.29 1.29 1.96 2.26
STRANDED CONDUCTOR
STYLES
WH3P-1A 740 7/0.08 0.25 0.91 1.12
WH3P-1A 738 7/0.10 0.31 0.97 1.17
WH3P-1A 736 7/0.13 0.38 1.04 1.25
WH3P-1A 734 7/0.16 0.48 1.14 1.35
WH3P-1A 1938 19/0.10 0.51 1.14 1.35
WH3P-1A 732 7/0.20 0.61 1.27 1.47
WH3P-1A 1936 19/0.13 0.64 1.27 1.47
WH3P-1A 730 7/0.25 0.76 1.42 1.63
WH3P-1A 1934 19/0.16 0.81 1.42 1.63
WH3P-1A 728 7/0.32 0.97 1.63 1.83
WH3P-1A 1932 19/0.20 1.02 1.63 1.83
WH3P-1A 726 7/0.4 1.22 1.88 2.13
WH3P-1A 1930 19/0.25 1.27 1.88 2.13
WH3P-1A 1929 19/0.29 1.45 2.11 2.41
WH3P-1A 2630 19/0.25 1.52 2.18 2.49
WH3P-1A 1927 19/0.36 1.83 2.49 2.90
45
JSS 51034: 1992
Reaffirmed 2002
WH3P-1A 1925 19/0.45 2.31 2.97 3.38

WH3P-1A 3728 37/0.32 2.26 2.92 2.33
WH3P-1A 6530 65/0.25 2.36 3.02 3.43
WH3P-1A 3726 37/0.40 2.82 3.48 3.89
WH3P-1A 13329 133/0.29 4.29 5.06 5.56
WH3P-1A 13327 133/0.36 5.41 6.43 6.93
16.3.14. Range- As in Table 15 Being insulated wires the Defence Stores code
size (style reference) covered under Table 14.
Table 15 RANGE
Colour/style Colour if WH1P-1A 132 Defence Stores Catalogue

Code/ Reference Insulation Number 6145 –
Number/
0 Black
1 Brown
2 Red
3 Orange
4 Yellow No. of styles under 16.3.13
(Table 14)-31
5 Green
6 Blue
7 Violet Total No. of DS Cat Nos. to
be included :
31 x 19 – 589
8 Grey 19 Nos.
9 White
90 White/Black
91 White/Brown
92 White/Red
93 White/Orange
94 White/Yellow
95 White/Green
96 White/Blue
97 White/Violet
98 White/Grey
Under Pattern Nos.
WH3P-1A

Note 2 – DS Cat Nos will be included later.
46
JSS 51034: 1992
Reaffirmed 2002
16.4 Pattern WH1F-1A: Wire Electrical, High Temperature, 250 V, FEP

Insulated.

the conductor and Bend Test (see clause 13.15) conditioning Temperature.

annealed copper
(See table 2, 6.1e) and table 5
Conductor Resistance : see Table 9

Strength

Voltage
2/

10
K = 15290
d – Conductor diameter
16.4.7 Insulation material : Extruded Fluorinated Ethylene

Propylene (FEP)
Insulation

Constant
Strength
47
JSS 51034: 1992
Reaffirmed 2002

+ 1 deg C

16.4.10 Wrap Back : Not Applicable

max
Extruded FEP Insulation
Fig. 5 – Outline Drawings for Pattern WH1F – 1A

Conductor dimensional limits, etc., have been defined in Table 8.

17 for each style Reference
covered.
48
JSS 51034: 1992
Reaffirmed 2002
TABLE 16 DIMENSIONS

Diameter of
each strands)
1 2 3 4 5
WH1F-1A 132 1/0.20 0.20 0.46 0.56
WH1F-1A 130 1/0.25 0.25 0.51 0.61
WH1F-1A 128 1/0.32 0.32 0.58 0.69
WH1F-1A 126 1/0.40 0.40 0.66 0.76
WH1F-1A 124 1/0.51 0.51 0.76 0.86
WH1F-1A 122 1/0.64 0.64 0.89 1.02
WH1F-1A 120 1/0.81 0.81 1.07 1.17
WH1F-1A 740 7/0.08 0.25 0.51 0.61
WH1F-1A 738 7/0.10 0.31 0.56 0.66
WH1F-1A 736 7/0.13 0.38 0.64 0.74
WH1F-1A 734 7/0.16 0.48 0.74 0.84
WH1F-1A 1938 19/0.10 0.51 0.74 0.84
WH1F-1A 732 7/0.20 0.61 0.86 0.965
WH1F-1A 1936 19/0.13 0.64 0.86 0.965
WH1F-1A 730 7/0.25 0.76 1.02 1.12
WH1F-1A 1934 19/0.16 0.81 1.02 1.12
WH1F-1A 728 7/0.32 0.97 1.22 1.32
WH1F-1A 1932 19/0.20 1.02 1.22 1.32
49
JSS 51034: 1992
Reaffirmed 2002
16.4.14 Range- As in Table 17. Being insulated wires the Defence Stores
Catalogue Numbers vary in accordance with the different colours accommodated
under each size (style reference) covered under the table 16.
TABLE 17
(Clauses 16.4.13 and 16.4.14, See clause 7.1 also)
Colour/style Colour if Insulation WH1F-1A 132 Defence Stores

