NIMB Installation Standards (SE000-00-EIM-110)

NAVSEA SE000-00-EIM-110(0967-LP-000-0110)

NAVYINSTALLATION

ANDMAINTENANCE BOOK

(NIMB)

INSTALLATIONSTANDARDS

DISTRIBUTION STATEMENT B: DISTRIBUTION AUTHORIZED TO U.S. GOVERNMENT AGENCIES AND THEIRCONTRACTORS; ADMINISTRATIVE/OPERATIONAL USE; DATE OF PUBLICATION.OTHER REQUESTS SHALL BE REFERRED TO THE NAVAL SEA SYSTEMSCOMMAND (SEA--91Q3).

WARNING: THIS DOCUMENT CONTAINS TECHNICAL DATA WHOSE EXPORT IS RESTRICTEDBY THE ARMS EXPORT CONTROL ACT (TITLE 22, U.S.C. SEC. 2751 ET. SEQ.) OREXECUTIVE ORDER 12470. VIOLATIONS OF THESE EXPORT LAWS ARE SUBJECTTO SEVERE CRIMINAL PENALTIES.

DESTRUCTION NOTICE: DESTROY BY ANY METHOD THAT WILL PREVENT DISCLOSURE OF CONTENTSOR RECONSTRUCTION OF THE DOCUMENT.

SUPERSEDES NAVSEA SE000-00-EIM-110 (0967-LP-000-0110) BASIC EDITION OF SEPT. 1977

PUBLISHED BY DIRECTION OF,COMMANDER, NAVAL SEA SYSTEMS COMMAND

FOR OFFICIAL USE ONLY1 SEPT. 1995

INSTALLATION NAVSEA SE000-00-EIM-110 CHANGESSTANDARDS

BOX SCORE

EDITION PUBLICATIONDATE

STOCKNUMBER

LATEST EIBCOVERED(1)

Basic September 1977 0967-LP-000-0110 947

Change 9(2) (2) (2)

NOTES

(1) The number listed in this column indicates that this handbook issue incorporates information from EIB issues upto and including the one shown. In addition to this column entry, a source reference code is inserted immediatelyfollowing the last line of copy of pertinent articles picked up in NIMB handbooks. The following examples show the codingmethod used to identify origin of material used:

ORIGIN CODEEIB 750 (750)EIB 13S (Shore Quarterly Supplement) (13S)Naval Ship Systems Command Technical News Vol. 14, No. 6 (TN14-6)CEIB 7 (Classified EIB)* (C7)

* Only articles which have been revised to omit classified data but retain information of value and lasting interest.

(2) This change reserved for Tab Separator Package.

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INSTALLATION NAVSEA SE000-00-EIM-110 CHANGESSTANDARDS

RECORD OF CHANGES

CHANGEACN NO.

DATE OFCHANGE

TITLE OR BRIEFDESCRIPTION

ENTEREDBY

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INSTALLATION NAVSEA SE000-00-EIM-110 CONTENTSSTANDARDS

TABLE OF CONTENTSPARAGRAPH PAGE

SECTION 1 GENERAL1-1 PURPOSE...................................................................................................................1-11-2 SCOPE.......................................................................................................................1-11-3 USE AND APPLICATION..............................................................................................1-11-4 DEFINITIONS..............................................................................................................1-11-4.1 INSTALLING ACTIVITY/INSTALLER...............................................................................1-11-4.2 INSTALL/INSTALLING/INSTALLATION............................................................................1-11-4.3 INTERCONNECTING CABLES......................................................................................1-11-4.4 INSTALLATION CONTROL DRAWINGS (ICDs)...............................................................1-11-4.5 AUTHORIZED APPROVAL............................................................................................1-11-4.6 ENCLOSURE..............................................................................................................1-11-5 PRECEDENCE............................................................................................................1-11-6 SAFETY......................................................................................................................1-21-6.1 PERSONNEL SAFETY..................................................................................................1-21-6.2 INSTALLATION SAFETY REQUIREMENTS.....................................................................1-21-7 WORKMANSHIP..........................................................................................................1-21-7.1 SKILLS.......................................................................................................................1-21-7.2 EQUIPMENT AND MATERIAL PROTECTION...................................................................1-21-7.3 GOOD HOUSEKEEPING PRACTICES............................................................................1-21-8 GOVERNMENT DRAWINGS..........................................................................................1-21-8.1 INSTALLATION CONTROL DRAWINGS..........................................................................1-21-8.2 NAVSEA ENGINEERING DRAWINGS............................................................................1-21-9 QUALITY ASSURANCE................................................................................................1-31-9.1 EQUIPMENT AND MATERIAL........................................................................................1-31-9.2 TOOLS AND PLANT EQUIPMENT..................................................................................1-31-9.3 PERSONNEL...............................................................................................................1-3

SECTION 2 CABLE, FLEXIBLE AND SEMI-RIGID2-1 INTRODUCTION..........................................................................................................2-12-2 SCOPE.......................................................................................................................2-12-3 CABLE SELECTION.....................................................................................................2-12-3.1 ELECTRICAL CABLES..................................................................................................2-12-3.2 PORTABLE POWER AND CONTROL CABLES................................................................2-12-3.3 COAXIAL CABLES, FLEXIBLE AND SEMI-RIGID..............................................................2-12-3.4 CABLE TYPE AND SIZE...............................................................................................2-12-4 CABLE STORAGE........................................................................................................2-22-5 CABLE HANDLING......................................................................................................2-22-6 CABLE BENDS............................................................................................................2-32-7 CABLE PROTECTION...................................................................................................2-42-8 CABLE TESTING..........................................................................................................2-42-8.1 VISUAL INSPECTION...................................................................................................2-42-8.2 CONTINUITY CHECKS................................................................................................2-42-8.3 INSULATION RESISTANCE TESTS................................................................................2-42-8.3.1 Power, Lighting and Control Cables.................................................................................2-42-8.3.2 Multiconductor Cables...................................................................................................2-52-8.3.3 Coaxial Cables.............................................................................................................2-52-8.3.4 Moisture Absorption......................................................................................................2-52-8.4 ATTENUATION AND VOLTAGE STANDING-WAVE-RATIO MEASUREMENTS......................2-52-9 CABLE CLASSIFICATION.............................................................................................2-5

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2-9.1 CONSTRUCTION.........................................................................................................2-52-9.2 SERVICE....................................................................................................................2-52-9.3 APPLICATION.............................................................................................................2-52-9.4 COAXIAL CABLES........................................................................................................2-52-10 CABLE ROUTING/GROUPING/SPACING......................................................................2-102-11 STANDARD METHODS FOR CABLING INSTALLATION...................................................2-102-12 CABLE SUBSTITUTION/REPLACEMENT........................................................................2-102-12.1 LOW SMOKE CABLES.................................................................................................2-102-12.2 OTHER TYPES OF CABLE...........................................................................................2-112-13 CABLE AND CONDUCTOR IDENTIFICATION................................................................2-152-13.1 CABLE TAGS..............................................................................................................2-152-13.2 CONNECTOR DESTINATION TAGS..............................................................................2-152-13.3 CIRCUIT OR SYSTEM DESIGNATIONS........................................................................2-152-13.4 CONDUCTOR MARKING.............................................................................................2-182-13.5 CONDUCTOR COLOR CODING...................................................................................2-182-14 CABLE BONDING AND GROUNDING...........................................................................2-192-15 CONDUCTOR FORMING AND SHAPING WITHIN ENCLOSURES...................................2-192-15.1 GENERAL GUIDELINES..............................................................................................2-202-15.2 CONDUCTOR FORMING WITH LACING CORD.............................................................2-222-15.3 CONDUCTOR FORMING WITH PLASTIC STRAPS.........................................................2-222-15.4 CONDUCTOR FORMING ACROSS HINGED UNITS.......................................................2-232-16 SOLDERING REQUIREMENTS AND PROCEDURES......................................................2-232-16.1 SOLDERING IRONS...................................................................................................2-232-17 CABLE ENTRANCE TO EQUIPMENT.............................................................................2-252-18 PRESSURIZATION AND JACKET REPAIR INSTRUCTIONS............................................2-262-18.1 PRESSURIZATION.....................................................................................................2-262-18.2 JACKET REPAIR........................................................................................................2-262-18.2.1 Procedures for Repair of Coaxial Cables.........................................................................2-282-18.2.2 List of Jacket Repair Materials.......................................................................................2-282-19 CABLE TERMINATIONS...............................................................................................2-282-19.1 GENERAL GUIDELINE AND REQUIREMENTS...............................................................2-282-19.2 CABLE AND CONDUCTOR TERMINATION WITHIN AN ENCLOSURE..............................2-282-19.3 CABLE AND CONDUCTOR SHIELD TERMINATIONS.....................................................2-292-19.4 SEMI-RIGID CABLE END PREPARATION......................................................................2-322-20 COAXIAL CONNECTORS.............................................................................................2-342-20.1 SELECTION...............................................................................................................2-342-20.2 INSTALLATION...........................................................................................................2-352-20.3 WEATHERPROOFING METHODS.................................................................................2-352-21 ELECTRICAL CONNECTORS.......................................................................................2-352-21.1 SELECTION...............................................................................................................2-352-21.2 INSTALLATION REQUIREMENTS.................................................................................2-362-21.3 CONTACT CRIMPING INSTRUCTIONS.........................................................................2-372-21.4 CONTACT INSERTION INSTRUCTION..........................................................................2-382-21.5 CONTACT REMOVAL INSTRUCTIONS..........................................................................2-382-21.6 STYLE 1-TYPE A SHIELD ENVIRONMENTAL BACKSHELL ASSEMBLY INSTRUCTIONS....2-392-21.7 STYLE 1 - TYPE A ARMOR ENVIRONMENTAL BACKSHELL ASSEMBLY INSTRUCTIONS..2-402-21.8 STYLE 1 - TYPE B ENVIRONMENTAL BACKSHELL ASSEMBLY INSTRUCTIONS..............2-412-21.9 STYLE 1 - TYPE C SHIELD TERMINATED TO BACKSHELL ASSEMBLY INSTRUCTIONS...2-412-21.10 STYLE 2 ADAPTER TRANSITION BACKSHELL ASSEMBLIES..........................................2-43

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SECTION 3 SUPPORT EQUIPMENT3-1 INTRODUCTION..........................................................................................................3-13-2 PURPOSE...................................................................................................................3-13-3 SCOPE.......................................................................................................................3-13-4 SELECTION................................................................................................................3-13-5 SUPPORT EQUIPMENT/SYSTEMS INSTALLATION REQUIREMENTS................................3-13-5.1 COMPRESSED AIR SYSTEMS......................................................................................3-13-5.2 DRY AIR SYSTEMS.....................................................................................................3-13-5.3 COOLING WATER SYSTEMS........................................................................................3-13-5.4 FIRE CONTROL SYSTEMS...........................................................................................3-13-5.5 CONNECTION BOXES..................................................................................................3-13-6 SAFETY SUPPORT EQUIPMENT/ ITEMS........................................................................3-23-6.1 SAFETY DISCONNECT SWITCHES...............................................................................3-23-6.2 CIRCUIT DISABLEMENT..............................................................................................3-23-6.3 ANTENNA SAFETY DISCONNECT SWITCH...................................................................3-23-6.4 BATTLE SHORT SWITCH..............................................................................................3-23-6.5 CONVENIENCE RECEPTACLES...................................................................................3-23-6.6 WARNING SIGNS........................................................................................................3-23-6.6.1 Radio Frequency Hazard Signs.......................................................................................3-23-6.7 SAFETY SHORTING PROBES.......................................................................................3-4

SECTION 4 ANTENNAS4-1 INTRODUCTION..........................................................................................................4-14-2 PURPOSE...................................................................................................................4-14-3 SCOPE.......................................................................................................................4-14-4 GENERAL REQUIREMENTS.........................................................................................4-14-4.1 SELECTION................................................................................................................4-14-4.2 LOCATION..................................................................................................................4-14-4.3 INSTALLATION............................................................................................................4-14-4.4 FOUNDATIONS...........................................................................................................4-14-4.5 PRESERVATION..........................................................................................................4-14-4.6 PERSONNEL PROTECTION..........................................................................................4-2

SECTION 5 WAVEGUIDE AND RIGID COAXIAL LINES5-1 RECTANGULAR WAVEGUIDE......................................................................................5-25-1.1 INTRODUCTION..........................................................................................................5-25-1.1.1 Waveguide Accessories................................................................................................5-25-1.1.1.1 Bend Assemblies..........................................................................................................5-25-1.1.1.2 Flexible Assemblies......................................................................................................5-25-1.1.1.3 Twist Assemblies..........................................................................................................5-25-1.1.1.4 Adapter Assemblies......................................................................................................5-35-1.1.1.5 Flanges.......................................................................................................................5-35-1.1.1.6 Waveguide Pressure Windows........................................................................................5-35-1.2 TECHNICAL CAPABILITIES..........................................................................................5-35-1.3 SHOP PREFABRICATION GUIDELINES.........................................................................5-35-1.3.1 Inspection...................................................................................................................5-35-1.3.2 Storage.......................................................................................................................5-35-1.3.3 Handling......................................................................................................................5-35-1.3.4 Layout of Waveguide Run..............................................................................................5-3

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5-1.4 ANNEALING................................................................................................................5-45-1.5 MANDRELS AND FILLERS...........................................................................................5-45-1.6 BENDING...................................................................................................................5-45-1.7 TWISTING...................................................................................................................5-45-1.8 FLANGES...................................................................................................................5-45-1.8.1 Contact Flanges...........................................................................................................5-55-1.8.2 Choke Flanges.............................................................................................................5-55-1.8.3 Cover Flanges.............................................................................................................5-55-1.9 BRAZING....................................................................................................................5-55-1.10 CLEANING AGENTS....................................................................................................5-55-1.11 CLEANING REQUIREMENTS........................................................................................5-55-1.12 SEALING AND PAINTING.............................................................................................5-55-1.12.1 Chemical Conversion....................................................................................................5-55-1.12.2 Protection by Painting...................................................................................................5-55-1.13 SHOP FABRICATION PROCEDURE..............................................................................5-55-1.13.1 Fabrication Data Procurement........................................................................................5-55-1.13.2 Annealing....................................................................................................................5-65-1.13.3 Mandrel Selection.........................................................................................................5-65-1.13.4 Bending and Twisting.....................................................................................................5-65-1.13.5 Surface Check.............................................................................................................5-65-1.13.6 Cutting........................................................................................................................5-65-1.13.7 Quality Assurance Check...............................................................................................5-65-1.13.8 Cleaning for Brazing......................................................................................................5-65-1.13.9 Flange to Waveguide Fit................................................................................................5-65-1.13.10 Brazing Operation.........................................................................................................5-65-1.13.11 Hydrostatic Test...........................................................................................................5-65-1.13.12 Post Braze Cleaning......................................................................................................5-75-1.13.13 Post Fabrication Inspection............................................................................................5-75-1.13.14 Chemical Conversion Application....................................................................................5-75-1.13.15 Chemical Conversion Inspection.....................................................................................5-75-1.13.16 Painting of Assembly....................................................................................................5-75-1.13.17 Fabrication Inspection...................................................................................................5-85-1.13.18 Pre-Brazing Inspection...................................................................................................5-85-1.13.19 Post-Brazing Inspection.................................................................................................5-85-1.13.19.1 Interior of Waveguide....................................................................................................5-85-1.13.19.2 Exterior of Waveguide...................................................................................................5-85-1.13.20 Post Chemical Conversion Inspection.............................................................................5-95-1.13.21 Post Painting Inspection................................................................................................5-95-1.14 PRESSURIZING AND PURGING...................................................................................5-95-1.15 Dry Air Systems...........................................................................................................5-95-1.15.1 Air Connections............................................................................................................5-95-1.15.2 Purging.......................................................................................................................5-95-2 RECTANGULAR WAVEGUIDE INSTALLATION PROCEDURES.........................................5-95-2.1 GENERAL REQUIREMENTS.........................................................................................5-95-2.1.1 Length of Run..............................................................................................................5-95-2.1.2 Location of Run............................................................................................................5-95-2.1.3 Sequence of Installation...............................................................................................5-105-2.1.4 Clearance...................................................................................................................5-105-2.1.5 Protection of Waveguide...............................................................................................5-105-2.1.6 Welding to Ships Structure............................................................................................5-10

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5-2.1.7 Precautions against Moisture and Dirt.............................................................................5-105-2.1.8 Structural Fouling........................................................................................................5-105-2.1.9 Galvanic Action...........................................................................................................5-105-2.1.10 Types of Waveguide Supports (Hangers)........................................................................5-105-2.1.11 Penetrations, Deck and Bulkhead...................................................................................5-105-2.1.12 Waveguide Markings....................................................................................................5-105-2.1.13 Grounding of Waveguide...............................................................................................5-105-2.1.14 Hardware....................................................................................................................5-105-2.1.15 Restrictions for Parallel Runs........................................................................................5-105-2.1.16 Straightness of Runs...................................................................................................5-105-2.1.17 Alignment of Flange Joints............................................................................................5-105-2.1.18 Pressurization.............................................................................................................5-105-2.1.19 Flexible Waveguide......................................................................................................5-105-2.1.20 Expansion Joints.........................................................................................................5-105-2.1.21 Preservation...............................................................................................................5-115-2.2 PROTECTION OF WAVEGUIDE...................................................................................5-115-2.2.1 Sealing of Individual Sections........................................................................................5-115-2.2.2 Sealing of Assembled Sections......................................................................................5-115-2.2.3 Flange Face Protection................................................................................................5-115-2.2.4 Transporting Waveguide Sections and Components..........................................................5-115-2.2.5 Warping of Long Waveguide Sections.............................................................................5-115-2.3 LAYOUT OF WAVEGUIDE RUNS.................................................................................5-115-2.3.1 Templates..................................................................................................................5-115-2.3.2 Layout.......................................................................................................................5-115-2.3.3 Penetrations, Deck and Bulkhead...................................................................................5-115-2.3.4 Supports, Waveguide...................................................................................................5-135-2.3.5 Double Ogee Curve.....................................................................................................5-135-2.4 WAVEGUIDE SUPPORTS (HANGERS)..........................................................................5-135-2.4.1 Type of Material...........................................................................................................5-135-2.4.2 Size of Material............................................................................................................5-135-2.4.3 Support Damage to Waveguide Wall..............................................................................5-135-2.4.4 Fitting Support to Waveguide........................................................................................5-135-2.4.5 Isolation of Waveguide and Support...............................................................................5-135-2.4.6 Adjustable Supports.....................................................................................................5-135-2.4.7 Location of Supports....................................................................................................5-135-2.4.8 Spacing of Supports.....................................................................................................5-135-2.4.9 Isolation Methods........................................................................................................5-135-2.4.10 Plastisol Coating Procedures.........................................................................................5-155-2.4.10.1 Surface Preparation.....................................................................................................5-155-2.4.10.2 Priming......................................................................................................................5-155-2.4.10.3 Application of Plastisol.................................................................................................5-165-2.4.11 Hardware....................................................................................................................5-165-2.5 PENETRATIONS, DECK AND BULKHEADS...................................................................5-175-2.5.1 Non-Watertight Bulkheads and Decks.............................................................................5-175-2.5.2 Watertight Deck and Bulkheads.....................................................................................5-175-2.5.3 Typical Methods..........................................................................................................5-175-2.5.4 Split Sleeve Assemblies for Rectangular Waveguides.......................................................5-175-2.5.5 Multi-Cable Transit (MCT) Devices.................................................................................5-205-2.5.6 Transit Device Modification for Rigid Coaxial Lines...........................................................5-205-2.5.7 Transit Device Modification for Rectangular Waveguide.....................................................5-20

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5-2.6 OVERALL WAVEGUIDE RUN ASSEMBLY PROCEDURES..............................................5-225-2.6.1 Shipboard Installation Pre-Requirements.........................................................................5-225-2.6.2 Assembly Sequence....................................................................................................5-225-2.6.3 Material Ordering Sequence...........................................................................................5-225-2.6.4 Inspection Prior to Assembly.........................................................................................5-225-2.6.5 Installing Waveguide Supports (Hangers)........................................................................5-235-2.6.6 Pressurization During Assembly.....................................................................................5-235-2.6.7 Waveguide Hardware....................................................................................................5-245-2.6.8 Illustrative Installation Explanations................................................................................5-285-2.7 PURGING AND PRESSURIZING (SHIPBOARD)............................................................5-305-2.7.1 Temporary Pressurization..............................................................................................5-305-2.7.2 Tightness Test............................................................................................................5-305-2.7.3 Method for Detecting Leaks...........................................................................................5-305-2.7.4 Purging Procedures......................................................................................................5-305-2.7.5 Purging Requirements..................................................................................................5-305-2.8 GROUNDING OF WAVEGUIDE RUNS..........................................................................5-305-2.9 PRESERVATION OF WAVEGUIDE...............................................................................5-305-2.9.1 Exterior Surface Painting...............................................................................................5-315-2.9.2 Waveguide Requiring Additional Heat Dissipation.............................................................5-315-2.9.3 Flange Joint Protection after Installation.........................................................................5-315-2.10 QUALITY CONTROL INSPECTION...............................................................................5-315-2.10.1 Straight Line Deviation.................................................................................................5-315-2.10.2 Penetration Alignment..................................................................................................5-315-2.10.3 Support Alignment.......................................................................................................5-315-2.10.4 Flange Joint Alignment.................................................................................................5-315-2.10.5 Dents and Cuts...........................................................................................................5-315-2.10.6 Isolation.....................................................................................................................5-315-2.10.7 Support Fit.................................................................................................................5-315-2.10.8 Support Spacing..........................................................................................................5-315-2.10.9 Quantity of Supports....................................................................................................5-315-2.10.10 Protective Guards........................................................................................................5-315-2.10.11 Flange Faces..............................................................................................................5-315-2.10.12 Protective Labels and Markings......................................................................................5-325-2.10.13 Pressurization.............................................................................................................5-325-2.10.14 Component Certification...............................................................................................5-325-2.10.15 Clearance and Access.................................................................................................5-325-2.10.16 Preservation...............................................................................................................5-325-2.10.17 Parallel Transmission Line Runs....................................................................................5-325-2.10.18 Grounding...................................................................................................................5-325-2.11 ELECTRICAL REQUIREMENTS AND TESTS..................................................................5-325-2.11.1 Test Equipment Requirements.......................................................................................5-325-2.11.2 Insertion Loss Measurements........................................................................................5-325-2.11.2.1 Theoretical Attenuation.................................................................................................5-325-2.11.2.2 Maximum Allowable Insertion Loss..................................................................................5-325-2.11.3 Voltage Standing Wave Ratio Measurements...................................................................5-335-2.11.4 Test Reports...............................................................................................................5-335-3 RIGID COAXIAL LINES................................................................................................5-335-3.1 INTRODUCTION.........................................................................................................5-335-3.2 PRE-FABRICATION....................................................................................................5-335-3.3 INSPECTION..............................................................................................................5-34

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5-3.4 STORAGE..................................................................................................................5-345-3.5 HANDLING................................................................................................................5-355-3.6 STRAIGHT SECTIONS, INNER COUPLING AND FLANGES............................................5-355-3.7 ELBOW ASSEMBLIES..................................................................................................5-355-3.8 GAS INLET AND GAS BARRIER COUPLINGS...............................................................5-355-3.9 REDUCERS...............................................................................................................5-355-3.10 ADAPTERS................................................................................................................5-355-3.11 FLEXIBLE COAXIAL ASSEMBLIES.................................................................................5-375-3.12 STRAIGHT ASSEMBLIES.............................................................................................5-375-3.13 FABRICATION............................................................................................................5-375-3.13.1 Cutting Outer Conductor...............................................................................................5-375-3.13.2 Installing Flanges........................................................................................................5-385-3.13.3 Cutting Inner Conductor...............................................................................................5-385-3.13.4 Installing Field Flange (For Emergency Repair of Copper Lines).........................................5-395-3.14 CHEMICAL CONVERSION...........................................................................................5-395-3.14.1 Inspection of Coating...................................................................................................5-395-3.14.2 Removal of Chemical Film............................................................................................5-395-3.15 PAINTING..................................................................................................................5-395-3.15.1 Before Installation........................................................................................................5-395-3.15.2 After Installation..........................................................................................................5-395-3.16 PRESSURIZING AND PURGING..................................................................................5-395-4 RIGID COAXIAL LINES INSTALLATION PROCEDURES..................................................5-405-4.1 GENERAL REQUIREMENTS........................................................................................5-405-4.1.1 Length of Run.............................................................................................................5-405-4.1.2 Location of Run...........................................................................................................5-405-4.1.3 Sequence of Installation...............................................................................................5-405-4.1.4 Clearance...................................................................................................................5-405-4.1.5 Protection of Rigid Coaxial Lines....................................................................................5-405-4.1.6 Welding to Ship's Structure...........................................................................................5-405-4.1.7 Protection against Moisture and Dirt...............................................................................5-405-4.1.8 Structural Fouling........................................................................................................5-405-4.1.9 Galvanic Action...........................................................................................................5-405-4.1.10 Type of Rigid Coaxial Line Supports (Hangers).................................................................5-405-4.1.11 Penetrations, Deck and Bulkhead...................................................................................5-405-4.1.12 Transmission Line Markings...........................................................................................5-405-4.1.13 Grounding of Rigid Coaxial Transmission Lines................................................................5-405-4.1.14 Hardware....................................................................................................................5-405-4.1.15 Restrictions for Parallel Runs........................................................................................5-405-4.1.16 Preservation...............................................................................................................5-405-4.1.17 Straightness of Run.....................................................................................................5-405-4.1.18 Flange Joint Alignment.................................................................................................5-415-4.1.19 Pressurization.............................................................................................................5-415-4.1.20 Expansion Joints.........................................................................................................5-415-4.2 HANDLING RIGID COAXIAL TRANSMISSION LINE GUIDELINES....................................5-415-4.2.1 Sealing of Individual Sections........................................................................................5-415-4.2.2 Sealing of Assembled Sections......................................................................................5-415-4.2.3 Flange Face Protection................................................................................................5-415-4.2.4 Transporting Rigid Coaxial Sections and Components.......................................................5-415-4.2.5 Warping of Long Rigid Coaxial Sections..........................................................................5-415-4.2.6 Protection Against Hand Contamination..........................................................................5-41

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5-4.3 LAYOUT OF RIGID COAXIAL RUNS.............................................................................5-415-4.3.1 Templates..................................................................................................................5-415-4.3.2 Penetrations, Deck and Bulkhead...................................................................................5-415-4.3.3 Supports, Rigid Coaxial Line..........................................................................................5-415-4.4 RIGID COAXIAL LINE SUPPORTS (HANGERS) REQUIREMENTS....................................5-415-4.4.1 Type of Material...........................................................................................................5-415-4.4.2 Size of Material............................................................................................................5-415-4.4.3 Support Damage to Outer Conductor..............................................................................5-415-4.4.4 Isolation of Outer Conductor and Support........................................................................5-415-4.4.5 Adjustable Supports.....................................................................................................5-425-4.4.6 Location of Supports....................................................................................................5-435-4.4.7 Fitting Support to Rigid Coaxial Line...............................................................................5-435-4.4.8 Spacing of Supports.....................................................................................................5-435-4.4.9 Isolation Methods........................................................................................................5-435-4.4.10 Hardware Requirements................................................................................................5-435-4.5 PENETRATIONS, DECK AND BULKHEAD.....................................................................5-445-4.5.1 Non-Watertight Decks and Bulkheads.............................................................................5-445-4.5.2 Watertight Decks and Bulkheads....................................................................................5-445-4.5.3 Typical Methods..........................................................................................................5-445-4.6 OVERALL RIGID COAXIAL RUN INSTALLATION PROCEDURES.....................................5-445-4.6.1 Shipboard Installation Pre-Requirements.........................................................................5-445-4.6.2 Assembly Sequence....................................................................................................5-455-4.6.3 Material Ordering Sequence...........................................................................................5-455-4.6.4 Inspection Prior to Installation.......................................................................................5-455-4.6.5 Assembly Details........................................................................................................5-455-4.6.6 Inner Coupling and Misalignment....................................................................................5-455-4.6.7 Reference to Detail Illustrations.....................................................................................5-455-4.6.8 Flange Joint Assembly.................................................................................................5-455-4.6.9 Misalignment Compensation..........................................................................................5-485-4.6.10 Mitered Elbows............................................................................................................5-495-4.6.11 Swivel Flanges............................................................................................................5-495-4.6.12 Pressurization Requirement...........................................................................................5-495-4.6.13 Hardware....................................................................................................................5-495-4.6.14 Illustrative Installation Explanation..................................................................................5-495-4.7 PURGING AND PRESSURIZING..................................................................................5-515-4.7.1 Temporary Pressurization..............................................................................................5-515-4.7.2 Tightness Tests...........................................................................................................5-515-4.7.3 Method for Detecting Leaks...........................................................................................5-515-4.7.4 Purging Procedures......................................................................................................5-515-4.7.5 Purging......................................................................................................................5-515-4.8 GROUNDING OF RIGID COAXIAL TRANSMISSION LINE...............................................5-515-4.9 PRESERVATION OF RIGID COAXIAL RUNS.................................................................5-515-4.9.1 Exterior Surface Painting...............................................................................................5-515-4.9.2 Rigid Coaxial Lines Requiring Additional Heat Dissipation..................................................5-515-4.9.3 Flange Joint Protection after Installation.........................................................................5-515-4.10 QUALITY CONTROL INSPECTION...............................................................................5-515-4.11 ELECTRICAL REQUIREMENTS AND TESTS..................................................................5-515-4.11.1 Test Equipment Requirements.......................................................................................5-525-4.11.2 Continuity...................................................................................................................5-525-4.11.3 Insertion Loss Measurements........................................................................................5-52

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5-4.11.4 Voltage Standing Wave Ratio Measurements...................................................................5-525-4.11.5 Test Reports...............................................................................................................5-525-5 ELLIPTICAL WAVEGUIDE............................................................................................5-525-5.1 INTRODUCTION.........................................................................................................5-525-5.2 ELLIPTICAL WAVEGUIDE CHARACTERISTICS.............................................................5-525-5.2.1 Electrical Characteristics..............................................................................................5-525-5.2.2 Physical Characteristics...............................................................................................5-525-5.3 ACCESSORIES..........................................................................................................5-525-5.3.1 Couplings...................................................................................................................5-535-5.3.2 Transitions..................................................................................................................5-535-5.3.3 Rectangular Waveguide Assemblies...............................................................................5-545-5.4 TECHNICAL CAPABILITIES.........................................................................................5-545-5.5 SHOP PREFABRICATION GUIDELINES........................................................................5-545-5.6 BENDING..................................................................................................................5-545-5.7 TWISTING..................................................................................................................5-555-5.8 SUPPORTS................................................................................................................5-555-5.8.1 Design.......................................................................................................................5-555-5.8.2 Material......................................................................................................................5-555-5.8.3 Location.....................................................................................................................5-555-5.8.4 Isolation Material.........................................................................................................5-555-5.8.5 Hardware....................................................................................................................5-555-5.9 PENETRATIONS.........................................................................................................5-555-5.9.1 Non-Watertight Penetrations.........................................................................................5-555-5.9.2 Watertight Penetrations................................................................................................5-565-5.10 PRESERVATION.........................................................................................................5-565-5.10.1 Chemical Conversion Coatings......................................................................................5-565-5.10.2 Protective Paint Coatings.............................................................................................5-565-5.10.3 Mating Joint Protection.................................................................................................5-565-5.11 DRY AIR REQUIREMENTS..........................................................................................5-575-5.11.1 Air Connections...........................................................................................................5-575-5.11.2 Purging......................................................................................................................5-575-6. ELLIPTICAL WAVEGUIDE INSTALLATION PROCEDURES..............................................5-575-6.1 GENERAL REQUIREMENTS........................................................................................5-575-6.2 PROTECTION OF ELLIPTICAL WAVEGUIDE.................................................................5-575-6.3 LAYOUT OF ELLIPTICAL WAVEGUIDE.........................................................................5-575-6.4 ELLIPTICAL WAVEGUIDE SUPPORTS..........................................................................5-575-6.5 PENETRATIONS.........................................................................................................5-575-6.6 INSTALLATION INSTRUCTIONS...................................................................................5-575-6.6.1 Site Preparation...........................................................................................................5-575-6.6.2 On Site Handling and Storage........................................................................................5-575-6.6.3 Temporary Support of Waveguide..................................................................................5-585-6.6.4 On Site Bending and Twisting.........................................................................................5-585-6.6.5 Cutting of Elliptical Waveguide......................................................................................5-585-6.6.6 Chemical Conversion Coating.......................................................................................5-585-6.6.7 Coupling and Transition Assembly..................................................................................5-585-6.6.8 Split Sleeve Assembly..................................................................................................5-585-6.6.9 Elliptical Waveguide Support Installation.........................................................................5-585-6.6.10 Installation of Rectangular Sections...............................................................................5-605-6.6.11 Overall Elliptical Waveguide Run....................................................................................5-605-6.7 PURGING AND PRESSURIZATION (SHIPBOARD).........................................................5-60

xiiORIGINAL



5-6.8 GROUNDING OF ELLIPTICAL WAVEGUIDE RUNS........................................................5-625-6.9 PRESERVATION OF ELLIPTICAL WAVEGUIDE RUNS...................................................5-625-6.9.1 Coupling and Transition Sealing.....................................................................................5-625-6.10 QUALITY CONTROL INSPECTION...............................................................................5-625-6.10.1 Couplings and Transitions.............................................................................................5-625-6.11 ELECTRICAL REQUIREMENTS AND TESTS..................................................................5-62

SECTION 6 EQUIPMENT INSTALLATION6-1 INTRODUCTION..........................................................................................................6-16-2 PURPOSE...................................................................................................................6-16-3 SCOPE.......................................................................................................................6-16-4 SELECTION REQUIREMENTS.......................................................................................6-16-4.1 EQUIPMENT SUPPLIED BY THE GOVERNMENT............................................................6-16-4.2 EQUIPMENT SUPPLIED BY THE INSTALLING ACTIVITY.................................................6-16-4.3 EQUIPMENT FABRICATED BY INSTALLING ACTIVITY....................................................6-16-5 INSTALLATION REQUIREMENTS..................................................................................6-16-5.1 LOCATION..................................................................................................................6-16-5.2 FOUNDATIONS...........................................................................................................6-26-5.3 FASTENERS...............................................................................................................6-26-5.4 HABITABILITY.............................................................................................................6-26-5.5 ACCESSIBILITY..........................................................................................................6-26-5.6 GROUNDING AND BONDING.......................................................................................6-26-5.7 SAFETY......................................................................................................................6-26-6 EQUIPMENT IDENTIFICATION......................................................................................6-26-6.1 UNIT IDENTITY...........................................................................................................6-26-6.2 ANTENNA IDENTIFICATION PLATES.............................................................................6-26-6.3 ABBREVIATIONS.........................................................................................................6-26-6.4 ATTACHED COMPONENT IDENTIFICATION...................................................................6-26-7 OPERATING INSTRUCTION CHARTS............................................................................6-26-7.1 MATERIAL EXCEPTIONS..............................................................................................6-26-7.2 FINISH.......................................................................................................................6-26-7.3 LETTERING.................................................................................................................6-26-7.4 SIZE...........................................................................................................................6-26-7.5 LOCATION..................................................................................................................6-26-8 EQUIPMENT PROTECTION...........................................................................................6-36-8.1 PROTECTION FROM RODENTS AND INSECTS..............................................................6-36-8.2 CLEANLINESS--A FORM OF PROTECTION....................................................................6-36-8.3 DAMAGED EQUIPMENT REPAIR OR REPLACEMENT.....................................................6-36-8.4 PROTECTION FROM VANDALISM.................................................................................6-36-9 SECURE EQUIPMENT..................................................................................................6-36-10 INTERFACE COMPATIBILITY........................................................................................6-4

xiiiORIGINAL


LIST OF FIGURESFIGURES PAGE

Figure 2-1 Typical Semi-rigid Cable Straightening Device................................................................2-3Figure 2-2 Simplified Rigging for Semi-rigid Cable Straightening Device............................................2-4Figure 2-3 Typical Flexible Coaxial Cable Construction...................................................................2-6Figure 2-4 Typical Flexible Two-Conductor Coaxial Cable Construction..............................................2-7Figure 2-5 Typical Flexible Triaxial Cable Construction....................................................................2-7Figure 2-6 Typical Semi-rigid Foam Dielectric Coaxial Cable Construction.........................................2-8Figure 2-7 Typical Semi-rigid Semi-air-dielectric (Plastic Tubes) Coaxial Cable Construction................2-8Figure 2-8 Typical Semi-rigid Semi-air-dielectric (Spiral Strip) Coaxial Cable Construction....................2-9Figure 2-9 Typical Semi-rigid Semi-air-dielectric (Spiral Strip) Coaxial Cable Construction

Utilizing Corrugated Tubes..........................................................................................2-9Figure 2-10 Typical Cable Tag.....................................................................................................2-15Figure 2-11 Typical Method for Connector and Antenna Cable Identification Tags...............................2-16Figure 2-12 Conductor Marking Between Like Terminals...................................................................2-19Figure 2-13 Conductor Marking Between Unlike Terminals................................................................2-20Figure 2-14 Conductor Marking Between Equipment Units and Junction Box.......................................2-21Figure 2-15 Typical Method of Conductor Forming with Lacing Tape..................................................2-22Figure 2-16 Method of Splicing Doubled Lacing Tape......................................................................2-23Figure 2-17 Typical Completed Laced Form..................................................................................2-23Figure 2-18 Acceptable Method of Conductor Forming with MIL-S-23190 Self-clinching Straps

and MS25281 Support Clamps....................................................................................2-24Figure 2-19 Typical Completed Form using Plastic Straps...............................................................2-25Figure 2-20 Tool MS90387 for use with MS23190 Straps..................................................................2-25Figure 2-21 Conductor Bundle Strapping using Tool MS90387..........................................................2-26Figure 2-22 Routing of Conductor Bundle over Hinge......................................................................2-27Figure 2-23 Typical Cable Entry Extension Box..............................................................................2-28Figure 2-24 Nylon Stuffing Tube Assembly using Spanner Wrenches................................................2-28Figure 2-25 Conductors Properly Terminated in MIL-T-7928 Lugs......................................................2-30Figure 2-26 Typical Method of Termination Shields with MIL-F-21608 Ferrules and