Code/ Reference Catalogue Number
Number/ 6145 –
0 Black
1 Brown
2 Red
3 Orange
16.4.13 (Table 16)-18
5 Green
6 Blue
7 Violet Total No. of DS Cat
Nos.19 Nos. to be
included :
18 x 19 – 342
8 Grey 19 Nos.
9 White
90 White/Black
91 White/Brown
92 White/Red
93 White/Orange
94 White/Yellow
95 White/Green
96 White/Blue
97 White/Violet
98 White/Grey
Total Ds Cat Nos. =
342
Under Pattern Nos.
WH1F-1A
NOTE 1- See Appendix ‘A’ for colour coding.
50
JSS 51034: 1992
Reaffirmed 2002
16.5 Pattern WH2F-1A: Wire Electrical, High Temperature, 600 V,FEP

Insulated.

the conductor and Bend Test ( see clause 13.15) conditioning Temperature.

6.1e) and table 5

Strength

Voltage
2/

10
K = 15290

Propylene (FEP)

Insulation

constant
Strength

51
JSS 51034: 1992
Reaffirmed 2002

+ 1 deg C


max
16.5.12 Outline Drawing and Dimensions : -
Extruded FEP Insulation

Conductor dimensional limits, etc., have been defined in Table 9.

17 for each style Reference
covered.
52
JSS 51034: 1992
Reaffirmed 2002
TABLE 18 DIMENSIONS

Diameter of
each strands)
1 2 3 4 5
WH2F-1A 132 1/0.20 0.20 0.61 0.81
WH2F-1A 130 1/0.25 0.25 0.66 0.86
WH2F-1A 128 1/0.32 0.32 0.74 0.94
WH2F-1A 126 1/0.40 0.40 0.81 1.02
WH2F-1A 124 1/0.51 0.51 0.91 1.12
WH2F-1A 122 1/0.64 0.64 1.04 1.27
WH2F-1A 120 1/0.81 0.81 1.47 1.68
WH2F-1A 118 1/1.02 1.02 1.42 1.68
WH2F-1A 116 1/1.29 1.29 1.70 2.06
WH2F-1A 114 1/1.63 1.63 2.03 2.39
WH2F-1A 740 7/0.08 0.25 0.66 0.86
WH2F-1A 738 7/0.10 0.31 0.71 0.91
WH2F-1A 736 7/0.13 0.38 0.79 0.99
WH2F-1A 734 7/0.16 0.48 0.89 1.09
WH2F-1A 1938 19/0.10 0.51 0.89 1.09
WH2F-1A 732 7/0.20 0.61 1.02 1.22
WH2F-1A 1936 19/0.13 0.64 1.02 1.22
WH2F-1A 730 7/0.25 0.76 1.17 1.37
WH2F-1A 1934 19/0.16 0.81 1.17 1.37
WH2F-1A 728 7/0.32 0.97 1.63 1.83
WH2F-1A 1932 19/0.20 1.02 1.63 1.83
WH2F-1A 726 7/0.40 1.22 1.63 1.88
WH2F-1A1930 19/0.25 1.27 1.63 1.88
WH2F-1A 1929 19/0.29 1.45 1.85 2.21
WH2F-1A 1927 19/0.36 1.83 2.24 2.59
53
JSS 51034: 1992
Reaffirmed 2002
16.5.14 Range- As in Table 19. Being insulated wires the Defence Stores
Catalogue Numbers vary in accordance with the different colours accommodated
under each size (style reference) covered under the table 18.
TABLE 19

Number/ –
0 Black
1 Brown
2 Red
3 Orange
16.5.13 (Table 19)-28
5 Green
6 Blue
Nos.19 Nos. to be
included :
28 x 19 – 532
8 Grey 19 Nos.
9 White
90 White/Black
91 White/Brown
92 White/Red
93 White/Orange
94 White/Yellow
95 White/Green
96 White/Blue
97 White/Violet
98 White/Grey
Under Pattern Nos.
WH2F-1A
NOTE 1 – See Appendix ‘A’ for colour coding.

NOTE 2- DS Cat Nos. will be included later.
54
JSS 51034: 1992
Reaffirmed 2002
16.6 Pattern WH3F-1A: Wire Electrical, High Temperature, 1000 V,FEP

Insulated.

the conductor and Bend Test ( see clause 13.15) conditioning Temperature.

annealed copper (see table 2 6.1e)
and table 5

Strength

Voltage
2/

10
K = 15290

Propylene (FEP)

Insulation

constant
Strength

55
JSS 51034: 1992
Reaffirmed 2002

+ 1 deg C


max
NOTE: All dimensions are in millimeter. See Table 21 for dimensions
NOTE: Conductor will be either solid or stranded as specified. Conductor

dimensional limits, etc., have been defined in Table 9.

21 for each style reference
covered.
56
JSS 51034: 1992
Reaffirmed 2002
TABLE 20 DIMENSIONS

Diameter of
each strands)
1 2 3 4 5
WH3F-1A 132 1/0.20 0.20 0.84 1.04
WH3F-1A 130 1/0.25 0.25 0.91 1.12
WH3F-1A 128 1/0.32 0.32 0.99 1.19
WH3F-1A 126 1/0.40 0.40 1.09 1.27
WH3F-1A 124 1/0.51 0.51 1.17 1.37
WH3F-1A 122 1/0.64 0.64 1.30 1.52
WH3F-1A 120 1/0.81 0.81 1.47 1.68
WH3F-1A 118 1/1.02 1.02 1.68 1.96
WH3F-1A 116 1/1.29 1.29 1.96 2.26
WH3F-1A 114 1/1.63 1.63 2.29 2.69
WH3F-1A 740 7/0.08 0.20 0.89 1.09
WH3F-1A 738 7/0.10 0.31 0.97 1.17
WH3F-1A 736 7/0.13 0.38 1.04 1.25
WH3F-1A 734 7/0.16 0.48 1.14 1.35
WH3F-1A 1938 19/0.10 0.51 1.14 1.35
WH3F-1A1936 19/0.13 0.64 1.27 1.47
WH3F-1A 732 7/0.20 0.61 1.27 1.47
WH3F-1A 730 7/0.25 0.76 1.42 1.63
WH3F-1A 1934 19/0.16 0.81 1.42 1.63
WH3F-1A 728 7/0.32 0.97 1.63 1.83
WH3F-1A 1932 19/0.20 1.02 1.63 1.83
WH3F-1A 726 7/0.40 1.22 1.88 2.13
WH3F-1A 1930 19/0.25 1.27 1.88 2.13
WH3F-1A 1929 19/0.29 1.45 2.11 2.41
WH3F-1A 2630 26/0.25 1.52 2.18 2.49
WH3F-1A 1927 19/0.36 1.83 2.49 2.90
57
JSS 51034: 1992
Reaffirmed 2002
WH3F-1A 4130 41/0.25 1.93 2.59 3.00

WH3F-1A 1925 19/0.45 2.31 2.97 3.38
WH3F-1A 6530 65/0.25 2.36 3.02 3.43
WH3F-1A 3726 37/0.40 2.82 3.48 3.89
WH3F-1A 10530 105/0.25 3.05 3.71 4.12
WH3F-1A 13329 133/0.29 4.29 5.06 5.56
WH3F-1A 13327 133/0.36 5.51 7.26 7.65
16.6.14 Range- AS in Fig. 21 Being insulated wires the Defence Catalogue

Numbers vary in accordance with the different colours accommodated under each size
(Style Reference) served under Table 20.
TABLE 21 RANGE

Number/ –
0 Black
1 Brown
2 Red
3 Orange
16.6.13 (Table 20)-33
5 Green
6 Blue
Nos.19 Nos. to be
included :
33 x 19 – 627
8 Grey 19 Nos.
9 White
90 White/Black
91 White/Brown
92 White/Red
93 White/Orange
94 White/Yellow
95 White/Green
96 White/Blue
97 White/Violet
98 White/Grey
Under Pattern Nos.
WH3F-1A
NOTE 1 – See Appendix ‘A’ for colour coding.
58
JSS 51034: 1992
Reaffirmed 2002
17.0 SUGGESTIONS FOR IMPROVEMENT
17.1 Any suggestions for improvement of this document may be addressed to : -
The Director
Directorate of Standardisation
Ministry of Defence
New Delhi – 110011.
59
JSS 51034: 1992
Reaffirmed 2002
APPENDIX ‘A’
COLOUR SCHEME AND COLOUR CODING
A.0 Scope – This appendix describes the colour Scheme and Colour coding to
be followed for solid coloured wires and those wires using coloured helical stripes or
bands for insulation colouring.
A.1 Colour Scheme for Identification of Cores (Striping and Banding) –