MIL-C-22520 Crimping Tool........................................................................................2-31Figure 2-27 Pigtailing Method of Shield Termination........................................................................2-32Figure 2-28 Typical Extractor Tool for Shield Terminations...............................................................2-32Figure 2-29 Small Semi-rigid Cable End Preparation.......................................................................2-33Figure 2-30 Large Semi-rigid Cable End Preparation.......................................................................2-34Figure 2-31 Connector Assembly Tool..........................................................................................2-37Figure 2-32 Connector Accessory Tools.......................................................................................2-38Figure 2-33 Crimp Contact Conductor Stripping Dimensions............................................................2-38Figure 2-34 Insertion Tool Application for Crimp Contacts...............................................................2-39Figure 2-35 Removal Tool Application for Crimp Contacts...............................................................2-40Figure 2-36 Style 1 - Type A Shield Environmental Backshell Assembly Breakdown.............................2-40Figure 2-37 Style 1 - Type A Armor Environmental Backshell Assembly Breakdown.............................2-41Figure 2-38 Style 1 - Type B Environmental Backshell Assembly Breakdown.......................................2-42Figure 2-39 Style 1 - Type C Overall Shield Termination to Backshell - Assembly Breakdown................2-43Figure 2-40 Style 1 - Type C Individual Shield Termination to Backshell - Assembly Breakdown.............2-43Figure 2-41 Style 2 - Type B Environmental Backshell Assembly Breakdown.......................................2-44Figure 5-1 Waveguide Side and Bend Identification........................................................................5-4Figure 5-2 End View of Waveguide Showing Cutting Requirements...................................................5-6Figure 5-3 Alignment of Flange to Waveguide...............................................................................5-7Figure 5-4 Waveguide Template Fabrication Details......................................................................5-12Figure 5-5 Double Ogee Curve Around Obstruction.......................................................................5-13Figure 5-6 Adjustable Waveguide Support Fabrication Details........................................................5-14Figure 5-7 Adjustable Waveguide Support...................................................................................5-14

iiORIGINAL


LIST OF FIGURESFIGURES PAGE

Figure 5-8 Waveguide Support Spacing.......................................................................................5-15Figure 5-9 Typical Plastisol Coated Waveguide Support................................................................5-16Figure 5-10 Typical Method of Penetrating Airtight Bulkheads...........................................................5-17Figure 5-11 Typical Split Sleeve Assembly for Small Waveguide......................................................5-18Figure 5-12 Typical Split Sleeve Assembly for Large Waveguide......................................................5-19Figure 5-13 Typical Split Sleeve Assembly for Multiple Waveguide Run.............................................5-20Figure 5-14 Multi-Cable Transit Device Assembly Identification........................................................5-21Figure 5-15 Waveguide Brace Plates for Use with Multi-Cable Transit Device.....................................5-21Figure 5-16 Two-Frame Multi-Cable Transit Device Bulkhead Installed-Front View................................5-22Figure 5-17 Two-Frame Multi-Cable Transit Device Bulkhead Installed-Side View.................................5-23Figure 5-18 Two-Frame Multi-Cable Transit Device Deck Installed-Plan View.......................................5-24Figure 5-19 Two-Frame Multi-Cable Transit Device Deck Installed-Side View.......................................5-25Figure 5-20 Protective Enclosure for Deck Penetration-Side View......................................................5-26Figure 5-21 Protective Enclosure for Deck Penetration-Front Elevation View.......................................5-27Figure 5-22 Illustrative Reference Guide with Reference Notes 1 through 20......................................5-28Figure 5-23 Method for Temporary Pressurization...........................................................................5-30Figure 5-24 Typical Test Set-up for Composite VSWR Measurements...............................................5-34Figure 5-25 Typical Test Set-up for Return Loss Signature..............................................................5-34Figure 5-26 Adapter Connection Parts and Nomenclature................................................................5-36Figure 5-27 Wood Plug Used for Cutting Rigid Coaxial Line.............................................................5-38Figure 5-28 Wood Plug Shown Inserted in Outer Conductor of Rigid Coaxial Line................................5-38Figure 5-29 Tube Cutter With Single-Sided Wheel Used for Cutting Rigid Coaxial Line.........................5-38Figure 5-30 Free Flange Connection Parts and Nomenclature..........................................................5-39Figure 5-31 Adjustable Support Fabrication Details for Rigid Coaxial line...........................................5-42Figure 5-32 Typical Plastisol Coated Support for Rigid Coaxial Line..................................................5-43Figure 5-33 Typical Split Sleeve Assembly for Rigid Coaxial Line......................................................5-44Figure 5-34 Rigid Coaxial Transmission Line Parts and Nomenclature..............................................5-46Figure 5-35 Cut-Away View of inner Coupling (Bullet).......................................................................5-46Figure 5-36 Flange Dimensions for Rigid Coaxial Transmission Line................................................5-46Figure 5-37 Inner Coupling (Bullet) Dimensions for Rigid Coaxial Transmission Line............................5-46Figure 5-38 Cut-Away View of Rotatable (Swivel) Flange..................................................................5-47Figure 5-39 Cut-Away View of Rigid Coaxial Transmission Line with Swivel Flange Inner.......................5-47Figure 5-40 90-Degree Mitered Elbow for Rigid Coaxial Transmission Line..........................................5-47Figure 5-41 45-Degree Mitered Elbow for Rigid Coaxial Transmission Line..........................................5-48Figure 5-42 Cut-Away View of Gas Barrier for Rigid Coaxial Transmission Line....................................5-48Figure 5-43 Illustrative Reference Guide with Reference Notes 1 through 16......................................5-50Figure 5-44 Coupling for use with Small Elliptical Waveguide............................................................5-54Figure 5-45 Coupling for use with Large Elliptical Waveguide............................................................5-54Figure 5-46 Transition for Interfacing Elliptical Waveguide to Rectangular Waveguide..........................5-54Figure 5-47 Typical Elliptical Waveguide Support............................................................................5-55Figure 5-48 Typical Split Sleeve Assembly for Elliptical Waveguide...................................................5-56Figure 5-49 Coupling Assembly Identification for Small Elliptical Waveguide......................................5-59Figure 5-50 Coupling Assembly Identification for Large Elliptical Waveguide......................................5-59Figure 5-51 Transition Assembly Identification for Large Elliptical Waveguide.....................................5-60Figure 5-52 Typical Assembly Showing Transition Coupling and Large Elliptical Waveguide...................5-61Figure 5-53 Typical Relationship of Elliptical to Rectangular Waveguide Components..........................5-61

iiiORIGINAL


LIST OF TABLESTABLES PAGE

Table 2-1 MIL-C-24643 (MIL-C-24643 (Low Smoke) Cable Application.............................................2-11Table 2-2 MIL-C-24640 (Light Weight) Cable Application...............................................................2-13Table 2-3 MIL-C-915 Cable Application......................................................................................2-14Table 2-4 Special Purpose Cable Application..............................................................................2-14Table 3-1 Radio Frequency Hazard (RADHAZ) Signs....................................................................3-3Table 5-1 Rigid Coaxial Line To Flexible Coaxial Cable Adapter Termination Data.............................5-36Table 5-2 Cut-Back Dimensions For Rigid Coaxial Transmission Line.............................................5-37Table 5-3 Flange Assembly Torques..........................................................................................5-49Table 5-4 Elliptical Waveguide Electrical Characteristics..............................................................5-53Table 5-5 Elliptical Waveguide Physical Characteristics...............................................................5-53

ivORIGINAL

INSTALLATION NAVSEA SE000-00-EIM-110 REFERENCESTANDARDS DOCUMENTS

LIST OF REFERENCE DOCUMENTS

MILITARY SPECIFICATIONS

MIL-C-17 Cables, Radio Frequency, Flexible and Semi-rigid, General Specification for

MIL-W-85 Waveguides, Rigid, Rectangular, General Specification for

MIL-W-287 Waveguide Assemblies, Flexible Twistable and Non-Twistable, General Specification for

MIL-J-641 Jacks, Telephone, General Specification for

MIL-P442 Plugs, Telephone, and Accessory Screws, General Specification for

MIL-C-915 Cable and Cord, Electrical, For Shipboard Use, General Specification for

MIL-Y-1140 Yarn, Cord, Sleeving, Cloth and Tape-Glass, General Specification for

MIL-1-3064 Insulation, Electrical, Plastic Sealer

MIL-C-3432 Cable and Wire, Electrical (Power and Control; Semi-Flexible, Flex-Flexible and Extra-

Flexible, 300 and 600 volts)

MIL-L-3890 Lines, Radio Frequency Transmission (Coaxial Air Dielectric) General Specification for

MIL-F-3922 Flanges, Waveguide, General Purpose, General Specification for

MIL-W-3970 Waveguide Assemblies, Rigid, General Specification for

MIL-C-5015 Connectors, Electric, AN Type, General Specification for

MIL-C-5541 Chemical Conversion Coatings on Aluminum and Aluminum Alloys, General

Specification for

MIL-R-6855 Rubber, Synthetic, Sheets, Strips, Molded or Extruded Shapes

MIL-B-7883 Brazing of Steels, Copper, Copper Alloys, Nickel Alloys, Aluminum and Aluminum

Alloys, General Specification for

MIL-M-15562 Matting, Floor, Rubber, Insulating for High Voltage Application, General Specification for

MIL-P-20689 Plastic Plastisol (For Coating Metallic Objects)

MIL-F-21608 Ferrule, Shield Terminating, Crimp Style

MIL-C-22520 Crimping Tools, Terminal, Hand, Wire Termination, General Specification for

MIL-A-22641 Adapters, Coaxial to Waveguide, General Specification for

MIL-C-22667 Cable, Special Purpose, Buoyant, Electrical, Type RG-298/U (Submarine Use)

MIL-C-22931 Cables, Radio Frequency, Semi-Rigid, Coaxial, Semi-Air Dielectric

MIL-C-22992 Connectors, Plugs and Receptacle Electrical, Waterproof, Quick Disconnect, Heavy

Duty Type, General Specification for

MIL-C-23020 Cable, Coaxial (For Submarine use)

MIL-S-23190 Straps, Clamps, and Mounting Hardware, Plastic for Cable Harness Tying and Support

MIL-P-23236 Paint Coating Systems, Steel Ship Tank, Fuel and Salt Water Ballast

MIL-W-23351 Waveguides, Single Ridged and Double Ridged, General Specification for

vORIGINAL




MIL-C-23806 Cable, Radio Frequency, Coaxial, Semi-Rigid, Foam Dielectric, General Specification

for

MIL-F-24044 Flanges, Coaxial Line, Rigid Air Dielectric, General Specification for

MIL-E-24142 Enclosures for Electrical Fitting s and Fixtures, General Specification for

MIL-G-24211 Gaskets, Waveguide Flanges, General Specification for

MIL-C-24301 Cable, Special Purpose, Radio Frequency, Buoyant Type RG-374/U

MIL-P-24441 Paint, Epoxy-Polymide, General Specification for

MIL-C-24640 Cables Electric, Lightweight, Shipboard

MIL-C-24643 Cable and Cord, Electrical, Low Smoke, for Shipboard Use, General Specification for.

MIL-C-26482 Connectors, Electric, Circular, Miniature, Quick Disconnect, Environment Resisting,

General Specification for

MIL-C-28726 Cable, Special Purpose, Radio Frequency, Buoyant, Type RG-384/U

MIL-C-28777 Cable Assembly, Electronic Test Equipment, (3 Wire, 3 Prong, 125 Volt, Molded)

Grounding Plug Connector, General Specification for

MIL-L-28796 Line Assemblies, Radio Frequency Transmission, General Specification for

MIL-F-39000 Flanges, Waveguide, Ridged, General Specification for

MIL-C-39004 Coupling Assemblies, Quick-Disconnect, General Purpose, for Subminiature Waveguide

Flanges, General Specification for

MIL-C-39012 Connectors, Coaxial, Radio Frequency, General Specification for

MIL-C-39024 Connectors, Electrical: Jacks, Tip (Test Point, Panel or Printed Wiring Type), General

Specification for

MIL-R-46089 Rubber, Sponge, Silicone, Closed Cell

MIL-A-46106 Adhesive-Sealants, Silicone, RTV, General Purpose (For Electrical and Mechanical

Sealing)

MIL-R-46846 Rubber, Synthetic, Heat Shrinkable

MIL-A-55339 Adapters, Connector, Coaxial, Radio Frequency, (Between Series and Within Series),

General Specification for

MIL-C-81302 Cleaning Compound, Solvent Trichlorotrifluorethane, General Specification for

MIL-C-81511 Connectors, Electrical, Circular, High Density, Quick Disconnect, Environment

Resisting; and Accessories, General Specification for

MIL-C-81703 Connectors, Electric, Circular, Miniature, Rack and Panel or Push-Pull Coupling,

Environment Resisting; General Specification for

MIL-I-81969 Installing and Removal Tools, Connector Electrical Contact, General Specification for

viORIGINAL




MIL-C-85049 Backshells, Cable Sealing and Shield Termination Connector, Electric

FEDERAL SPECIFICATIONS

L-P-387 Plastic Sheet, Laminated, Thermosetting (For Design Plates)

L-P-535 Plastic Sheet (Sheeting); Plastic Strip, Vinyl Chloride Polymer and Vinyl Chloride-Vinyl

Acetate Copolymer, Rigid

W-S-570 Soldering Iron, Electric

FF-N-836 Nut: Square, Hexagon, Cap, Slotted, Castellated, Clinch, Knurled, Welding and Single

Ball Seat

FF-S-85 Screw, Cap, Slotted and Hexagon Head

FF-S-86 Screw, Cap, Socket-Head

FF-W-84 Washers, Lock (Spring)

FF-W-92 Washers, Metal, Flat (Plain)

FF-W-100 Washers, Lock, Tooth

MILITARY STANDARDS

DoD-STD-2003-1(NAVY) Electric Plant Standard Methods for Surface Ships

MIL-STD-12 Abbreviation for use on Drawing sand in Technical Type Publications

MIL-STD-130 Identification Marking of U.S. Military Property

MIL-STD-242 Electronic Equipment Parts Selected Standards

MIL-STD-454 Standard General Requirements for Electronic Equipment

MIL-STD-645 Dip Brazing of Aluminum Alloys

MIL-STD-1277 Splices, Clips, Terminals, Terminal Boards, Binding Posts; Electrical

MIL-STD-1310 Shipboard Bonding, Grounding, and Other Techniques for Electromagnetic Compatibility

and Safety

MIL-STD-1327 Flanges, Coaxial and Waveguide; and Coupling Assemblies, Selection of

MIL-STD-1353 Electrical Connectors and Associated Hardware, Selection and Use of

MIL-STD-1358 Waveguide, Rectangular, Ridged and Circular, Selection of

MIL-STD-1399 Interface Standards for Shipboard Systems

MIL-STD-1646 Servicing Tools for Electric Contacts and Connections, Selection and Use of

MIL-STD-1680 Installation Criteria for Shipboard Secure Electrical Information Processing Systems

MIL-STD-1683 Connectors and Jacketed Cable, Electric, Selection Standard for Shipboard Use

viiORIGINAL



MILITARY STANDARDS

MS3400 Connectors, Receptacle, Electric, Wall Mounting, Front Release, Crimp Contact, AN

Type

MS3401 Connectors, Receptacle, Electric, Cable Connecting, Front Release, Crimp Contact,

AN Type

MS3406 Connectors, Plug, Electric, Front Release, Crimp Contact, AN Type

MS3408 Connectors, Plug, Electric, 90° Assembly, Crimp Contact, AN Type

MS3409 Connectors, Plug, Electric, 45° Assembly, Crimp Contact, AN Type

MS3480 Tool, Connector Assembly for MIL-C-5015 Connectors



MS18297 Cable, Navy, Insulation Resistance

MS90387 Tool, Hand Adjustable, for Plastic Tiedown Straps

NAVSEA DRAWINGS

805-1639213 Card Holder

805-1749000 Visible File, Bulkhead Mounted

RE-D2697984 Safety Shorting Probe Fabrication Detail

5003000 Safety Shorting Probe Set and Stowage Assembly

MILITARY PUBLICATIONS

0910-LP-422-4700 General Specifications for Overhaul of Surface Ships (S9AAO-AB-GOS-010)

0910-LP-432-5900 General Specifications for Ships of the U.S. Navy (S9AA0-AA-SPN-010/GEN-SPEC)

0910-LP-705-7600 Standard Maintenance Practices, Miniature/Microminiature (2M), Electronic Assembly

Repair (NAVSEA SE004-AK-TRS-010/2M)

0967-LP-034-4010 Index, Electronic Equipment and Systems Installation Control Drawings - Volume 1



0967-LP-177-3010 Communication Antenna Fundamentals, Volume 1

0967-LP-177-3020 Installation Details, Communication Antenna Systems, Volume 2

0967-LP-177-3040 Shipboard Antenna Systems, Testing and Maintenance, Communication Antenna

Systems, Volume 4

0967-LP-177-3050 Shipboard Antenna Systems, Antenna Data Sheets, Volume 5

viiiORIGINAL



MILITARY PUBLICATIONS

DDS304-2 Design Data Sheet, Electrical Cables, Ratings and Characteristics

DoD 6050.5 Hazardous Material Information System (HMIS)

DoD 6055.11 Protection of DoD Personnel from Exposure to Electromagnetic Fields (EMF) at Radio

Frequencies (RF) from 3 Kilohertz (KHz) to 200 Gigahertz (GHz).

OPNAVINST 5100.19B Navy Occupational Safety and Health (NAVOSH) Program Manual fro Forces Afloat

OPNAVINST 5100.23 Chapter 22, Non-Ionizing Radiation.

MIL-HDBK-216 RF Transmission Lines and Fittings

MIL-HDBK-290 Standard Electrical Symbol List

MIL-HDBK-299 Cable Comparison Handbook, Data Pertaining to Shipboard Electrical Cable

MIL-HDBK-660 Fabrication of Rigid Waveguide Assemblies (Sweep Bends and Twists)

NAVSEA STD-407-5287561 Industrial Electromagnetic Compatibility (IEMC) Work Process Instructions

SE000-00-EIM-100 Electronics Installation and Maintenance Book - General

SE000-00-EIM-130 Electronic Installation and Maintenance Book - Test Methods and Practices

S9086-KC-STM-010/CH-300 R2 Naval Ships Technical Manual Chapter 300 Electric Plant - General

TL150-AD-MM0-011/NEDALS NAVSEA Engineering Drawing Asset Locator System (NEDALS)

OTHER PUBLICATIONS

IEEE C95.1-1991 Institute of Electrical and Electronics Engineers (IEEE) C95.1-1991, "IEEE Standard for

Safety Levels with Respect to Human Exposure to Radio Frequency Electromagnetic

Fields, 3 kHz to 300 GHz,"

ixORIGINAL

INSTALLATION NAVSEA SE000-00-EIM-110 PREFACESTANDARDS

PREFACE

POLICY AND PURPOSE ORGANIZATION

The Navy Installation and Maintenance Book(NIMB), formally know as the Electronics Installation andMaintenance Book (EIMB), was established as themedium for collecting, publishing, and distributing, inone convenient source document, those subordinatemaintenance and repair policies, installation practices,and overall electronic equipment and material handlingprocedures required to implement the major policies setforth in Chapter 400 of the Naval Ships' TechnicalManual. All data contained within the NIMB derive theirauthority from Chapter 400 of the Naval Ships'Technical Manual

The NIMB is organized into a series of handbooksto afford maximum flexibility and ease in handling. Thehandbooks are stocked and issued as separate items sothat individual handbooks may be obtained as needed.

The handbooks fall within two categories: generalinformation handbooks, and equipment orientedhandbooks. The general information handbooks containdata which are of interest to all personnel involved ininstallation and maintenance, regardless of theirequipment specialty. The titles of the various generalinformation handbooks give an overall idea of their datacontent; the General Handbook includes more completedescriptions of each handbook.

Since its inception, the NIMB has been expandedto include selected information of general interest toelectronic installation and maintenance personnel.These items are such as would generally be contained intextbooks, periodicals or technical papers, and form(along with the information cited above) acomprehensive reference document. In application, theNIMB is to be used for information and guidance by allmilitary and civilian personnel involved in theinstallation, maintenance, and repair of electronicequipment under cognizance, or technical control, of theNaval Sea Systems Command (NAVSEA). Theinformation, instructions, and procedures, in the NIMBsupplement instructions and data supplied in equipmenttechnical manuals and other approved maintenancepublications

The equipment handbooks are devoted toinformation about particular classes of equipment. Theyinclude general test procedures, adjustments, generalservicing information, and field change identificationdata.

All handbooks of the series are listed below withtheir NAVSEA numbers. The NAVSEA numbers servealso as the stock numbers to be used on anyrequisitions submitted.

HANDBOOK TITLE NAVSEA NUMBER

INFORMATION SOURCESNIMB General Information Handbooks

General SE000-00-EIM-100Periodic revisions are made to provide the best

current data in the NIMB and keep abreast of newdevelopments. In doing this, many source documentsare researched to obtain pertinent information. Some ofthese sources include the Electronics InformationBulletin (EIB), electronics and other textbooks, industrymagazines and periodicals, and various militaryinstallation and maintenance related publications. Incertain cases, NAVSEA publications have beenincorporated into the NIMB in their entirety and, as aresult, have been canceled. A list of the documentswhich have been superseded by the NIMB and are nolonger available is given in Section I of the GeneralHandbook

Installation Standards SE000-00-EIM-110Electronic Circuits SE000-00-EIM-120Test Methods & Practices SE000-00-EIM-130Reference Data SE000-00-EIM-140EMI Reduction SE000-00-EIM-150General Maintenance SE000-00-EIM-160

NIMB Equipment-Oriented Handbooks

Communications SE000-00-EIM-010Radar SE000-00-EIM-020Sonar SE000-00-EIM-030Test Equipment SE000-00-EIM-040Radiac SE000-00-EIM-050Countermeasures SE000-00-EIM-070

xORIGINAL

INSTALLATION NAVSEA SE000-00-EIM-110 PREFACESTANDARDS

DISTRIBUTION SUGGESTIONS /CORRECTIONS

Initial Set: An 'AF" Restriction Code has beenassigned to NAVSEA SE000-00-EIM-000 to control theover-requisitioning of the NIMB Series. Fleet and shoreactivities requiring an initial set of the NIMB Series (13handbooks with all changes and heavy-duty binders)should submit their requisition (DD Form 1348 withwritten justification) through their Supply Officer or area,for issue approval to:

NAVSEA recognizes that users of the NIMB willhave occasion to offer corrections or suggestions.Beneficial comments and any pertinent data which maybe of use in improving this publication should beforwarded to NAVSEA.

A NAVSEA Technical Manual Deficiency andEvaluation Report (TMDER) is available on page XII.

Complete information should be given whenpreparing suggestions. Suggestors are encouraged toinclude their names and addresses so that clarifyingcorrespondence can be initiated when necessary. Suchcorrespondence will be by letter directly to the individualconcerned.

COMMANDER,NAVAL SEA SYSTEMS COMMAND,SEA 91Q3WASHINGTON, DC 22242-5160

If a comment sheet is not available, or ifcorrespondence is lengthy, corrections or suggestionsshould be directed to the following:

Use the following data on the DD-1348,

Block A - 288 NAVPUBFORMCEN PHILAStock No. - 0967-LP-000-0000 COMMANDER,Unit of Issue - SE NAVAL SEA SYSTEMS COMMAND,Fund - 00 SEA 91Q3

WASHINGTON, DC 22242-5160All other blocks are to be filled in as normally done bythe requisitioner when ordering publications.

Changes and Revisions: The NIMB is continuouslybeing updated. For efficiency these changes andrevisions are automatically distributed to using activitieswho are on the Automatic Distribution List for the NIMB.

Requests and/or changes to the NIMB AutomaticDistribution List and any problems in requisitioningshould be directed to:

COMMANDER,NAVAL SEA SYSTEMS COMMAND,SEA 91Q3WASHINGTON, DC 22242-5160

Individual Handbooks: To order individualhandbooks and changes, use the stock numbers listedin the Box Score on page ii. Using the stock number forthe "BASIC" provides the handbook and all applicablechanges.

xiORIGINAL

NAVSEA (USER) TECHNICAL MANUAL DEFICIENCY/EVALUATION REPORT (TMDER)(NAVSEA S0005-AA-GYD-030/TMMP & NAVSEAINST 4160.3A)

(Insert Class. of TMDER Her and AT Bottom of Page) CLASSIFICATION:

INSTRUCTION: Continue on 8 1/2" x 11" paper if additional space is needed.

USE THIS REPORT TO INDICATE DEFICIENCIES, PROBLEMS AND RECOMMENDATIONS RELATING TO PUBLICATION.FOR UNCLASSIFIED TMDERS, (SEE OPNAVINST 5510.1H FOR MAILING CLASSIFIED TMDER'S),SEND TMDER TO: COMMANDER ( (91Q3)) NAVAL SEA SYSTEMS COMMAND 2531 JEFFERSON DAVIS HWY ARLINGTON VA 22242-5160

1.2.

1. NAVSEA TECHNICAL MANUAL NO. 2. VOL. PART

4. REV. NO/DATE ORTM CH. NO/DATE

5. SYSTEM/EQUIPMENT NOMENCLATURE 6. SYSTEM/EQUIPMENT IDENTIFICATION (MK/MOD/ANPART NO)

A. EXCELLENT B. GOOD C. FAIR D. POOR E. COMPLETE F. INCOMPLETE

8. GENERAL COMMENTS

7. USER'S EVALUATION OF MANUAL (Check Appropriate Blocks)

9. RECOMMENDED CHANGES TO PUBLICATION

PAGENO.A.

PARA-GRAPH

B.

LINENO.C

FIGNO.D.

TABLEE.

F. RECOMMENDED CHANGES AND REASONSTYPE OF PROBLEM [( INDICATE SAFETY (S), MAJOR (M), OR MINOR (P)]

10. ORIGINATOR'S NAME AND WORKCENTER (Please Print)

11. SIGNATURE OF 3M COORDINATOR 12. DATE SIGNED 13. AUTOVON/COMM. NO.

14. SHIP HULL NO. AND/OR STATION ADDRESS (DO NOT ABBREVIATE)

15. THIS SPACE NSDSA

A. CONTROL NO. B. COG ISEA C. DATE

RECEIVED FORWARDED DUE

D. PRIORITY E. TRANSMITTED TO

NAVSEA 4160/1 (Rev. 10-89(REPLACES NAVSEA 9086/10. DESTROY STOCK)

CLASSIFICATION:

SE000-00-EIM-110 / 0967-LP-000-0110 BOOK (NIMB) - INSTALLATION STANDARDSNAVY INSTALLATION AND MAINTENANCE3. TITLE

NAVSEA SE000-00-EIM-110

SECTION 1GENERAL

INSTALLATION NAVSEA SE000-00-EIM-110 GENERALSTANDARDS

GENERAL

1-1 PURPOSE 1-4.1 INSTALLING ACTIVITY/INSTALLERInstalling Activity and/or Installer is defined as any

military, commercial or industrial establishment orindividual involved with electronic equipment/systemsinstallations aboard Naval ships.

The purpose of the Installation Standards Handbookis to provide guidance and instructions pertinent to theproper installation of electronic equipments and systemsaboard Naval ships. This handbook is published for theguidance of all personnel, military activities and privateindustry responsible for or engaged in the installation ofelectronic equipments and systems.

1-4.2 INSTALL/INSTALLING/INSTALLATIONThe words "install", "installing" and "installation" as

used in this document includes whatever design,procurement, fabrication, material handling, labor, materialmounting/fastening, inspection, testing, repair,maintenance and etc. that is required to install and makeoperational any electronic equipment/system aboardNaval ships.

1-2 SCOPE

The information contained in the InstallationStandards Handbook has been carefully selected andarranged so that it is easily identified and retrieved. Toensure current and correct information is always availableto the user of this handbook, the referencing ofappropriate documents and publications is utilized wherepracticable in lieu of reproducing data from existingdocuments.

1-4.3 INTERCONNECTING CABLESThe term "interconnecting cable/s" as used in the

Installation Standards Handbook shall mean any jacketed(single and multiconductor) cable, both electrical and radiofrequency, that is used to electrically interface any twoseparately enclosed electrical/electronic units includingterminal and distribution boxes.

The handbook consists of the following:Section 1 General

1-4.4 INSTALLATION CONTROL DRAWINGS(ICDS)

Section 2 Cable InformationSection 3 Special Purpose EquipmentSection 4 Antennas

Installation Control Drawings (normally called ICDs)are Department of the Navy drawings that provideshipboard installation data for electronic equipment and/orsystems.

Section 5 Radio Frequency TransmissionLines (Waveguides and RigidCoaxial)

Section 6 Equipment Installation

1-4.5 AUTHORIZED APPROVAL1-3 USE AND APPLICATION

The term "Authorized Approval" as used in theInstallation Standards Handbook shall mean that whenrequired written approval shall be obtained, through propergovernment channels, from the cognizant Department ofthe Navy, Command, Center, Activity, Office or Division.

When properly used, the Installation StandardsHandbook is a quick and convenient source of informationfor shipboard installation of electronics equipments andsystems. The design, procurement, fabrication,procedures and methods required to properly installelectronic equipment encompass a large number ofspecifications, standards, handbooks, publications anddrawings. Through the compilation of data not covered bythese documents and the referencing of these documentsin the appropriate text the Installation Standards Handbookbecomes a single vital instrument that should be used byevery individual, military activity, or commercial enterpriseinvolved with Naval shipboard electronic installations. Forthis handbook to be complete, the Installing Activityshould maintain a repository of the referenced documents.The Installing Activity should ensure the referenceddocuments are kept updated and are the correct revisionreferenced by a specific contract.

1-4.6 ENCLOSUREThe word "enclosure" as used in this document shall

mean any equipment cabinet or case, connection box,distribution panel or box, switch box, jack box, console,radio or radar or NTDS switchboard, transfer panel, controlpanel, and any other device used in electronic systemsaboard Navy ships.

1-5 PRECEDENCE

Conflicting statements between the InstallationStandards Handbook and any document referenced hereinshall be resolved by appropriate Government authority withNAVSEA 0910-LP-432-5900 General Specifications forShips of the U.S. Navy (S9AA0-AA-SPN-010/GEN-SPEC),taking precedence over all other documents whereapplicable. NAVSEA 0910-LP-432-5900 GeneralSpecifications for Ships of the U.S. Navy (S9AA0-AA-SPN-010/GEN-SPEC) is the primary document for newconstruction and S9AAO-AB-GOS-010, GeneralSpecifications for Overhaul of Surface Ships is the

1-4 DEFINITIONS

The definition of words, terms and phrases can varydepending upon the document subject, context, andconnotation. To assist the user in understanding thisdocument, the following definitions shall apply.

1-1ORIGINAL


document that relates to ship overhaul actions. could be caused by careless handling and storage, badhousekeeping, congested work areas and exposure toundesirable environmental conditions.1-6 SAFETY

1-7.3 GOOD HOUSEKEEPING PRACTICESSafety is a subject about which many documentshave been written, and since the purpose of theInstallation Standards Handbook is to cover requirements,methods and procedures for the installing of electronicequipment aboard Naval ships, the safety Informationcontained herein is limited to general topics that assist theinstaller in accomplishing the Installation task in a safemanner in addition to providing a shipboard installationthat meets safety requirements for Navy operating andmaintenance personnel.

Good housekeeping shall be practiced at all timesduring the installation process.

The interior of equipment shall be kept free of dust,dirt, grime, moisture, and foreign objects that could becaused by chipping, welding, grinding, torch brazing orburning, painting and similar work functions encounteredduring ship construction, repair, overhaul or alterations.

After the shipboard installation is complete, theInstalling Activity shall ensure that all units are thoroughlycleaned internally and externally, and the external finish, ifdamaged, is repaired to a condition comparable to theoriginal finish.

1-6.1 PERSONNEL SAFETYEnsure that prescribed safety precautions applicable

to a specific installation task are understood and strictlyenforced. 1-8 GOVERNMENT DRAWINGS

It is the individual's responsibility to himself and hisfellow worker to adhere to the safety precautionsprescribed by the parent organization.

The list of government drawings relative to shipboardelectronic installations has become too extensive tocontinue listing in this document. Information concerningthe source and indexes of these drawings is covered in thefollowing subparagraphs.

1-6.2 INSTALLATION SAFETY REQUIREMENTSTo ensure a safe environment for operational and

maintenance personnel, the Installing Activity shallcomply with the following requirements. 1-8.1 INSTALLATION CONTROL DRAWINGS

(a) Electronic equipment installed aboard Navalships shall comply with MIL-STD-454, requirement 1.

The Installation Control Drawing Index consists ofthree volumes. Volume 1, NAVSEA 0967-LP-034-4010provides a complete listing of all available ICDs and ispublished semiannually with update supplementsdistributed monthly. Volume 1 lists the drawings bothalphanumerically by nomenclature and numerically by the"RE" number. Volume 2, NAVSEA 0967-LP-034-4020,provides a cross reference between old drawings numbersto new drawing numbers. Volume 3, NAVSEA 0967-LP-034-4030 consists of a listing of mono detail drawingsarranged both alphanumerically by nomenclature andnumerically by drawing number.

(b) Materials and procedures required in theinstallation of electronic equipment aboard Naval shipsshall comply with the requirements of NAVSEA SE000-00-EIM-100 Section 3 and the specific ship specifications.

(c) Grounding of electronic equipment, includingcabling, installed aboard Naval ships shall comply with therequirements of MIL-STD-1310.

(d) Safety warning and instruction signs shall beinstalled in areas containing electronic equipment inaccordance with the requirements of NAVSEA SE000-00-EIM-100, Section 3 and the specific ships specifications. Requests for Index copies should obtained through

the National Supply system using the provided NSN's.(e) Portable electronic equipment received withungrounded two contact cable assemblies shall bemodified for a grounded three contact cable assembly inaccordance with MIL-C-28777.

Information for requesting copies of ICDs iscontained in Volume 1, NAVSEA 0967-LP-034-4010.

An ICD Index is also maintained in the NEDALSelectronic database as described below.

1-7 WORKMANSHIP

1-8.2 NAVSEA ENGINEERING DRAWINGSWorkmanship shall be first class in every respectand shall be in accordance with the applicablerequirements stated throughout the Installation StandardsHandbook, ships specifications, applicable instructionspromulgated for electronic equipment and ancillarycomponents, quality assurance manuals, and the followinggeneral requirements.

The NAVSEA Engineering Drawing Asset LocatorSystem (NEDALS) provides a complete automatedelectronic listing of available engineering drawings underNAVSEA cognizance. NEDALS updates are provided byEngineering Drawing Maintenance Activities (EDMAs) suchas In-Service Engineering Activities (ISEAs) and planningyards or from automated logistic data bases such as theWeapon System File (WSF), Ship Configuration andLogistic Support Information System (SCLSIS) and theFederal Supply Catalogue (FSC) using formats specifiedunder NEDALS.

1-7.1 SKILLSAll personnel involved with a specific installation shall

be properly trained and capable of accomplishing thefunctions of their respective skills.

1-7.2 EQUIPMENT AND MATERIALPROTECTION

Equipment and materials required for a specificinstallation shall be protected from possible damage that

1-2ORIGINAL


Requests for NEDALS information and access shallbe addressed to: 1-9.2 TOOLS AND PLANT EQUIPMENT

Tools and plant equipment required for theinstallation of shipboard electronic systems are to be:Naval Engineering Drawing Support Activity

(NEDSA) 1. Maintained in good working condition at alltimes.Naval Ordnance Station

Louisville, KY 40214-5001 2. Tested and calibrated where applicable.

1-9 QUALITY ASSURANCE3. Appropriately used and applicable to the

intended function.

1-9.3 PERSONNELThe Installing Activity shall be responsible forimplementing a quality assurance program that will ensurethe following:

Personnel are to be trained in the use and applicationof all tools, plant equipment, methods and proceduresrequired for the installation of electronic systems aboardNavy ships.1-9.1 EQUIPMENT AND MATERIAL

Government furnished equipment and materialrequired for shipboard electronic installations will be:

1. Protected from weather and physical damageduring storage and handling.

2. Equipment and material installed is that whichis called for by ships specifications, and applicabledocuments.

3. Equipment and material is installed inaccordance with ships specification and applicabledocuments.

4. The completed installation is operational inaccordance with ships specification and applicabledocuments.

1-3ORIGINAL


SECTION 2CABLE, FLEXIBLE AND SEMI-RIGID

INSTALLATION NAVSEA SE000-00-EIM-110 CABLE, FLEXIBLESTANDARDS AND SEMI-RIGID

SECTION 2CABLE, FLEXIBLE AND SEMI-RIGID

2-1 INTRODUCTIONcables.

2. MIL-C-22931 for semi-rigid, semi-air-dielectriccoaxial cables.

The effectiveness of an electronic system isdependent on many factors. Circuit design, durability ofthe equipment in its environment, suitable location of thecomponents and proper installation of the interconnectingcables are but a few of these factors. One of the mostcritical of these factors is the installation ofinterconnecting cables which involves cable handling,hanging, structural penetrations, terminations, connectorattachments and proper shielding where applicable. Agood installation of interconnecting cables giving a highdegree of reliability can be accomplished with properplanning guidance, the use of correct materials and toolsand a desire to give good workmanship

3. MIL-C-23806 for semi-rigid, foam filleddielectric coaxial cables.

4. MIL-C-23020 coaxial cables for submarineuse.

5. MIL-C-22667 , MIL-C-24301 and MIL-C-28726for Buoyant cable applications.

2-3.4 CABLE TYPE AND SIZEThe type and size of cables used in shipboard

electronic installations shall be as follows:(a) Navy cable types and sizes shall be as

shown on ICDs. Deviation from cable types and sizesshown on ICDs can be made only with authorizedapproval from the cognizant equipment activity. Whereelectrical cables classed as discontinued and/or obsoleteare shown on ICDs, the current replacement cable typeshown on MIL-HDBK-216 shall be used.

2-2 SCOPE

This section describes, illustrates, and referencesdata, handbooks, standards and specifications forapproved materials and methods required for theinstallation of interconnecting cables used in shipboardelectronic systems. Included in this section is data forcoaxial cables and coaxial connectors. Fabrication andinstallation of rectangular waveguide, rigid coaxial linesand elliptical waveguide components are covered insection 5 of this document.

(b) MIL-HDBK-299 and DDS304-2 shall be usedfor guidance where the Installing Activity design sectionis responsible for determining the correct electrical cabletype and size to be used in a specific installation.

(c) MIL-STD-242 and MIL-HDBK-216 shall beused for guidance where the Installing Activity designsection is responsible for determining the correct RFcoaxial cable type and size to be used in a specificinstallation.

2-3 CABLE SELECTION (d) Jacketed cables without metal armor shall beused in electronic installations aboard Naval ships.Armored cables may be used where there is noequivalent cables of the unarmored type.

Cables for use in shipboard electronic installationsshall be selected in accordance with MIL-STD-242 andcomply with the requirements stated herein. Cablesreferenced in ICDs, ShipAlts, Guidance plans, TechnicalManuals, and ship installation drawings shall not bereplaced with substitute cables without authorizedapproval.

(e) Electrical cable types shall be selected inaccordance with the intended application such as powerand lighting, control, or electronic, communication andinstrumentation. MIL-HDBK-299 shall be used forguidance in selecting the correct type cable for a specificapplication.2-3.1 ELECTRICAL CABLES

(f) Electrical cable types shall be selected inaccordance with the intended service such as non-flexingservice or repeated flexing service. MIL-HDBK-299 shallbe used for guidance in selecting the correct type cablefor a specific service.

Electrical cables required for power, lighting, control,communications, instrumentation and electronicapplication shall comply with Military Specification MIL-C-24643 (Low Smoke) and MIL-C-915.

2-3.2 PORTABLE POWER AND CONTROLCABLES

(g) Electrical cables are classified as eitherwatertight or non-watertight. The non-watertight

cables may be used for applications within a watertightcompartment and non-critical areas above the shipwatertightness level. MIL-HDBK-299 shall be used forguidance in determining which cables are watertight ornon-watertight.