Colour identification shall be accomplished by use of solid colour insulation as
specified in clause 16 or as an alternate method, by use of a single coloured helical
stripes or circumferential band over white insulation. Coloured helical stripes or
circumferential bends shall be based only on all white insulation whenever colour
combination other than solid coloured wires are necessary. Not more than three
stripes or bends shall be used. Stripes and bands shall be applied in the same
direction.
A.1.1 Sequence – In the sequence of applying helical stripes or circumferential

bands on a wire, the first stripe or band shall be distinguishably wider than the second
third stripe or band within the group. Helical stripes shall run parallel to each other
and shall be continues, clearly defined and constant in width and spacing throughout
the length of the wire. Circumferential bands shall be parallel to each other around the
circumference of the wire, shall be clearly defined shall be constant in width and
spacing, and shall be continues in repeated colour groupings for the length of the wire
unless otherwise specified.
A.1.2 Stripe or bandwidth – The width of the stripe or band shall be measured
perpendicular to the axis (center line) of the stripe or band. The width of the wide (
first) stripe or band shall be not less than two third(2/3) the nominal diameter of the
wire. The narrow (second) stripe or band shall be not less than one half (1/2) nor more
than three quarters (3/4) the width of the wide (first) stripe or band. The third stripe
shall be of the same width or band as the second stripe or band.
A.1.3 Stripe or band spacing – On single stripe or band colouring the spacing
between each stripe or band shall be not less than twice the width of the individual
stripe or band. On multiple stripe or band colouring, the spacing between stripes or
band within a grouping shall be not less than the width of the narrow stripe or band.
A.1.4 Length of Lay (spacing between groups) – The length of lay of each stripe
shall not exceed 50m.
A.1.5 Spacing between groups or bands – The spacing between groups of bands
shall be at regular intervals along the wire. The spacing separating a group of bands
from the next grouping shall be not exceeds 75mm.
A.2 Colour Coding
A.2.1 Colour Coding shall be as specified in Table 22.

60
JSS 51034: 1992
Reaffirmed 2002
TABLE 22 COLOUR CODING
BASE COLOUR FIRST STRIPE SECOND STRIPE COLOUR CODE

OR BAND OR BAND NUMBER
Black 0
Brown 1
Red 2
Orange 3
Yellow 4
Green 5
Blue 6
Violet 7
Grey 8
White 9
White Black 90
White Brown 91
White Red 92
White Orange 93
White Yellow 94
White Green 95
White Blue 96
White Violet 97
White Grey 98
White Black Brown 901
White Black Red 902
White Black Orange 903
White Black Yellow 904
White Black Green 905
White Black Blue 906
61
JSS 51034: 1992
Reaffirmed 2002
BASE COLOUR FIRST STRIPE OR SECOND THIRD COLOUR CODE

BAND STRIPE OR STRIPE OR NUMBER
BAND BAND
White Black Violet 907
White Black Grey 908
White Brown Red 912
White Brown Orange 913
White Brown Yellow 914
White Brown Green 915
White Brown Blue 916
White Brown Violet 917
White Brown Grey 918
White Red Orange 923
White Red Yellow 924
White Red Green 925
White Red Blue 926
White Red Violet 927
White Red Grey 928
White Orange Yellow 934
White Orange Green 935
White Orange Blue 936
White Orange Violet 937
White Orange Grey 938
White Yellow Green 945
White Yellow Blue 946
White Yellow Violet 947
White Yellow Grey 948
White Green Blue 956
White Green Violet 957
White Green Grey 958
White Blue Violet 967
White Blue Grey 968
White Violet Grey 978
White Black Brown Red 9012
White Black Brown Orange 9013
White Black Brown Yellow 9014
White Black Brown Green 9015
White Black Brown Blue 9016
White Black Brown Violet 9017
White Black Brown Grey 9018
62
JSS 51034: 1992
Reaffirmed 2002
BASE FIRST SECOND THIRD COLOUR

COLOUR STRIPE OR STRIPE OR STRIPE OR CODE
BAND BAND BAND NUMBER
White Black Red Orange 9023
White Black Red Yellow 9024
White Black Red Green 9025
White Black Red Blue 9026
White Black Red Violet 9027
White Black Red Grey 9028
White Black Orange Yellow 9034
White Black Orange Green 9035
White Black Orange Blue 9036
White Black Orange Violet 9037
White Black Orange Grey 9038
White Black Yellow Green 9045
White Black Yellow Blue 9046
White Black Yellow Violet 9047
White Black Yellow Grey 9048
White Black Green Blue 9056
White Black Green Violet 9057
White Black Green Grey 9058
White Black Blue Violet 9067
White Black Blue Grey 9068
White Black Violet Grey 9078
White Brown Red Orange 9123
White Brown Red Yellow 9124
White Brown Red Green 9125
White Brown Red Blue 9126
White Brown Red Violet 9127
White Brown Red Grey 9128
White Brown Orange Yellow 9134
White Brown Orange Green 9135
White Brown Orange Blue 9136
White Brown Orange Violet 9137
White Brown Orange Grey 9138
White Brown Yellow Green 9145
White Brown Yellow Blue 9146
White Brown Yellow Violet 9147
White Brown Yellow Grey 9148
63
JSS 51034: 1992
Reaffirmed 2002
BASE FIRST SECOND THIRD COLOUR

COLOUR STRIPE OR STRIPE OR STRIPE OR CODE
BAND BAND BAND NUMBER
White Brown Green Blue 9156
White Brown Green Violet 9157
White Brown Green Grey 9158
White Brown Blue Yellow 9167
White Brown Blue Grey 9168
White Brown Violet Grey 9178
White Red Orange Yellow 9234
White Red Orange Green 9235
White Red Orange Blue 9236
White Red Orange Violet 9237
White Red Orange Grey 9238
White Red Yellow Green 9245
White Red Yellow Blue 9246
White Red Yellow Violet 9247
White Red Yellow Grey 9248
White Red Green Blue 9256
White Red Green Violet 9257
White Red Green Grey 9258
White Red Blue Violet 9267
White Red Blue Grey 9268
White Red Violet Grey 9278
White Orange Yellow Green 9345
White Orange Yellow Blue 9346
White Orange Yellow Violet 9347
White Orange Yellow Grey 9348
White Orange Green Blue 9356
White Orange Green Violet 9357
White Orange Green Grey 9358
White Orange Blue Violet 9367
White Orange Blue Grey 9368
White Orange Violet Grey 9378
White Yellow Green Blue 9456
White Yellow Green Violet 9457
White Yellow Green Grey 9458
White Yellow Blue Violet 9467
White Yellow Blue Grey 9468
White Yellow Violet Grey 9478
White Green Blue Violet 9567
White Green Blue Grey 9568
White Green Violet Grey 9578
White Blue Violet Grey 9678
64
JSS 51034: 1992
Reaffirmed 2002
APPENDIX B
CONTINUITY OF COATING OF SILVER
B.0 Scope – This Appendix describes the method of test for the determination
of continuity of silver coating on copper.
B.1 Testing
B.1.1 Test Specimen – Test specimens shall each have length of 150mm. they
shall be tagged or marked to correspond with the coil, spool or reel from which they
were cut.
B.1.1.1 Treatment of Specimens – The specimens shall be thoroughly cleaned by

immersion in a suitable organic solvent such as benzine, other or trichloroethylene for
atleast 3 minutes, then removed and wiped dry with clean, soft cloth (Caution : Note
1). The specimens thus cleaned shall be kept wrapped in a clean, dry cloth until tested.
The part of the specimen to be immersed in the test solution shall not be handled.
Care shall be taken to avoid abrasion by the cut end.
B.1.2 Special Solutions
B.1.2.1 Sodium Polysulphide Solution – A concentrated solution shall be made by

dissolving sodium sulphide crystals in distilled water until the solution is saturated at
about 21oC and adding sufficient flowers of sulphur (in excess of 250 g per liter of
solution) to provide complete saturation as shown by the presence in solution of an
excess of sulphur after the solution has been allowed to stand for atleast 24 hours. The
test solution shall be made by diluting as portion of the concentrated solution with
distilled water to a specific gravity of 1.142 at 15.6oC. the sodium polysulphide test
solution should have sufficient strength to blacken thoroughly a piece of clean
uncoated copper wire in 5 sec. a portion of the test solution used for testing samples
shall not be considered to be exhausted until it fails to blacken a piece of clean copper
as described above. (see Note 2).
B.1.2.2 Hydrochoric Acid Solution – (sp gr 1.088) – commercial HCL (sp gr 1.12)
shall be diluted with distilled water to a specific gravity of 1.088 measured at 15.6oC.
a portion of the HCL solution having a volume of 180 ml shall be considered
exhausted if it falls to remove within 15 sec., the discolouration of the silver due to
the polysulphide immersion.
B.1.3 Procedure
B.1.3.1 Immersion in Polysulphide Solution – A length of atleast 110 mm from

each of the clean specimens shall be immersed for 30 sec., in the sodium polysulphide
solution. Describes in para B.1.2.1, maintained at a temperature between 15.6oC and
21oC.
65
JSS 51034: 1992
Reaffirmed 2002
B.1.3.2 Washing – After the immersion, the specimens shall be immediately be

thoroughly washed in clean water and wiped dry with a clean, soft cloth.
B1.3.3 Immersion in Hydrochloric Acid – After washing, the specimen