Portable power and control cables shall comply withMilitary Specification MIL-C-3432. Power cableassemblies for use with portable test equipment requiring125 VDC or 125 VAC shall comply with MilitarySpecification MIL-C-28777. (h) The ambient temperature a cable will

experience in a shipboard installation will determine if ahigh temperature cable is required. Where possiblecables shall be routed around high heat areas. Whereelectrical cables must pass through a high temperaturearea, MIL-HDBK-299 and DDS304-2 may be used fordetermining the correct cable type and conductor size foruse in an area whose ambient temperature does not

2-3.3 COAXIAL CABLES, FLEXIBLE AND SEMI-RIGID

Coaxial cables required for radio frequencyapplication shall comply with the following militaryspecifications:

1. MIL-C-17 for flexible and semi-rigid coaxial

2-1ORIGINAL


exceed 50° Celsius. For ambient temperatures of either60° Celsius or 70° Celsius the ampacity derating factorsMIL-HDBK-299 shall be used for determining the correctcable type and size for a specific installation. Where RFcoaxial cables must pass through a high temperaturearea, MIL-STD-242 and MIL-HDBK-216 shall be used forguidance in the selection of the correct high temperaturecable for a specific installation.

prior to installation. If the attenuation exceeds themaximum value shown on the specification sheet, thecable shall be rejected.

Cables that have been in storage for a prolongedperiod may be installed provided a visual inspectionshows that it has sustained no mechanical damage thatwould impair the watertight integrity of its outer sheath.

Cables, especially coaxial, shall be stored so thatdamaging pressure is not applied. Cables should bestored on reels whenever possible. Cable shall not bestored by hanging on hooks, dowels, or pegs.

(i) The ampacity of a specific cable shall notexceed the values given in MIL-HDBK-299. Conductorsin multiconductor cables shall not be paralleled to obtaincurrent carrying capacity. Conductors in multiconductorcables may be paralleled to meet the voltage droplimitations. The allowable voltage drop for multiconductorcables used for interconnecting various units ofelectronic equipment shall conform with circuitrequirements.

When cables are stored or set aside for installation,the ends of the cable shall be sealed against moistureabsorption by one of the cable end sealing methodsshown in MIL-STD 2003, figure 1A14.

Sealing cable ends may be omitted when theinterval between cutting a length of cable and thetermination made to connectors or equipment is 48 hoursor less, and the exposed ends are not subjected tomoisture during excessive temperature changes.

(j) The requirement for shielded conductors orshielded cables is controlled by the type of information tobe carried in the cable conductors. The appropriate ICDsand MIL-STD-1680 shall be referred to for specificinformation regarding which circuits require shielding.

Transfer of cables from a cold to a warm, highhumidity location, which would cause moisture absorption,shall be avoided.(k) The interface characteristics of cables,

connectors, equipment cable entrance areas, andequipment electrical terminal connections shall beconsidered when selecting cables for shipboardelectronics installations. The compatibility betweencables and equipment shall be such that a high degree ofreliability is maintained during a ships normal operationalperiod.

2-5 CABLE HANDLING

The handling of cable is just as important to a goodshipboard installation as any other phase of the overallinstallation.

When handling cables, both before and duringinstallation, avoid abrasion, crushing, twisting or kinking.Twisting or kinking is most likely to occur when a cable isremoved from a reel or unwound from a coil.

(l) Characteristic impedance, capacitance,frequency, maximum operating voltages, VSWR,attenuation, type of dielectric, type of outer conductorand type of approved connectors are critical factors thatshall be considered in selecting an RF coaxial cable thatwill correctly interface electronic equipments. MIL-STD-242, MIL-HDBK-216 and coaxial cable specificationsheets shall be referred to for technical information toassist in selecting the correct flexible coaxial or semi-rigidcoaxial cable for a specific installation.

The use of block and tackle, chain falls, or othermechanical devices to pull interconnecting cables orcoaxial cables in electronic installations shall beprohibited. Cables shall not be left laying on decks wherethey are subjected to damage. Cables and cable endsshall be kept coiled and suspended above the deck untilinstallation can be completed.

Special care shall be given to the handling of coaxialcables in order to comply with the above requirements.Kinks, twists, sharp bends, stretching by applyingexcessive pressure to pull-in, crushing caused by beingwalked on or other heavy objects can easily change thedimensions of the dielectric in a coaxial cable. This inturn changes the characteristic impedance of the cableat the damaged area causing increased VSWR andsignal loss during system operation.

(m) Semi-rigid coaxial cable shall include jacketedouter conductors.

2-4 CABLE STORAGE

Cable shall be stored in a dry place, which is notsubject to accidental flooding, protected from theweather, and subjected to a minimum variation oftemperature. Flammable materials and chemicals shallnot be stored in the same area with cables. A straightening device similar to that shown in

Figure 2-1 shall be used for straightening semi-rigidcoaxial cable as it is removed from a shipping/storagereel. Figure 2-2 illustrates the use of a straighteningdevice on semi-rigid cable.

Coaxial cables shall be stored in an area where theambient temperature is less than 66° Celsius. If thecable is exposed to higher temperature, the attenuationand VSWR shall be tested in accordance with MIL-C-17

2-2ORIGINAL


Figure 2-1. Typical Semi-rigid Cable Straightening Device

2-6 CABLE BENDSThe minimum bend radius for flexible coaxial cables

shall be 10 times the cable diameter, except when thecable is subject to repeated flexure; in which case, theminimum bend radius shall be 20 times the cablediameter.

Cables may be easily damaged during installationby careless shaping or forming that could result in anunreliable operational system. Although these coaxial cables are called flexible

coaxial cables, they are not designed primarily forcontinuous flexure or twisting. If a limited degree offlexure is necessary, the cable should be installed so thatthe radius of bend changes in one direction only, ratherthan undergoing a reversal.

Cables shall be formed in a sweep bend and shouldbe made over a mandrel, if practicable. Bends atterminal entrances, where stuffing tubes are required,shall be made via angle stuffing tubes. Straight stuffingtubes may be used in place of angle stuffing tubes if thebend in the cable is not less than the minimum bendradius specified for that cable.

Bends and offsets in semi-rigid coaxial cables shallhave the largest curvature possible.

The minimum bend radius for electrical cable shallbe as specified in MIL-HDBK-299 and DDS304-2.

2-3ORIGINAL


Figure 2-2. Simplified Rigging for Semi-rigid Cable Straightening Device

Bends and offsets shall be formed with a mandrelcapable of providing a smooth bend without ripples orridges appearing in the outer conductor. The inside bendradius shall be not less than those listed in the followingtable for semi-rigid coaxial cables.

to dampness shall, prior to installation, receive aninsulation resistance test in accordance with paragraph2.8.3 of this document Cables that cannot be brought tothe minimum acceptable insulation resistance valuesshall be rejected.

Cables shall be visually inspected for physicaldamage after shipboard installation is completed. Anyindication that the cable has been subjected to excessiveheat, damaged by heavy or sharp objects, orpermanently twisted or kinked shall be justification forreplacement of cable. Coaxial cable that has had thedielectric deformed or changed by any condition shall bereplaced.

Nominal Cable O.D. Min. Bend Radius0.375 4 inches0.500 5 inches0.875 10 inches1.625 25 inches3.125 50 inches

2-7 CABLE PROTECTION Coaxial cables showing any signs of deformity, suchas kinks, flatness, twists, split jackets or indentationsshall be rejected.Interconnecting cables shall be properly protected,

mechanically and electrically, by approved protectivematerials and methods in those cases where possibledamage of any type is apparent or suspected.

The Installing Activity shall, at the time of visualinspection, determine what caused the cable damage andtake the necessary corrective action prior to replacementof the new cable.Coaxial cables installed on masts, in the beam

pattern of radars operating in the 200 MHz - 450 MHzrange, shall be shielded from radiation in accordance withthe requirements of MIL-STD-1310.

2-8.2 CONTINUITY CHECKSContinuity checks shall be made on all conductors

in all cables after the installation is completed includingthe attachment of connectors and/or terminal lugs. Thisis to certify that there are no open or shorted conductorsinside the cable sheath and that the connectors arecorrectly terminated and identified.

2-8 CABLE TESTING

Cables installed in shipboard electronic systemsshall receive visual inspections, continuity checks andinsulation resistance tests prior to energizing ofequipment. Coaxial cables shall, in addition to theabove, be tested for attenuation and voltage standingwave ratio (VSWR). This requirement may be relaxed forcertain types of coaxial cables when used for suchpurposes as video and audio circuits.

2-8.3 INSULATION RESISTANCE TESTSNAVSEA S9086-KC-STM-010/CH-300 R2, Chapter

300, may be used as a guide for methods of conductinginsulation resistance tests on all cables in accordancewith the following categories:

2-8.1 VISUAL INSPECTION 2-8.3.1 Power, Lighting and Control CablesInsulation resistance measurements for power,

lighting and control cables used in electronic installationsshall be made between each conductor and all otherconductors of the same cable, and between each

Cables shall be visually inspected for signs ofphysical damage and dampness prior to shipboardinstallation. Cable showing signs of physical damageshall not be installed. Cables that have been subjected

2-4ORIGINAL


conductor and ground. Minimum insulation resistancevalues shall be determined from Military Standard MS-18297.

treatment, run another insulation test. If the cable showsa marked improvement continue the current treatmentuntil the cable meets the required insulation resistancevalue. If no improvement is shown after four hours oftreatment, the cable shall be replaced.2-8.3.2 Multiconductor Cables

Insulation resistance measurements formulticonductor cables with conductors of less than 1700circular mil area in size shall be made between eachconductor and all other conductors of the same cable,and between each conductor and ground. These cablesinclude twisted pair, triads, shielded and unshielded, thatare normally used in interior communications andinstrumentation systems. The minimum insulationresistance values for these cables shall be 50,000 ohms.

2-8.4 ATTENUATION AND VOLTAGESTANDING-WAVE-RATIO MEASUREMENTS

Attenuation and VSWR tests shall be conducted onall flexible and semi-rigid coaxial cables. Test readingsshall not exceed those specified in MIL-C-17 or by thecable manufacturer for a specified cable.

NAVSEA SE000-00-EIM-130 may be used for testmethods and guidance for testing of coaxial cables.Technical data is available in MIL-HDBK-216 in additionto the coaxial cable general specifications.

2-8.3.3 Coaxial CablesInsulation resistance tests shall be made on coaxial

cables prior to shipboard installation and upon completionof installation. The tests conducted after completion ofinstallation shall include the installed connectors but withthe cables disconnected from the equipment.

2-9 CABLE CLASSIFICATION

All shipboard cables are classified as to theirconstruction, service and application to ensure anoptimum installation and still maintain the ships structuralintegrity. To assist the installer in selecting the correctcables, the different classifications are discussed in thefollowing subparagraphs.

The 500-volt megohmeter used for these tests shallhave a resistance range capable of accurately indicatingthe values required by this test Acceptable insulationresistance values for cables with polyethylene orpolytetrafluorethylene (Teflon) dielectric shall equal orexceed the following: 2-9.1 CONSTRUCTION

The construction of shipboard cables is classifiedas either watertight or non-watertight. Non-watertightcables may be used for runs that are either totally withinone compartment or totally within two contiguouscompartments. In either case non watertight cable shallnot be used where a watertight deck or watertight bulkheadbelow Flooding Water Level II, is penetrated.

Length Insulation resistance(feet) (megohms)

100 (or less) 40,000200 20,000500 8,000

1,000 4,000

2-9.2 SERVICEInsulation resistance values of coaxial cables withsynthetic rubber dielectric shall equal or exceed 1,000megohms for lengths up to 1,000 feet. The service of shipboard cables is classified as

either flexing or nonflexing. Nonflexing cables are usedfor interconnecting permanently installed equipment,such as consoles, transmitters, receivers, panels,junction boxes and switchboards. Cables for flexingservice are used for connection to portable equipment, orto permanently installed equipment where cables arerequired to withstand repeated flexing or twisting, such asrotating directors, gun mounts, or missile launchers.

Insulation resistance values of cables with dielectricmaterial arranged in layers of conducting and non-conducting rubber shall equal or exceed 500 megohmsfor lengths up to 1,000 feet .

Insulation resistance values of cables withmagnesium oxide dielectric shall equal or exceed 10,000megohms for lengths up to 1,000 feet.

Cables not meeting the minimum insulationresistance values shall be replaced. 2-9.3 APPLICATION2-8.3.4 Moisture Absorption Shipboard cables are classified in three general

application groups; power and lighting circuits, controlcircuits, and communications, instrumentation andelectronic circuits.

For cables that have an unsatisfactory insulationresistance value due to moisture absorption, theInstalling Activity may either replace the cable or takecorrective action similar to the following methods.

2-9.4 COAXIAL CABLES(a) If it is determined that the moisturepenetration is confined to the cable ends, a length notgreater than four feet may be cut from each end and anew measurement of insulation resistance shall be made.If this method does not raise the insulation resistance tothe acceptable value, but does show a definiteimprovement, proceed to the following method.

Coaxial cables are classified as flexible and semi-rigid as to their construction and grouped according totheir use and function in the radio frequency range. MIL-STD-242 and MIL-HDBK-216 shall be used for guidancein determining the correct coaxial cable for a specificinstallation.

(b) Moisture intrusion localized at the cable endscan usually be driven out by passing a current notgreater than that for which the cable is rated, through thecable for a few hours. Check for temperature rise in thecable sheath, and after approximately four hours of

The three basic types of flexible coaxial cables aresingle conductor, two conductor and triaxial.Construction of typical coaxial cables of each type areshown in Figures 2-3, 2-4, and 2-5 with identification ofindividual components.

2-5ORIGINAL


Figure 2-6 through Figure 2-9 shows how thedifferent types of semi-rigid coaxial cables areconstructed. It is readily observed that any distortion in

the outer conductor of these cables will change itscharacteristic impedance resulting in an operationaldegradation of the cable.

Figure 2-3. Typical Flexible Coaxial Cable Construction

2-6ORIGINAL


Figure 2-4. Typical Flexible Two-Conductor Coaxial Cable Construction

Figure 2-5. Typical Flexible Triaxial Cable Construction

2-7ORIGINAL


Figure 2-6. Typical Semi-rigid Foam Dielectric Coaxial Cable Construction

Figure 2-7. Typical Semi-rigid Semi-air-dielectric (Plastic Tubes) Coaxial Cable Construction

2-8ORIGINAL


Figure 2-8. Typical Semi-rigid Semi-air-dielectric (Spiral Strip) Coaxial Cable Construction

Figure 2-9. Typical Semi-rigid Semi-air-dielectric (Spiral Strip) Coaxial Cable Construction Utilizing Corrugated Tubes

2-9ORIGINAL


2-10 CABLE ROUTING/GROUPING/SPACING 2-11 STANDARD METHODS FOR CABLINGINSTALLATION

It is necessary during the planning stage andthroughout the installation, to route, group, space,segregate and isolate the cables in categories to provideproper protection and operation of cables and circuitscomprising the electronics system.

Cables required for shipboard electronic systemsshall be installed using the appropriate standard methodsshown in DoD-STD-2003-1(NAVY) for the following:

1. Supporting and securing cables to decks andbulkheads.For routing, grouping and spacing of electrical and

coaxial cables used in electronic installations, themethods of DoD-STD-2003 and the following generalguidelines shall apply:

2. Cable penetration of decks and bulkheads onsurface ships.

3. Cable penetration of interior subdivisionbulkheads in submarines.1. Locate and arrange cables to permit

maximum heat dissipation. 4. Installation of stuffing tubes, multicabletransits, and riser boxes.2. Spaces harmful to cable or subject to

explosion hazards shall be avoided. 5. Cables passing through stowage spaces andtanks.3. Locate cableways so that cables will not be

disturbed by disassembly or removal of machinery orequipment.

6. Protection of cables against heat,condensation, moisture and mechanical damage.

4. Cables not associated with an equipmentshall not be fastened to electronic equipment cabinets.

7. Cable end sealing.8. Splicing of MIL-C-24643 (Low Smoke) and

MIL-C-915 jacketed cable.5. Route cables so as not to impair theairtightness or watertight integrity of decks or bulkheads. 9. Preparation of cable ends.

6. Cable runs shall not be routed acrosssections of ships structure subject to removal forshipment of machinery or equipment.

Coaxial cables should be supported by pre-formedhangers whenever practicable and spaced along the cableto maintain minimum stress and strain on cable andconnectors.7. Cables crossing expansion joints shall have

slack allowances at such points at least equal to themaximum movement of the expansion joint.

As a preventive measure against the spread of fire,all cables penetrating non-airtight and non-fume tightbulkheads shall have sealing compound in accordancewith MIL-I-3064 formed in the openings between cablesand the bulkhead.

8. Cables from electronic equipment shall entercableways in a curve of sufficient radius to preventtransmission of stresses to the equipment during severecableway deflection.

2-12 CABLE SUBSTITUTION/REPLACEMENT9. Cables exposed to the weather shall be keptto a minimum.

10. Cables shall be installed so that slack existsto allow for deflection of bulkheads.

Advances in the state-of-the-art have brought abouta considerable change in cable construction andapplication. This has resulted in cables being classed asobsolete, canceled, discontinued or no longer required fora specific system or installation. One of the majorchanges in cable construction is the deletion of armorwhich is no longer required in shipboard installations.Another major change is the generation of a new family ofnon-watertight lower cost cables for applications withinwatertight compartments and non-critical areas.

11. Cables shall be routed so as to avoidphysical and electrical interference with other cables andequipment, and to minimize damage from battle action.

12. Main runs of electronic cable should follow thecable runs of lighting and power installations whenpossible.

13. Where possible coaxial cables shall be routedso that the overall length is kept to a minimum.

14. Coaxial cable runs near hydraulic fluid pipingshall have drip proof shields or other barriers installed forprotection from leak damage.

2-12.1 LOW SMOKE CABLESAll cables except portable and flexible (repeated

flexing service) types and silicone rubber insulated typeof MIL-C-24643 and MIL-C-915 shall be installed intemperatures above 35 degrees F whenever possible.Low Smoke cables are provided a "LS" cable designation,for example LSDSGU, LSMDU and LSDRW.

15. Coaxial cables shall be routed on inboardsides of beams or other supporting structures to provideprotection from battle damage.

16. Coaxial cables shall not be secured directlyto ballistic decks, ballistic bulkheads or shell plating.When crossing such structures is required, the cablesshall be secured to beams or supported on hangers.

MIL-HDBK-299 and General Specifications for Shipsof the U.S. Navy (S9AA0-AA-SPN-010/GEN-SPEC),Section 304 shall be used as guidance for substitution orreplacement of canceled, discontinued or obsolete cabletypes shown on ICDs, ShipAlts, or ships installationplans.

Radar Modulator cables, radio transmitter antennacables and sonar transducer cables shall be separated atleast 18 inches from all other cables except at the areawhere they enter the equipment. Sonar hydrophonecables shall be separated at least 6 inches from all othercables or installed in flexible conduit.

Electrical and dimensional parameters of thereplacement cable should be checked for compatibilitywith the system and termination's before deciding onsubstitution shown. Tables 2-1 provides examples of lowsmoke cables and their typical application.

2-10ORIGINAL


2-12.2 OTHER TYPES OF CABLElightweight cables and there typical usage. Table 2-3shows samples of MIL-C-915 cable and their application.Table 2-4 provides guidance for special purpose cables.Table 2-2 provides examples of MIL-C-24640

General UsageFor all portions of power, lighting, interior communication, weapons control andelectronics systems, except where circuit parameters (e.g., audio or radio frequency,low level microphone, synchro, scale voltage, and other types of signals) requirespecial types of cable. Types LSMU, LS3U, LSDNW, LSTNW, LSFNW, LSMNW,LSSHOF, LSDHOF, LSTHOF, LSFHOF, LSMHOF, LSDCOP, LSTCOP, andLSMCOS shall be used only for runs that are either totally within one compartment ortotally within two contiguous compartments. However, these type cables shall not beused where a watertight deck or watertight bulkhead below Flooding Water Level II(FWL-II) is penetrated. Type SG cable shall be used for connections between the shipservice generators and their respective switchboards, between sections of the shipservice switchboards, between switchboards, and between switchboards and loadcenters.

LSDNWLSTNWLSFNWLSMNWLSSSGULSDSGULSTSGULSFSGULS6SGULS7SGULSMSCULSMULS3U

LSSHOFLSDHOFLSTHOFLSFHOFLSMHOFLSDCOPLSTCOPLSMCOS

High Voltage - 60 HzFor 3000 Volt and 5000 Volt, three phase power applications

LS5KVTSGU

Casualty Power LSTHOF-42

400 Hz PowerFor 400 Hz service for static frequency changer or motor generator cables, bus ties,and feeders where cable of lower impedance is required to reduce voltage drop.

LS6SGU

Audio and TelephoneFor audio, telephone, call bell, announcing, and alarm systems. May also be used forother interior communication and weapons control systems provided ampere rating ofthe cable and voltage drop for the system are not exceeded. Types LSTPNW andLSTTOP shall be used only for runs that are either totally within one compartment ortotally within two contiguous compartments. However, this type cable shall not beused where a watertight deck or watertight bulkhead below FWL-II is penetrated.

LSTPNWLSTTSU

LSTTOP

Radio LSSRWLSDRWLSTRW

Radio FrequencyFor applications up to two Megahertz. Maximum total copper operating temperatureshall not exceed 75 degrees C.

LSTTRS LSTTRS

Position Indicator LSPI

Degaussing LSSSGULSDSGULSTSGULSFSGULS6SGULSMDULSMDYLSMSCU

Table 2-1. MIL-C-24643 (MIL-C-24643 (Low Smoke) Cable Application

2-11ORIGINAL


CABLE TYPE

MIL-C-24643 (LOW SMOKE) CABLE APPLICATIONNON-FLEXING

SERVICEREPEATEDFLEXINGSERVICE

Thermocouple and PyrometerTemperature range:Type LSTCTX, 125 to 260 degrees C.Type LSTCJX, 150 to 540 degrees C.Type LSTCKX, 260 to 870 degrees C.

LSTCTXLSTCJXLSTCKXLSTCJULSTCTULSPBTMU

Shielded CircuitsFor combat systems, interior communications, lighting, and power circuits, whereshielding of 400 Hz (e.g. synchro, pulse, scale voltage) signals, or other signals isrequired. Where a watertight deck or bulkhead below FWL-II is penetrated, typesLSlSMWU, LS2SWAU, LSlSWU, LS2SWU, LS2UW, LS2WAU, and LS3SWU shall beused.

LS1SAULS1SMULS1SMWULS1SWULS1SULS1S50MULS1S75MULS2AULS2SJLS2SWAULS2SWULS2SULS2UWLS2WAULS2ULS3SJLS3SULS3SWULS4SJLSMS

LSTTRS

Microphone Circuits LSMCOSLSMMOP

Table 2-1 MIL-C-24643 (Low Smoke) Cable Application (cont)

NOTE: The cables may be provided with variations in armor, unarmored and unarmored with overall shields as specifiedon the application specification sheet of MIL-C-24643.

2-12ORIGINAL


CABLE TYPE

MIL-C-24640 (LIGHT WEIGHT) CABLE APPLICATIONNON-FLEXING


General UsageFor all portions of power, lighting, interior communication, weapons control andelectronics systems, except where circuit parameters (e.g., audio or radio frequency,low level microphone, synchro, scale voltage, and other types of signals) requirespecial types of cable. Types DX, TX, FX, and MXO shall be used only for runs thatare either totally within one compartment or totally within two contiguouscompartments. However, these type cables shall not be used where a watertight deckor watertight bulkhead below Flooding Water Level II (FWL-II) is penetrated.

DXTXFXDXWTXWFXW7XWMXOMXCW

Audio and TelephoneFor audio, telephone, call bell, announcing, and alarm systems. May also be used forother interior communication and weapons control systems provided ampere rating ofthe cable and voltage drop for the system are not exceeded. Type TTX shall be usedonly for runs that are either totally within one compartment or totally within twocontiguous compartments. However, this type cable shall not be used where awatertight deck or watertight bulkhead below FWL-II is penetrated.

TTXTTXW

Radio FrequencyFor applications up to two megahertz. Maximum total copper operating temperatureshall not exceed 75 degrees C.

TTXS

Shielded CircuitsFor combat systems, interior communications, lighting, and| power circuits, where shielding of 400 Hz (e.g. synchro, pulse, scale voltage)signals, or other signals is required. Where a watertight deck or bulkhead belowFWL-II is penetrated, types 1XSOW, 2XSAW, 2XSW, 2XOW, and 3XSW shall beused.

2XAO1XMSO2XSMXSO3XS2XO2XSO1XSOW2XSAW2XSW2XOW3XSW

Table 2-2. MIL-C-24640 (Light Weight) Cable Application

NOTE: The cables may be provided with variations in armor, unarmored and unarmored with overall shields as specifiedon the application specification sheet of MIL-C-24640.

2-13ORIGINAL


CABLE TYPE

MIL-C-915 CABLE APPLICATIONNON-FLEXING


Outboard and SubmersibleFor hydrophones, transducers, outboard dial telephones, retractable antennae, andsimilar equipment. Types lPR-A20E, 1PR-16, 7PR-16, 2SPR-16, 3PR-16, 1Q-16,1TR-16, and TSPR-16S are only for submarine outboard use.

MSPWTSPA1PR-A20E1PR-167PR-162SPR-163PR-161Q-161TR-167SPR-16S

MSPTSP5SSS2SDSSFSSTSSMWFDSWSMCSFlSWF2SWFTPUM

Welding Electrode Circuit TRFTRXF

Shore to Ship Power THOF-400THOF-500

400 Hz Aircraft Servicing CVSF-4

DC Aircraft Servicing JAS-250

Table 2-3. MIL-C-915 Cable Application

SPECIAL PURPOSE CABLE APPLICATION CABLE TYPE

Equipment Subjected to Damage by Hydraulic Fluids MIL-C-21609

Cable Assembly Electronic Test Equipment MIL-C-28777

Cable, Coaxial for Submarine Use MIL-C-23020

Table 2-4. Special Purpose Cable Application

NOTE: Cables in accordance with MIL-C-21609 may be used only where the cable run is totally within one compartmentor totally within two adjacent compartments. However, these types of cables shall not be used where a watertight deck orwatertight bulkhead below FWL-11 is penetrated.

2-14ORIGINAL


2-13 CABLE AND CONDUCTOR IDENTIFICATIONInterconnecting cables, including the individual

conductors, shall be identified and marked in accordancewith the following.

Figure 2-10. Typical Cable Tag

2-13.1 CABLE TAGSMaterial, tag dimensions and lettering shall be the sameas that for cable tags and installed as shown on Figure 2-11.Cable identification tags shall be installed as close

as practicable to each point of termination and on bothsides of decks and bulkheads except for the followingconditions.

2-13.3 CIRCUIT OR SYSTEM DESIGNATIONSElectronic system cables shall be assigned circuit

and/or system designations in accordance with thefollowing:

Where through cable runs within a space are directand traceable such as a vertical run between decks, onlyone cable tag is required. (a) Cables supplying power to electronic

equipment shall be designated as specified for power andlighting circuits up to the first unit of electronic equipmentor to the receptacle to which the electronic equipmentconnects. Power cables between units of electronicequipment shall have electronic designations.

Local cable runs within a space that can be easilytraced should have only one cable tag.

Additional cable tags shall be installed wherenecessary for tracing cables through congested areas.

Cable tags shall be of soft aluminum material andsecured to the cable with soft aluminum strips as shownin Figure 2-10 or other suitable means to ensurepermanent attachment. Where cables are subjected torough handling, the aluminum securing strip should bereinforced with a wrap of insulation tape.

(b) Where electronic equipment is energizeddirectly from an interior communication or fire controlswitchboard, the cable between the switchboard and theelectronic equipment shall carry an electronic designationwith the cable number preceded by a cipher; for example,R-ES-01, R-ES-02.

2-13.2 CONNECTOR DESTINATION TAGS (c) Where electronic equipment is energized froman interior communication or fire control switchboard byway of a local cutout switch, the cable between theswitchboard and the local switch shall carry an electronicdesignation with the cable number preceded by anadditional cipher; for example, R-ES-001, R-ES-002.

Electronic equipment/system cables that terminatein a connector shall have a tag placed on the cable nextto the connector, designating the jack number to whichthe connector is attached. When cables connect to anantenna, the antenna number and type shall be indicatedon the tag located at the equipment end of the cable.

2-15ORIGINAL


Figure 2-11. Typical Method for Connector and Antenna Cable Identification Tags.

R-BC Radio beacons(d) Cables supplying IC, Navigational or R-AW

Meteorological circuits Fire Control data to electronicequipment shall be designated as specified for IC,Navigational or Fire Control Circuits up to the first unit ofelectronic equipment.

R-BN Infrared beaconsR-BR Radar beaconsR-BS Sonar beacons

Countermeasures (R-C)R-CI Electronic countermeasures intercept and

analysis(e) Where two or more systems or circuits areinstalled requiring identical designating letters,differentiating numbers in sequence beginning with thenumber 1 shall precede the first designating letter; forexample 1R-ES4, 2R-ES4.

R-CS Sonar countermeasures systemsR-CT Electronic countermeasures jamming and

deceptionData (R-D)

(f) Circuit or system letter designations shall beselected from the following list per General Specificationsfor Ships of the U.S. Navy (S9AA0-AA-SPN-010/GEN-SPEC):

R-DA Data, analogR-DAD Analog to digital convertersR-DC Radar and sonar data convertersR-DD Data, digitalR-DDA Digital to analog converters

Meteorological equipments (R-A) R-DR Data DisplayR-AW Meteorological circuits Radar (R-E)

Beacons (R-B) R-EA Air search radar

2-16ORIGINAL


R-EC Carrier-controlled approach radar Infrared equipment (R-N)R-ED Radar identification R-NC Infrared communicationR-EE Air search with height determining capability R-ND Infrared detectionR-EF Height determining radars R-NR Infrared receiving circuitsR-EG Guided missile tracking radar R-NT Infrared transmitting circuitsR-EI Instrumentation radar R-NX Infrared facsimile circuitsR-EM Mortar locator radar R-NY Infrared teletype circuitsR-ER Radar remote indicators Optical equipment (R-C)R-ES Surface search radars R-OC Optical communication systems (digital)R-ET Radar trainer Special purpose circuits (R-P)R-EW Aircraft early warning radar R-PA Radiation monitoringR-EZ Three coordinate radar R-PB Target simulation equipment

Weapon control radar (R-F) R-PC Trunking cablesR-FB Guided missile weapon control radar R-PD Radiometric sextantR-FBS Combined missile and gun control radar R-PE Automatic test and monitor system (for

external cable marking, see "T" designatorbelow)

R-FG Heavy machine gun battery weapon controlradar

R-FL Light machine-gun control radar Radio communications (R-R)R-FM Surface battery weapon control radar R-RA Radio antenna (including frequency meter

extension circuits)R-FS Double purpose battery weapon controlradar R-RB Radio entertainment receiving circuits

Telemetering systems or remote control electronicsguidance (R-G)

R-RC Radio channel selectionR-RD Radio direction finder circuits

R-GA Telemetry receiver functions R-RH HicapcomR-GB Telemetry data reduction systems (analog) R-RN Radio navigationR-GC Telemetry data reduction systems (digital) R-RQ Combination radio receiver and transmitter

control circuits (transceiver)R-GD Telemetry data reduction systems(combination digital and analog) R-RR Radio receiving circuits including cables

between units of a receiver setR-GE Telemetry data receive and reductioncapability, reduction portion-analog R-RS Radio synchronization

R-GF Telemetry data receive and reductioncapability, reduction portion-digital

R-RT Radio transmitter control (including cablesbetween units of a transmitter set)

R-GG Telemetry data receive and reductioncapability, reduction portion-analog anddigital

R-RX Radio facsimileTeletype (R- )

R-RY RadioR-GM Electronic guidance remote control or

remote telemeteringR-ISR IC

Sonar (R-S)CW passive tracking equipments (R-H) R-SA Azimuth echo ranging sonar

R-HA CW passive tracking R-SB Underwater communicationsI FF equipments (R-I) R-SC Sonar computing

R-IA IFF used with air search radar R-SD Depth determining equipmentR-IC Radar recognition R-SE Depth charge direction indicator and range

estimatorR-IE Circuits of IFF equipments operating inconjunction with instrumentation radar R-SG Active ranging

R-IF IFF used with weapons control radar R-SH Sonar hoist-lower controlR-IM IFF test equipment R-SI Sonar identificationR-IR IFF used with surface search radar R-SK Scanning sonarR-IT IFF transponder circuits R-SL Listening sonarR-IU IFF used with sonar R-SM Sonar monitoringR-IZ IFF used with three coordinate scanning

radarR-SN Passive rangingR-SQ Combination depth-azimuth sonar

Timing functions (R-K) R-SO BathythermographR-KT Precision timing R-SR Sonar remote indicator

Automatic vectoring (R-L) R-SS Sounding sonar R-LA Automatic vectoring R-ST Attack teacher and sonar trainer

Missile support circuits (R-M) R-SU Underwater object locatorR-MA Command control equipment R-SV Variable depth sonarR-MB Camera systems R-SW Sonar interceptR-MC Missile control R-SX Doppler sonarR-MD Missile tracking Television (R-T)R-MF Drone control R-TC Television, closed circuitR-MH Impact prediction R-TM Television, monitoringR-MQ Target acquisition R-TV Television, entertainmentR-MT Drone tracking

2-17ORIGINAL


(g) Red designated cables shall have the symbol"/Q" added to the circuit or system designation; forexample R-RY/Q.

indicate the unit and terminal board on the opposite endof the conductor and the third group indicates theterminal to which the conductor is connected on theopposite end.(h) Cables installed between R-PE systems and

monitored equipments shall have the symbol "/T" addedto the circuit or system designation; for example R-ES/T.

(b) The opposite side of the sleeving shallindicate the cable circuit designation and cable number,for example R-ES10.(i) Cables used with experimental circuits,

equipments or systems shall have the symbol "/E" addedto the circuit or system designation; for example R-ES/E.

Inactive conductors shall have identificationmarkers with "SPARE" stamped on one side and thecircuit designation and cable number stamped on theopposite side.2-13.4 CONDUCTOR MARKING

(c) The identification marker shall always beinstalled with the left hand marking group next to the lugor terminal connection. The sleeving shall be positionedso that it can be easily read without disturbing equipmentcircuitry. Figures 2-12 through 2-14 are examples ofconductor identification (marked sleeving) and cableidentification (cable tags).

Cables used in electronic circuits shall haveidentification markers on each conductor at their point oftermination. The identification markers (marked sleeving)shall contain marking information in accordance with thefollowing.

(a) The sleeving on each conductor used inelectronic systems, other than sonar, shall be marked inthe following sequence: (1) the terminal to which theconductor will be connected, (2) the unit and terminalboard to which the conductor is connected on theopposite end, (3) the terminal to which the conductor isconnected on the opposite end. Each of thesedesignations will be separated by a dash. The order ofmarking is such that the first appearing set of numbersand letters reading from left to right will be thedesignation corresponding to the terminal to which theconductor will be connected. The center marking will

2-13.5 CONDUCTOR COLOR CODINGColor coding of the individual conductors of

multiconductor cables (except 3-conductor cables forportable tools and equipment) shall comply with MIL-C-915. MIL-HDBK-299 may be used for guidance in thedetermination and assignment of conductor terminationsby color code.

Conductor color coding is not applicable to coaxialcables.

2-18ORIGINAL


Figure 2-12. Conductor Marking Between Like Terminals

2-14 CABLE BONDING AND GROUNDINGThe outer conductor of semi-rigid coaxial cables

shall be connected to ground potential points only.

2-15 CONDUCTOR FORMING AND SHAPINGWITHIN ENCLOSURES

Bonding and grounding of cables used in shipboardelectronics installations shall be in accordance with MIL-STD-1310, MIL-STD-1680, DoD-STD-2003 and theapplicable ICDs. In case of a conflict of methods, MIL-STD-1310 shall take precedence over other documentsfor all installations except secure spaces, in which MIL-STD-1680 shall be the controlling document.

It is important that the installer perform high qualityworkmanship in the forming and shaping of conductorswithin equipment enclosures used in electronicinstallations. Bad workmanship such as cut conductorinsulation, kinked conductors, conductors rubbing againstsharp edges, or conductors pulled tight to reachterminals can result in shorted, open or intermittentcircuits developing from ship vibration.

The braids (outer conductor) of single conductor andtwo conductor coaxial cables, and the outer braid (shield)of triaxial cables shall be connected to ground potentialpoints only.

2-19ORIGINAL


Figure 2-13. Conductor Marking Between Unlike Terminals

In order to reduce or eliminate circuit malfunctionsresulting from bad workmanship, the following guidelinesshall be used for conductor forming, shaping and routingwithin enclosures of equipments used in shipboardelectronic installations.

twisted triad cables shall not be separated until thetermination point has been reached. The pairs or triadsshall be straightened and lay in a straight line in theoverall group.

(d) The shield and jacket on shielded singleconductors, shielded pairs and shielded triads shallremain on the conductors until the termination point hasbeen reached.

2-15.1 GENERAL GUIDELINES The workmanship procedures and methods used by

the installer shall be equal to or exceed the followinggeneral guidelines:

(e) The conductor groups shall be formed by theuse of lacing or self-clinching straps in accordance withparagraphs 2-15.2 or 2-15.3 respectively.(a) Conductors shall be thoroughly cleaned and

visually examined for cuts, nicks, kinks or twists in theinsulation covering prior to forming into group.

(f) The active conductors of each cable shall beformed into a group and shaped so as not to interferewith equipment maintenance and troubleshooting.(b) Individual conductors of multiconductor

cables DSGU, TSGU, FSGU, MSCU, DNW, TNW,FNW, MNW and similar types shall be straightened andthe conductors shall lay in a straight line in the overallgroup.

(g) The spare conductors of a specific cableshall be of sufficient length to reach the furthermostterminal served by any active conductor in that cable.The spare conductors shall be grouped together,beginning at the point of entry to the equipment, by the(c) The individual conductors of twisted pair and

2-20ORIGINAL


Figure 2-14. Conductor Marking Between Equipment Units and Junction Box

same method used for forming the active groups.The ends of spare conductors shall be insulated fromeach other as well as being insulated from possiblecontact with the enclosure or any internal component Thespare conductor group shall be placed so as not tointerfere with servicing maintenance, troubleshooting orequipment operation. Where there are twisted pairs ortriads, shielded and unshielded, that consist of activeconductors and spares, the spare conductors shallremain in the pair or triad until the termination point isreached, at which time the end of the spare conductor willbe properly identified and insulated from possible contactwith terminal points or metal surfaces. For secureinstallations, all spare conductors shall be grounded inaccordance with the requirements of MIL-STD-1680.

as to cross a terminal block or in any way obstructaccess to the terminals.

(k) Where the terminals are close to the point ofentry for a specific group and a direct route would resultin too rigid a form, an indirect route should be used. Itwould be better practice to route the group around theenclosure and approach the terminals from the sidefarthest from the point of entry.