immediately be immersed for 15 sec in the HCL solution described in paragraph
B.1.2.2 thoroughly washed in clean water, and wiped dry with a clean, soft cloth.
B.1.3.4 Examination of Specimens – After immersion and washing, the specimen

shall be examined to ascertain if copper exposed through penings in the silver coating
has been blackened by action of the sodium polysulphide. The specimen is examined
with the normal eye against a white background. The specimens shall be considered to
have failed if, by such blackening, exposed copper is revealed. No attention shall be
paid to blackening within 13 mm, of the cut end.
66
JSS 51034: 1992
Reaffirmed 2002
APPENDIX C
THICKNESS OF COATING OF SILVER
C.0 Scope This appendix describes the method of test for the
determination of thickness of silver coating over copper wires.
C.1 Testing
C.1.1 Reagents
C.1.1.1 Nitric acid (1 :4)
C.1.1.2 Nitric acid wash solution (1 :99)
C.1.1.3 Sodium chloride solution ( 100g of Nacl per litre)
C1.1.4 Alcohol wash solution Mix equal volumes of special denatured alcohol
and water
C.1.2 Procedure
C.1.2.1 Weight to the nearest 0.1 mg, a portion of the sample of silver coated wire
of a length equivalent to 40 mg of silver. Transfer the sample to a 600ml chemically
resistant glass beaker and add 20 ml of HNO3 (1:4) sample. Cover the beaker, warm
gently until solution is complete, and boil to expel brown fumes. Dilute the solution
with distilled water using approximately 50 ml of water per gram of sample. Heat to
boiling, remove from the hot plate, and add slowly with rapid stirring, 10 ml of NaCl
solution. Boil the solution to 2 to 3 minutes to catalogue, the AgCl precipitate. Allow
to cool and the precipitate to settle.
C.1.2.2 Filter using a tared No. 10 porosity filtering crucible. Wash free of copper
salts with HNO3 wash solution by two to four washings with alcohol wash solution.
Dry in an oven at 205oC to constant weight. Cool and weight sd AgCl.
C.1.3 Calculation
The Weight of silver used = Ax 0.7526

Where A is the weight of Agcl in g
Volume of silver used = Weight of silver

Density of silver (10.5 g/cc)
Thickness of silver = Volume of silver

D x 1
Where D is the diameter and 1 length othe wire
over which silver is Coated.
67
JSS 51034: 1992
Reaffirmed 2002
NOTE 1 Caution : Consideration should be given to toxicity and flammability

when selecting solvent cleaners.
NOTE 2 It is important that the polysulphate solution be of proper composition and

strength at the time of test. A solution which is not saturated with sulphur or which
has been made from decomposed sodium sulphide crystals may give a false indication
of failure. Therefore, the requirement that the solution be tested by observing its
blackening effect on a bright copper wire is significant. Significant also is the
requirement that the solution be saturated with sulphur by allowing the solution to
stand atleast 24 hours after preparation. Attention is called also to the necessity for the
use of sodium sulphide which has not deteriorated through exposure to air, and if
exposure has occurred the crystals should be tested for purity.
NOTE 3 Whether the silver is applied by electroplating or by mechanical classing,

cladding, coatings less than 1 µm in thickness will not pass the ‘Continuity of
Coating’ test.
68
JSS 51034: 1992
Reaffirmed 2002
APPENDIX D’
TENSILE STRENGTH AND ELONGATION OF STRANDED CONDUCTORS
D.0 This appendix describes the test procedure for determining the tensile
strength and elongation of conductor strands used for the stranded conductors of
finished wire.
D.1 Test Specimens – Five specimens shall be taken for testing. Each specimen
shall be atleast 50 cm in length.
NOTE : In case of difficulties in removing longer length of conductor

strands from the finished wire, use of representative samples of conductor
strands prior to twisting is permitted.
D.2 Test apparatus – The test apparatus shall consist of a test machine and a
steel scale graduated to 1 mm or finer.
D.2.1 Test machine – The test machine shall be designed to meet the following
requirements.
The grip of the machine shall be power actuated and of spool type which
can produce as nearly as possible uniformly distributed pure axial tension in the
specimen. The applied tension shall be indicated by a dial, scale or automatic recorder
to within + 1%, when properly calibrated. The indicator shall remain at the position
of maximum force after rapture of the specimen. A spring balanced type of machine is
satisfactory if equipped to prevent recoil of the spring. The rate of travel of grips shall
be 25+ 5 cm per minute under no load and shall be uniform. The machine shall
accommodate spacemen of 25 cm bench length. The machine shall be of such
capacity that the maximum load required to break the specimen is not greater than 85
percent nor less than 15 percent of the rated capacity.
D.3 Test procedure – Two parallel bench marks 25 cm + 1 mm apart shall be

placed on the specimen without damaging the conductor. The conductor diameter
shall be measured with a micrometer caliper graduated to 0.0025 mm at a place
equally distributed between the bench marks, the minimum value recorded as D. after
measuring the diameter, the specimen shall be placed on the machine such that the
bench marks are between the spools but not in contract with the spools. The grips
shall be actuated and shall move at the rate of 25 + 5 cm per minute. After the rupture
of the specimen, the breaking force shall be read from the indicator to the nearest
grams and the value recorded as F/ If the specimens breaks
Outside the within 2.5 cm of either bench marks, the shall be discarded
and optional specimen tested until the breaks are obtained within the breaks are
obtained within the prescribed portion. The broken specimen shall be placed
immediately on a smooth surface and the ruptured areas fitted together as closely as
possible with the two portions placed on the straight line and the distance between the
bench marks measured to the nearest 1 mm. the length shall be recorded as L.
69
JSS 51034: 1992
Reaffirmed 2002
D.4 Calculations
The tensile strength of the specimen shall be calculated as follows:
Tensile strength
4F x 10 4
(N/m2) = П (D)2
Where,
F= Breaking force in grams.

D = Minimum diameter of the specimen in mm
D.4.2 The elongation shall be calculated as follows “
Elongation percent = (L – 25) x 100

-------------------
25
D.5 Test Results
D.5.1 The tensile strength or elongation of the conductor specimen shall be the
average of the results obtained from the specimen tested.
70
JSS 51034: 1992
Reaffirmed 2002
APPENDIX ‘E’
INSULATION TENSILE STRENGTH AND ELONGATION
E.0 Scope – This appendix describes the method of test for determination of
tensile strength and elongation insulation of the finished wire.
E.1 Testing
E.1.1 Testing machine – A testing machine which meet the following

requirements shall be used.
(a) The machine shall be power driven.

(b) The applied tension shall be indicated to within + 1 percent by a dial
or scale or automatic recorder when properly calibrated.
(c) The indicator shall remain at the point of maximum force after
rupture of the specimens.
(d) The rate of travel of the power actuated grip shall be 500 mm + 25
mm per minute and shall be uniform at all times.
(e) The machine when used for given specimen, shall be such capacity
that the maximum load required to break the specimen is not greater
than 85 nor less then 15 percent of the rated capacity.
E.1.2 Test Specimens – As preparation of dump bell-shaped specimens is not

practicable, straight specimens of insulation in the form of as tube shall be used for
testing. These shall be free from nicks. If possible, the specimens shall be cut with a
single stroke of the cutting pool. For cutting support use of rubber belting, leather
belting, light card-board, or other material with a smooth, slighting yielding surface
that will not injure the cutting edge during the cutting is permitted.
E.1.3 Test procedure – The specimen shall be placed in the grips of the machine
and adjusted symmetrically in order that the tension will be distributed uniformly over
the cross section. If the tension is greater on the side of the specimen than the other,
the maximum strength of the specimen will not be developed. The force shall be
applied to the specimen at such a rate that the power actuated grip will travel at as
uniform speed of 50 mm min and 500 mm + 25 mm max per minute. The grips shall
be either wedged type or toggle clamps shall be used. Following additional details
shall be applicable.
E.1.3.1 Tensile strength test – The distance between the edge of the clamp at the
start of the test shall be 76 mm + 3 mm. After rupture of the specimen the breaking
force shall be noted from the dial or scale or by means of an autographic or spark
recorder and the value noted.
E.1.3.2 Elongation test – The test specimens shall have two parallel bench marks
symmetrically on the straight contrasting coloured ink such that the distance between
the bench (gauge) marks is 25.4 + 0.076 mm. The marks shall be not more than 0.25
mm wide. Care shall be taken not to injure the specimens. Other details being the
71
JSS 51034: 1992
Reaffirmed 2002
same as the procedure for the tensile Strength Test the test specimen shall be placed
on the grips of the testing machine and the force applied. The distance between the
two bench marks on the test specimen shall be noted continuously to the nearest 2 mm
by means of the manner as not to touch the specimen or only very lightly touch it on
the front or back. Two operators may be required to conduct this test. The distance
between the bench marks when the specimen ruptures together with the original
distance between the bench marks shall be recorded.
NOTE: Unless otherwise specified, the elongation shall be determined on

the same specimen and at the same time as the tensile strength.
E.1.4 Test results and calculations
E.1.4.1 For tensile strength test – The cross- sectional area ‘C’ of the test specimen
shall be determined in square mm using the formula:
C2 = П (D2-d2)
(mm) 4
Where,
D = measured overall diameter of the finished wire measured as in clause 13.1.2.2 in

mm.
d = nominal diameter of conductor as specified in clause 16 and measured as in clause

13.1.2.1 in mm.
The tensile strength of the specimen shall be calculated as follows :
Tensile Strength
(N/m2) = f x 107
C
Where,
F = breaking force in kg.