(l) The group or bundle shall be protected frompossible damage on sharp edges by the use ofsupporting clamps, synthetic tubing, several wrappings ofelectrical tape, or an equivalent method in the area of thesharp edges.

(m) Where supports are required for keeping theconductor group or bundle in place, the support shall beplastic clamps or tie down straps in accordance with MIL-S-23190. The conductor group shall be routed and thesupport clamp installed in such a manner that theconductor and form are not distorted nor the airtight orwatertight integrity of the enclosure is changed.

(h) If more than one cable enters an enclosurethe individual cable groups may be bunched togetherforming a bundle.

(i) Nylon lace shall be doubled when used forforming conductors within an enclosure of an electronicsystems installation.

(j) No group should be routed in such a manner

2-21ORIGINAL


2-15.2 CONDUCTOR FORMING WITH LACINGCORD

may exceed 121° Celsius or where flame resistance isspecified, the lacing material shall conform to MIL-Y-1140 glass tape treated with silicone resin. The lacingprocedure shall be in accordance with Figures 2-15, 2-16,2-17 and the following:

Where lacing tape is used for forming conductorswithin an enclosure, the lacing tape shall be of a non-nutrient material such as nylon. Where temperatures

Figure 2-15. Typical Method of Conductor Forming with Lacing Tape

(a) A double wrap of lacing tape shall be used inall electronic installations. A single tape is shown inFigure 2-15 for explanation purposes.

all starting, terminating and splicing knots.(i) Figure 2-17 shows a typical example of a

wiring form correctly laced.(b) The lacing of the main cable auxiliary lines

and final breakouts shall be started with a clove hitch asshown in detail "B" of Figure 2-15. An overhand knot shallbe tied over the clove hitch as indicated in detail 'IC" ofFigure 2-15.

2-15.3 CONDUCTOR FORMING WITH PLASTICSTRAPSWhere plastic straps are used for forming conductorswithin an enclosure of an electronic installation, thestraps shall be selected from MIL-STD-242, Part II,section 200. Plastic straps shall not be used inequipment having prolonged excessively hightemperatures or in equipment whose temperatureexceeds 85° Celsius. Where the temperature within anenclosure exceeds 85° Celsius the metal clamp withoutcushion shall be selected from MIL-STD-242, Part II,section 200. The acceptable method of conductorforming using plastic straps and clamps is shown inFigures 2-18 and 2-19. he general guidelines given inparagraph 2.15.1 shall apply when forming conductorswith plastic straps. Only straps of natural color shall beused in electronic installations. Figures 2-20 and 2-21show an acceptable tool for installing plastic straps. Careshall be taken to prevent cutting of conductor insulationwhen installing T plastic straps. Where coaxial cables areincluded in the conductor bundle, ensure the tensionsetting on tool MS90387 is no greater than that requiredto prevent axial slippage.

(c) A, lock stitch shall then be tied as shown indetails "D", "E", and "F" of Figure 2-15. The conductorsshall be laced its entire length using the lock stitch asshown in detail "A" of Figure 2-15. The lacing shall beterminated with two lock stitches.

(d) Lock stitching on the main line and auxiliarylines shall be placed immediately adjacent to and on bothsides of breakouts that are to be laced.

(e) The lacing of auxiliary lines and finalbreakouts shall be anchored to the main section bypassing the lacing tape through the lock stitches on themain section and then using the starting hitch and knotshown in detail "B" and "C" of Figure 2-15

(f) The spacing between lock stitches onconductor sections 5/8 inch or smaller in diameter shallbe 1/2 inch to 3/4 inch. On conductor sections largerthan 5/8 inch in diameter, the spacing shall be 1/2 inch to1 inch.

(g) If it is necessary to splice two pieces oflacing together, a knot as shown in figure 2-16 shall beused.

(h) A binder such as Glyptol shall be applied to

2-22ORIGINAL


Figure 2-16. Method of Splicing Doubled Lacing Tape

Figure 2-17. Typical Completed Laced Form

2-23ORIGINAL


Figure 2-18. Acceptable Method of Conductor Forming with MIL-S-23190Self-clinching Straps and MS25281 Support Clamps

2-15.4 CONDUCTOR FORMING ACROSSHINGED UNITS

for a specific soldering job. Sloppy soldered connectionscan cause equipment malfunctions after a system hasbeen in operation. This is especially true for a shipboardinstallation that is subject to ship vibration while at sea.Therefore, the procedures, material, tools and methodsused for making soldered electrical and electronicconnections shall comply with the procedures outlined inthe 2M documentation (910-LP-705-7600) and (MIL-STD-454, requirement 5.

Where one or more groups of conductors areterminated on a section of equipment that is hinged, caremust be taken in routing the group across the hinge. Ifthe group crosses the hinge directly, the conductors willbe subject to excessive bending that would ultimatelyresult in broken conductors. To avoid this, the groupmust be routed for as great a distance as possible in adirection parallel and close to the hinge. The conductorswill be subjected to a slight twisting, rather than a bendingmotion, over a greater length of conductor and are lesslikely to fracture. Figure 2-22 shows the correct andincorrect way of routing groups over a hinge.

CAUTION

SOLDERING GUNS SHALL NOT BE USED

2-16.1 SOLDERING IRONS2-16 SOLDERING REQUIREMENTS ANDPROCEDURES

Soldering irons shall conform to W-S-570 and therequirements stated herein:

1. Soldering irons shall be of the temperaturecontrolled type.It is imperative that the installer practice excellent

workmanship and use only the correct materials and tools

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Figure 2-19. Typical Completed Form using Plastic Straps

Figure 2-20. Tool MS90387 for use with MS23190 Straps

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Figure 2-21. Conductor Bundle Strapping using Tool MS90387

2. Soldering irons shall have a three conductorcable with grounded type plug.

applicable ICDs.4. Where connectors are used for cable

entrance to equipment, the cables shall be installed sothat the connectors are easily removed for servicing andmaintenance.

3. The size and shape of the soldering iron andtip shall permit soldering with maximum ease and controlwithout causing damage to the adjacent areas orconnections. 5. Where electronic equipment or enclosures

have cable entrance plates, the cable shall enter theequipment through the plate designated on the applicableICDs. If the cable is not designated to enter a specificentrance plate on the ICDs, the cable shall enter theentrance plate nearest to its termination point.

4. The soldering iron shall heat the joint arearapidly and maintain proper soldering temperature at thejoint throughout the operation.

2-17 CABLE ENTRANCE TO EQUIPMENT6. Cables shall not enter equipment through an

access plate that is used to cover terminal boards orstuds. If no other entrance plate is available, theterminal board access plate entrance shall be modifiedby the addition of a fabricated extension box that willpermit cable entry through the edge of the extension box,as indicated in Figure 2-23. This method may also beused for compact equipment where there is not sufficientroom for cable trees and spare conductors within theenclosure.

Cable entry into equipment enclosures shall complywith the following requirements and the applicablemethods shown in DoD-STD-2003.

1. Cable entry into bulkhead mounted non-watertight equipment shall be through the bottom or lowerhalf of the side where practicable.

2. Where clamps are used for cable entry intoequipment tops, the cable clamp shall be sealed with aplastic sealer.

3. Cable entry to equipment via connector plugsand receptacles shall be as designated and shown on

2-26ORIGINAL


Figure 2-22. Routing of Conductor Bundle over Hinge

7. Where cable entry to electronic equipment willbe through nylon stuffing tubes, the tubes shall beinstalled using spanner wrenches similar to those shownin Figure 2-24.

ports. The requirements for the dry air leakage, purgingand pressurization of Section 5 of this document shallapply to semi-rigid semi-air dielectric coaxial cables.Although these cables are designed to withstand 30 psig,the recommended pressure for semi-rigid semi-air coaxialcables is 5-10 psig.2-18 PRESSURIZATION AND JACKET REPAIR

INSTRUCTIONS 2-18.2 JACKET REPAIRThe following special instructions are intended as

guidelines to assist the installer in obtaining the optimuminstallation.

Flexible and semi-rigid coaxial cables that have hadtheir jackets damaged during or after installation shall bereplaced where practicable. The cable jacket may berepaired if cable replacement is cost prohibitive orreplacement time would delay ship departure. Coaxialcables that have a damaged shield as well as a damagedjacket shall be replaced and not repaired. Authorizedapproval shall be obtained prior to repairing of coaxialcable jackets. When applicable coaxial cable jacketsshall be repaired in accordance with the followingprocedures and materials.

2-18.1 PRESSURIZATIONSemi-rigid coaxial cables may be classed in two

categories in reference to dielectric types. One categorywould be the solid or foam dielectric cables that do notrequire pressurization. The other category is the semi-airdielectric type that requires dry air pressurization.

Pressurization and purging of semi-rigid semi-air -dielectric coaxial cables shall be via connectors with gas

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Figure 2-23. Typical Cable Entry Extension Box

Figure 2-24. Nylon Stuffing Tube Assembly using Spanner Wrenches

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2-18.2.1 Procedures for Repair of Coaxial Cables3/4"- Scotch 33

Step 1 . Remove all damaged jackets and,wherever possible, the intact jacket up to approximately 1inch on each end of the damaged area. Scarf edges andsand and clean jacket with lint-free wiper over entire areato be repaired. Use a fine rile or non-conductive abrasivestrip to sand jacket. Care must be taken not to damagethe braided outer conductor of the cable.

CoatingCompound

Liquid Plastic-Scotch-kote (NSN 9G5970-000-962-3335)

2-19 CABLE TERMINATIONS

For a shipboard electronics system to operate witha high reliability the low loss transfer of electrical, digitaland radio frequency data is largely dependent upon theworkmanship and type materials used in the installation ofmulticonductor and coaxial cables. Careful preparation ofcables terminating either at terminal boards or inconnectors shall be of primary concern to all installers.It is the intent of this subsection to assist the InstallingActivity in properly terminating cables by discussions,illustrations and referencing of approved materials,components, tools, methods and requirements coveredby specifications and standards.

Step 2. Wrap a single quarter-lapped layer ofcorrugated polyester barrier tape over the braided outerconductor and approximately one half inch onto thescarfed jacket on both sides. The ends of the barriertape should be held on the cable with short lengths ofpressure sensitive vinyl tape.

Step 3. Wrap a single half-lapped layer of rubbertape over patch area and onto the scarfed areaapproximately one half inch beyond the barrier tape.Wrap multiple half-lapped layers of rubber tape over thearea to build up low spots and make a uniform diameterover the patched area. The tape should be stretchedwhile wrapping. 2-19.1 GENERAL GUIDELINE AND

REQUIREMENTSStep 4. Overwrap the entire patch with three half-lapped layers of pressure sensitive plastic tape. Be surethat the plastic tape overlaps the rubber tape byapproximately one half inch. The tape should be appliedwith stretch but relax the last two turns. Air core coaxialcables require extra care so as not to distort the cablewhen wrapping with the tape.

The general guidelines and requirements for theterminating of shipboard electronic system cables shallbe as follows:

(a) Cable entrance to enclosures shall complywith paragraph 2-17.

(b) Conductor forming and lacing withinenclosures shall comply with paragraph 2-15.Step 5. Cover the entire patch with three coats of

liquid plastic coating material. The first coat should belightly applied in an expeditious manner. Each coatshould be allowed to dry tack free between applications.

(c) Cables terminating in connectors shall haveconnector identification tags in accordance withparagraph 2-13.

(d) Conductor identification (marked sleeving)shall comply with paragraph 2-11.

(e) Cable end sealing when required shall complywith paragraph 2-13.

CAUTION (f) ICDs, ShipAlts and specific ship installationplans shall not be deviated from, as to type ofconnectors, lugs, terminal boards and similarcomponents, without authorized approval.

ADEQUATE VENTILATION SHOULD BEPROVIDED TO AVOID EXPOSURE OFPERSONNEL TO TOXIC VAPORS. (g) There shall be no stress or strain on the

cable between the enclosure and cable supports. Provideonly enough stack to allow for ships action such asvibration and equipment shock mount deflection.

(h) Terminating of coaxial cables shall complywith paragraphs 2-18 and 2-20.

2-18.2.2 List of Jacket Repair Materials (i) Terminating of multiconductor electricalcables with connectors shall comply with paragraph 2-21.

2-19.2 CABLE AND CONDUCTOR TERMINATIONWITHIN AN ENCLOSURE

Description Materials Mfg.

Barrier tape Corrugated Polyester DupontThe procedures, methods and materials required for

cable and conductor termination within an enclosure shallbe as stated herein:

0.00142 x 3/4" or equal

Rubber tape Self-fusing Ethylene 3M Co. or(a) Cable entrance clamps or stuffing tubes

should be arranged and installed in the enclosure to givea neat and orderly appearance to the cable entrance.

Propylene Rubber equalBased-Scotch 23

(b) The cable end shall be of sufficient length toreach the farthest connection point within the enclosure.

Vinyl-plastic Pressure sensitive, 3M Co. orequal

(c) The point at which the cable jacket is cut andremoved from conductor ends shall comply with therequirements of paragraphs 2-15 and 2-17.

Flame retardant,Cold and weatherresistance, 0.007 x

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(d) There shall be no cut or break in theconductor insulation resulting from jacket removal in thecable termination process.

Under no circumstances shall there be two or moreconductors crimped in the same terminal lug.

(l) Binding head screws and barrel nuts that aresupplied with terminal boards shall not be replaced withdifferent type screws or nuts.

(e) Terminal boards for use in enclosures ofelectronic systems shall be selected from MIL-STD-1277in accordance with MIL-STD-242. (m) Lock washers and/or flat washers are not

required for use with binding head screws or barrel nutssupplied with terminal boards selected from MIL-STD-1277.

(f) Terminal lugs for use in terminatingconductors of multiconductor cables in electronicsystems shall be selected from MIL-STD-1277 inaccordance with MIL-STD-242. (n) Marked sleeving installed on conductors in

accordance with paragraph 2-13 shall fit snugly over theterminal lug barrel after crimping. This applies to bothinsulated and uninsulated lugs.

(g) The use and application of terminal boardsand terminal lugs shall comply with MIL-STD-454,Requirements 19.

(h) Crimping tools used for crimping terminallugs shall be the type recommended by the terminal lugspecification or the equivalent.

(o) The insulation may be cut or stripped fromthe conductor end by any suitable tool approved by theInstalling Activity, providing a clean cut in the insulationis made perpendicular to the axis of the conductor anddoes not nick or cut any strands.

(i) Wire stripping tools shall be of the type thatwill ensure against nicking, cutting or damaging the bareconductor in any way. (p) The bare conductor strands shall be cleaned

prior to attachment of lug and the bare conductor endshall extend all the way through the terminal lug barrel asshown in Figure 2-25.

(j) There shall be no strands missing from aconductor end terminated in any enclosure of anelectronic installation.

(k) There shall be only one conductor per lug.

Figure 2-25. Conductors Properly Terminated in MIL-T-7928 Lugs

2-19.3 CABLE AND CONDUCTOR SHIELDTERMINATIONS

terminals or enclosure ground.(e) Shields shall not be stripped off conductors

where they enter an enclosure, but shall remain on theconductor/s to within 3 inches of the conductor/stermination point.

The shields of shielded single conductors, shieldedpairs, shielded triads and cables with overall shields shallbe terminated as stated herein. (f) Shield connectors, inner and outer ferrules,

collector and compression rings and similar devices usedto terminate shields shall meet the performancerequirements of MIL-F-21608.

(a) Shields of shielded conductors and/or cablesshall be terminated only at the termination pointsindicated on ICDs, ShipAlts, Ship Installation Plans, andEquipment Technical Manuals. (g) Crimping tools used for shield termination

shall comply with the requirements of MIL-C-22520.(b) Shield termination within a multi-pin connectorshall be in accordance with ICDs, ShipAlts, EquipmentTechnical Manuals and connector assembly instructions.

(h) The conductor insulation at the point of shieldtermination shall show no signs of nicks, cuts orcompressed areas.(c) Where shields are indicated as floating (no

termination) they shall be insulated from possible contactwith the enclosure, component parts or conductorterminations.

(i) Insulation resistance tests shall be made onall shield terminations and conductors in accordance withparagraph 2-8 of this document.

(j) Figure 2-26 is a typical method of terminatingconductor shields with MIL-F-21608 ferrules and a MIL-C-22520 crimping tool.

(d) Cables that are interfaced by means ofconnection boxes and other equipment. shall have theindividual shields treated as continuous conductors.These shield shall be insulated to prevent touching other

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Figure 2-26. Typical Method of Termination Shields with MIL-F-21608 Ferrules and MIL-C-22520 Crimping Tool

The following instructional steps are to assist theinstaller.

accommodated by selecting the proper size outer sleeve.For daisy chain grounding.

Step 1 . Slip outer sleeve over insulation jacketafter stripping. Trim braid to within 1/2" of insulation asshown in Step I Figure 2-26.

Step 5. Outer sleeve covers all exposed strandsas shown in Step 5 Figure 2-26.

Step 6. Compress in tool M22520/5 as shown inStep 6 Figure 2-26. (Tool will not release until fullcompression stroke is completed).

Step 2. Fan braid by rotating center conductorand slip inner sleeve under braid as shown in Step 2Figure 2-26. (k) Within compact or congested enclosures with

insufficient space for shield termination using ferrulesand crimping tools, the alternate method shown inFigures 2-27 and 2-28 may be used. The followinginstructive steps are to assist the installer in removingthe shield without damage to the conductors.

Step 3. Position inner sleeve to extend about1/16" beyond braid as shown in Step 3 Figure 2-26.

Step 4. Slip ground lead under outer sleeve(Front or Back) and SLIDE outer sleeve over braid asshown in Step 4 Figure 2-26. Two ground wires can be

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Figure 2-27. Pigtailing Method of Shield Termination

Figure 2-28. Typical Extractor Tool for Shield Terminations

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Step 1 . Determine length of pigtail required fortermination. Cut and remove outer insulation jacket asillustrated in Step I of Figure 2-27. Care shall be used toprevent cutting into braided shield or damaging it.

illustrated in Step 1 of Figure 2-27. Care shall be used toprevent cutting into braided shield or damaging it.

Step 2. Slide the pointed tube between shield andconductor/s insulation to the point of shield termination.

Step 2. Push shield back over conductor/s until abubble forms at the jacket termination as illustrated inStep 2 of Figure 2-27.

Step 3. Carefully bend shielded conductor/s atthe end of pointed tube approximately 60 degrees and,with a back and forth sideways motion, work the point ofthe tube through the shield as illustrated in Figure 2-28.Step 3. Insert a pointed tool (pick) into the shield

bubble as close to jacket termination as practicable.Move the tool with a circular motion until a hole is formedlarge enough to pass the doubled conductor/s asillustrated in Step 3 of Figure 2-27. While forming thehole, care shall be taken not to break any of the shieldstrands.

Step 4. Enlarge the hole until it is of sufficientsize to pass the double conductor/s. Be careful not tobreak any of the shield strands.

Step 5. Insert plunger into open end of tube andcarefully push the conductor/s back through opening inshield as illustrated in Figure 2-30. Use extreme care soas not to damage conductor/s insulation.Step 4. Carefully bend conductor/s and shield at

the formed hole while inserting the pointed tool betweenconductor/s and shield as illustrated in Step 4 of Figure2-27, then pull the conductor/s completely through theformed hole.

Step 6. Remove tool from shield and form shieldinto a compact braided conductor as illustrated in Step 5of Figure 2-29.

Step 7. Insulate the braid with synthetic tubing toprevent contact with conductor terminations.Step 5. Stretch the empty section of shield and

form it into a compact braided conductor as illustrated inStep 5 of Figure 2-27. 2-19.4 SEMI-RIGID CABLE END PREPARATION

Step 6. Insulate the braid with synthetic tubing toprevent contact with conductor terminations. Figure 2-28illustrates the same pigtailing method with the use of anextractor tool. These tools are commercially available ormay be fabricated by the Installing Activity. The use ofan extractor tool is described in the following steps:

Figures 2-29 and 2-30 are illustrative methods ofsemi-rigid cable end preparation to assist the installerworking with semi-rigid cables. Variation in methods andtechnology by the installer is recommended, where itimproves the end product and the completed installationmeets all electrical and mechanical requirements for aspecific cable.Step 1 . Determine length of pigtail required for

termination. Cut and remove outer insulation jacket as

Figure 2-29. Small Semi-rigid Cable End Preparation

2-33ORIGINAL


Figure 2-30. Large Semi-rigid Cable End Preparation

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Step 1 . Cut cable (sheath, insulation and innerconductor) with cable shears. These shears make use ofspecially shaped cutting blades to ensure minimumdamage to cable. Step 1, Figure 2-29 shows theappearance of the cable after the cut has been made.

the short section of sheath outward removing it from thecable thus exposing the insulating skin, as shown in Step3, Figure 2-30.

Step 4. Since particles of aluminum might enterthe interior of the cable during the next operation brushthe entire surface of the Polystyrene skin, particularly theedge of the cable where it meets the skin, making certainthat no chips are lodged in this area, as shown in Step 4,Figure 2-30.

Step 2. Apply sheath cutter to cable placingcutting wheel approximately 1-1/2" from end of cable, asshown in Step 2, Figure 2-29. This cutter is only used tocut approximately one-half way through the outer sheathof the cable. In cutting this sheath be sure to advancethe cutter roller slowly so that no burr is produced insidethe cable sheath.

Step 5. Using "hot knife" cut through insulationskin and helix close to the ends of cable, as shown inStep 5, Figure 2-30. This operation will heat seal thelaminations of the helix thus far retained in place by theburr formed in Step No. 1.CAUTION

Step 6. Using smaller Rotary Cutter cut the innerconductor midway between the sheath ends, as shown inStep 6, Figure 2-30. This will produce two cable ends withthe inner connectors projecting 1 inch beyond the outerconductors.

DO NOT FLEX SHEATH EXCESSIVELYMAXIMUM DEFLECTION PERMISSIBLE IS1/16" AT CABLE END

2-20 COAXIAL CONNECTORSStep 3. Using pliers carefully flex partially cutsheath end until the sheath parts at the cut line.Separate aluminum sheath at cut approximately 1/2".Step 3, Figure 2-29 cross-section shows the effect ofcutting the cable sheath as described in Steps 2 and 3.The smooth radius produced at the sheath I.D. is a resultof parting the sheath as specified in Step 3 rather thancutting completely through and producing a large internalburr which would have to be removed. Do not remove cutsheath end.

Radio frequency coaxial cables are normallyterminated with what are commonly called coaxconnectors. These connectors are designed to matchthe cable characteristic impedance over a givenfrequency range, provide RF shielding, and when properlyassembled on a coaxial cable and coupled to a matingconnector will provide a stable RF circuit with low signalloss. The intent of this subsection is to provideinformation and guidance to the Installing Activity in theselection and installation of RF coaxial connectorsrequired for shipboard electronic systems.

Step 4. (Applicable to RG-253/U and RG-254/U)- Using a sharp razor knife cut through the polyethylenetubes being careful not to nick the inner conductor. Keepthe knife at right angles to the cable axis and the side ofknife blade adjacent to the outer conductor. 2-20.1 SELECTION

Coaxial connectors shall be selected from MIL-STD-1353 and MIL-C-39012 in accordance with MIL-STD-242and as stated herein:

Step 5. (Applicable to RG-232/U, RG-237/ U andRG-245/U) - Using a hot knife cutting tool, carefully meltthe polystyrene sheath and helix. Remove outer sheathcut end, polystyrene sheath and helix exposing the innerconductor as shown in Step 5, Figure 2-29. The innerpolystyrene skin and helix which remain inside the cableare now fused into one solid mass.

(a) MIL-HDBK-216 may be used for generaltechnical guidance in the selection of coaxial connectors.For detailed technical data, the user should refer to themilitary specification for a specific coaxial connector.

(b) Deviation from the coaxial connector typesshown on ICDs shall require authorized approval.

The following procedures are to assist the installer inpreparation of large semi-rigid cable.

(c) Connectors for use on flexible coaxial cablesshall be procured by the military specification partnumber, except where equipment receptacle interfacingdictates the use of connectors typed by the "UG"nomenclature and never assigned a new militaryspecification part number, in which case procurementshall be by the "UG" number.

Step 1 . Apply Rotary cutter to cable and cutthrough aluminum sheath. In so doing advance thecutter rollers rapidly in order to throw a heavy burr on theinside surface of the sheath. Make a similar cut 2" fromthe first one thus producing a 2" section of sheath whichis supported only by the Polystyrene helix and theinsulating skin just inside the sheath, as shown in Step 1,Figure 2-30. The burrs formed hold the helix in place andprevent the thin laminations from unraveling.

(d) Connectors for use on semi-rigid coaxialcables shall be procured by the military specification partnumber where applicable. Where there is no applicablemilitary specification, the semi-rigid coaxial cableconnectors should be the type recommended by thecable manufacturer.

Step 2. Using a fine tooth hacksaw carefully sawalmost through the section of sheath which has beenparted from the cable in the previous step, cutting at a45 degree angle to the center line of the cable, as shownin Step 2, Figure 2-30. Make certain that the saw doesnot cut through the sheath as this would permit chips ofaluminum to enter the cable interior.

(e) Category "D" connectors in accordance withMIL-C-39012 should be used wherever applicable.

(f) Coaxial connector adapters shall not be usedto interface coaxial cables and/or equipment ofpermanently installed shipboard systems.

Step 3. Place a small screw driver under a corneredge of the ring of sheath at the saw cut, pry upward andelevate further with pliers. Fold this corner piece backupon itself, take a new hold upon it with the pliers and fold

(g) Coaxial connector adapters may be used fortemporary interface of coaxial cables and/or equipment

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for testing purposes or as an interim fix for returningequipment to an operational status until the correctinterface can be accomplished.

For additional protection apply three coats ofsealing compound complying with MIL-A-46106 to theexterior surface after heating of the tape or sleeving.Manufacturers procedures for applying heat shrinkabletape and sleeves should be followed for obtaining thebest weatherproof seal.

(h) Coaxial connector adapters for use withshipboard electronic systems shall comply with therequirements of MIL-A- 55339

(i) When selecting coaxial connectors,preference should be given to threaded type connectorsfor greater stability and better performance. Bayonettype connectors, such as "BNC" and "C" should be usedonly when the need for quick connect and disconnectoutweigh the inherent advantages of the threaded type.

2-21 ELECTRICAL CONNECTORS

Along with the ever advancing state-of-the-art inelectronic systems, the electrical connector hasassumed a vast number of sizes, shapes, configurationsand names. This large variety of connectors is requiredfor the interfacing of complex electronic systems andfunctions. Electrical connectors required for shipboardelectronic installations, in addition to being compatiblewith the electronic equipment, must meet the Navyrequirements for compatibility with MIL-C-24643 (LowSmoke) and MIL-C-915 jacketed cable and rugged enoughto withstand shock and vibration from the ships action atsea or in battle.

2-20.2 INSTALLATIONCoaxial connectors shall be installed as stated

herein.(a) Assembly instructions are supplied with

coaxial connectors that comply with MIL-C-39012.(b) The specification sheets of MIL-C-39012

provides cable stripping dimensions, crimping tool anddie number for specific connectors.

Electrical connectors incorrectly selected andimproperly installed, play a major part in shipboardelectronic equipment malfunctions. The installer shoulduse care in his selection and installation of electricalconnectors to ensure this will not be a weak point in thesystem that could possibly cause equipment downtimeduring a critical operation.

(c) Crimping tools for crimp type coaxialconnectors shall comply with MIL-C-22520.

(d) MIL-HDBK-216 may be used as assemblyinstruction guidance for coaxial connectors not coveredby MIL-C-39012.

(e) Coaxial connectors when properly installedshall meet the applicable cable retention forcerequirements of MIL-C-39012. The requirements, guidelines, references and

instructions stated herein shall apply to all shipboardelectronic installations requiring electrical connectors forinterfacing MIL-C-24643 (Low Smoke) and MIL-C-915cable to equipments.

(f) Coaxial connectors exposed to the weather,salt spray, moisture and stack gasses shall beweatherproofed within 24 hours after assembly.

(g) Weatherproofed connections shall bechecked at least monthly for signs of deterioration. Atthe first signs of deterioration, the old weatherproofingshall be removed, the connectors checked for damageand replaced if necessary. The sealing area should bethoroughly cleaned and new weatherproofing applied byone of the methods of paragraph 2-20.3.

2-21.1 SELECTIONElectrical connectors required for interconnecting

shipboard cables to electronic equipment are normallysupplied with the equipment. Where the cableconnectors are not supplied with equipment and where theinstaller is required to fabricate consoles, connectionboxes, panels, enclosures and similar equipment or tomodify electronic equipment or systems, the followingselection requirements shall apply:

2-20.3 WEATHERPROOFING METHODSDeterioration of coaxial connectors due to the

corrosive action resulting from moisture, salt and stackgasses is a serious problem aboard ships. Coaxialconnectors exposed to the weather shall beweatherproofed by one of the following methods or theequivalent.

(a) Where equipment, with electrical connectorreceptacles installed, is received without cableconnectors, the cable connectors selected shall becompatible with Navy shipboard cable and shall be inaccordance with the same military specification as arethe equipment installed receptacles.

(a) Weatherproofing may be accomplished byencapsulating the connector and a portion of the cablewith plastic electrical insulating adhesive tape sealed withthree coatings of sealing compound complying with MIL-A-46106.

(b) Electrical connectors for use with MIL-C-24643 (Low Smoke) and MIL-C-915 jacketed cable inshipboard electronic installations shall be selected inaccordance with MIL-STD-242.

(b) Weatherproofing may be accomplished byencapsulating the connector and a portion of the cablewith heat shrinkable self-sealing tape or heat shrinkablesleeving with the interior sleeve surface coated with anadhesive.

(c) Where general duty MIL-C-5015 connectorsother than class D, are referenced on ICDs or othermilitary documents, and not supplied with the equipment,they shall be replaced with MIL-C-5015 class D or classDJ connectors. "DJ" is the identification given to classD connector assemblies that include the backshellassembly and cable strain relief clamp.

(c) Weatherproofing may also be accomplishedby encapsulating the connector and a portion of the cablewith cold shrinkable tubing. NAVSEA STD-407-5287561,Industrial Electromagnetic Compatibility (IEMC) WorkProcess Instructions contains a current list of approvedcold shrink tubing and the applicable installationprocedures.

(d) Where general duty electrical connectors arerequired for equipment enclosures fabricated or modifiedby the Installing Activity, they shall be MIL-C-5015 class

2-36ORIGINAL


D or DJ connectors selected from MIL-STD-1353. accordance with ICDs, Technical Manuals, ShipAlts andship installation plans.(e) Where heavy duty electrical connectors are

required for equipment enclosures fabricated or modifiedby the Installing Activity, they shall be selected fromMIL-C-22992. These connectors shall be used in circuitshaving a current flow that exceeds the requirements ofMIL-C-5015 connectors.

(c) Where connectors are installed on both endsof a cable, the conductors shall be connected to likecontacts, for example, pin-A of one connector shallconnect to pin-A of the other connector, except forspecial installations that require interfacing of equipmentsnot normally designed for use in a common system.(f) Where test point connectors are required for

equipment enclosures fabricated or modified by theInstalling Activity, they shall be selected from MIL-C-39024 in accordance with MIL-STD-242. Banana plugsand jacks shall not be used.

(d) The assignment of conductors to connectorpin numbers by color code or conductor number shall bein accordance with MIL-STD-1683. Where the conductorassignment shown on ICDs differs from that shown inMIL-STD-1683, the conductor assignment shall be asshown in MIL-STD-1683.

(g) Telephone-type plugs and jacks shall beselected from MIL-STD-242 and shall conform to MIL-J-641 and MIL-P-642. (e) Electrical connectors, once installed, become

a part of the shipboard cable and shall be subjected tothe applicable test requirements for that specific cable.

(h) Connectors for use on portable power cablesshall be the molded rubber type as directed in MIL-C-28777. (f) Crimping tools, insertion and extraction tools

shall be selected from MIL-STD-1646 and comply with therequirements of MIL-C-22520 and MIL-I-81969.

(i) MIL-STD-1683 shall be used for selectingMIL-C-5015 connector shell size and insert combinationto fit a particular MIL-C-24643 (Low Smoke) and MIL-C-915 cable.

(g) Crimp contact connectors shall havecontacts and sealing plugs installed in all unusedpositions.(j) To ensure installation of quality products, ail

connectors and/or accessories shall be specified,selected, procured and referenced by their military partnumber.

(h) Assembly tools used to hold the coupling endof connectors shall comply with MS3480 for MIL-C-5015connectors, MS3481 for MIL-C-26482 connectors andMS3482 for MIL-C-81511 connectors. Figure 2-31 is arepresentative drawing of MS3480 tools for MIL-C-5015connectors.

(k) Connector plugs or receptacles whichcontinue to be energized after unmating shall have sockettype contacts.

2-21.2 INSTALLATION REQUIREMENTS(i) Assembly tools used to tighten the

accessory hardware (backshell assemblies) should becushion-jaw pliers or strap wrenches similar to thoseillustrated in Figure 2-32.

The installation of electrical connectors used inshipboard electronic systems shall comply with thefollowing requirements. (j) Electrical connectors exposed to the weather,

salt spray, moisture and stack gasses shall beweatherproofed within 24 hours after assembly. Theweatherproofing method used shall comply with paragraph2-20.3.

(a) The connector types shown on ICDs and shipinstallation plans shall not be deviated from, withoutauthorized approval.

(b) The hookup configuration (pin-to-pinconnection) of electrical connectors shall be in

Figure 2-31. Connector Assembly Tool

2-37ORIGINAL


Figure 2-32. Connector Accessory Tools

(k) Weatherproofed connectors shall be checkedat least monthly for signs of deterioration. At the firstsigns of deterioration, the old weatherproofing shall beremoved, the connectors checked for damage andreplaced if necessary. The sealing area should bethoroughly cleaned and new weatherproofing applied.

2-21.3 CONTACT CRIMPING INSTRUCTIONSThe following instructions including Figure 2-33

provides guidance for the proper crimping of MIL-C-5015connector contacts with MIL-C-22520 crimping tools.

Step 1 . Remove a section of jacket from cableend to be terminated and clean conductors. The properlength of exposed conductors will depend upon type ofconnector and backshell assembly required forinstallation.

Step 2. Where cable being terminated hasshielded conductors or an overall shield to be terminatedin specified contacts, prepare the shields in accordancewith the requirements of paragraph 2-19.3.

Step 3. Strip insulation from conductor ends inaccordance with stripping dimensions shown in Figure 2-33 for the specified conductor size. Do not cut, nick orpick wire strands.

Step 4. Select the correct basic crimping tooland positioner (turret head) from MIL-STD-1646 for typecontact to be crimped.

Figure 2-33. Crimp Contact Conductor StrippingDimensions

2-38ORIGINAL


Step 5. Release the contact locator, rotate tocorrect contact size and push back into its latchedposition flush with body of crimping tool.

Step 6. Adjust the selector to the correct wiresize to be crimped. Cycle the tool once to be sure theindentors are fully open.

Step 7. Before inserting the contact, inspect it tobe sure it is not bent. Bent contacts should never bestraightened and used. They should be replaced.

Step 8. Insert the contact, with strippedconductor in place, as far as it will go into the properlocator.

Step 9. Squeeze the tool handles together. Thetool will not release the contact unless the indentors inthe tool head have been fully actuated.

Step 10. Release the tool handles and remove theconductor with crimped on contact. Inspect the contactto see that the wire is visible through the inspection hole.The end of conductor insulation should be within 0.0625inch of crimped contact.

Figure 2-34. Insertion Tool Application for CrimpContacts

2-21.5 CONTACT REMOVAL INSTRUCTIONSStep 11. Check contact after crimping for

distortion. If excess distortion occurs, change setting ofcrimp tool and recrimp a new contact on the conductor.

The following instructions including Figure 2-35provide guidance for the proper removal of crimpedcontacts from MIL-C-5015 front release connectors.

2-21.4 CONTACT INSERTION INSTRUCTION Step 1 . Disassemble and slide backshellassembly back over the cable.

The following instructions including Figure 2-34provides guidance for the proper insertion of crimpedcontacts in MIL-C-5015 front release connectors.

Step 2. Select the correct removal tool for theconnector and being disassembled from MIL-STD-1646.The same tool fits over both pins and sockets.

Step 1 . Remove the end bell assembly from theshell or barrel. Slide end bell and backshell assembly inthe proper order over the prepared cable end forreassembly after all the required contacts are crimped.

CAUTION

When removing contacts crimped to AWG-4 size conductors and larger, all theconnector contacts must be releasedwith the removal tool and moved backenough to assure disengagement from theretaining spring. This is to counteract therigidity and springback of the heavierconductor. When all contacts arereleased the connector is disengagedfrom the cable. The problem can now becorrected.

Step 2. Insert a wired contact into the rear of thesoft, integral rear grommet (see Figure 2-34). Push thecontact forward until the shoulder of the contact isslightly exposed behind the grommet.

Step 3. Select the correct insertion tool for theconnector being assembled from MIL-STD-1646. Thesame tool fits both pins and sockets.

Step 4. With the connector held secure, positionthe correct insertion tool over the rear of the contact withfront of tool against rear contact shoulder. No insertiontool is required for size 8 contact and larger because theconductor is stiff enough to push contact into place.

Step 5. Apply firm, steady pressure pushing thecontact through the resilient sealing barriers and into thehard insulator until the contact bottoms. Just prior tobottoming, a snap may be heard as the contact retainingspring snaps into the locking groove on the contact.Overinsertion is impossible. Remove insertion tool andpull on conductor to ensure contact has locked in place.If contact does not lock into position, check contact forcorrect size or malformation and replace if necessary.

Step 3. Sheath the front of the contact with theproper size removal tool and push with rear of tool to fullybottom the tool tip by slightly rotating the rear of tool in aclockwise direction. This opens the contact retainingspring, releasing the contact. (No added pressure on therear of the tool will aid removal.) With the tip bottomed,push the thrust sleeve forward moving contact backthrough the sealing barriers. When removing contactscrimped to No.-8 size conductors and larger, you mustassist the tool. After the tool has bottomed on theselarger sizes, releasing the contact, pull back on the wireat the rear of the connector to overcome wire rigidity whileusing the thrust sleeve.

Step 6. Repeat steps 4 and 5 for remainder ofcontacts working from one side of insulator to the other.

Step 7. After all wired contacts have beeninstalled, fill empty cavities with unwired contacts andsealing plugs. This assures a good seal and providesspare contacts for field use.

Step 8. Make a visual inspection to see that allcontacts have been inserted fully and correctly inaccordance with ICDs. Reassemble end bell andbackshell assembly accordingly.

Step 4. To reassemble, repeat steps 3 through 8of the contact insertion instructions in paragraph 2-21.4.

2-39ORIGINAL


ENVIRONMENTAL BACKSHELL ASSEMBLYINSTRUCTIONS

The following instructions including Figure 2-36provide guidance for the proper assembling of style 1 -type A shield environmental backshells. Theseinstructions are applicable to MIL-C-85049 backshells forMIL-C-5015 crimp connectors, MIL-C-81703 series 3crimp connectors and MIL-C-26482 series 2 crimpconnectors. The straight backshell assembly is shown inFigure 2-36 for ease of identification.

These instructions are applicable to installationsrequiring the overall shield of a multiconductor cable tobe terminated (grounded) to the connector housing(backshell) and be environmentally sealed.