C – Cross-sectional area of the unstretched specimen in mm.
72
JSS 51034: 1992
Reaffirmed 2002
E.1.4.2 For Elongation Test
The elongation of the specimen shall be calculated as follows:
Elongation percent: D-G X 100

G
Where,
D = Distance between the bench marks at the moments of rupture of

the specimen in mm.
G = Distance between the bench marks on the unstretched specimen in

mm.
73
JSS 51034: 1992
Reaffirmed 2002
REPLACEMENT GUIDE
WH1P 1A 1) MIL-W-16878E/20
MIL-W-16878E/6B
WH2P 1A 1) MIL-W-16878E/21
MIL-W-16878E/4B
WH3P 1A 1) MIL-W-16878E/22
MIL-W-16878E/5B
WH1F-1A MIL-W-16878E/13A
WH2F-1A MIL-W-16878E/11A
WH3F-1A MIL-W-16878E/12C
1) These JSS Patterns will also replace the equivalent earlier JSS 51004
Patterns as follows:
JSS 51004 FEB 1976

WH1P-1A WE1TD
WH2P-1A WE2TD
WH3P-1A WE3TD
74

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RAKSHA MANTRALAYA

JOINT SERVICES SPECIFICATION

DETAILED SPECIFICATION FOR WIRE ELECTRICAL, HIGH

JSS 51034: 1992

JOINT SERVICES SPECIFICATION

DETAILED SPECIFICATION FOR WIRE ELECTRICAL, HIGH

Amendment Amendment Amended by

2. RELATED SPECIFICATIONS AND DOCUMENTS 2

3. INFORMATION TO BE SUPPLIED BY THE PURCHASER 3

4. ILLUSTRATIONS AND DRAWINGS 3

7. MATERIAL, PROCESS AND FINISHES 5

10. QUALIFICATION APPROVAL AND MAINTENANCE OF 9

11. BATCH ACCEPTANCE PROCEDURE 10

12. TEST PROCEDURE 12

13. TEST DETAILS 12

14. LIST OF PATTERNS 28

15. TECHNICAL NOTES 28

16. LIST OF STANDARDS 29

17. SUGGESTIONS FOR IMPROVEMENT 29

APPENDIX ‘A’ to ‘E’ 60-73

0.1 This specification has been prepared by Electronics Components

0.2 This Specifications is approved by the Ministry of Defence and is

The Officer – in – Charge

0.6 Copies oft this specifications can be obtained on payment from : -

1.1 This specification relates to the requirements of Wire Electrical, High

1.2 For the perpose of interpretation or construction in case of any omission,

(a) This specifications, and

2. RELATED SPECIFICATIONS AND DOCUMENTS

2.1 Joint Service Specification

JSS 50101: 1985 : Environmental Test Methods for Service

JSS 50102: 1985 : Procedure for the Qualification Approval and

JSS 50102: 1985 : Procedure for Preparation and updating of Joint

2.2 Other specifications

IS 9938: 1981 : Recommended colours for PVC Installation for

IS 10673: 1983 : Sampling Plans and Procedures for Inspection by

2.3 Source of Supply

2.3.1 Joint Service Specifications can be had from : -

2.3.2 IS Specifications can be had from :-

Bureau of India Standards

3. INFORMATION TO BE SUPPLIED BY THE PURCHASER

3.1 When ordering wire electrical, high temperature covered in this

(a) Title and number of this specification.

4. ILLUSTRATIONS AND DRAWINGS

4.2 Dimensions – Dimensions are in millimeters.

(a) The first letter ‘W’ represents ‘Wire Electrical’

1B Soft or Annealed Copper Nickel

Conductor Size code Stranding (NO of strands/ Dia of

Examples of Style References

WH2P-1A 1934 Wire Electrical, High Temperature, 600 V, PTPE Insulated

WH3F-1A 13327 Wire Electrical, High temperature 1000V,FEP Insulated, with

7. MATERIAL, PROCESS AND FINISHES

7.2 Workmanship, Processes and Finishes – Wire electrical, High

7.2.1 Conductor – The conductor shall consists of single stranded or bunched

Conductor material- It shall be one of the following in clause 16: -

Type 1 – soft or annealed copper

7.2.1.3 Conductor splicing – Splices shall not be made in a standard conductor as

7.2.2.1 Insulation aterial – Either spiral wrapped and fuzed, or

Propylene (FEP) insulation, as specified in clause 16 shall meet the requirements of