Figure 2-35. Removal Tool Application for CrimpContacts

2-21.6 STYLE 1-TYPE A SHIELD

Figure 2-36. Style 1 - Type A Shield Environmental Backshell Assembly Breakdown

The numbers in parentheses refer to the componentnumbers shown in Figure 2-36.

Step 9. Assemble sleeve (1) to connector andtighten securely using applicable tools in accordance withparagraphs 2-21.2(h) and 2-21.2(i).Step 1 . Temporarily assemble sleeve (1) to

connector. Step 10. Flare shield over tapered end of ferrule(2) and slide the other ferrule (3) into place over shield.Trim any exposed ends of shield strands.

Step 2. Place remaining backshell assemblycomponents (2) through (7) on cable in sequence shownIn Figure 2-36. Keep these components at a convenientdistance from end of cable, so they will not Interfere withsubsequent assembly steps.

Step 11. Engage ferrule (3) with sleeve (1) andtighten securely. Ensure that there is no stress onterminated conductors.

Step 3. Insert cable into sleeve (1) and bottomagainst connector. Hold cable in position and mark cablejacket at rear end of sleeve (1).

Step 12. Engage rear adapter (4) on sleeve (1)and tighten securely.

Step 13. Insert grommet (5) and grommet follower(6) into rear adapter (4).Step 4. Remove sleeve (1) from connector and

place on cable with components in step 2 above. Step 14. Engage clamp assembly (7) to rearadapter (4) and tighten securely.Step 5. Trim cable jacket and shield at mark made

in Step 3. See MIL-STD-1683 for specific conductor tocontact assignments and allow sufficient length forconductor crossovers.

Step 15. Tighten saddle clamps securely aroundcable jacket.

Step 16. Test for correctness of hookup,continuity, and insulation resistance.Step 6. Strip jacket 0.5 inch back from trim point

in step 5 to expose shield.2-21.7 STYLE 1 - TYPE A ARMORENVIRONMENTAL BACKSHELL ASSEMBLYINSTRUCTIONS

Step 7. Prepare and terminate conductors inaccordance with contact crimping instructions ofparagraph 2-21.3 and MIL-STD-1683.

Step 8. Insert the conductors with crimpedcontacts in connector in accordance with contactinsertion Instructions of paragraph 2-21.4.

The following instructions including Figure 2-37provide guidance for the proper assembling of style 1 -

2-40ORIGINAL


type A armor environmental backshells. Theseinstructions are applicable to MIL-C-85049 backshells,for MIL-C-5015 crimp connectors, MIL-C-81703 series 3crimp connectors and MIL-C-26482 series 2 crimpconnectors. The backshell assembly is shown in Figure2-37 for ease of identification.

These instructions are applicable to specialinstallations requiring armored cable.


Figure 2-37. Style 1 - Type A Armor Environmental Backshell Assembly Breakdown

Step 1 . Temporarily assemble sleeve (1) toconnector.

(3) into sleeve (1).Step 11. Engage rear adapter (4) with sleeve (1)

and tighten securely.Step 2. Place remaining backshell assemblycomponents (2) through (7) on cable in sequence shownin Figure 2-37. Keep these components at a convenientdistance from end of cable, so they will not interfere withsubsequent assembly steps.

Step 12. Slide inner ferrule (5) into rear adapter(4).

Step 13. Flare armor over inner ferrule (5) andslide outer ferrule (6) into place over armor. Trim excessarmor strands.Step 3. Insert cable into sleeve (1) and bottom

against connector. Hold cable in position and mark cablearmor 0.250 inch from rear end of sleeve (1).

Step 14. Loosen rear adapter (4) slightly andgently force cable towards connector until inner ferrulebottoms out inside rear adapter (4). Retighten rearadapter (4).

Step 4. Remove sleeve (1) from connector andplace on cable with components in step 2 above.

Step 5. To expose individual cable conductors,trim jacket as follows: For clamp sizes 8 and smaller, trimjacket at a point 0.375 inch forward (toward connector)from mark made in Step 3. For clamp sizes 10 andlarger, trim jacket 0.50 inch forward of mark made in Step3. See MIL-STD-1683 for specific conductor to contactassignments and allow sufficient length for conductorcrossovers.

Step 15. With outer ferrule (6) in place as in Step13, engage clamp (7) and tighten securely.

Step 16. Tighten saddle clamps securely aroundcable armor.

Step 17. Test for correctness of hookup,continuity, and insulation resistance.

2-21.8 STYLE 1 - TYPE B ENVIRONMENTALBACKSHELL ASSEMBLY INSTRUCTIONSStep 6. Trim armor as follows: For clamp sizes 8

and smaller, trim armor 1.125 inches from end of jacket(0.750 inch from step 3 mark). For clamp sizes 10 andlarger, trim armor 1.50 inches from end of jacket (1 inchfrom step 3 mark).

The following instructions including Figure 2-38provide guidance for the proper assembling of style 1 -type B environmental backshells. These instructions areapplicable to MIL-C-85049 backshells, for MIL-C-5015crimp connectors, MIL-C-81703 series 3 crimpconnectors and MIL-C-26482 series 2 crimp connectors.These instructions are also applicable to MS3400DJ,MS3401DJ, MS3406DJ, MS3408DJ and MS3409DJconnector assemblies. The type B environmentalbackshell assembly is the most widely used assemblybecause of its applicability to shielded and unshieldedMIL-C-24643 (Low Smoke) and MIL-C-915 cables.

Step 7. Prepare and terminate conductors inaccordance with contact crimping instructions ofparagraph 2-21.3 and MIL-STD-1683.

Step 8. Insert the conductors with crimpedcontacts in connector in accordance with contactinsertion instructions of paragraph 2-21.4.

Step 9. Assemble sleeve (1) to connector andtighten securely using applicable tools in accordance withparagraphs 2-21.1(h) and 2-21.2(i).

Step 10. Slide grommet (2) and grommet follower

2-41ORIGINAL


Figure 2-38. Style 1 - Type B Environmental Backshell Assembly Breakdown


Step 9. Slide grommet (2) into sleeve (1) andposition grommet follower (3) on grommet (2).


Step 10. Attach clamp (4) to sleeve and tightensecurely.

Step 2. Place grommet (2), grommet follower (3)and clamp (4) on cable in sequence shown in Figure 2-38.Keep these components at a convenient distance fromend of cable, so they will not interfere with subsequentassembly steps.


Step 12. Test for correctness of hookup,continuity, and insulation resistance.

2-21.9 STYLE 1 - TYPE C SHIELD TERMINATEDTO BACKSHELL ASSEMBLY INSTRUCTIONS

Step 3 . Insert cable into sleeve (1) and bottomagainst connector. Hold cable in position and mark cablejacket at rear end of sleeve (1). The following instructions including Figures 2-39 and

2-40 provide guidance for the proper assembling of style1 - type C shield terminating backshells. Theseinstructions are applicable to MIL-C-85049 backshells, forMIL-C-5015 crimp connectors, MIL-C-81703 series 3crimp connectors and MIL-C-26482 series 2 crimpconnectors.


Step 5. Trim cable jacket at mark made in step 3above. Depending on type of connector contacttermination (solder, crimp, etc.) the length of individualconductors may require shortening by 0.750 inch toassure that the cable jacket win be in proper positionwhen grommet (2) is clamped. See MIL-STD-1683 forspecific conductor to contact assignments and allowsufficient length for conductor crossovers.

These instructions are applicable to installationsrequiring the overall shield or individual conductor shieldsof a multiconductor cable to be terminated (grounded) tothe conductor housing (backshell) without beingenvironmentally sealed.Step 6. Prepare and terminate conductors, and

shields where applicable, in accordance with contactcrimping instructions of paragraph 2-21.3.

The numbers in parentheses refer to the componentnumbers shown in Figures 2-39 and 2-40.

Step 7. Insert the terminated conductors, andshields where applicable, in connector in accordance withcontact insertion instructions of paragraph 2-21.4 andMIL-STD-1683.


Step 2. Place ferrules (2 and 3) and clamp (4) oncable in sequence shown. Keep these components at aconvenient distance from end of cable, so they will notinterfere with subsequent assembly steps.

Step 8. Assemble sleeve (1) to connector andtighten securely using applicable tools in accordance withparagraphs 2-21.2(h) and 2-21.2(i).

2-42ORIGINAL


Figure 2-39. Style 1 - Type C Overall Shield Termination to Backshell - Assembly Breakdown

Figure 2-40. Style 1 - Type C Individual Shield Termination to Backshell - Assembly Breakdown

Step 3. Insert cable into sleeve (1) and bottomagainst connector. Hold cable in position and mark cablejacket at rear end of sleeve (1).

NOTE

Steps 7 through 9 apply to cables withindividually shielded conductors.


NOTEStep 7. Trim jacket 0.50 inch back from mark

made in Step 3.For cables with overall shields do steps 5and 6 and skip steps 7 through 9 andcontinue with steps 10 through 18. Forcables with individual conductor shieldsskip steps 5 and 6 and continue withsteps 7 through 18.

Step 8. Prepare each conductor shield by thepigtail method described in paragraph 2-19.3(k).

Step 9. Cut off excess shield pigtails and combout, arranging strands for uniform distribution aroundcircumference of tapered end of inner ferrule (2). Wherecables have both individual shields and an overall shield,care should be used to ensure that all shields make firmcontact between the inner ferrule (2) and outer ferrule (3).

Step 10. Prepare and terminate conductors inaccordance with crimping instructions of paragraph 2-21.3.

Step 5. Trim cable jacket and overall shield atmark made in step 3 above.

Step 6. Strip cable jacket to expose shield: Forclamp size 8 and smaller, strip jacket 0.375 inch fromtrim point made in step 5; for clamp sizes 10 and largerstrip jacket 0.50 inch from trim point made in Step 5.

Step 11. Insert the terminated conductors inconnector in accordance with contact insertioninstructions of paragraph 2-21.4 and MIL-STD-1683.

Step 12. Assemble sleeve (1) to connector andtighten securely using applicable tools in accordance with

2-43ORIGINAL


paragraph 2-21.2(h) and 2-21.2(i). instructions are written for use with the backshellassembly described in paragraph 2-21.8 but are easilyadaptable to the instructions covered in paragraphs 2-21.6, 2-21.7 and 2-21.9.

Step 13. Slide inner ferrule (2) into sleeve (1) andbottom out.

Step 14. Flare shield (prepared in steps 5 and 6)or shields (prepared in steps 7, 8 and 9) over tapered endof inner ferrule (2) and gently force cable towardconnector until shield or shields cover taper on ferrule(2).

Procurement information for style 2 adaptertransition backshell assemblies can be found on MIL-C-85049 standard drawings.

The numbers in parentheses refer to the componentnumbers shown in Figure 2-41.Step 15. Insert outer ferrule (3) into sleeve (1)

over shield or shields. Step 1 . Temporarily assemble sleeve (1) toadapter transition assembly and adapter transitionassembly to connector.

Step 16. Attach clamp (4) to sleeve (1) andtighten securely.


Step 2. Place grommet (2), grommet follower (3)and clamp (4) on cable in sequence shown in Figure 2-41.Keep these components at a convenient distance fromend of cable, so they will not interfere with subsequentassembly steps.

Step 18. Test for correctness of hookup,continuity and insulation resistance.

2-21.10 STYLE 2 ADAPTER TRANSITIONBACKSHELL ASSEMBLIES NOTE

The following instructions including Figure 2-41provides guidance for the proper assembling of style 2adapter transitions to type B backshell assemblies. Theadapter transition assembly is required where the existingshell size is too small for interfacing with a backshellassembly selected for a specific cable diameter. These

When assembling other type backshells,substitute the appropriate step in lieu ofthe above.

Figure 2-41. Style 2 - Type B Environmental Backshell Assembly Breakdown

Step 3. Cut back cable jacket approximately 1.50inches from cable end. This is to reduce overall cablediameter so the conductors can bottom againstconnector.

Step 6. Trim cable jacket at mark made in step 4above. Depending on type of connector contacttermination, the length of individual conductors mayrequire shortening by 0.750 inch to assure that the cablejacket will be in proper position when grommet (2) isclamped. See MIL-STD-1683 for specific conductor tocontact assignments and allow sufficient length forconductor crossovers.

Step 4. Insert cable end prepared in step 3 intosleeve (1) and adapter transition assembly and bottomagainst connector. Hold cable in position and mark cablejacket at rear end of sleeve.

Step 5. Remove sleeve (1) from adaptertransition assembly and place on cable with componentsin step 2 above.

Step 7. Prepare and terminate conductors, andshields where applicable, in accordance with contactcrimping instruction of paragraph 2-21.3 and MIL-STD-1683

.

2-44ORIGINAL


Step 8. Remove adapter transition assemblyfrom connector and place on cable with components instep 2 above.

Step 9. Insert the terminated conductors, andshields where applicable, in connector in accordance withcontact insertion instructions of paragraph 2-21.4.

Step 10. Assemble adapter transition assembly toconnector and sleeve (1) to adapter transition assemblyand tighten securely using applicable tools in accordancewith paragraphs (h) and 2-21.2 (i).

Step 11. Slide grommet (2) into sleeve (1) andposition grommet follower (3) on grommet (2)

Step 12. Attach clamp (4) to sleeve and tightensecurely.


Step 14. Test for correctness of hookup,continuity and insulation resistance.

2-45ORIGINAL


SECTION 3SUPPORT EQUIPMENT

INSTALLATION NAVSEA SE000-00-EIM-110 SUPPORTSTANDARDS EQUIPMENT

SECTION 3SUPPORT EQUIPMENT

3-1 INTRODUCTIONequipment/systems installation complies with themethods, materials, procedures, and requirements statedand/or referenced herein.

A shipboard electronic system installation involvesmuch more than installing the electronic enclosures andassociated cabling. The complexity, design andoperational functions of an electronic system orequipment determines the type of support equipment orsystems required to complete the shipboard installation.For some fire control system installations the electronicequipment installation is considered as the supportequipment. Regardless of the classification (support orotherwise) placed on an equipment or system, if itinterfaces with electronic equipments or is required foruse with electronic equipment (such as test equipment,shorting probes or wanting signs) the installationrequirements, methods and procedures either referencedor stated throughout this handbook shall apply.

3-5.1 COMPRESSED AIR SYSTEMSCompressed air systems that interface with

electronic equipment shall comply with the requirementsof MIL-STD-1399 Section 106.

3-5.2 DRY AIR SYSTEMSDry air systems that interface with electronic

equipment shall comply with the requirements of MIL-STD-1399 Section 102.

Dry air systems that interface with RF transmissionlines shall comply with the requirements of Section 5 ofthis document.

3-5.3 COOLING WATER SYSTEMS

3-2 PURPOSECooling water systems that interface with electronic


The purpose of this section is to make the Installeraware of the importance of electronic support equipmentor systems, and the Installer's responsibility to ensurethe installation of support equipment is comparable withthe associated electronic equipment or system and doesnot degrade either system.

3-5.4 FIRE CONTROL SYSTEMSFire control systems that interface with electronic


3-5.5 CONNECTION BOXES3-3 SCOPE Connection boxes are required in complex shipboard

electronics systems to provide multiple data pathsthrough interconnecting cables to or from equipment withlimited connections.

The intent of this section is to assist the InstallingActivity in obtaining the optimum installation through thereferencing of appropriate documentation and generalrequirements. Where conflict arises the requirements ofNAVSEA 0910-LP-432-5900 General Specifications forShips of the U.S. Navy (S9AA0-AA-SPN-010/GEN-SPEC) shall take precedence over an other documentsreferenced or requirements stated herein.

Connection boxes, often referred to as junction,branch, terminal or distribution boxes, consisting of anenclosure containing terminal board/s, provides a meansof terminating jacketed cable in an approved method thatwill keep signal loss at a minimum and still providemultiple signal data paths.

3-4 SELECTION Connection boxes shall be installed when specifiedin ICDs, ShipAlts, Technical Manuals or ships installationdrawings.The selection of support equipment/systems and

items for shipboard electronic installations is determinedby the cognizant Government activity based on theelectronic equipment/system requirements, type ship andits function in the fleet. The Government either providesthe equipment or item to the Installing Activity, orprovides sufficient parameters for procurement and/orfabrication by the Installing Activity through guidancedocuments such as ICDs, ShipAlts and StandardDrawings.

Some electronic systems supply special connectionboxes as a part of the equipment or have the capabilityfor multiple inputs or outputs designed into the system.For electronic systems requiring connection boxes, andthey are not supplied with the equipment, the InstallingActivity shall select, locate and install the requiredconnection boxes in accordance with the followingrequirements.

(a) Connection boxes shall be selected from MIL-HDBK-290 as a selection tool, and applied into thesystem as dictated by the function and arrangement ofthe distribution circuits.

3-5 SUPPORT EQUIPMENT/SYSTEMSINSTALLATION REQUIREMENTS

(b) The size of connection boxes selected for theelectronics system shall be the nearest standard size boxsuitable to accommodate the actual number of installedcircuits unless specified otherwise on ICDs or StandardDrawings. No provision shall be made for spare circuitsin such boxes, other than excess box capacity resulting

Support equipment/systems shall provide thefunctional capabilities required by the ICDs, StandardDrawings, and/or equipment Technical Manuals for aspecific electronic equipment/system.

The Installing Activity shall ensure the support

3-1ORIGINAL


from the above selection. (rms) volts or greater existing within the equipment whichcannot be disabled by that system's main power switch,shall have disconnect switches or protective devices andspecial warning signs (label plates). Radar indicators areincluded in this requirement . The maintenance (inputsignal) disconnect switch for radar indicators shall beinstalled as close as practicable to its associatedindicator.

For complex systems of which there is no standardconnection box of sufficient size, the Installing Activityshall fabricate or procure a connection box in accordancewith the applicable specifications of MIL-E-24142.

(c) Connection boxes shall be fitted with terminaltubes to maintain their watertightness except where thewiring equipment is located in enclosed spaces above thewatertightness level, or where the wiring equipment islocated in a compartment below the watertightness leveland the omission of the terminal tubes would not result inthe loss of otherwise operable portions of a system in theevent the compartment was flooded.

3-6.3 ANTENNA SAFETY DISCONNECTSWITCH

Safety disconnect switches shall be installed for allrotatable antennas (except submarine and ECMantennas) that will disable antenna rotation andequipment radiation prior to personnel entering theantenna swing circle. The antenna safety disconnectswitch shall be located as near the antenna aspracticable and easily accessible. The antenna safetydisconnect switch shall not have by-pass capabilitiesexcept for systems that require a battle short switch.

Connection boxes located below access coaming orfalse decks shall be watertight.

(d) The methods of DoD-STD-2003 shall be usedfor the installation of connection boxes.

(e) Connection boxes shall be installed for readyaccess to conductor connections.

(f) Connection boxes shall be located with-in theships structure where possible.

3-6.4 BATTLE SHORT SWITCH(g) Where possible, cable should enterthrough bulkhead and mounting surface for

connection boxes that must be located outside ships'structure.

When required by the individual equipmentspecifications, a battle short switch shall be provided onthe main operating console or assembly to short circuitall safety interlocks and antenna safety disconnectswitches where applicable. An indicator light readilyvisible to personnel shall indicate that the battle shortswitch is ON. The battle short switch shall also illuminateall interlock indicator lights. Battle short switches shallnot be added to any system by the Installing Activitywithout written authorized approval.

(h) Wiring diagrams showing terminal boardconfigurations, conductor terminations and jumpers whereapplicable shall be provided inside all connection boxes.

(i) Connection boxes that contain signal or powercables for Red processors may have to be modified toconform to the requirements of MIL-STD-1680.

3-6 SAFETY SUPPORT EQUIPMENT/ ITEMS3-6.5 CONVENIENCE RECEPTACLES

Safety support equipment or items shall provide thefunctional capabilities required by the ICD's, StandardDrawings, and/or Technical Manuals for the applicableelectronic installation.

Electronic equipment, including portable testequipment, installed aboard Naval ships shall not haveconvenience receptacles built into the system or unit.Government furnished and Installing Activity furnishedelectronic equipment which has an electrical conveniencereceptacle shall have the circuit de-energized and thereceptacle covered with a blanking plate by the InstallingActivity.

The Installing Activity shall ensure safety supportequipment or items are installed in accordance with themethods, materials, procedures and requirements statedand/or referenced herein.

3-6.1 SAFETY DISCONNECT SWITCHES 3-6.6 WARNING SIGNSEach item of electronic equipment connected

directly to the ships' electrical power distribution systemshall be provided with switches for disconnecting theequipment from the electrical power distribution systemand any other power sources. These disconnect switchesshall be located within the compartment or space in whichthe equipment is located. When practicable electronicequipment distribution panels or boxes with switches,when located within the compartment or space, shall beused as the disconnecting means. Where the electronicequipment distribution panel or box is located outside thecompartment or space it serves, single disconnectswitches located as close as practicable to theequipment it serves shall be used. All remotely locateditems of an electronic system shall have safetydisconnect switches that will allow independent disconnectof the electrical power in the associated equipment.

Warning signs are for the purpose of warningpersonnel of dangerous voltages, poisonous effects ofstack gases, possible presence of explosive vapors,electromagnetic radiation hazards and other dangerswhich may cause injuries to personnel.

NAVSEA SE000-00-EIM-100 Section 3 may be usedfor guidance in the selection and procurement of warningsigns. DoD 6050.5, Hazardous Material InformationSystem (HMIS) shall be used for design guidance forwarning not covered by NAVSEA SE000-00-EIM-100.

Consult your local safety and health staffconcerning any questions regarding hazardous materialand hazardous material warning signs.

3-6.6.1 Radio Frequency Hazard SignsThe following Radio Frequency Hazard (RADHAZ)

Signs are available from National Stock system.

3-6.2 CIRCUIT DISABLEMENTSign Specifications: Base Material .004 outdoor

white vinyl with permanent acrylic adhesive backing; sliton back of vinyl Labels are screen printed with ultra violetEach item of electronic equipment with inputs of 30

3-2ORIGINAL


inks for maximum durability; Bleeds are screened asrequested by artwork. with Black ink; Red and yellowchecked triangle in 5" square or 12" square sizes.

table 3-1 for the individual Radio Frequency Hazardsigns. If the supply of RADHAZ signs are depleted fromthe national supply system, contact NISE East Code 372for a supply of additional signs.The National Stock Numbers (NSN) are listed in

(1) RADIO FREQ HAZ WARNING-KEEP MOVING PERSONNEL/5"FORM #: 101/5 TYPE: 1/5" RF MOVING PERS LABELNEW NSN: 7690-01-377-5893SUPERSEDED NSN: 0967-LP-183-8010

(2) RADIO FREQ HAZ WARNING-KEEP MOVING PERSONNEL/12"FORM #: 101/12 TYPE: 1/12" RF MOVING PERS LABELNEW NSN: 7690-01-377-5894SUPERSEDED NSN: 0967-LP-183-8010

(3) RADIO FREQ HAZ WARNING-BEYOND THIS POINT/5"FORM #: 102/5 TYPE: 2/5" RF BEYOND POINT LABELNEW NSN: 7690-01-377-5895SUPERSEDED NSN: 0967-LP-153-8010

(4) RADIO FREQ HAZ WARNING-BEYOND THIS POINT/12"FORM #: 102/12 TYPE: 2/12" RF BEYOND POINT LABELNEW NSN: 7690-01-377-5082SUPERSEDED NSN: 0967-LP-153-8010

(5) RADIO FREQ HAZ WARNING-BURN HAZARD/5"FORM #: 103/5 TYPE: 3/5" RF BURN LABELNEW NSN: 7690-01-377-5896SUPERSEDED NSN: 0967-LP-315-2010

(6) RADIO FREQ HAZ WARNING-BURN HAZARD/12"FORM #: 103/12 TYPE: 3/12" RF BURN LABELNEW NSN: 7690-01-377-5898SUPERSEDED NSN: 0967-LP-315-2010

(7) RADIO FREQ HAZ WARNING-FUEL OPNS/5"FORM #: 104/5 TYPE: 4/5" RF FUEL OPNS LABELNEW NSN: 7690-01-377-5899SUPERSEDED NSN: 0967-LP-315-1010

(8) RADIO FREQ HAZ WARNING-FUEL OPNS/12"FORM #: 104/12 TYPE: 4/12" RF FUEL OPNS LABELNEW NSN: 7690-01-377-5900SUPERSEDED NSN: 0967-LP-315-1010

(9) RADIO FREQ HAZ WARNING-BLANK/SPEC COND/5"FORM #: 105/5 TYPE: 5/5" RF BLANK LABELNEW NSN: 7690-01-377-5374SUPERSEDED NSN: 0967-LP-350-1010 and 0967-LP-096-3010

(10) RADIO FREQ HAZ WARNING-BLANK/SPEC COND/12"FORM #: 105/12 TYPE: 5/12" RF BLANK LABELNEW NSN: 7690-01-377-5375SUPERSEDED NSN: 0967-LP-350-1010/0967-LP-096-3010

(11) RADIO FREQ HAZ WARNING-SECURE UNAUTH RADIO/5"FORM #: 106/5 TYPE: 6/5" RF SECURE RADIO LABELNEW NSN: 7690-01-377-5444SUPERSEDED NSN: 0967-LP-090-1010/0967-LP-350-1010

(12) RADIO FREQ HAZ WARNING-SECURE UNAUTH RADIO/12"FORM #: 106/12" TYPE: 6/12" RF SECURE RADIO LABELNEW NSN: 7690-01-377-5447SUPERSEDED NSN: 0967-LP-090-1010/0967-LP-350-1010

Table 3-1. Radio Frequency Hazard (RADHAZ) Signs

3-3ORIGINAL


(13) RADIO FREQ HAZ WARNING-ORDNANCE HANDLING/5"FORM #: 107/5 TYPE: 7/5" RF ORD/HERO LABELNEW NSN: 7690-01-377-5901SUPERSEDED NSN: 0967-LP-090-1010

(14) RAD HAZ WARNING-OPERATE TRANSMITTERS/5"FORM #: 108/5 TYPE: 8/5" TRANS OPERNEW NSN: 7690-01-377-5902SUPERSEDED NSN: 0967-LP-090-1010

Table 3-1. Radio Frequency Hazard (RADHAZ) Signs (cont)

3-6.7 SAFETY SHORTING PROBESsafety shorting probe that complies with NAVSEADrawing No. 5003000-revision A, and shall not beinstalled in electronic compartments or spaces.A general purpose safety shorting probe set shall be

installed in each compartment or space containingelectronic equipments. The safety shorting probe setincluding two probe tips and a stowage assembly shallcomply with the latest revision of NAVSEA Drawing No.5003000. The stowage assembly shall be located in areadily accessible area and the view shall not be blockedfrom the normal traffic or work area of the space.

Special purpose shorting probes supplied withcertain electronics equipments are not consideredgeneral purpose safety shorting probes and are to beused only with the equipment with which they areprovided. The existence of these special purposeshorting probes do not relieve the requirements for ageneral purpose safety shorting probe set in eachelectronic equipment compartment or space.The safety shorting probe (25 kV), NSN No.

9G5975-01-029-4176 and safety shorting probe (7.5 kV),NSN No. 9G5975-00-146-1797, in accordance withNAVSEA Drawing RE-D2697984 has been superseded bythe

The requirements of this paragraph are applicable toall new construction and ShipAlts in which the approvedsafety shorting probe set has not been previouslyinstalled.

3-4ORIGINAL


SECTION 4ANTENNAS

INSTALLATION NAVSEA SE000-00-EIM-110 ANTENNASSTANDARDS

SECTION 4ANTENNAS

4-1 INTRODUCTION 4-4 GENERAL REQUIREMENTS

An antenna may be defined as a conductor orsystem of conductors used to radiate or receiveelectromagnetic energy. An efficient antenna system isan important link in the propagation and reception of thisenergy and the intelligence it conveys. This becomesvery evident when an antenna failure occurs.

The general requirements stated herein areapplicable to shipboard installations of all types ofantennas.

4-4.1 SELECTIONAntennas installed aboard Navy ships shall be the

types shown on ICDs, equipment technical manuals,NAVSEA fire control drawings or ShipAlts. There shall beno deviation from the antennas types shown withoutauthorized approval from NAVSEC 6170. Forcommunication type antennas and associated equipmentunder the cognizance of Naval Electronic SystemsCommand, joint authorized approval shall be obtainedfrom NAVSEC 6170 and NAVELEX 510.

The radio frequency energy that is generated by thetransmitter serves a useful purpose only when it isradiated into space in the form of electromagneticenergy. The antenna, as the interface between thetransmitter and free space, is required to convert thepower from the transmitter into electromagnetic energyas efficiency as possible and to direct this energy whereit will be useful. Since the majority of antennas are usedboth for transmitting and receiving, the various propertiesof individual antennas apply to both modes of operation.Thus it is apparent that the antenna is a major element ofthe transmitting/receiving system, and it is of greatimportance that the best methods be used in the designand installation of shipboard antennas.

4-4.2 LOCATIONThe locating of antennas aboard Navy ships is a

critical procedure and shall be accomplished only byqualified design activities. All shipboard antennalocations shall be approved by the Naval ShipEngineering Center SEC 6170. The locating ofcommunication type antennas and associated equipmentunder the cognizance of Naval Electronic SystemsCommand, shall be jointly approved by NAVSEC 6170and NAVELEX 510. There shall be no deviation ofantenna locations without written approval of cognizantauthority.

The complex structures of ships and theiroperational requirements necessitate the use of varioustypes of antennas. These types include wire rope fans,whips, cages, dipoles, probes and trussed monopoles forcommunication systems as well as a wide variety ofrotating antennas of all shapes and sizes required forradar, ECM, and fire control systems, not to mention thespecially designed antennas for submarine installations.The selection and use of the different types is oftengoverned by the limited space aboard ships. Because ofthese limitations, shipboard antennas are oftencompromises that provide the most efficient performancewithin imposed limitations.

4-4.3 INSTALLATIONShipboard antennas shall be installed in accordance

with the following:(a) Installation of communication antennas shall

comply with the requirements of NAVSEA 0967-LP-177-3020.

4-2 PURPOSE (b) Installation of radar, fire control and ECMantennas shall comply with the applicable ICDs, technicalmanuals, ordnance drawings and specific antennainstallation manuals.

The purpose of this section is to make the installeraware of the limitations and constraints placed upon theoverall antenna systems installed aboard Navy ships,and the installing activity's responsibility to ensure thatantennas are located and installed in accordance with thelatest approved documents referenced by a specificship's specification or ShipAlt.

4-4.4 FOUNDATIONSAntenna foundations, brackets and supports shall

comply with the applicable requirements of ICDs,ordnance drawings, and technical manuals.Communication antenna foundations, brackets andsupports shall comply with the requirements of NAVSEA0967-LP-177-3020 and the applicable requirements listedabove.

4-3 SCOPE

The intent of this section is to assist the installingactivity in obtaining the optimum installation through thereferencing of appropriate documentation and generalrequirements. Where conflict arises the requirements ofNAVSEA 0910-LP-432-5900 General Specifications forShips of the U.S. Navy (S9AA0-AA-SPN-010/GEN-SPEC) shall take precedence over all documentsreferenced or requirements stated herein.

4-4.5 PRESERVATIONThe cleaning and painting of applicable antenna

components shall comply with the applicablerequirements of NAVSEA 0967-LP-177-3020, ICDs andordnance drawings, technical manuals and specificantenna installation manuals.

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INSTALLATION NAVSEA SE000-00-EIM-110 ANTENNASSTANDARDS

4-4.6 PERSONNEL PROTECTION NOTESafeguards against RF radiation hazards and RF

burn hazards, including the posting of warning signs atdangerous radiation areas, shall be provided inaccordance with OPNAVINST 5100.23, Chapter 22 -Non-Ionizing Radiation and the DoD INST 6055.11, Protectionof DoD Personnel from Exposure to ElectromagneticFields (EMF) at Radio Frequencies (RFD) from 3Kilohertz (KHz) to 200 Gigahertz (GHz).

As of the publication date of thisdocument, the Personnel HazardsExposure Criteria stated in OP-3565 andOPNAVINST 5100.23 has beensuperseded by DoD INST 6055.11. TheDoD INST is virtually identical to thecivilian Personnel Hazards ExposureCriteria outlined in IEEE C95.1-1991.

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SECTION 5WAVEGUIDES AND

RIGID COAXIAL LINES

INSTALLATION NAVSEA SE000-00-EIM-110 WAVEGUIDES ANDSTANDARDS RIGID COAXIAL LINES

SECTION 5WAVEGUIDES AND RIGID COAXIAL LINES

This section contains information and illustrations for shop fabrication and shipboard installation of rigidtransmission lines. Guidance is provided to select transmission lines and fittings from Military Standards. MilitarySpecifications are referenced for use in obtaining technical data.

This section shall be used with the standards and specifications referenced herein. The value of this section will begreatly decreased if copies of the standards and specifications referenced are not made a part of each appendix. Indexcover sheets for each appendix are provided for the standards and specifications referenced herein.

The fabrication and illustration procedures shown in this section are for all approved shipboard rigid transmissionlines. Exceptions or additions are covered where necessary for different metals.

All references made to military documents and nomenclature throughout this section were made to the basicdocument or nomenclature number. Unless otherwise stated the current issue, revision or modification shall prevail.

Section 5 is divided into six subsections as follows:5-1 and 5-2 covers rectangular waveguide shop fabrication and shipboard installation.5-3 and 5-4 covers rigid coaxial air dielectric transmission line shop fabrication and shipboard installation.5-5 and 5-6 covers elliptical waveguide shop fabrication and shipboard installation.The materials methods and procedures in subsections 5-1, 5-3 and 5-5 are for use by shore activity fabrication

shops (military and commercial) and are not applicable for shipboard shops.

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5-1 RECTANGULAR WAVEGUIDEwould supplement ship installation plans which aredeveloped from the Installation Control Drawings (ICD)for specific equipments.

5-1.1 INTRODUCTION 5-1.1.1 Waveguide AccessoriesTo facilitate installing straight sections of waveguide

the following accessories are available. For selection ofapproved accessories see MIL-STD-242 or otherspecified documents.

A waveguide is a means of transferring electricalenergy. Any material or combination of material, whichwill confine and propagate electrical and magnetic fieldsof radio frequency energy may be called a waveguide.See MIL-STD-242, Section 500, for selection of approvedwaveguide. For dimensions and details see MIL-W-85 orother specified documents.

5-1.1.1.1 Bend AssembliesWaveguide bend assemblies shall not be

indiscriminately installed for alignment purposes or toclear an object. that is blocking the waveguide run. Ifrelocating the interfering object is impossible orimpracticable, then bends may be installed. These shallbe 45, 60, or 90 degree bends procured in accordancewith MIL-W-3970 (see Appendix 5-E). Where bends of adifferent angle or radius are required, or the number ofwaveguide joints is reduced as a result of fabricating asection of waveguide with multiple bends, they shall befabricated in accordance with the procedures outlined inthis document and shall meet the requirements of MIL-W-3970. The procedures of this document for bendingwaveguide are not applicable to waveguides of 6.5 inchesor greater in width. large waveguide bend assemblies shallbe procured and meet the requirements of MIL-W-3970.

A complete understanding of the wave propagationin a waveguide is not necessary for fabrication andinstallation. However, a general familiarity with thenomenclature and fabrication methods aid inunderstanding why emphasis should be placed on whatappears to be insignificant points in waveguidefabrication. The proper type and size of waveguide isdetermined by the equipment designer and government.Any changes to types, parts or installation plans shall notbe made without authorization.

In a typical shipboard installation, in relation to thetransmitter the associated radiating antenna is remotelylocated. Therefore a transmission line is required tocouple the transmitter to the antenna. The transmissionline can be either rigid and flexible coaxial cable or rigidand flexible rectangular waveguide. Rectangularwaveguide is preferable due to its higher energy handlingcapabilities and lower energy losses at certainfrequencies. Rigid rectangular waveguide transmissionline is fabricated from drawn tubing made of aluminum,bronze, copper, or silver. The waveguide is normallysupplied in 10-foot to 14-foot sections. These sectionsare connected together by the use of the flanges whichmay or may not be attached when delivered.

Fabricated bends shall be designed so that theirphysical bend length is an integral multiple of the halfwavelength of the mid-frequency of the associatedequipment. The extremities of a bend shall not be closerthan one inch to the flange.

5-1.1.1.2 Flexible AssembliesFlexible waveguide assemblies shall be used only to

compensate or eliminate excessive stress caused bydifferent expansion and contraction rates of the shipsstructure, or excessive movement caused by vibrationand shock. Flexible sections, when required, shall be asshort as possible and installed at right angles to thedirection in which the greatest movement shall occur.Flexible waveguides assemblies shall not be used foralignment purposes or to take up fixed slack in a run.Flexible sections shall be in a normal free state afterinstallation, they shall not be stretched or compressed inorder to mate with their interfacing components. Flexiblesections shall meet the requirements of MIL-W-287 (seeappendix 5-E).

When the transmitter or receiver is separated fromthe antenna which is usually located high on thesuperstructure or a mast, there are often many obstaclesthat have to be moved or bypassed. This results in therequirement for varying straight lengths, bends, twists,and flexible sections, when required, that will have to beprocured or fabricated depending on their availability orthe capabilities of the installer.

Although waveguide has a comparatively lowinherent loss, other losses resulting from interiordimensional variance and surface finish discontinuities atbends, twists, and flanges, can be introduced whichreduce efficiency of an electronic system. Thesevariations in most cases are due to the equipment usedin bending and twisting waveguide or the lack of knowledgeor experience. When planning a waveguide run, it isimportant that it be short and as straight as possible.This means installing the minimum of bends, twists andflanges. This along with ensuring that the bends, twists,and flanges are properly fabricated and installed will helpensure the equipment performing as it was designed.This section will be devoted primarily to giving thefabricator and installer a better idea of the problems hewill encounter and how to plan and estimate the workrequired in waveguide installation. Further, it will showwhich standards are used for selection of material andwhich military specifications are used for details for anygiven item or work process required. This information

5-1.1.1.3 Twist AssembliesTwist assemblies shall be installed only when it is

necessary to change the plane of the transmission linerun for interfacing with equipment that cannot berelocated. Standard twist assemblies in accordance withMIL-W-3970 shall be used wherever practicable (seeAppendix 5-E). Where twist assemblies of a speciallength or degree of twist is not available through MIL-W-3970, and the waveguide wide dimension does not exceed6.5 inches, they shall be fabricated in accordance withthe procedures outlined in this document and shall meetthe requirements of MIL-W-3970.

Fabricated twists shall be designed so that the twistdoes not exceed 90 degrees and the physical length is anintegral multiple of the half wavelength of the mid-frequency of the associated equipment. The extremities

5-2ORIGINAL


of a twist shall not be closer than one inch to the flange. indication that the contents could be damaged and shallbe opened carefully in order to see that there is noapparent damage. Insure that the waveguide issupported properly and that waveguide ends of flangesare sealed to keep dirt and air out, and are protectedagainst rough handling.

5-1.1.1.4 Adapter AssembliesAdapters are designed to allow changing from

waveguide to coaxial cable when required. For typesavailable and design data required see MIL-HDBK-216and MIL-A-22641 (see Appendix 5-E).

5-1.3.2 Storage5-1.1.1.5 Flanges Whether left crated or uncrated, waveguide sections

and components shall be stored in a cool, dry location toreduce minimum oxidation, and discoloration. Packedand unpacked sections shall be stored in a horizontalposition and shall be supported to prevent distortion.Stored waveguide sections, fittings, parts, flange faces,and coupling edges shall be covered with heavy papercaps or lintless cloth to prevent damage and entrance ofdust or other foreign matter.

Flanges are used to connect waveguide andassemblies together. They are provided separately orsupplied with various waveguide assemblies. For typesand design data of the flange and gasket see MIL-F-3922and MIL-G-24211 (see Appendix 5-C and 5-E). Whenflanges must be brazed on waveguide follow proceduresoutlined in 5-1.8 and 5-1.9.

5-1.1.1.6 Waveguide Pressure Windows5-1.3.3 HandlingPressure windows are required when waveguide is

pressurized and the equipment it connects to is notpressurized. For types and design details of windows, ifrequired, see a manufacturer's catalog for the waveguidespecified.

When unpacking or handling waveguide, the boxshall be placed so that it is resting firmly in a horizontalposition. Box cover nails shall be removed with nailpuller. Prying the cover off the box may dent some ofthe waveguide sections. Carefully remove collar blocksto avoid damaging. One of the end seals may beremoved in order to examine a waveguide section beforeinstallation and shall be replaced after examination. Thesame protective care also applies to fittings, assemblies,and accessories. Rubber 0-rings and other small partsand pieces are packed separately.

5-1.2 TECHNICAL CAPABILITIESThe activity performing waveguide fabrication and

shipboard installation shall have the following:1. Ship or class waveguide installation plans.2. Technical capability to bend, twist and flange

waveguide.3. Training programs for all trades involved in

the process of fabricating, painting, and installing. NOTE4. Area which can be protected and set up to

suit waveguide fabrication (cleaning, annealing, bending,and painting).

Human perspiration and acid from theskin have a detrimental effect onconductive surface. Therefore,conducting surfaces shall not be touchedwith bare hands. Clean cotton glovesshall be worn at all times when handlingwaveguide and fittings.

5. Form bending machine or equal with metalshims or metal alloy.

6. Two support type twisting machines usingmetal alloy.

7. Quartz lamp brazing furnace or dip brazingequipment and appropriate alignment jigs for brazingflanges to waveguide.

8. Adequate facilities for brazing, cleaning,rinsing, and chemical conversion.

5-1.3.4 Layout of Waveguide Run9. Procedures for inspecting dimensional andsurface finishes of incoming and fabricated waveguide forcompliance with MIL-W-85 or other documents asspecified.

The design of a waveguide run shall be attemptedonly by qualified design personnel. No substitution ormodification is to be made from Waveguide InstallationControl Drawings and Installation Manuals withoutapproval. The following factors should be kept in mind:

10. Procedures, facilities, and equipment forelectrically and electronically testing fabricatedwaveguide.

1. Waveguide run to be short and direct aspossible.

11. Clean, dust-free paint area.12. Procedures for handling waveguide while in

storage, fabrication, and delivery to prevent damage;protection for inside finish, flange surfaces, and againstdistortion or denting the waveguide.

2. Two "E" or two "H" bends shall not beconnected directly together unless no other arrangementis possible.

3. Use as few bends and twists as possible.

5-1.3 SHOP PREFABRICATION GUIDELINES 4. Waveguide takes priority over vents,wireways, piping, lighting and similar obstructions.

The inspection, storage, handling and layout designshall be in accordance with the following guidelines.

5. Bends shall have the largest radius possibleconsistent with waveguide used. In no case must thebend radii or length of twist be less than that shown onICDs or in MIL-HDBK-660. Prefabricated bends inaccordance with MIL-W-3970 should be used if a verytight bend is required or if the installing activity does not

5-1.3.1 InspectionBoxes containing waveguide shall be examined for

breaks immediately upon receipt. A broken box is an

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possess either the skill or facilities required in MIL-HDBK-660 (see Appendix 5-E).

documents specified for dimension and surface finishrequirements prior to fabrication. Waveguide should notbe bent unless interfering items cannot be relocated orfactory bends cannot be used or are not available at thecorrect angle. Waveguide is bent in the "E" plane whichis parallel to the short dimensions of the rectangularcross section or the "H" plane which is parallel to the longdimensions of the cross section (see Figure 5-1). Bendsare more easily remembered by "E" for "EASY" and "H"for "HARD".

6. After receipt of ship waveguide installationplan showing the design and location of waveguide run, atemplate shall be made. This along with the waveguideinstallation plan, will provide the fabrication shop withaccurate information as to length, shape, and angle ofstraight sections, bends and twists. Template fabricationdetails are defined in paragraph 5-2.3.

5-1.4 ANNEALING For minimum bend radius refer to MIL-HDBK-660and Installation Control Drawings. Minimum bend radiusand type of bends allowed may vary with the samewaveguide depending on mid-frequency of the associatedequipment. All bending shall be in accordance with MIL-HDBK-660 and the completed assembly shall meet therequirements of MIL-W-3970.

Prior to bending waveguide it must be annealed.Annealing serves to soften and reduce brittleness in thewaveguide. After annealing, the waveguide shall beallowed to cool at room temperature.

It should be noted that, depending upon the bendradius and size of waveguide and on method of bending,the cross section of the waveguide may becomedistorted with a thinner outside curved wall and wrinkledinside wall with trapezoidal shaped walls parallel to theplane of the bend, sometimes appearing as a buckle.The annealing process coupled with the proper use ofmandrels can help prevent distortion. Annealing ofwaveguide shall be as specified in MIL-HDBK-660 (seeAppendix 5-D).

5-1.7 TWISTINGTwisting the waveguide is sometimes required in

addition to bending because of clearance and supportproblems, and the relative position of equipment. As inthe case of the bending process, waveguide walls willcollapse if twisted without using a mandrel. Again theinterior dimensions of the waveguide are, electrically, thecritical dimensions. For minimum twist length refer toMIL-HDBK-660 and ICDs. There are several types ofequipment used in fabricating twists in waveguide. Therequired annealing, use of twisting mandrels, and methodof twisting shall be in accordance with MIL-HDBK-660.The completed assembly shall meet the requirements ofMIL-W-3970.

5-1.5 MANDRELS AND FILLERSElectrically the interior dimension and surface finish

of the waveguide are the critical areas. Mandrels andfillers are used to keep distortion of the interiordimensions, or damage to the surface finish to aminimum during the bending or twisting process. Fordetailed bending and twisting information using mandrelsand fillers see MIL-HDBK-660. 5-1.8 FLANGES

5-1.6 BENDINGFlanges for use with rectangular waveguide shall be

selected from MIL-STD-1327 and meet the requirementsof MIL-F-3922.All waveguide shall conform to MIL-W-85 or other

Figure 5-1. Waveguide Side and Bend Identification

Flanges shall be attached to rectangular waveguidein accordance with MIL-HDBK-660 and MIL-B-7883.Flanges are designed for attachment to waveguide by twogeneral methods. One is the "through" type which allowsthe waveguide to pass all the way through the flange untilit is flush with the flange face. The other type, called"socket", varies in that the waveguide does not passthrough the flange but fits into a socket on the opposite

side from the flange face.Where an aluminum flange must mate with copper

or brass flanges, zinc plate the copper or brass flange toprevent corrosion from electrolysis between dissimilarmetals.

Flanges are classed into three general types as tothe design of the flange mating face.

5-4ORIGINAL


5-1.8.1 Contact Flanges(a) Bending alloy, if used, shall be thoroughly

removed immediately after completion of the bending ortwisting process and prior to the flange brazing process.Contact flanges are designed with two types of

mating surfaces. The flat faced type contact flangerequires a gasket in accordance with MIL-G-24211 whenused with a pressurized line. The grooved face typecontact flange is supplied with a pressure seal inaccordance with MIL-F-3922. Contact flanges areavailable in both the through type and socket typemethods of attaching to the waveguide.

(b) All grease, oil, dirt, scale and chemicalconversion coatings shall be removed from the brazingareas of the waveguide and flange prior to the attachmentof flange to waveguide by the bracing process.

(c) After all fabrication work is completed, andprior to chemical conversion application, the waveguideassembly shall be thoroughly cleaned, rinsed and dried.

A contact flange mates with another contact flangewith the same military part number or "UG" nomenclature.Contact flanges cannot be mated with a choke flange orcover flange.

(d) The chemical conversion coating shall beapplied immediately after the final cleaning has beenaccomplished.

5-1.12 SEALING AND PAINTING5-1.8.2 Choke FlangesThe waveguide assembly shall be sealed against

corrosion and receive a protective paint coating inaccordance with the following.

Choke flanges are designed with a cavity betweenthe choke and its associated cover flange thatconstitutes a half-wave shorted line in series with thewaveguide, which presents a minimum electricaldiscontinuity. These flanges use the socket type methodof attaching to the waveguide.

5-1.12.1 Chemical ConversionAll interior and exterior surfaces of waveguide

assemblies shall receive a chemical conversion coating.Aluminum waveguide assemblies shall have a chemicalconversion coating in accordance with MIL-C-5541, class3. Copper waveguide assemblies shall have a chemicalconversion coating in accordance with Iridite No. 7PMixture C, or the equivalent (see Appendix 5-D).

A gasket (pressure seal) is supplied with each chokeflange.

Choke flanges must be mated with a cover flangedesigned with the same interface characteristics. SeeMIL-STD-1327, MIL-F-3922 and MIL-HDBK-216 for themating choke and cover flanges assigned for a specificwaveguide.

Prior to the application of the chemical conversion,ensure the waveguide assembly has been properlycleaned. The waveguide assembly shall be carefullyhandled throughout the coating process. Mechanicaldamage or contamination from uncovered hands or soiledgloves shall be avoided. Soiled areas shall be recleanedwith either organic or inorganic solvent, or both, asrequired. Damaged areas from which the chemicalconversion coating has been removed shall be repaired,recleaned and recoated.

5-1.8.3 Cover FlangesCover flanges are designed as a mating flange for

use with its assigned choke flange having the sameinterface characteristics. These flanges are attached tothe waveguide either by the socket type method or thethrough method.

Gaskets for use with cover flanges are supplied as apart of the associated choke flange.

5-1.12.2 Protection by Painting5-1.9 BRAZING The waveguide assembly, after completion of

chemical conversion process, shall have the exteriorsurfaces (excluding flange faces) protected with an epoxycoating as shown in paragraph 5-1.13.16.

The general brazing requirements shall conform toMIL-HDBK-660 and MIL-B-7883 (see Appendix 5-D).

5-1.10 CLEANING AGENTS Ensure the waveguide assembly does not becomecontaminated or soiled between the chemical conversionprocess and the painting process. The waveguideassembly shall be sealed to prevent any paint getting onthe interior surface of assembly or on the flange facesduring the painting process.

The cleaning agents used to remove oil, grease,paint, scale, oxide, flux, conversion coatings, dirt or theneutralizer after acid baths shall not remove the parentmetal or leave residue that would cause waveguideinterior dimensions to exceed tolerances specified in thewaveguide military specifications.

5-1.13 SHOP FABRICATION PROCEDUREFor cleaning details see MIL-HDBK-660, MIL-B-7883and MIL-STD-645. Waveguide assembly fabrication is broken down into

step by step procedures in the following subparagraphs inorder to facilitate planning and quality control. For detailson annealing, filler mandrels, bending, twisting, cuttingand attaching flanges see MIL-HDBK-660 and MIL-B-7883 (see Appendix 5-D). For details on cleaning,sealing and painting requirements see paragraphs 5-1.10,5-1.11, and 5-1.12.

Observe the safety precautions for those coming incontact with, handling or using chemicals. Personnelhandling alkaline or acidic cleaners shall wear protectiveface shields, rubber gloves and aprons. In case ofcontact with skin or clothing, flush with water immediately.In case of acid contact with skin or eyes, get medicalattention as soon as possible.

5-1.11 CLEANING REQUIREMENTS 5-1.13.1 Fabrication Data ProcurementProcure the necessary design information, plans or

sketches required to install the waveguide run. Usingships installation plan, template waveguide run to

The installing activity shall comply with the followinggeneral requirements for cleaning waveguide during thefabrication process of waveguide assemblies.

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determine exact dimensions of bends, twists and straightsections.

foreign substance such as oil, paint, dirt, or scale thatmight interfere with the brazing. See paragraphs 5-1.10and 5-1.11.

5-1.13.2 Annealing5-1.13.9 Flange to Waveguide FitAnneal the sections of waveguide that require

bending or twisting. Check for proper annealingtemperatures for type of metal being annealed.

Ensure the waveguide end is square in all threeplanes to within ±1/2 degree as shown in Figure 5-2. Fitthe selected flanges to the waveguide. Ensure the chokeflange, when used, is installed on the assembly in such amanner that the choke end faces the transmitter. Whenthe flange is fitted to the waveguide in preparation forbrazing, the clearance between mating surfaces shall be0.002 inch to 0.010 inch for laps less than 0.250 inchlong. Longer laps may require clearance up to 0.025inch. The alignment fit between flange and waveguideshall not exceed 0.004 inch on the step. See Figure 5-3for explanation of lap clearance and step alignment.Clearances and alignment shall be maintained during thebrazing operation.

5-1.13.3 Mandrel SelectionAfter completion of annealing process, select the

correct mandrel or bending alloy required for the type ofbend or twist to be made and the type of bending ortwisting equipment used.

5-1.13.4 Bending and TwistingCarefully bend or twist the specified section of

waveguide to match the template dimensions. Ensurewaveguide has been bent or twisted in accordance withdesign plans.

5-1.13.5 Surface Check When flanges designed for heavywall waveguide arenot available, then either the waveguide or the selectedflange shall be modified similar to the method shown inMIL-HDBK-660.

Check the quality of the waveguide surface that hasbeen bent or twisted to ensure it has not been distortedwith bulges, puckers and/or wrinkles.

5-1.13.10 Brazing Operation5-1.13.6 CuttingBrazing of flanges to waveguide shall be in

accordance with MIL-HDBK-660, MIL-STD-645 and MIL-B-7883. The brazing method used should be determined bytype of material to be brazed, physical size of material tobe brazed and the type of shop equipment. Ensure therequired clearance and alignment dimensions aremaintained until the brazing operation is completed.

After completion of bending and twisting process,cut waveguide sections to the exact length determinedfrom templates. Straight sections not requiringannealing, bending and twisting shall be cut to the properlength as determined by the waveguide run template.

5-1.13.7 Quality Assurance Check

5-1.13.11 Hydrostatic TestPerform a quality assurance check, prior to cleaningfor brazing, to inspect the waveguide as specified inparagraph 5-1.13.17 and 5-1.13.18. The waveguide assembly, after completion of

brazing operation, shall be subjected to the internal airpressure in pounds force per square inch gage specified,while immersed in water. The air pressure shall notexceed the design specified pressure.

5-1.13.8 Cleaning for BrazingAfter satisfactory acceptance of the quality

assurance check, clean the mating surfaces andadjacent areas of the waveguide and flanges of any

Figure 5-2. End View of Waveguide Showing Cutting Requirements

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Figure 5-3. Alignment of Flange to Waveguide

NOTEassemblies, and the coating manufacturers' instructionsfor copper alloy assemblies.

5-1.13.16 Painting of AssemblyExcessive pressure will deformwaveguide walls. The temperature of thewater used for this test shall be test shallbe 20° C ± 5° C. Any bubbles coming fromwithin the assembly shall be consideredas leakage. Bubbles which are the resultof entrapped air on the exterior parts ofthe assembly shall not be considered asleaks. The assembly under test shallremain immersed for a minimum of fiveminutes. Any indication of leakageduring this time shall be reason forrejection of assembly.

Upon acceptance, and prior to shipboardinstallation, thewaveguide assembly shall be painted inaccordance with the following guidelines:

(a) Seal both flange surfaces to prevent paintaccumulation on interior surface and on flange faces. Arubber gasket with blanking plate secured by utilizing theflange bolting holes is suggested.

(b) Clean surfaces with mineral spirits to removedirt, grease, or other contaminants, being careful not toremove MIL-C-5541 chemically treated surfaces.

(c) Apply MIL-P-24441 epoxy polyamide coatingsystem in accordance with the following:

The coating system shall consist of one coat ofFormula 150 Primer - 2 to 4 mils dry film thickness; andtwo coats of Formula 151 (Haze Gray) - each coat 2 to 3mils dry film thickness. Total minimum dry film thicknessfor coating system shall be 8.0 mils.

(d) Remove any trace of paint that may be onthe flanges with a solvent and lint-free cloth. It is easierto remove the paint while it is still wet. Do not allowsolvent to come in contact with the interior surface of thewaveguide.

5-1.13.12 Post Braze CleaningPost braze cleaning shall be accomplished

immediately after the hydrostatic test and shall be inaccordance with paragraphs 5-1.10 and 5-1.11. (e) When paint is dry, remove the flange covers.

(f) Do touch-up painting or other painting onboard ship.5-1.13.13 Post Fabrication Inspection

A post fabrication inspection shall be conductedimmediately after the post braze cleaning operation, formaterial condition, in accordance with paragraphs 5-1.13.17 and 5-1.13.18.

(g) Inspect paint finish.(h) Seal both ends of waveguide assembly to

prevent intrusion of moisture and foreign matter.(i) Exercise extreme care when transporting the

waveguide assembly.5-1.13.14 Chemical Conversion Application(j) Store or ship the waveguide assembly to the

point of installation.The chemical conversion coating shall be applied tothe waveguide assembly upon satisfactory completion ofpost braze inspection. The chemical conversion coatingshall be applied in accordance with paragraph 5-1.12.

NOTE

It is of prime importance that thewaveguide be protected from physicaldamage and/or contamination during allphases of fabrication, shipping and

5-1.13.15 Chemical Conversion InspectionInspect the chemical conversion coating for proper

application to the interior and exterior surfaces, includingflanges, of the waveguide assembly. Ensure the coatingis in accordance with MIL-C-5541 for aluminum

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installation. To ignore this may result inelectronic malfunction or the rejection ofthe waveguide.

waveguide installed, allowing for "E" and "H" bends.(b) Check twist so it does not exceed 90 degrees

in a minimum length allowed for the waveguide installed.(c) The extremities of a bend or twist shall not be

closer than one inch to flange.(d) The interior surfaces of the waveguide,

particularly in the area of bends and twists, shall not showevidence of compression rings, stretch marks, crack,deposits of bending alloy, or any irregularities mentionedin paragraph 5-1.13.17.

5-1.13.17 Fabrication InspectionDuring the fabrication process and upon completion

of all work, the waveguide assembly should be inspectedfor quality using the following guidelines and MIL-W-85(see Appendix 5-A).

NOTE(a) The interior and exterior surfaces of thewaveguide shall be bright, smooth, dry, and free ofscales and oxides. In order to adequately inspect the interior

of the waveguide, an instrument such as aborescope may be required.

(b) The maximum bow that the waveguide maydisplay is not more than 0.010 inch edgewise and 0.020inch flatwise between any two points located two feetapart on the concave external surface of the waveguide.The waveguide shall be so positioned during themeasurement that gravity will not tend to increase theamount of bow.

5-1.13.19 Post-Brazing InspectionAfter the brazing process is complete and all flux

has been removed from the waveguide assembly, it mustbe inspected for quality using MIL-STD-645 and MIL-B-7883 (Appendix 5-D) and the following guidelines.

(c) The maximum twist along the longitudinal axisshall not exceed one degree per foot of length on face ofthe exterior surface. The waveguide shall be placed on aflat, horizontal, reference plane. One end shall be held inphysical contact by a suitable means while the other endof the waveguide remains free. By the use of anengraved transport protractor segment, determine theangle line on the protractor which coincides to the nearestdegree with the surface of the waveguide while the edgeof the protractor is kept parallel to the reference plane.

5-1.13.19.1 Interior of Waveguidea) The joint must be smooth and completely

filled. There shall be no voids, laps, porosity, excessfiller metal.

b) The fit between the waveguide tubing and theflange shall be 0.002 inch to 0.010 inch for laps less than1/4 inch long. Clearance up to 0.025 inch are allowablefor laps greater than 1/4 inch. The maximum surfaceroughness for all surfaces that will constitute a portion ofthe joint is 63 microinches.

NOTE

Waveguide with a noticeable, butacceptable, flatwise bow shall bepositioned with the side of the convexcurvature in contact with the referenceplane.

c) Misalignment between the tubing and theflange (called the step) at their junction shall not exceed0.004 inch after the flange is in the final position.

5-1.13.19.2 Exterior of Waveguidea) The maximum allowable diameter of any

porosity indication is 0.015 inch. The maximum allowabledepth of any porosity is 10 percent of the braze depth.Per each linear inch of braze fillet, one porosity indicationof maximum size is permitted.

(d) The maximum interior surface roughnessshall not exceed 63 microinches for waveguide with amajor interior cross-sectional dimension up to 4 inches,and 125 microinches for all waveguide with a majorinterior cross-sectional dimension of more than 4 inches.See MIL-W-85 (see Appendix 5-A) for waveguide otherthan aluminum.

b) Porosity cluster indications are permitted,providing the sum of all the porosity diameters do notexceed 0.015 inch and/or the diameter of the cluster isnot greater than 50 percent of the braze fillet width. Nomore than one cluster of maximum size, or 2 or moreclusters that, if combined, would equal the maximumsize, is permitted per linear inch of braze fillet.

(e) Scratches not more than one mil (0.001 inch)deep will be permitted in the longitudinal direction of thewaveguide with internal measurements of by 0.311 inch orlarger.

c) The term "Linear Porosity" is applicable whenthe minority of the porosity is oriented in a line. Themaximum length of linear porosity is 3/16 inch in eachlinear inch of braze-fillet.

(f) The waveguide shall exhibit good commercialmanufacturing practices, straightness from end to end,smoothness throughout, the absence of burrs, die marks,chatter marks, dirt, grease, scales and splinters, or anyother defect that will change the inside dimensions.

d) For the purpose of this procedure, a crack isdefined as a discontinuity viewed under 10 powermagnification which is revealed as being a continuousvoid with a discernible length. The maximum allowablesize of a crack shall not be longer than 3/32 of an inchand not deeper than 10 percent of the braze fillet depth.The maximum number of the maximum allowable sizecracks is one per each linear inch of braze fillet. More

5-1.13.18 Pre-Brazing InspectionAfter the bending and twisting process and prior to

brazing, the waveguide assembly shall be inspected usingthe following guidelines:

(a) Check minimum radius allowed for the

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cracks, smaller than the maximum allowable size perlinear inch of braze fillet, are acceptable, providing theyare randomly dispersed around the circumference of thejoint, and that the sum of their lengths does not totalmore than 3/32 of an inch per each linear inch of brazefillet.

make no provisions and the dry air system on board shipis used or supplemented (see paragraph 5-2.7).

The source of dry air for the waveguide should belocated at the farthest point from the purge valve.

5-1.15 DRY AIR SYSTEMSe) Blisters in the base metal, residual flux,

unmelted brazing metal, excess brazing metal to theextent that it may interfere with the function of theassembly, or under cutting of the base metal to an extentgreater than five percent of the base metal thicknessand/or 15 percent cumulative of the braze length, iscause for rejection of the assembly.

Dry air is obtained by using a compressor and adesiccant dehydrator, to dry the air, or from the ship'sService Dry Air Main. The electronics dry air systemimprovement program currently being accomplished byshipalts, provides a central dry air system arrangement.This system consists of a refrigerant dehydrator, oilfilters, desiccant dehydrator of the electric heater selfreactivating type, and a particulate filter. A dewpointindicator with audible and visible alarms is an integral partof the desiccant dehydrator, electrical contacts areprovided for connections to actuate remote audible andvisual alarms in the radar power room and CC. The ratedcapability of the dehydrator is to deliver air at a minimumof -40° C. dewpoint at 80 PSIG. This dry air is suppliedthe control panels and then to the waveguide. Thecontrol panel consists of an inlet and outlet pressuregage, a flow meter, moisture indicator, two pressurereducing valves, inlet and outlet shut-off valves and arelief valve sized to provide adequate pressure relievingcapacity to insure that waveguides will not beoverpressurized by malfunction. See the Electronic DryAir System Operation and Maintenance Manual andapplicable ShipAlts for details.

5-1.13.20 Post Chemical Conversion InspectionAfter the assembly has received the chemical

conversion, it shall be inspected to ensure that 100percent of the interior and exterior surface has receivedadequate coverage. The waveguide shall be inspected atthis time for physical irregularities, such as ridges,stretch marks, cracks, etc., because the chemical filmtends to make the irregularities more visible. Suchirregularities shall be located.

5-1.13.21 Post Painting InspectionAfter the waveguide assembly has been painted on

the exterior, inspect for the following:1. The interior of the waveguide must exhibit a

smooth, highly reflective surface. The surface must befree from ripples, bubbles, fish hooks, dust, or conditionsthat would degrade the excellence of the finish. 5-1.15.1 Air Connections

2. Ensure the exterior of the waveguidecoverage is adequate.

Electronic equipments which have no dry air systemdesigned into it, shall have the dry air input installed viaan air fitting on the gas barrier, waveguide adapter,waveguide flange or the side wall of the waveguide. Whenthe fittings for input air or purge valve is installed on theside wall of the waveguide, precautions must be taken toinsure a smooth surface on waveguide interior where thefitting is attached to the waveguide.

3. Ensure there is no paint on the faces of theflanges.

4. Inspect the position of the flanges to ensurethat the matched flanges of the opposite waveguidecannot be misaligned at the time of installation.

5. Ensure each piece of waveguide is properlyidentified, as per applicable plans.

5-1.15.2 Purging6. Ensure the waveguide interior is clean, thatthe waveguide ends are sealed. A purge valve shall be installed at the lowest point in

the transmission line adjacent to the transmitter, wherethe waveguide can be purged of moist air, or theaccumulation of water.

5-1.14 PRESSURIZING AND PURGINGTransmission lines should be pressurized with dry air

and shall be capable of being purged in accordance withInstallation Control Drawings or as specified. Thetransmission line will be more efficient if the interior isdry. Moisture increases the attenuation of the systemand reduces the maximum permissible operatingvoltages. To remove the moisture from the line it mustbe purged with clean dry air. Purging should be doneafter installation, or when transmission line has beenopened for repairs or has been inoperative. Dry air is airwhich has had sufficient moisture removed from it so thatthe remaining moisture does not condense, on the innersurface of the transmission line, over the temperaturerange and pressure variations the line will be exposed to.The air within the line must be sufficiently dry so that itsdewpoint is below the temperature limit to which it may besubjected. Several methods are available both for thesupply of dry air and introducing it to the transmissionline. Some electronic equipments provide units andfittings for dry air service. Other electronic equipments

5-2 RECTANGULAR WAVEGUIDEINSTALLATION PROCEDURES

5-2.1 GENERAL REQUIREMENTSThe installation of waveguide runs shall meet the

following requirements.

5-2.1.1 Length of RunThe Run shall be as short and as direct as possible

with a minimum amount of bends, twists and joints.

5-2.1.2 Location of RunThe location of the waveguide run shall take

precedence over piping, ventilation, ducting, cablehangers, wireways and lighting fixtures. The waveguiderun shall be located so it will not be disturbed by removalof deck plates, gratings, machinery or service areas.

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Locate the waveguide run to avoid electrical interferencefrom equipment cables or other transmission lines.

flange. Paragraph 5-2.5 provides general designinformation for acceptable type deck and bulkheadpenetrations.Waveguide should not penetrate any explosive or

flammable liquid storage space unless enclosed by aflame tight trunk. 5-2.1.12 Waveguide Markings

The finished waveguide components shall beidentified per MIL-STD-130, paragraph 4.1, except metalstamping shall not be used. The identification shall be ina progressive manner to ensure correct remating of thematched flanges during installation and/or maintenance.Warning labels shall be applied to a visible area of thewaveguide, approximately three feet apart after thetransmission line has been painted or touched-up. Spraylabels with weatherproof lacquer. Labels shall read "DONOT STRIKE".

5-2.1.3 Sequence of InstallationThe complexity of the system, equipment location

and physical size of waveguide will determine thesequence of installation. Where practicable, thesequence of installation should begin at the antenna.When assembly sequence is from transmitter to antennathe top section should be covered at all times to preventintrusion of foreign matter.

5-2.1.4 Clearance5-2.1.13 Grounding of WaveguideA clearance of two inches minimum shall be

provided from all objects to which the waveguide is notconnected, to prevent damage when subjected tounderway movement, shock or vibration. Clearancebetween the underside of the waveguide installation andthe deck shall not be less than seventy-seven inches inareas where normal passage occurs.

Waveguide runs shall be grounded in accordancewith MIL-STD-1310(NAVY).

5-2.1.14 HardwareFlange assembly hardware shall be that which is

supplied with the flange. Where replacement of missinghardware is required, the hardware shall be in accordancewith the specific flange specification. Waveguide supporthardware shall comply with paragraph 5-2.4.11 of thisdocument.

5-2.1.5 Protection of WaveguideThe transmission line run for each installation shall

be protected from pedestrian traffic or where accidentaldamage is most likely to occur. Protective guards shallbe removable and of sufficient size and strength to insurethat the waveguide cannot be struck, attached to, oraccidentally damaged. Expanded metal construction ispreferred. These protective guards shall be installedaround waveguide at platforms, catwalks, ladders and onthe overhead as required. The waveguide shall beprotected against physical damage from battle action,heat and water.

5-2.1.15 Restrictions for Parallel RunsWhen parallel transmission line runs are installed for

the same system, and there is a possibility ofinterference from flange joint RF leakage, the flangeconnections shall be staggered so that no two flangeconnections will be located within six inches of eachother.

5-2.1.16 Straightness of Runs5-2.1.6 Welding to Ships Structure Waveguide runs shall not deviate from a straight

line by more than 1/4 inch at any point.Waveguides shall not be welded to ship's structureor any assembly to be mounted in ship's structure. 5-2.1.17 Alignment of Flange Joints5-2.1.7 Precautions against Moisture and Dirt To prevent stresses being applied to the waveguide

or the flanges, waveguide joints shall be arranged so thatflanges will mate with bolt holes in alignment within 1/32inch and flange faces shall be parallel and not separatedby more than 1/64 inch prior to bolting.

Care shall be taken to prevent the entrance ofmoisture and dirt into the waveguide at all times duringinstallation.

5-2.1.8 Structural Fouling5-2.1.18 PressurizationWaveguide runs shall be located so they will not be

disturbed by the removal of deck plates, gratings ormachinery.

All waveguide runs shall be pressurized to preventcorrosion and maintain equipment performanceparameters. Check ship installation plans or shipalt forrequirements.5-2.1.9 Galvanic Action

Waveguides shall be isolated from supports toprevent galvanic action. 5-2.1.19 Flexible Waveguide

Short sections of flexible waveguide whendesignated shall be used where excessive expansion fromthermal or ship structural members may be anticipated.Flexible waveguide shall not be used for alignment ofwaveguide.

5-2.1.10 Types of Waveguide Supports (Hangers)Waveguide runs shall be installed with alignment

type supports in such a manner so that no stress orstrain shall be placed on any joint or section. Paragraph5-2.4 provides general design information for acceptabletype waveguide supports. 5-2.1.20 Expansion Joints

Compensation for expansion and contraction mustbe made when waveguide runs cross expansion joints. Aflexible section will be used only as designated on shipsinstallation plans and shall be installed parallel to theexpansion joint.

5-2.1.11 Penetrations, Deck and BulkheadDeck and bulkhead penetrations shall comply with

the ships structural requirements and permit the installingor removal of waveguide sections including the attached

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5-2.1.21 Preservation 5-2.3 LAYOUT OF WAVEGUIDE RUNSNo waveguide shall be installed without the interior

and exterior being finished as directed herein.After the design and exact location of the waveguide

run has been determined, the first step in actualinstallation is the layout of the shipboard run by the useof templates. The entire waveguide run shall betemplated, so the fabrication shop can be provided withaccurate information as to bends, twists, flanges,sectional lengths, flange positions and overall length ofrun.

5-2.2 PROTECTION OF WAVEGUIDEProtection of waveguide from shop to ship and

during installation shall be in accordance with the followingrequirements:

5-2.2.1 Sealing of Individual Sections5-2.3.1 TemplatesWaveguide sections and assemblies shall remain

sealed against moisture and foreign matter intrusion untilthey are installed aboard ship. The sealing caps orplates shall be removed from each section or assemblyas it is installed in the waveguide run.

The waveguide templates shall be made from 1/2inch pipe and the flange templates made from 1/2 inchplate steel cut to the specific flange dimensions. The 1/2inch pipe can be cut and shaped to give the optimumwaveguide run. The pipe will retain its shape and providea more accurate guideline for shop fabrication. Theflange templates can be adjusted to indicate the truebend and/or twist information required by the fabricationshop. Details for fabricating flange templates can beobtained from MIL-STD-1327 and MIL-F-3922 (seeappendix 5-C).

5-2.2.2 Sealing of Assembled SectionsDuring installation the ends of partially assembled

runs shall be kept sealed against moisture and dirt.

5-2.2.3 Flange Face ProtectionFlange faces shall be protected against physical

damage during shipping and installation.5-2.3.2 Layout5-2.2.4 Transporting Waveguide Sections and

Components A typical layout using 1/2 inch pipe for waveguidetemplates and 1/2 inch mild steel blocks for flangetemplates is shown in Figure 5-4.

Waveguide sections and components shall betransported from shop to ship in cradles that will preventbending, warping, and physical damage. 5-2.3.3 Penetrations, Deck and Bulkhead

5-2.2.5 Warping of Long Waveguide Sections Deck and bulkhead openings should be cut andpenetration assemblies fabricated at the time thetemplates are made (See 5-2.5).

Care should be taken in handling long sections ofwaveguide to prevent bending or warping. Never lift along section by the ends only.

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Figure 5-4. Waveguide Template Fabrication Details

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5-2.3.4 Supports, Waveguidewaveguide run that cannot be relocated, a large radius "E"plane double ogee curve (Figure 5-5) is recommended.The templates for this should be carefully made so theshop fabricated bends when assembled will absorb shipmotion, expansion and contraction without excessivestrain on joints or distortion of waveguide.

Basic information needed for waveguide supportscan also be obtained at the time of templating thewaveguide run.

5-2.3.5 Double Ogee CurveWhenever there is an obstruction in the preferred

Figure 5-5. Double Ogee Curve Around Obstruction

5-2.4 WAVEGUIDE SUPPORTS (HANGERS)prevent any stress, strain or bind on any segment of theoverall waveguide run.

5-2.4.8 Spacing of SupportsWaveguide supports shall meet the followingrequirements.

Distance between waveguide supports shall neverexceed 5 feet There shall be a minimum of 2 supports foreach waveguide section that exceeds 24 inches in length.The supports shall not be installed closer than 6 inchesto any flange connection. Figure 5-8 shows typicallyinstalled waveguide supports.

5-2.4.1 Type of MaterialWaveguide support material shall be compatible with

ships structure. Galvanic action between dissimilarmetals shall be prevented by isolating the waveguidefrom the support in accordance with paragraph 5-2.4.9.See Figures 5-6 and 5-7 for fabrication details. 5-2.4.9 Isolation Methods5-2.4.2 Size of Material To prevent electrolytic corrosion between the

waveguide and waveguide support, one of the followingmethods of isolation shall be used.

Supports shall be of sufficient width and thicknessto support the waveguide against damage from vibrationor shock (see Figure 5-6 Note 4). (a) Coat pieces that ordinarily would contact

waveguide with vinyl plastic (PLASTISOL) not less than1/16 inch thick. The outside surface of the coatedsupport shall then be scraped clean in the area of thehole used for bolting hanger sections together. This is toassure a good bond to ground. See Figure 5-9 forPlastisol application. The Plastisol method shall not beused unless the Installing Activity has the facilities andexpertise that will produce a quality product with smoothsurfaces and accurate dimensions that will not damagethe waveguide.

5-2.4.3 Support Damage to Waveguide WallSupports shall provide a snug fit but never tight

enough to cause deformation or damage to thewaveguide wall.

5-2.4.4 Fitting Support to WaveguideSupports installed for each section of waveguide

shall fit snug enough to hold the waveguide, allowing forisolation material thickness covered in 5-2.4.9. Foroutside dimensions of waveguide see MIL-W-85. (b) Use 3/16 inch thick Neoprene, MIL-R-6855,

Class 11, Grade 30 as a liner between waveguide andwaveguide support.

5-2.4.5 Isolation of Waveguide and SupportSupports shall be isolated from the waveguide by

the method outlined in paragraph 5-2.4.9.(c) With this method, isolation is obtained by

using a sealer, putty and plastic tape applied around thewaveguide at point where waveguide support will beattached. The method of application should be asfollows:

5-2.4.6 Adjustable SupportsAll supports shall be fabricated to be adjustable in

two directions (See Figures 5-6 and 5-7).Step 1 . Apply one coat of Scotch-kote sealer to

waveguide at point of support contact Width of areacovered should be approximately 0.5 inch wider thanwaveguide support.

5-2.4.7 Location of SupportsNever force the waveguide to the support position,

always locate the supports in such a manner as to

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Figure 5-6. Adjustable Waveguide Support Fabrication Details

Figure 5-7. Adjustable Waveguide Support

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Figure 5-8. Waveguide Support Spacing

Step 2. Apply one layer of Scotchfil putty towaveguide at point of support contact. Thickness ofputty should be approximately 0.125 inch and widthshould extend approximately 0.125 inch beyond eachedge of support clamps.

removed. All loose joints, small holes, and porous weldsmust be eliminated as they trap air and cause blisteringof the coating during cure. It is not necessary to grindwelds and metal as smooth as in sheet-lining work sincethe plastisol will assume the contour of the metal and, tosome degree, fill in and smooth over a rough surface.The surfaces should be cleaned by abrasive blasting asthis method provides a surface for maximum bondstrength. (For soft metals such as aluminum, suitablealkali cleaning agents made up as specified in 5-1.10may be used in lieu of sandblasting. Chemical residuesmust be thoroughly removed by hot water rinse). Afterabrasives blasting or chemical cleaning and immediatelyprior to application of the primer the surfaces should bedegreased by solvent washing.

Step 3. Apply Scotch # 33 plastic tape over theputty until the waveguide fits snugly within the supportclamp.

Step 4. After the waveguide support clamp isbolted in place, apply one coat of Scotch-kote sealer overclamp assembly to provide a weathertight seal.

Step 5. Paint completed assembly in accordancewith ships requirements for the specific area involved.

5-2.4.10 Plastisol Coating ProceduresSupports that are to be coated with Plastisol shall

be in accordance with the following procedures. 5-2.4.10.2 Priming

5-2.4.10.1 Surface PreparationPlastisol when applied to bare metal has little or no

adhesion and can easily be stripped off. However,Plastisol applied over an approved primer (specified bythe Plastisol manufacturer)

Surfaces to be coated with plastisol must be free ofall traces of oil, rust, scale, and dirt. All welds must bechipped and all flux from soldering or brazing must be

5-15ORIGINAL


Figure 5-9. Typical Plastisol Coated Waveguide Support

has excellent adhesion. Therefore, when applyingthe primer, do not apply it to surfaces from which theplastisol coating will be removed, such as the bolt holeareas used for grounding purposes. Primers containsolvents; therefore, the proper safety precautionspertaining to the use of solvents should be followed. Theprimer can be applied by brushing, spraying, or dipping,as follows:

Withdraw the article slowly from the Plastisol tank in sucha manner that the excess fluid compound can run off at asingle point which will not be readily visible on the finishedarticle. Allow the article to drain until all dripping hasstopped. Return the article to the oven at 177° Celsiusto 190° Celsius for 10 to 20 minutes, or until densefumes are emitted from the coated article, indicatingcomplete fusion. Remove the article from the oven andsuspend it on a rack until it is cooled to roomtemperature. Trim all drip marks and excess plastisolfrom areas which are not supposed to be covered.Plastisol coatings, if damaged, can be patched with aheatcuring putty or an air drying vinyl putty which isavailable from the Plastisol manufacturers. Because ofdifferences of specific heat, cooling rate, mass, etc. ofthe materials to be coated, dip coating of various articleswith Plastisol requires that the process be preciselytailored to the article. The above procedure is adequatefor the average product. However, specific instructionsshould be obtained for special products.

a) Over aluminum: Apply one coat of pre-treatment, formula 117, and allow to dry for 10 minutes.Then apply one coat of Plastisol primer and air dry for 20minutes minimum, but not more than 16 hours.

b) Other metals: Apply a single coat of Plastisolprimer directly to the metal surface and allow to dry for aminimum of 20 minutes, but not more than 16 hours.

5-2.4.10.3 Application of PlastisolSuspend the primed article in a forced-draft air oven

at 177° Celsius for 10 to 20 minutes or until the metalreaches the oven temperature. Remove the article fromthe oven and immediately immerse it in the plastisol,leaving it completely immersed for 30 to 60 seconds,depending upon the thickness of coating desired.

5-2.4.11 HardwareWaveguide support hardware shall meet the

5-16ORIGINAL


following requirements. openings including coamings and/or doubler plates shallmeet the structural requirements of the ship.(a) Waveguide supports exposed to weather shall

be assembled with corrosion resistant steel hardware thatmeets the following specifications:

Where a waveguide run passes through a bulkheadwith air/dust/fume tight requirements, a coaming shouldbe installed in the bulkhead. The inside diameter of thecoaming shall be of sufficient size to pass the waveguidesection complete with attached flanges. The void spacebetween waveguide and coaming should be filled with asilicone sponge rubber barrier complying with MIL-R-46089. Figure 5-10 illustrates a typical non-watertightbulkhead penetration with air/dust/fume tightrequirements.

FF-N-836 NutsFF-S-85 Cap Screw, slotted and hex headFF-W-84 Washers, lock (spring)FF-W-100 Washers, lock (tooth)f(b) Waveguide supports installed inside ship's

structure and not exposed to weather may be assembledwith standard type cadmium plated hardware, unlessotherwise specified on Installation Control Drawings.

5-2.5 PENETRATIONS, DECK ANDBULKHEADS

Where a waveguide run passes through a non-watertight deck, a protective sleeve shall be installed.The sleeve shall be fabricated from material compatiblewith ships structure and with the inside dimensionssufficient to pass the waveguide section complete withattached flanges. The sleeve height above the non-watertight deck shall be greater than all other coamingswithin the area. This is to minimize damage to waveguidefrom flooding. When air-tightness is required, the voidspace between waveguide and sleeve shall be filled with aplastic sealer complying with MIL-I-3064.

Transmission line penetrations in ships structureshall meet the following requirements.

5-2.5.1 Non-Watertight Bulkheads and DecksWhere a waveguide run passes through a non-

watertight/non-airtight bulkhead, a clearance hole is allthat is required. The clearance hole shall be of sufficientsize to pass the waveguide section complete withattached flanges. The location and size of bulkhead

Figure 5-10. Typical Method of Penetrating Airtight Bulkheads

5-2.5.2 Watertight Deck and Bulkheadsthe waveguide is much easier with the split sleeveassembly than with the multicable transit device. Multi-cable transit devices should only be used in congestedareas where there is not sufficient space for passingcables and waveguides through the deck or bulkhead withseparate penetration devices.

Where a waveguide passes through a water-tightbulkhead or deck the fittings used shall be watertight andcomply with the structural requirements of the ship. Thewatertight fittings shall not be welded, brazed or solderedto the waveguide and shall be capable of disassembly forremoval of waveguide section complete with flange.

These methods, discussed in detail in paragraphs 5-2.5.4 through 5-2.5.7, are to be used as guidance by theInstalling Activity in designing, fabricating and improvingdeck and bulkhead penetrations that will meet or surpassthe requirements of this document.

5-2.5.3 Typical MethodsSplit sleeve assemblies and multi-cable transit

devices are typical methods of passing transmissionlines through watertight decks and bulkheads. The splitsleeve assembly method is preferred over the multi-cabletransit device and is the most widely used. Alignment to

5-2.5.4 Split Sleeve Assemblies for RectangularWaveguides

A split sleeve assembly used for passing

5-17ORIGINAL


rectangular waveguide through watertight decks orbulkheads will provide the means for removal andreplacement of a waveguide section without thepreviously required shop brazing and fabrication.

bulkhead split sleeve assemblies provided for guidance tothe Installing Activity. Material type and thickness,hardware type and size, dimensions and shapes will varydepending on the waveguide type, location, type of deckor bulkhead being penetrated and the ships function inthe fleet. The following basic requirements are providedto assist the Installing Activity in designing, fabricatingand installing the correct split sleeve assembly.

The Installing Activity shall design, fabricate andinstall split sleeve assemblies for waveguide runs thatmeet the structural and shock requirements for eachspecific installation and the requirements stated herein.

Figures 5-11, 5-12 and 5-13 are typical deck/

Figure 5-11. Typical Split Sleeve Assembly for Small Waveguide

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Figure 5-12. Typical Split Sleeve Assembly for Large Waveguide

(a) Material for the deck/bulkhead sleeve and thebottom flange plate shall be selected for compatibilitywith ships structure.

watertight seal. The inside dimensions of the web plateassemblies that surround the waveguide shall be 0.125inch larger than the outside dimensions of the specifiedwaveguide. This is required for forming a watertight sealwith the liquid silicone rubber.

(b) Material for the top flange plate and web plateassemblies shall be selected for compatibility with thewaveguide. (h) Web plate assemblies, when fabricated from

aluminum, shall have a chemical conversion coating inaccordance with MIL-C-5541.

(c) Material for the web gaskets and plategaskets shall comply with MIL-R-6855, class 2, Type A.

(d) The liquid silicone rubber shall comply withMIL-A-46106, Type 2. Refer to Figures 5-11, 5-12 and 5-13 for component part identification.

(i) Fastening hardware shall be corrosionresistant steel and comply with specifications referencedin 5-2.4.11.

(e) The deck/bulkhead sleeve may berectangular, oval or round and the inside dimensions shallbe sufficient for passing the waveguide with attachedflanges.

(j) The split sleeve assembly shall be fabricatedand installed in the deck or bulkhead parallel to thewaveguide run so that the completed assembly will notplace any stress or strain on the waveguide run or deformthe waveguide wall in any manner.(f) The quantity and size of fastening holes

through flange plates, plate gaskets, web plates and webgaskets shall be determined by the overall size of thesplit sleeve assembly to meet the watertight and shockrequirements for a specific installation.

(k) Liquid silicone rubber shall be applied to thecomplete area between the waveguide and adjacentsurfaces of both web plate assemblies. After web platesare bolted in place, remove excess rubber from exteriorsurfaces. Ensure there are no gaps or holes in thesealant between waveguide and web plates.

(g) The size and shape of web plate assembliesshall be determined by the size and shape of thewaveguide and shall be of sufficient height to ensure a

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Figure 5-13. Typical Split Sleeve Assembly for Multiple Waveguide Run

(l) Figure 5-11 is a typical split sleeve assemblyfor a small waveguide utilizing a section of pipe for thedeck/bulkhead sleeve.

outer wall collapse during the compression process. liquidsilicone rubber complying with MIL-A-46106, Type 2, shallbe used to make an airtight seal between the rigid coaxialline and the insert block.Figure 5-12 is a typical split sleeve assembly for a

large waveguide utilizing a welded rectangular deckbulkhead sleeve. 5-2.5.7 Transit Device Modification for Rectangular

WaveguideFigure 5-13 is a typical split sleeve assembly with alarge oval deck/bulkhead sleeve that will accommodatetwo parallel waveguide runs.

When using multi-cable transit devices for passingrectangular waveguide through watertight decks orbulkheads, two braceplates are required to prevent wallcave-in or distortion of the waveguide during thecompression process.

5-2.5.5 Multi-Cable Transit (MCT) DevicesThe multi-cable transit device is a modular system

that utilizes standard units and dimensions to allowmaximum flexibility and compatibility with variousnumbers and sizes of cables. Final sealed units willprovide watertight, airtight and fireproof bulkhead or deckpenetrations

NOTE:

Multi-Cable Transit device use on weatherdecks is not authorized per MIL-STD-2003.

Complete installation and assembly instructions formulti-cable transit devices are covered in DoD-STD-2003.

These braceplates shall be carefully fabricated toprovide a close fit around the waveguide with thebraceplate edges cut on an angle to prevent excessivepressure being applied to the waveguide.

The multi-cable transit device can be used forpassing waveguide and/or rigid coaxial lines throughwatertight decks or bulkheads with minor modifications asdescribed in paragraphs 5-2.5.6 and 5-2.5.7. Figure 5-14identifies components of an assembled multi-cabletransit device modified to accept rectangular waveguideand rigid coaxial transmission lines.

For aluminum waveguide the braceplates shall befabricated from 0.125 inch aluminum sheet and from0.125 mild steel sheet for use with copper waveguide.The width of the braceplates shall be 2.362 inches (sameas length of insert blocks). Braceplates shall have achemical conversion coating to prevent galvanic actionwith the waveguide. The exterior surface of braceplatesshall be coated with liquid silicone rubber. The spacebetween the waveguide and braceplates shall be filled withliquid silicone rubber. liquid silicone rubber shall complywith MIL-A-46106, Type 2.

5-2.5.6 Transit Device Modification for RigidCoaxial Lines

When using multi-cable transit devices for passingrigid coaxial lines through watertight decks or bulkheads,the insert blocks shall be selected with the insidediameter of the hole approximately 0.125 inch larger thanthe rigid coaxial line outside diameter. This is to prevent

5-20ORIGINAL


Figure 5-15 illustrates typical braceplates for usewith rectangular waveguide and multi-cable transitdevices. Figures 5-16 through 5-21 are typical

installations of multi-cable transit devices modified forrectangular waveguide.

Figure 5-14. Multi-Cable Transit Device Assembly Identification

Figure 5-15. Waveguide Brace Plates for Use with Multi-Cable Transit Device

5-21ORIGINAL


Figure 5-16. Two-Frame Multi-Cable Transit Device, Bulkhead Installed-Front View

5-2.6 OVERALL WAVEGUIDE RUN ASSEMBLYPROCEDURES

the Installer should use extreme care when assemblingthe waveguide run to prevent foreign matter from enteringthe assembled sections.

Ensure the flange faces are clean and gaskets or"O" rings are properly seated. The flange bolts shall betightened in a staggered sequence to ensure a smoothtight fit with even pressure around the entire perimeter ofthe flange.

The assembly and installation of waveguide runaboard ship shall be in accordance with the followingrequirements and procedures.

5-2.6.1 Shipboard Installation Pre-RequirementsThe actual shipboard installation assembly of

waveguide sections and components shall not begin untilall shop fabrication work has been completed, all bulkheadand deck cuts have been made, deck/ bulkhead sleevestack welded in place and electronic equipment installed.

Only gaskets supplied with the flanges or thosepurchased in accordance with MIL-F-3922 or MIL-G-24211shall be used. See paragraph 5-2.1 for alignmentrequirements.

5-2.6.3 Material Ordering Sequence

NOTE Waveguide sections should be requested from shopstorage in sequence of ship assembly and installed onship when received. Waveguide sections should neverbe left laying around aboard ship. Waveguide sectionsshall be received at installation site sealed againstmoisture and dirt.

The deck/bulkhead sleeve should be tackwelded in such a manner that it can beeasily aligned with waveguide run priorto final welding. 5-2.6.4 Inspection Prior to Assembly

The ship installer shall visually inspect eachwaveguide section prior to placing in waveguide run. Anysection of waveguide shall be rejected and returned toshop for rework or replacement if found to contain any ofthe following defects.

5-2.6.2 Assembly SequenceThe sequence of assembly of waveguide sections

and components will vary depending on the complexity ofthe system, physical size and weight of waveguidesections and length of vertical run. The preferredsequence of assembly would begin at the antenna andterminate at the transmitter. This would preventunnoticed foreign objects from falling into the assembledsections. Since this sequence is not always practical,

1. Dents in waveguide surface or flange facesurface.

2. Deep scratches in flange face surface.3. Unsealed.

5-22ORIGINAL


Figure 5-17. Two-Frame Multi-Cable Transit Device, Bulkhead Installed-Side View

4. Dirt or grease inside waveguide or on flangeface.

supports to ships structure. Equal care should be givento the assembly of deck or bulkhead fittings that is givento the waveguide support installations.5. Ripple in waveguide surface.

5-2.6.5 Installing Waveguide Supports (Hangers) 5-2.6.6 Pressurization During AssemblyWhenever possible the complete waveguide run

shall be assembled and held in place by temporarymeans before securing to waveguide supports orassembling to the deck/bulkhead penetration device.This is to ensure no stress, strain or bind is placed onany flange connection. After the waveguide run has beenproperly aligned the supports should be installed andadjusted to the waveguide. The waveguide should beprotected from possible damage while welding the

The assembled waveguide run should be pressurizedwith dry air or nitrogen to the specified PSIG for theparticular waveguide being installed, and maintained atthat level until system is ready for operation. Whenevera complete waveguide run cannot be installed in one workshift, the partially installed sections should bepressurized with dry air or nitrogen at the end of the workshift and maintained under pressure until installation ofthe run is resumed.

5-23ORIGINAL


5-2.6.7 Waveguide Hardwaretogether with corrosion resistant steel hardware. Thehardware shall conform to the following specifications:

All sections of the waveguide assembly shall be put

FF-W-84 Lock Washers (Spring) FF-S-86 Cap Screw, Socket HeadFF-W-100 Lock Washers (Tooth) FF-N-836 Nut, PlainFF-S-85 Cap Screw, slotted and hex head

Figure 5-18. Two-Frame Multi-Cable Transit Device, Deck Installed-Plan View

5-24ORIGINAL


Figure 5-19. Two-Frame Multi-Cable Transit Device, Deck Installed-Side View

5-25ORIGINAL


Figure 5-20. Protective Enclosure for Deck Penetration-Side View

5-26ORIGINAL


Figure 5-21. Protective Enclosure for Deck Penetration-Front Elevation View

5-27ORIGINAL


Figure 5-22. Illustrative Reference Guide with Reference Notes 1 through 20

5-2.6.8 Illustrative Installation Explanationsinstalled in accordance with ships guidance plans, andinstallation control drawings.

Figure 5-22 is an illustrative installation that can beused as a reference guide for solving problems. Figure5-22 was dawn to show as many installation conditions aspossible. An actual waveguide installation should alwaysbe as short and straight as possible with all bends, twistsand flange connections kept to a minimum.

2 90 ° H Bends

For Selection of Electrical and Mechanical Details See: MIL-HDBK-216 Section 8AFor Detail Dimensions - See: MIL-W-3970For Fabrication of - See: MIL-HDBK-660

NIMB Section 5Refer to Figure 5-22 when using the following

reference notes 1-20.Paragraph 5-1

1Electronic equipment shown as simplified block

diagrams. Antennas, waveguide switches, duplexers,filters, transmitter/receivers and other equipment shall be

5-28ORIGINAL


3 Flexible Section

See: NIMB Section 5, Paragraphs 5-2.1.11,5-2.3.3 and 5-2.5.

For Selection of Electrical and Mechanical NIMB Section 5, Figure 5-10Details - See:

11 Waveguide SupportsMIL-STD-242 Section 502See: NIMB Section 5, Paragraphs 5-2.1.9,MIL-HDBK-216 Section 8A

5-2.1.10 and 5-2.4.NIMB Section 5,NIMB Section 5, F Figures 5-6, 5-7 and 5-8Paragraph 5-2.1.19

12Waveguide Support Isolation

For Detail Dimensions - See: MIL-W-287

4 90 ° E Bends See: NIMB Section 5, ParagraphsFor Selection of Electrical and Mechanical 5-2.1.9 and 5-2.4.9Details - See: MIL-HDBK-216 Section 8A NIMB Section 5, Figure 5-9For Detail Dimensions - See: MIL-W-3970

13 Painting of Waveguide Exposed to WeatherSee: NIMB Section 5,\

For Fabrication of - See: MIL-HDBK-660NIMB Section 5,

Paragraphs 5-1.13.16 and 5-2 9.Paragraph 5-114

Painting of Waveguide Not Exposed to Weather5 45 ° Bends

See: NIMB Section 5, Paragraphs 5-1.1316For Selection of Electrical and Mechanicaland 52.9.Details - See: MIL-HDBK-216 Section 8A

15Purge Line - 1/4 Diameter tube installed to

comply with standard piping specifications.

For Detail Dimensions - See: MIL-W-3970For Fabrication of - See: MIL-HDBK-660

NIMB Section 5,16

Bleeder Valve - Located in Radar Room in anarea accessible to maintenance personnel but not tointerfere with equipment operation. Installation of valveshall comply with all piping specifications.

Paragraph 5-1

6Waveguide Twists

For Fabrication of - See: MIL-HDBK-660NIMB Section 5, 17

Ground StrapsParagraph 5-1

7Waveguide Sections, Straight

See: MIL-STD-1310(NAVY)NIMB Section 5, Paragraph 5-2.8

18 Pressure Window

For Selection of Electrical and Mechanical Details -Theory - See: MIL-STD-242F Section 501

See: NIMB Section 5, Paragraph 5-1.1.1.6.MIL-HDBK-216 Section 6AICDs for a specific system requirement.MIL-STD-1358

19 Dry Air Connection to WaveguideFor Detail Dimensions, Electrical and MechanicalDetails - See: MIL-W-85 (Rigid, Rectangular) See: NIMB Section 5, Paragraph 5-1.14.2

MIL-W-23351 (Ridged) ICDs for a specific system requirement.

8Flanges 20 Electronic Dry Air System and Components.

For Selection of Electrical and Mechanical Details -Theory - See:

See: NIMB Section 5, Paragraphs 5-1.14, 5-2.7,5-2.10.13.

MIL-STD-242 Sections 601 & 602 ICDs for a specific system requirement.MIL-HDBK-216 Section 7AMIL-STD-1327

For Detail Dimensions Electrical and MechanicalDetails - See:

MIL-F-3922 (For Rectangular W/G)MIL-F-39000 (For Ridged W/G)MIL-C-39004 (Subminiature W/G Disconnects)

For Assembly to W/G - See: MIL-HDBK-660NIMB Section 5,Paragraph 5-1

9Watertight Penetrations

See: NIMB Section 5, Paragraphs 5-2.1.11,5-2.3.3 and 5-2.5.NIMB Section 5, Figures 5-11 thru 5-21.DoD-STD-2003-1(NAVY),Section 4, Shts 170-180

10Non-Watertight Penetrations

5-29ORIGINAL


Figure 5-23. Method for Temporary Pressurization

5-2.7 PURGING AND PRESSURIZING(SHIPBOARD)

5-2.7.3 Method for Detecting LeaksA typical method of detecting leaks is to apply

undiluted liquid shampoo to the flange connection, orsuspected area. With pressure inside the waveguide,bubbles will appear where the nitrogen is escaping.

Dry air installation to be in accordance withParagraph 5-1.14 and the following:

5-2.7.1 Temporary Pressurization5-2.7.4 Purging Procedures

Temporary pressurizing of waveguide may be usedfor protection against moisture during shipboardinstallation, testing for air leaks, purging and maintaininga pressurized waveguide run until the ships electronicequipment dry air system is operational. Figure 5-23shows a typical temporary dry air system using bottlednitrogen that can be used for testing, purging andmaintaining temporary pressurization.

Purging of the waveguide run shall be accomplishedas soon as all leaks have been repaired. The followingprocedure is recommended for purging a waveguide run.

Step 1. Pressurize the system to the requiredPSIG and maintain this pressure for 2 hours.

Step 2. Bleed the waveguide run very slowlythrough the gas escape valve at the end of the purgeline, maintaining a constant pressure from the dry air ornitrogen source. Bleeding the line should continue for aminimum of 2 hours.CAUTION

Do not exceed the specified PSIG for theparticular waveguide being installed.

Step 3. Close the gas escape valve and checkto insure that the waveguide is pressurized to the requiredPSIG.

5-2.7.5 Purging Requirements5-2.7.2 Tightness Test Purging of the waveguide run shall be repeated

every time the line is opened for any reason. If the lineis opened for minor checks or inspection that takes onlya few minutes to complete, then the time limit specifiedin Step 1 of paragraph 5-2.7.4 can be omitted.

Immediately upon completion of the transmissionline installation a tightness test shall be conducted todetermine if leakage exists at any flange connections.The transmission line shall be pressurized to its specifiedpressure. The compressed dry air or nitrogen shall beallowed to stand in the transmission line until itstemperature equalizes. The pressure drop, corrected fortemperature changes, shall not exceed five percent ofthe test pressure after a test period of six hours. If, afterthe expiration of the test period, the pressure dropexceeds the permissible five percent drop, the systemshall be examined and leaks eliminated, and the tightnesstest repeated. Waveguide sections that have leaksthrough the brazed flange joints shall be rejected. Theymay be returned for shop refabrication in accordance withparagraph 5-1.13 or replaced with a new section. Epoxyor plastic type sealers shall not be used for seating leaksin transmission lines.

5-2.8 GROUNDING OF WAVEGUIDE RUNSWaveguide runs shall be considered to be at ground

potential unless proven otherwise by ElectromagneticInterference (EMI) Tests. When additional grounding isrequired, the bonding methods, materials, surfacepreparation and sealing shall be in accordance with MIL-STD-1310.

5-2.9 PRESERVATION OF WAVEGUIDEThe Preservation of waveguides to prevent corrosion

and contamination from weather or ozone shall be inaccordance with the following.

5-30ORIGINAL


5-2.9.1 Exterior Surface Paintinginstallation.

5-2.10.1 Straight Line DeviationAfter installation, touch-up exterior surfaces ofwaveguides (including areas exposed to, and not exposedto, the weather) with the MIL-P-24441 epoxy-polyamidecoating system described in Paragraph 5-1.13.16. Toimprove adhesion of epoxy-polyamide, lightly sandsurfaces to be painted, fair paint edges, and clean withmineral spirits to remove dirt, grease and othercontaminants. Apply thin coat of Formula 151, and whilestill tacky, apply one or two coats of Formula 151 to atotal minimum dry film thickness of 8.0 mils. Aftercompletion of the touch-up process, the transmission linemay receive, if desired, an additional coat of paint tomatch the surrounding areas.

Ensure the transmission line run, excluding bends,twists, offsets and flexible sections does not deviatemore than 0.250 inch from a straight line.

5-2.10.2 Penetration AlignmentThe deck and/or bulkhead penetration assemblies

shall meet the requirements of paragraph 5-2.5 and placeno stress or strain on the transmission line. Ensure theassembly is sealed against water and/or air.

5-2.10.3 Support AlignmentTransmission line supports (hangers) shall meet the

requirements of paragraph 5-2.4 and, when loosened,shall cause no resulting movement in the transmissionline that indicates improper alignment.

5-2.9.2 Waveguide Requiring Additional HeatDissipation

5-2.10.4 Flange Joint AlignmentWhere a flat black finish is needed to assist in heatdissipation generated by the transmission line, apply onecoat of Formula 153-Rol. 8 black epoxy-polyamide paint.Prior to application, lightly sand existing epoxy-polyamidepaint, clean with mineral spirits, and apply a thin coat ofFormula 153-Rol. 8, and while still tacky, apply a full coatof Formula 153-Rol. 8 approximately 2 mils dry filmthickness.

Flange bolts, when loosened, shall cause nomovement in either mating section that indicatesimproper flange fabrication or transmission. linealignment The flange bolting holes shall be aligned within0.0313 of an inch and the flange faces shall be paralleland not separated by more than 0.0156 of an inch.

5-2.10.5 Dents and Cuts5-2.9.3 Flange Joint Protection after InstallationThe overall outer surface of the transmission line

shall be checked for dents and deep cuts that maypossibly cause deformation of inner surfaces resulting inreduced system performance. Dents and cuts that wouldcause a change in the electrical characteristics shown inthe procurement specification for the specifictransmission line shall be cause for rejection of thatspecific section of transmission line.

Flange joints, including fastening hardware, shall becoated with a sealer after installation and all testing iscompleted. This sealer is to prevent corrosive build-upcaused by sea water seepage into flange faces andmating hardware.

An acceptable seal can be obtained with a spraycoating of clear polyurethane resin solution such asDexter Corporation's Laminar 48-C-24 or the equivalent.Using a narrow spray pattern, the polyurethane coatingshould be applied in such a manner as to assure anadequate How of material over the outer edges of flangejoints and fastener hardware. This method of sealing ispreferred since it provides a clear transparent coating,and early detection of corrosive build-up is possiblethrough periodic visual inspections.

5-2.10.6 IsolationTransmission line supports shall be properly isolated

to prevent galvanic action in accordance with paragraph5-2.4.

5-2.10.7 Support FitSupports (hangers) shall provide a snug fit with the

transmission line. There shall be no deformation of thetransmission line.

Another method of sealing transmission line flangejoints is with heat shrinkable tubing. When used, the heatshrinkable tubing shall comply with MIL-R-46846 andshould be slipped on the transmission line at each flangeconnection during the assembly process. The tubingmust be protected from damage until it can be shrunkinto place after all testing is completed. The method ofinstalling heat shrinkable tubing is a disadvantage ascompared to the ease and simplicity of applying Laminar48-C-24. Another disadvantage is that periodic visualinspections of flange joints for corrosive build-up cannotbe accomplished without destroying the tubing andreplacing with new ones.

5-2.10.8 Support SpacingSpacing between transmission line supports shall

not exceed five feet. The spacing of supports from aflange connection shall be a minimum of six inches for alltransmission lines, except large heavy waveguiderequiring special flange supports such as the AN/SPS-49waveguide.

5-2.10.9 Quantity of SupportsA minimum of two supports shall be installed on any

section that exceeds 24 inches in length.5-2.10 QUALITY CONTROL INSPECTION 5-2.10.10 Protective Guards

Quality Control Inspections shall be conductedduring the installation process and after completion of allwork to ensure the transmission line installation conformsto the ships installation drawings and this document.

Protective Guards shall be installed around thetransmission line in accordance with the requirements ofparagraph 5-2.1.

5-2.10.11 Flange FacesThe following subparagraphs provide guidelines toassist the Installing Activity in ensuring an optimum Flange faces shall be free of any paint or

5-31ORIGINAL


scratches. Exposed flanges shall remain covered withprotective caps until time of interfacing with matingflange.

determined by the installing activity. The selection shallbe based on the type of electrical test to be conducted,type of transmission line to be tested, systemconfiguration, transmission line and system frequencyband, and the test report requirements. Test equipmentused shall carry a current calibration certification and beoperational in accordance with the test equipmenttechnical manual.

5-2.10.12 Protective Labels and MarkingsEnsure "DO NOT STRIKE" labels and identification

markings are in accordance with the requirements ofparagraph 5-2.1.

5-2.10.13 Pressurization Where applicable, the ships test equipment shall beused. This will permit duplicating of tests by ships forcewhen complying with the system/ equipment maintenancerequirements.

Ensure the transmission line is pressurized to thecorrect PSI and that the dry air being supplied meets therequirements of MIL-STD-1399 Section 102. Insure thatoperating instructions and labels for the dry air systemare posted near applicable equipment. Ensure all valvesof the dry air system are identified. Ensure thetransmission line has been properly purged and thetightness test successfully completed in accordance withthe requirements of paragraph 5-2.7.

5-2.11.2 Insertion Loss MeasurementsIn general, the insertion loss, which is a function of

frequency, of an overall transmission line is the productof the theoretical attenuation and a "fabrication factor"added to the mismatch loss for the line and the insertionlosses of microwave components such as switches,circulators, isolators, filters and directional couplers.5-2.10.14 Component Certification

The transmission line theoretical attenuation valuesand the maximum allowable insertion loss values must becomputed prior to the insertion loss test.

Ensure, when applicable, that bend assemblies,twist assemblies, flexible assemblies, transmission linetype, fastener hardware and flanges are the type shownon ships installation drawings and comply with therequirements of this document

5-2.11.2.1 Theoretical AttenuationMIL-HDBK-216, Section 6 should be used for

computing the attenuation of rectangular waveguide andplotting the attenuation curve. A minimum of ten pointsshould be plotted across the frequency band to obtain amore accurate curve.

5-2.10.15 Clearance and AccessEnsure the transmission line run has a minimum

clearance of two inches from all objects as specified inparagraph 5-2.1.4. Ensure sufficient access has beenprovided for the assembly, installation, maintenance, andrepair of the transmission line.

The attenuation in dB per unit length as computed inMIL-HDBK-216 will be dB/inch. This is easily convertedto dB/foot.

Ensure the transmission line is not welded to anydeck, bulkhead, assembly or support.

When computing for the constant "K" using theequation in MIL-HDBK-216, the magnetic permeability ofwaveguide metal should be 4 π X 10 -7 (henry/meter).5-2.10.16 Preservation

Attenuation measurements greater than twentypercent of the computed values shall be corrected.

Ensure all flange joints have been sealed inaccordance with paragraph 5-2.9.3. Ensure thetransmission line run including supports anddeck/bulkhead penetrations are properly painted inaccordance with the applicable paragraphs of thisdocument.

5-2.11.2.2 Maximum Allowable Insertion LossThe following equation should be used for computing

the maximum allowable insertion loss for a transmissionline run. Values should be computed for both the low andhigh end of the required operating frequency band forcomparison with the measured values.

5-2.10.17 Parallel Transmission Line RunsEnsure parallel transmission line runs, when

installed, are in accordance with the requirements ofparagraph 5-2.1.15.

IL = A(l.2)(L) + 0.06 + Nwhere:IL = maximum allowable insertion loss in dB for a

specific frequency.5-2.10.18 GroundingA = Theoretical attenuation in dB/ft determined from

the attenuation curve for the specified transmission lineat a specific frequency.

Where applicable ensure transmission linegrounding complies with the requirements of MIL-STD-1310.

1.2 = Fabrication factor (This allows for fabricationand installation imperfections of the transmission line).5-2.11 ELECTRICAL REQUIREMENTS AND

TESTS L = Actual measured length in feet of the installedtransmission line.After satisfactory completion of installation, visual

inspections, tightness tests and final pressurization, andprior to initial equipment turn-on, the transmission lineshall be electrically tested in accordance with thefollowing requirements.

0.06 = Transmission line mismatch loss based on aVSWR of 1.25:1 (the maximum allowable for a shipboardinstallation).

N = Sum of the insertion losses (stated in dB) of allmicrowave components such as switches, couplers andfilters that may be in the transmission line betweentransmitter and antenna.

5-2.11.1 Test Equipment RequirementsThe type of test equipment and accessories

required for transmission line electrical tests shall be The measured insertion loss should not exceed the

5-32ORIGINAL


computed maximum allowable insertion loss for theoverall transmission line run.

and model of test equipment used; and any variationfrom detailed test procedures, so that the test may beduplicated at a later date.Information on insertion loss test methods and

practices may be found in NAVSEA SE000-00-EIM-130. It should be noted that the inclusion of a specificoperating frequency may classify the contents of thereport.5-2.11.3 Voltage Standing Wave Ratio Measurements

Voltage standing wave ratio (VSWR) measurementsshall be made on all transmission line installations.Ordinarily, transmission lines having a VSWR greaterthan 1.25:1, when terminated in a dummy load, andpresenting a VSWR of no greater than 1.05:1 to the line,shall be corrected, although some systems permit theVSWR to exceed the 1.25:1 and the 1.05:1. In theabsence of any clear system requirement, paragraph 5-2.11.2.2 will apply.

5-3 RIGID COAXIAL LINES

5-3.1 INTRODUCTIONA radio frequency transmission line which is pieced

together using rigid coaxial cable sections, bends andaccessories is known as a rigid coaxial transmission line.The word "rigid" refers to the coaxial cable sections,elbows and accessories which are rigid in that they areprimarily designed not to be bent nor formed at theinstallation site. The completed rigid transmission line isnot an inflexible or unyielding metallic channel, since it iscontinually expanding or contracting and therefore,provisions must be made to allow for these changes.

The test procedures and test set up for time domainreflectometry (TDR) and frequency domain reflectometry(FDR) measurements will vary depending on the systemcomplexity for the transmission line under test.

In addition to the general requirements for testreports required by paragraph 5-2.11.4 the VSWRmeasurements shall include a block diagram of the actualtest set up identifying the test equipment andaccessories used.

5-3.2 PRE-FABRICATIONThe fabrication of a rigid coaxial cable sections and

parts into a rigid transmission line requires care andprecision. This includes physical care for the cable'smetallic tubes which will not perform their functionproperty as a radio frequency transmission line if dentedor deformed in any way, and also personal care exercisedto be sure that no foreign matter is inadvertently leftwithin the transmission line assembly.

Figures 5-24 and 5-25 are simplified block diagramsfor making swept frequency composite VSWR and returnloss measurements and recording these measurementsin the form of graphs.

The test procedures should be divided into twoparts; (1) composite VSWR versus frequency and (2)return loss versus distance along the line. Thecomposite VSWR measurements will provide a VSWRsignature of the transmission line over the frequencyrange of the system and show whether or not it is withinVSWR specifications. The return loss measurements willprovide return loss signatures of the line and, if madejust after the line is initially installed, are useful forhistorical reference purposes. If the composite VSWRmeasurements show the line to be above 1.25:1, thereturn loss measuring equipment may be set up to theappropriate problem frequency(s) in an attempt to isolatethe location(s) of the discontinuity(s) creating the out-of-spec condition.

To assist in producing the best transmission lineinstallation, the installer will follow the manufacturer'sinstructions on the care and handling of rigidtransmission line sections, along with recommendedprocedures of this section and 5-4 for Installation. Theseprocedures will cover rigid coaxial cable handling andcare; starting with receipt of shipping container, throughuncrating, inspection, storage, on-the-job fabrication,installation purging and pressurizing procedures,preservation, and the electrical requirements and tests.The design of the rigid coaxial run shall be attempted byqualified design personnel. No substitutions ormodifications are to made to Installation ControlDrawings or other specified documents, without approval.In planning the layout of the Rigid Coaxial line theconditions in 5-4 shall be met.

5-2.11.4 Test ReportsIn general, test reports shall contain both computed

and measured insertion loss and VSWR values at thespecified frequencies; identification of the transmissionline under test by its assigned designator; the type, make

5-33ORIGINAL


Figure 5-24. Typical Test Set-up for Composite VSWR Measurements

Figure 5-25. Typical Test Set-up for Return Loss Signature

5-3.3 INSPECTION 5-3.4 STORAGEAs soon as possible after receipt of the rigid coaxial

transmission line shipping boxes, they should beexamined for breaks in their walls. A broken box is anindication that the contents may be damaged. If theboxes are in good condition it is better to leave thesections in the shipping boxes until they are to be used.All lines and parts shall be inspected prior to fabricationfor good workmanship and conformance with applicablespecifications.

Whether left crated or unpacked, the coaxial cablesections, coupling fittings and associated parts shall bestored in a cool dry location. The cool dry air is toreduce corrosion to a minimum. Unpacked section shallbe stored in a horizontal position and shall be adequatelysupported to prevent buckling and bowing. During stowingthey should not be dropped into position, but should becarefully set in place. The ends of each stored section,fittings and assemblies shall be sealed with heavy paper

5-34ORIGINAL


or plastic caps or lintless cloth to prevent the entrance ofdust or any foreign material. Flange faces and edges ofcoupling shall be protected by a cover to prevent theirbecoming damaged.

must join copper or brass flanges, platethe copper or brass flange with zinc toprevent corrosion from electrolysisbetween dissimilar metals.5-3.5 HANDLING

When unpacking the coaxial sections, each shippingbox shall be placed so that it is resting solidly in ahorizontal position. Nails in the box cover shall beremoved with a nail puller. Prying the cover off the boxmay dent some of the coaxial sections. Carefullyremove collar blocks to avoid damaging. If the section isencased in an individual cardboard tube, the tube shouldbe left in place for protection. To examine the coaxialsection, remove the protective fiber cover from one ofthe end flanges. After examination, replace the cover.The same care applies to angle sections, fittings, andparts. The gaskets, "O" rings, inner coupling, etc., areusually packed separately. When unpacking these items,do not touch any conducting surface with the hands.Perspiration and acid on the skin of the hands isdetrimental to electrical conductive surfaces.

5-3.7 ELBOW ASSEMBLIESRigid coaxial line sections may be connected

together by 45 degree or 90 degree mitered elbows.Elbows are connected to straight section and other rigidcoaxial accessories in the same manner as described in5-4.6.8. All assemblies shall meet the requirements ofMIL-L-28796 (See appendix 5-B).

5-3.8 GAS INLET AND GAS BARRIERCOUPLINGS

These gas fittings are available for all sizes oftransmission lines. The gas inlet is a 1/8 inch iron pipesize (IPS). The gas barrier is fitted between two flangesof adjacent assemblies. The assembly is similar to thatdescribed in 5-4.6.8. When installing the barrier, be surethe gas ports face the pressurized section of thetransmission line. All assemblies shall meet therequirements of MIL-L-28796 (see appendix 5-B).

5-3.6 STRAIGHT SECTIONS, INNER COUPLINGAND FLANGES

Copper or aluminum straight sections are suppliedin sizes 3/8 inch to 6-1/8 inches in diameter and in 20-foot lengths. Lines may be supplied with fixed flanges ateach end, or one end only, or with no flanges. MIL-STD-242 Section 603/701, MIL-STD-1327, MIL-L-3890 andMIL-F-24044 provides details for the rigid coaxial line,gaskets, inner coupling and flanges. (See Appendixes 5-Band 5-C)

5-3.9 REDUCERSReducers connect larger size coaxial lines to

smaller size lines in the following steps.Size 7/8" to 3/8" coaxial transmission lineSize 1-5/8" to 7/8" coaxial transmission lineSize 3-1/8" to 1-5/8" coaxial transmission lineSize 6-1/8" to 3-1/8" coaxial transmission lineRegardless of length, if one or both ends are

flanged, each section will be provided with one innercoupling, one "O" ring gasket, bolts, lockwashers and nutsrequired' for the size of line. If the section is deliveredwithout flanges, the hardware (See 5-2.6.7) will not beincluded. The installation of a rigid coaxial transmissionline consists of joining the flanged ends of two coaxialsections together and connecting the two innerconductors by means of an inner coupling commonlycalled a "bullet". Detailed assembly instructions will befound in each box of coaxial sections or parts. Theyshould be followed as closely as possible. Fabricationinstructions are primarily included here as an aid to, andclarification of, the manufacturer's instructions, andsecondly for use in the absence of such instructions.See 5-4.6.7 showing various size coaxial section,assembled with connectors and flanges. For detailassembly of flanged joints see 5-4.6.8.

The assembly is very similar to that for two straightsections. All assemblies shall meet the requirements ofMIL-L-28796 (See appendix 5-B).

5-3.10 ADAPTERSThese are all used to join rigid coaxial line to flexible

coaxial cable. One end of the adapter has a flange whichmates with the flange of the rigid coaxial transmissionline. The other end of the adapter is fitted with a coaxialconnector which mates with the flexible coaxial cable.See Figure 5-26 and Table 5-1 for information. Theconnector on the adapter for the flexible coaxial cable canbe either male (ML) or female (FL) plug. The adapterincludes the flexible cable connector, the inner coupling,"O" ring gasket, hardware to complete the connectionbetween adapter and the rigid coaxial transmission line.The mating connector for the flexible coaxial cable is notsupplied. Adapters are available to connect all sizes ofrigid coaxial cable to certain sizes of the flexible coaxialcable connectors. Refer to Figure 5-26 for adapterconnector parts and nomenclature. All assemblies shallmeet the requirements of MIL-L-3890 and MIL-HDBK-216Section 3 (See appendix 5-B).

NOTE

Ensure that transmission line meetsspecifications for roundness and wallthickness. Inspect line for dirt, corrosionand dents. Where an aluminum flange

5-35ORIGINAL


Figure 5-26. Adapter Connection Parts and Nomenclature

RIGID COAXCABLE SIZE

CONNECTORSERIES

CONNECTORFABRICATED

WITH ADAPTER

CONNECTORATTACHED TO

FLEXIBLE CABLE

7/8 N Female PlugUG-23F/U

Male PlugUG-21F/U

7/8 LC Female PlugUG-215A/U

Male PlugUG-154A/U

1-5/8 N Female PlugUG-23F/U

Male PlugUG-21F/U

1-5/8 LC Female PlugUG-215A/U

Male PlugUG-154A/U

3-1/8 N Female PlugUG-23F/U

Male PlugUG-21F/U

3-1/8 C Female PlugUG-570A/U

Male PlugUG-573B/U

Table 5-1. Rigid Coaxial Line To Flexible Coaxial Cable Adapter Termination Data

5-36ORIGINAL


5-3.11 FLEXIBLE COAXIAL ASSEMBLIESprocured in accordance With MI-L-28796. Straightassemblies that require cutting and flange attachmentshall comply with the fabrication requirements ofparagraph 5-3.13. The completed assembly shall meetthe requirements of MIL-L-27896 (see appendix 5-B).

Flexible coaxial assemblies with flanges aredesigned to compensate for undesirable stress causedby different expansion and contraction rates of the shipsstructure, vibration and shock. Flexible sections whennecessary shall be as short as possible and installed atright angles to the direction in which the greatestmovement shall occur. Flexible assemblies shall not beused for alignment purposes or to take up the fixed slackin a run. Flexible assemblies shall not be stretched orcompressed when installed and shall be in a normal freestate after installation. Flexible assemblies shall meetthe requirements of MIL-L-28796 (see appendix 5-B).

5-3.13 FABRICATIONThe fabrication of a section of rigid coaxial

transmission line shall be in accordance with the followinginstructions and the specific manufacturer's instructions.

5-3.13.1 Cutting Outer ConductorStep 1. Determine the exact length of coaxial

line needed, then deduct the amount required for theflange. This is the cutting point. Flange thickness varieswith the coaxial cable size. For cutting dimensions seeTable 5-2.

5-3.12 STRAIGHT ASSEMBLIESRigid coaxial transmission line assemblies in 20 foot

lengths, flanged on both ends or flanged on one end onlyto facilitate cutting length to suit final installation, can be

Table 5-2. Cut-Back Dimensions For Rigid Coaxial Transmission Line

5-37ORIGINAL


Step 2. Prepare a wooden plug whose largediameter fits snugly inside the coaxial cable outerconductor, and whose center rod fits snugly inside theinner conductor as shown in Figure 5-27.

Figure 5-27. Wood Plug Used for Cutting Rigid CoaxialLine Figure 5-29. Tube Cutter With Single-Sided Wheel Used

for Cutting Rigid Coaxial LineStep 3. Slide back the inner conductor of the

rigid coaxial section and insert wood plug into the outerconductor. Use the inner conductor to position plugunder cutting line as shown in Figure 5-28.

5-3.13.2 Installing FlangesStep 1. Clean end of outer conductor with a

garnet paper or fine non-carbon sandpaper. Length to becleaned will vary from 1-1/2 to 3 inches depending on thecoaxial cable size. Keep all chips, dust, dirt, and anyother foreign matter from entering tube. Always usecotton gloves when handling coaxial line and do not touchor contaminate cleaned sanded area.

NOTE

Lint free white cotton gloves must be wornwhen handling inner conductor and innersurface of outer conductor.

NOTE

Cleaning, attachment of flange, removal offlux and application of chemical film shallbe accomplished as one operation withouttime lapse between steps.

Step 2. Place the flange on the outer conductorwith the flange recess facing the end of the outerconductor. Aluminum flanges may be joined to the outerconductor by dip brazing or by inert gas metal arcwelding. Copper flanges shall be silver brazed to theouter conductor. In dip brazing, the filler metal is pre-positioned in the joint and the work is dipped into a bathwhich transfers heat to the joint and melts the filler alloy.See 5-1.9, 5-1.13 and MIL-B-7883 (Appendix 5-D) for dipbrazing of alloys and for process of cleaning parts prior tobrazing, process of brazing, and post brazing treatment.

Figure 5-28. Wood Plug Shown Inserted in OuterConductor of Rigid Coaxial Line

Step 4. Fit tube cutter with a standard cuttingwheel. Score a complete circle around the outerconductor at the cutting point as shown in Figure 5-29.The recommended method for scribing the circle is toalternately swing the cutter through an arc ofapproximately 30 degrees at a time, until the circle iscomplete. Ibis is a scoring operation only. Do notadvance the cutting rollers.

The flange shall be perpendicular to the outerconductor within 15 minutes for coaxial lines up to 1-5/8inches in diameter, and within 30 minutes for lines 1-5/8inches in diameter and larger.

Step 5. Remove the standard cutting wheel andinsert a single sided cutting wheel. Reposition the tubecutter around the outer conductor with the flat side of thewheel toward the end of the coaxial section where theflange will rest.

Step 3. Remove all flux after brazing.Step 4. Coat the sanded area, brazed area and

flange with chemical film in accordance with paragraph 5-3.14.

Step 5. The complete assembly is ready forpainting. See 5-3.15.Step 6. Cut through the outer conductor tube,

advancing the roller wheels just a little at a time so as tonot create a burr on the inside of the tube. 5-3.13.3 Cutting Inner Conductor

Step 1 . Determine the length to be cut from theinner conductor. This will vary depending on the coaxialcable size and the make and type of inner coupling. (Forcutting dimensions see Table 5-2.)

Step 7. Remove the wood plug and the innerconductor.

Step 8. Holding the outer conductor tube in adownward position remove burr on inside edge, if any,using a pocket knife or scraper. Step 2. Cut the inner conductor. It shall be cut

as described in paragraph 5-3.13.1 for the outerconductor. The end must be as square as possible with

5-38ORIGINAL


the inner conductor length. Repair of Copper Lines)Step 3. File the cut end smooth. Remove all

filings and any other foreign matter.Step 1. Place the free flange on the outer

conductor tubing with its recess facing the end to beflanged (see Figure 5-30).Step 4. Replace the inner conductor within the

outer conductor.

5-3.13.4 Installing Field Flange (For Emergency

Figure 5-30. Free Flange Connection Parts and Nomenclature

Step 2. Smear rosin base flux on the cleanedarea of the outer conductor tubing and on the inside ofthe adapter.

the mating flange. The part that is free &has fastening holes for hardware shallreceive the painting prescribed for beforeinstallation.

Step 3. Slide the adapter over the outerconductor tubing until its shoulder is flush against thetube end.

Step 4. Solder the adapter to the outer conductortubing. Use a torch with a very small flame, and softsolder. Apply the heat evenly and uniformly around theadapter. Feed the solder into the solder hole. When thesolder is flowing freely, use a glove, not pliers, and gentlyrotate adapter, at the same time pushing its shoulderflush against the tube end. Such a movement shouldpermit a uniform distribution of the solder. Wipe awayany excess solder.

5-3.14.1 Inspection of CoatingThe chemical film shall be inspected to ensure it

has been applied in accordance with MIL-C-5541 foraluminum, and the manufacturer's instructions for IriditeNo. 7P for copper.

5-3.14.2 Removal of Chemical FilmRemoval of chemical conversion film, when

required, shall be in accordance with the instructions ofMIL-C-5541 for aluminum or manufacturer's Iridite No. 7Pinstructions for copper.

Step 5. Remove heat and allow solder to cool.Approximately 1 minute.

Step 6. Remove excess flux with hot water.Step 7. Clean adapter and tubing adjacent to it,

inside and outside, thoroughly with fine sand paper. Allsand, dust, dirt, flux, solder, and any other foreign mattermust be wiped away.

5-3.15 PAINTINGAll rigid coaxial transmission lines shall be painted in

accordance with the following procedures and methods.

5-3.14 CHEMICAL CONVERSION 5-3.15.1 Before InstallationAll rigid coaxial transmission lines, assemblies and

components shall receive chemical conversionprotection. Copper lines shall be treated with Iridite No.7P, Mixture C (or equal), while aluminum lines shall betreated with a chemical conversion in accordance withMIL-C-5541.

The chemically filmed external surfaces of all rigidcoaxial transmission lines shall be painted in accordancewith the three coat, MIL-P-24441 epoxy-polyamide coatingsystem described in 5-1.13.16.

5-3.15.2 After Installation

CAUTIONTouch up external surfaces of rigid coaxial

transmission lines as necessary with MIL-P-24441 epoxy-polyamide coating system as described in 5-3.9.

Flange faces shall receive the chemicalconversion process and shall not bepainted. The flange face is that part of aswivel flange that is attached to the outerconductor & makes physical contact with

5-3.16 PRESSURIZING AND PURGINGPressurizing and purging air systems for rigid

coaxial transmission lines shall be as described in 5-1.14,except for air connections for which 5-3.8 and 5-4.6.8applies.

5-39ORIGINAL


5-4 RIGID COAXIAL LINES INSTALLATIONPROCEDURES

of moisture and dirt into the transmission line duringinstallation.

5-4.1.8 Structural FoulingRigid coaxial runs shall be located so they will not

be disturbed by the removal of deck plates, gratings ormachinery.

5-4.1 GENERAL REQUIREMENTSThe installation of rigid coaxial transmission lines

shall meet the following requirements. 5-4.1.9 Galvanic Action

5-4.1.1 Length of Run Rigid coaxial lines shall be isolated from supports toprevent galvanic action.The run shall be as short as possible with a

minimum amount of mitered elbows and connections. 5-4.1.10 Type of Rigid Coaxial Line Supports(Hangers)5-4.1.2 Location of Run

Rigid coaxial transmission lines shall be installedwith alignment type supports in such a manner that nostress or strain will be placed on any joint or section.

The location of the rigid coaxial transmission line runshall take precedence over piping, ventilation ducting,cable hangers, wireway runs and lighting fixtures. Thetransmission line run shall be located so it will not bedisturbed by the removal of deck plates, gratings,machinery or service areas. Locate the rigid coaxial lineto avoid electrical interference from equipment cables orother transmission lines.

5-4.1.11 Penetrations, Deck and BulkheadDeck and bulkhead penetrations shall comply with

the ships structural requirements and permit the installingor removal of rigid coaxial sections including the attachedflanges. Paragraph 5-4.5 provides general designinformation for acceptable type deck and bulkheadpenetrations.

5-4.1.3 Sequence of InstallationThe complexity of the system, equipment location

and the rigid coaxial transmission line run will determinethe sequence of installation. Whatever the sequencemay be, extreme care should be taken to prevent theinner conductor from slipping out of the outer conductorand being damaged during the assembly process.

5-4.1.12 Transmission Line MarkingsThe finished rigid coaxial line components shall be

identified per MIL-STD-130, paragraph 4.1, except metalstamping shall not be used. The identification shall be ina progressive manner to ensure correct remating of thematched flanges during installation and/or maintenance.Warning labels shall be applied to a visible area of thetransmission line, approximately three feet apart after thetransmission line has been painted or touched-up. Spraylabels with weatherproof lacquer. Labels shall read "DONOT STRIKE".

5-4.1.4 ClearanceA clearance of two inches minimum shall be

provided from all objects to which the rigid coaxialtransmission line is not connected, to prevent damagewhen subjected to underway movement, shock orvibration. Clearance between the underside of the rigidcoaxial line and the deck shall not be less than seventy-seven inches in areas where normal passage occurs.

5-4.1.13 Grounding of Rigid Coaxial TransmissionLines

5-4.1.5 Protection of Rigid Coaxial Lines All rigid coaxial transmission lines shall be groundedin accordance with MIL-STD-1310(SHIPS).The rigid coaxial transmission line for each

installation shall be protected from pedestrian traffic orwhere accidental damage is most likely to occur.Protective guards shall be removable and of sufficientsize and strength to ensure the rigid coaxial line cannotbe struck, attached to, or accidentally damaged.Expanded metal construction is preferred. Theseprotective guards shall be installed around rigid coaxiallines where the line passes through a compartment in avertical direction and where the rigid coaxial linepenetrates the weather deck to a height above the deckas required to provide adequate protection. Protectiveguards shall be installed around rigid coaxial lines atplatforms, catwalks, ladders and on the overhead, asrequired. The rigid coaxial line shall be protected againstphysical damage from battle action, heat and water.

5-4.1.14 HardwareFlange assembly hardware shall be that which is

supplied with the flange. Where replacement of missinghardware is required, the hardware shall be in accordancewith the specific flange specification. Transmission linesupport hardware shall comply with paragraph 5-4.4.10 ofthis document.

5-4.1.15 Restrictions for Parallel RunsWhen parallel transmission line runs are installed for

the same system, and there is a possibility ofinterference from flange joint RF leakage, the flangeconnections shall be staggered so that no two flangeconnections will be located within six inches of eachother.

5-4.1.6 Welding to Ship's Structure 5-4.1.16 PreservationRigid coaxial transmission lines shall not be welded

to ship's structure or any assembly to be mounted inship's structure.

No rigid coaxial transmission line shall be installedwithout the interior and exterior being finished as directedin paragraph 5-4.9.

5-4.1.7 Protection against Moisture and Dirt 5-4.1.17 Straightness of RunPrecautions shall be taken to prevent the entrance The transmission line shall not deviate from a

5-40ORIGINAL


straight line by more than 1/4 inch at any point to preventstress on the inner conductor and the possibility ofarcing.

shall be templated. The that the fabrication shop can beprovided with accurate information for flange assembly.By templating the complete run, all obstructions can beremoved, hole cuts made in made in decks andbulkheads, mitered elbows reduced to a minimum, andmost important the transmission line sections and elbowscan remain in safe storage during this period of roughwork.

5-4.1.18 Flange Joint AlignmentTo prevent stresses being applied to the

transmission line or the flanges, transmission line jointsshall be arranged so that flanges will mate with bolt holes,during alignment within 1/32 inch and flange faces shallbe parallel and not separated by more than 1/64 inchprior to bolting.

5-4.3.1 TemplatesThe templates for rigid coaxial transmission lines

need not be as accurate as those for waveguide. Elbowsare obtainable in 45 degree and 90 degree mitered bendswith rotatable flanges that can provide any desired angleneeded. This eliminates the template requirement fordifferent angle bends. Straight sections of rigid coaxialtransmission lies are obtainable in 10 feet and 20 feetlengths with one end already flanged. The mainrequirement for the template is to provide the shop withaccurate measurements for installing flanges on straightsections of rigid coaxial transmission lines. Theassembly of these flanges on the line is a shopfabrication job and should never be accomplished aboardship, except under an emergency condition. Templatesfor rigid coaxial transmission lines may be made fromany suitable material. Never use the transmission lineitself for templating. it is too easily damaged and anysmall indentation or warping is justification for rejection.

5-4.1.19 PressurizationAll rigid coaxial transmission lines shall be

pressurized to prevent corrosion and maintain equipmentperformance parameters.

5-4.1.20 Expansion JointsCompensation for expansion and contraction must

be made when rigid coaxial runs cross expansion joints.A flexible section will be used only as designated onship's installation plans and shall be installed parallel tothe expansion joint.

5-4.2 HANDLING RIGID COAXIALTRANSMISSION LINE GUIDELINES

Guidelines for the handling of rigid coaxialtransmission lines from shop to ship, and duringinstallation are as follows:

5-4.3.2 Penetrations, Deck and Bulkhead5-4.2.1 Sealing of Individual Sections Deck and bulkhead penetrations should be carefully

made at the time the templates are made, keeping inmind the overall run should be as straight and short aspossible.

The ends of all sections shall be kept sealed againstmoisture and dirt, except during assembly of run aboardship.

5-4.2.2 Sealing of Assembled Sections 5-4.3.3 Supports, Rigid Coaxial LineThe ends of partially assembled runs shall be kept

sealed against moisture and dirt, except during assemblyof run aboard ship.

Basic information needed for transmission linesupports shall be obtained at the time of templating theoverall run (see Figures 5-31 and 5-32).

5-4.2.3 Flange Face Protection 5-4.4 RIGID COAXIAL LINE SUPPORTS(HANGERS) REQUIREMENTSFlanges shall be protected against physical damage

during shipping and installation.Supports for rigid coaxial transmission lines shall he

fabricated and installed to meet the followingrequirements.

5-4.2.4 Transporting Rigid Coaxial Sections andComponents

5-4.4.1 Type of MaterialRigid coaxial transmission line sections shall betransported from shop to ship in cradles that will preventbending, warping, and physical damage. Supports shall be made of material compatible to

ship's structure.5-4.2.5 Warping of Long Rigid Coaxial Sections

5-4.4.2 Size of MaterialCare should be taken in handling long sections of

rigid coaxial lines to prevent distortion. Never lift a longsection by the ends only.

Supports shall be of sufficient width and thicknessto support the transmission line against damage due tovibration and shock.

5-4.2.6 Protection Against Hand Contamination5-4.4.3 Support Damage to Outer Conductor

Lint free gloves shall be used whenever handling theinner conductor, inner coupling and flange matingsurfaces.

Supports shall provide a snug fit but not tightenough to cause deformation or damage to the outerconductor.

5-4.3 LAYOUT OF RIGID COAXIAL RUNS 5-4.4.4 Isolation of Outer Conductor and SupportAfter the design and exact location of rigid coaxial

transmission line run has been determined, the first stepin actual installations is the layout of the shipboard ranby the use of templates. The entire transmission line run

All supports shall be isolated from the transmissionline by the method outlined in 5-2.4.9.

5-41ORIGINAL


5-4.4.5 Adjustable Supportstwo directions (see Figures 5-31 and 5-32).

All supports shall be fabricated to be adjustable in

Figure 5-31. Adjustable Support Fabrication Details for Rigid Coaxial line

5-42ORIGINAL


Figure 5-32. Typical Plastisol Coated Support for Rigid Coaxial Line

5-4.4.6 Location of Supports 5-4.4.9 Isolation MethodsNever force the transmission line to the support

position, always locate the supports in such a manner asto prevent any stress, strain or bind on any segment ofthe overall transmission line installation.

To prevent electrolytic corrosion between thetransmission line and the support, the support shall beisolated as detailed in 5-2.4.9.

5-4.4.10 Hardware Requirements5-4.4.7 Fitting Support to Rigid Coaxial Line Hardware required for rigid coaxial transmission line

supports shall meet the following requirements.Supports installed shall fit snug enough to hold thetransmission lines allowing for isolation material thicknesscovered in 5-2.4.9. For outside dimensions of rigidcoaxial line see MIL-L-3890, Appendix 5-B.

(a) Supports exposed to weather shall beassembled with corrosion resistant steel hardware thatmeets the following specifications.

5-4.4.8 Spacing of SupportsFF-N-836 NutsFF-S-85 Cap Screw, Slotted & Hex Head

Spacing between supports shall not exceed 5 feet.Supports shall not be closer than 6 inches to any flangeconnection. There shall be a minimum of 2 supports foreach section that exceeds 24 inches in length.

FF-W-84 Washers, Lock (Spring)FF-W-100 Washers, Lock (Tooth)(b) Supports installed inside ship's structure and

not exposed to weather shall be assembled with standardtype cadmium plated hardware, unless otherwisespecified on Installation Control Drawings.

5-43ORIGINAL


5-4.5 PENETRATIONS, DECK AND BULKHEADwatertight and comply with the structural requirements ofthe ship. The watertight fittings shall not be welded,brazed or soldered to the transmission line, and shall becapable of disassembly for removal of transmission linecomplete with flange.

Where rigid coaxial transmission line runspenetrates decks and bulkheads, the methods andprocedures used shall meet the following requirements.

5-4.5.3 Typical Methods5-4.5.1 Non-Watertight Decks and BulkheadsThe typical methods discussed in paragraphs 5-

2.5.3 through 5-2.5.7 for rectangular waveguide are ingeneral applicable to rigid coaxial transmission lines.

The requirements for a rigid coaxial transmissionline passing through a non-watertight/non-airtight deck orbulkhead or an air/dust/fume tight bulkhead are the sameas those outlined in paragraph 5-2.5.1 for waveguide.The typical method shown in Figure 5-10 is applicable torigid coaxial lines. The shape of the coaming would bedependent upon structural requirements.

The fabrication and assembly information covered inparagraph 5-2.5.4 are applicable to the typical splitsleeve assembly shown in Figure 5-33 for a rigid coaxialline.

Information for using multi-cable transit devices withrigid coaxial transmission lines is covered in paragraphs5-2.5.5 and 5-2.5.6.

5-4.5.2 Watertight Decks and BulkheadsWhere a rigid coaxial transmission line passes

through a watertight bulkhead or deck the fittings shall be

Figure 5-33. Typical Split Sleeve Assembly for Rigid Coaxial Line

5-4.6 OVERALL RIGID COAXIAL RUNINSTALLATION PROCEDURES

bulkhead and deck cuts have been made, deck/bulkheadsleeves tack welded in place and electronic equipmentinstalled.

NOTEThe assembly and installation of the rigid coaxial

transmission line aboard ship shall be in accordance withthe following requirements.

The deck/bulkhead sleeve should be tackwelded in such a manner that it can beeasily aligned with the rigid coaxialtransmission line prior to final welding.

5-4.6.1 Shipboard Installation Pre-RequirementsThe actual shipboard installation assembly of the

rigid coaxial transmission line sections shall not beginuntil all shop fabrication work has been completed, all

5-44ORIGINAL


5-4.6.2 Assembly Sequence 5-4.6.6 Inner Coupling and MisalignmentThe assembly sequence for rigid coaxial

transmission line runs will vary depending on thecomplexity of the system and equipment location.Because of the inner conductor construction, thepreferred sequence of assembly for a rigid coaxial linewould be from the transmitter to the antenna. This wouldmake the vertical run easier to assemble and would notrequire special precautions to prevent the inner conductorfrom slipping out of the rigid coaxial assembly. Theinstaller shall ensure the end of partially assembled runsremain covered, to prevent intrusion of foreign matterand moisture, until the next section is ready forassembly.

Assembling sections of rigid coaxial transmissionlines differ greatly from assembling of rigid waveguidetransmission lines in that the installer must pay carefulattention to inserting the inner coupling and also theinstaller can compensate for any slight misalignment offlanges made during brazing process.

5-4.6.7 Reference to Detail IllustrationsFigure 5-34 through 5-42 provides information that

will help in obtaining an ideal installation.

5-4.6.8 Flange Joint AssemblyRefer to Figure 5-34. Extreme care must be

maintained in handling and fitting of the coaxial line. Thethin wailed aluminum is susceptible to dents which willcause hot spots and consequently cause arcing. Checkthe inner connector to assure that the expansion spring isproperly seated to provide maximum spread of theconnector fingers and that the fingers are not bent.Check the inner conductor to assure that Teflon supportsare present and not damaged. As each section isinstalled, the inner conductor and inner coupling shall bewiped with FREON 113, Type 1, MIL-C-81302A, andcheese cloth to remove moisture, oils or foreign material.Lint free gloves or cheese cloth shall be used whenhandling the inner conductor or inner couplings. Press fitone end of the inner connector into the inner conductor ofa section of the transmission line. A twisting motion willaid in seating the shoulder of the inner connector snuglyagainst the inner conductor of the transmission line.When the inner connector is properly seated, one half ofthe inner coupling insulator will be exposed. Place the "O"ring gasket in the flange groove. Be sure both gasketand groove are clean, as any foreign matter may preventthe assembly being pressure tight. A thin film of siliconelubricant, MIL-A-46106, on the gasket will help hold thegasket in place during assembly, and aid in retainingpressure. Use silicone lubricant very sparingly and donot permit any grease on mating inner conductor surface.Engage the inner connector (extending from one section)with the inner conductor of the next section. The innerconnector must fit snugly. Push the assembly togethermaking certain the gasket remains in place and the innercoupling insulator seats properly in the flange. Turn theflanges so the alignment pins are opposite the alignmentholes, then push the flanges together. Check to assurethat the line is straight and that angles formed byinstalled elbows are maintained. Install the bolts,lockwashers and nuts, and bolt the flanges together bytightening the bolts evenly all around, applying

Ensure the flange faces are clean and "O" rings areproperly seated. The flange bolts shall be tightened in astaggered sequence to ensure a smooth tight fit witheven pressure around the entire parameter of the flange.

5-4.6.3 Material Ordering SequenceTransmission line sections should be requested

from shop storage in sequence of assembly and installedon ship when received. Transmission line sectionsshould never be left laying around aboard ship.Transmission line sections shall be received atinstallation site sealed against moisture and dirt.

5-4.6.4 Inspection Prior to InstallationThe ship installer shall visually inspect each

transmission line section prior to assembling in run. Anysection shall be rejected and returned to shop for re-workor replacement if found to contain any of the followingdefects.

1. Dents in outer conductor surface that wouldcause a change in the electrical characteristics specifiedin MIL-L-3890 (See Appendix 5-B).

2. Scratches in flange face surface that exceedthose specified in MIL-F-24044 (See Appendix 5-C).

3. Unsealed.4. Dirt or grease inside of transmission line, or

on flange face.5. Ripple in outer conductor surface indicating a

warped condition.

5-4.6.5 Assembly DetailsThe complete rigid coaxial transmission line shall be

assembled and held in place by temporary means beforesecuring the transmission line supports or assemblingthe penetration transit device. This is to ensure nostress, strain, or bind is placed on any flange connectionor section of the outer conductor.

5-45ORIGINAL


Figure 5-34. Rigid Coaxial Transmission Line Parts and Nomenclature

Figure 5-35. Cut-Away View of inner Coupling (Bullet)

Figure 5-36. Flange Dimensions for Rigid Coaxial Transmission Line

Figure 5-37. Inner Coupling (Bullet) Dimensions for Rigid Coaxial Transmission Line

5-46ORIGINAL


Figure 5-38. Cut-Away View of Rotatable (Swivel) Flange

Figure 5-39. Cut-Away View of Rigid Coaxial Transmission Line with Swivel Flange, Inner Coupling and "O" Ring in Place

Figure 5-40. 90-Degree Mitered Elbow for Rigid Coaxial Transmission Line

5-47ORIGINAL


Figure 5-41. 45-Degree Mitered Elbow for Rigid Coaxial Transmission Line

Figure 5-42. Cut-Away View of Gas Barrier for Rigid Coaxial Transmission Line

torque listed in Table 5-3. Box end wrenches or socketsshall be used for tightening flange bolts. Open endwrenches or adjustable wrenches can slip off bolt headand damage the outer conductor; therefore, they shallnot be used.

5-4.6.9 Misalignment CompensationThe assembled sections must form a straight line

(excluding mitered elbows) and the inner connectors mustbe seated property. If the flanges are not perfectlyperpendicular to the line, the result will be a slight offsetin the assembled sections. This can be compensated forby using swivel flanges and rotating one section of thetransmission line until the deviation from a straight line isless than 1/4 inch.

The assembly of a rigid coax to flexible coax adapterto the rigid coaxial line flange is similar to that outlinedabove. If the adapter is to be used as the pressurizinginlet for the rigid air dielectric line, remove the gas portvent plug and replace it with pressurizing fittings.

5-48ORIGINAL


RIGIDCOAXIALCABLE

FLANGE BOLTS TORQUE

SIZE(INCHES)

NUMBERREQ'D

SIZE LENGTH(INCHES)

FT.-LBS.

3/8

7/8

1-5/8

3-1/8

6-1/8

3

3

4

6

12

1/4-20

5/16-18

3/8-16

3/8-16

1

1-1/2

1-1/2

1-3/4

7-8

13-15

17

17

Table 5-3. Flange Assembly Torques

5-4.6.10 Mitered Elbowspressurized with dry air or nitrogen at the end of the workshift and maintained under pressure until installation ofthe run is resumed.Figures 5-40 and 5-41 are cut-away views of 90

degree and 45 degree mitered elbows respectively.Nonstandard elbows (other than 45 degree or 90 degree)shall not be used.

5-4.6.13 HardwareAll sections of the transmission line assembly shall

be put together with corrosion resistant steel hardwareand shall conform to the specifications shown in 5-2.6.7.5-4.6.11 Swivel Flanges

Elbows with swivel flanges are capable of providingany combination of offset required for matching the slopeof the transmission line run to the slope of a mast ormack.

5-4.6.14 Illustrative Installation ExplanationFigure 5-43 is an illustrative installation of rigid

coaxial transmission line that can be used as a referenceguide for solving problems and shows as manyinstallation conditions as possible. An actual rigid coaxialtransmission line run should always be as short andstraight as possible with the number of elbows andconnections kept to a minimum.

5-4.6.12 Pressurization RequirementThe assembled transmission line shall be

pressurized with dry air or nitrogen to the specified PSIGand maintained at that level until the system is ready foroperation. Whenever a complete run cannot be installedin one work shift, the partially installed sections shall be

5-49ORIGINAL

INSTALLATION NNAVSEA SE000-00-EIM-110 WAVEGUIDES ANDSTANDARDS RIGID COAXIAL LINES

Figure 5-43. Illustrative Reference Guide with Reference Notes 1 through 16

1Antennas, duplexers, filters, switches,

transmitters/receivers and other equipment shall beinstalled in accordance with guidance plans, installationcontrol drawings and NAVSEA 0902-LP-001-5000,General Specification for Ships.

of - See: MIL-STD-242 Section 701MIL-HDBK-216 Section 5A

For detail Dimensions - See: MIL-L3890 andMIL-L28796

7Flanges

290 Mitered Elbows For selection of, For selection of - See: MIL-STD-242

Section 6033

45 Mitered Elbows and detailed in MIL-STD-1327MIL-HDBK-216

4 l Flexible Sections formation on Section 11For detail Dimensions - See: MIL-F24044

5Gas Barriers these items, see

8Deck PenetrationsMIL-L-28796 and

Manufacturers See: NIMB Section 5, Paragraphs 54.1.11, 5-2.5, 54.5 catalogs. NIMB Section 5, Figures 5-14, 5-16

6Rigid Coaxial Transmission Lines F or selection

thru 5-21, 5-33DoD-STD-2003-1(NAVY),

5-50ORIGINAL


Section 4, Shts 170-180 undiluted liquid shampoo to the flange connection, orsuspected area. With pressure inside the transmissionline, bubbles will appear where the dry air is escaping.

9Bulkhead Penetrations

See: NIMB Section 5, Paragraphs 5-2.5, 54.1.11,5-4.7.4 Purging Procedures54.5

Purging of rigid coaxial transmission lines shallcomply with the procedures outlined in 5-2.74 forrectangular waveguide.

NIMB Section 5, Figures 5-10, 5-14, 516thru 5-21, 5-33DoD-STD-2003-1(NAVY),

5-4.7.5 PurgingSection 4, Shts 170-180

10Transmission Line Supports

Purging of the transmission line shall be repeatedevery time the line is opened for any reason. If the lineis opened for minor checks or inspections that take onlya few minutes to complete, then the time limit specifiedin Step 1 of 5-4.7.4 can be omitted.

See: NIMB Section 5, Paragraphs 54.1.9,5-4.1.10, 5-4.4NIMB Section 5, Figures 5-31 and 5-32

11 Support Isolation 5-4.8 GROUNDING OF RIGID COAXIALTRANSMISSION LINE

See: NIMB Section 5, Paragraphs 52.4.9,54.1.9,54.4.9

Rigid coaxial transmission line runs shall beconsidered to be at ground potential unless provenotherwise by electromagnetic interference (EMI) tests.When additional grounding is required the bonding,methods, materials, surface preparation and sealing shallbe in accordance with MIL-STD-1310.

NIMB Section 5, Figure 5-32EIB #712

12Painting of Transmission Line Exposed to

WeatherSee: NIMB Section 5, Paragraphs 53.15 and 54.9

5-4.9 PRESERVATION OF RIGID COAXIALRUNS

13 Painting of Transmission Line Not Exposed toWeather

See: NIMB Section 5, Paragraphs 53.15 and 5-4.9 The final preservation of rigid coaxial transmissionline runs shall be in accordance with the followingrequirements.

14Dry Air - 1/4" diameter tube installed to comply

with standard piping specifications. Connection to gasbarrier at antenna shall be of material that will not creategalvanic action.

5-4.9.1 Exterior Surface PaintingPainting prior to installation and touch-up painting as

necessary, subsequent to installation, shall beaccomplished with MIL-P-24441 epoxypolyamide coatingsystem described in 5.1.13.16 and 5-2.9, respectively.

15Purge Valve - Located in equipment room in an

area accessible to maintenance personnel but not tointerfere with equipment operation. Installation of valveshall comply with all piping specifications. Locate atlowest point in line adjacent to transmitter/receiver.

5-4.9.2 Rigid Coaxial Lines Requiring AdditionalHeat Dissipation

16Ground Straps

Where a flat black finish is needed to assist in heatdissipation generated by the transmission line, applyformula 153-Rol. 8 as described in 5-2.9.2.See: MIL-STD-1310(NAVY)

NIMB Section 5, Paragraph 54.85-4.9.3 Flange Joint Protection after Installation

5-4.7 PURGING AND PRESSURIZING Flange joints, including fastening hardware, shall becoated with a sealer after installation and all testing iscompleted. The requirements, methods and materialtypes of 5-2.9.3 for waveguide shall apply to rigid coaxialtransmission lines.

All rigid coaxial transmission lines shall be purgedand pressurized in accordance with the following methodsand procedures. Information on dry air systems can befound in 5-3.16.

5-4.10 QUALITY CONTROL INSPECTION5-4.7.1 Temporary PressurizationThe requirements for temporary pressurization of

rigid coaxial transmission lines are the same as those in5-2.71 for waveguide. The typical method of temporarypressurization shown in Figure 5-23 is applicable to rigidcoaxial transmission lines.

Quality control inspections shall be conductedduring the installation process and after completion of allwork to ensure the transmission line conforms to theships installation drawings and this document.

The guidelines listed in 5-2.10 for waveguide shallapply to rigid coaxial transmission lines.5-4.7.2 Tightness Tests

5-4.11 ELECTRICAL REQUIREMENTS ANDTESTS

Immediately upon completion of the rigid coaxialtransmission line installation a tightness test shall beconducted. The tightness test shall comply with therequirements of 5-2.7.2. After satisfactory completion of installation, visual

inspections, tightness tests and final pressurization, andprior to initial equipment turn-on, the transmission lineshall be electrically tested in accordance with the

5-4.7.3 Method for Detecting LeaksA typical method of detecting leaks is to apply

5-51ORIGINAL


following requirements: the use of fewer joints and connectors in a typicalinstallation with consequent reduced power loss, and lessopportunity for voltage breakdown at junctions. Thelargest size of elliptical waveguide currently beingextruded and wound onto reels is RG-395/U waveguide.However, RG-387/U elliptical waveguide is available in 20feet lengths whereas the maximum length of equivalentsize rectangular waveguide is available in only 14 footlengths,

5-4.11.1 Test Equipment RequirementsThe requirements of paragraph 5-2.11.1 shall apply

to the test equipment required for conducting theelectrical tests for rigid coaxial transmission lines.

5-4.11.2 ContinuityA test of the installation to determine continuity of

the center conductor shall be made. This test willdetermine if all inner connectors and inner conductorsmate with a minimum of resistance.

Elliptical waveguide is produced in long continuouslengths from corrugated copper or aluminum, and fromsmooth seamless aluminum. The only ellipticalwaveguide that is recognized for shipboard installationand discussed in this handbook will be the types thathave been assigned military nomenclature. Additionalinformation on elliptical waveguide may be found in MIL-HDBK-216 and the manufacturer's catalog.

5-4.11.3 Insertion Loss MeasurementsThe measured insertion loss for a rigid coaxial

transmission line shall not exceed the computedmaximum allowable insertion loss.

The maximum allowable insertion loss may becomputed using the method of paragraph 5-2.11.2. Theattenuation values can be obtained from plotting anattenuation curve using the theoretical values given inMIL-STD-3390 for the specific transmission line undertest.

5-5.2 ELLIPTICAL WAVEGUIDECHARACTERISTICS

The information provided herein applies to semi-rigid, field formable elliptical waveguide produced fromseamless pure aluminum.

5-4.11.4 Voltage Standing Wave Ratio Measurements5-5.2.1 Electrical CharacteristicsVoltage Standing Wave Ratio Measurements for

rigid coaxial transmission lines shall be made andrecorded in general agreement with paragraph Testequipment types will vary based on the lower frequencyband of rigid coaxial transmission lines. Figures 5-24 and5-25 are applicable with the exception of adapters used tointerface the test set-up to the transmission line undertest,

Electrical characteristics for elliptical waveguide withassigned military nomenclature are shown in tabular formin table 5-4 as guidance for the installing activity.Attenuation and average power curves for these sameelliptical waveguides can be found in MIL-HDBK-216.

5-5.2.2 Physical CharacteristicsPhysical characteristics for elliptical waveguide with

assigned military nomenclature are shown in tabular formin table 5-5 as guidance for the installing activity. Theelliptical waveguide is available in straight lengths oftwenty feet or on reels up to five hundred feet in lengthwith the exception of RG-387/U. Because of its physicalsize and weight, RG-387/U is available only in straightlengths of twenty feet or less.

5-4.11.5 Test ReportsTest reports for rigid coaxial transmission lines shall

comply with the requirements of paragraph 5-2.11.4.

5-5 ELLIPTICAL WAVEGUIDE

5-5.1 INTRODUCTION5-5.3 ACCESSORIESElliptical waveguides are defined as transmission

lines with elliptical inside cross sections. Thesewaveguides offer slightly higher power handlingcapabilities and lower attenuation than the equivalentrectangular waveguide. Elliptical waveguide operates inthe dominant ETE 11 mode of propagation which issimilar to the TE 10 mode for rectangular waveguide.

Elliptical waveguide, although designed forinstallation as one continuous length, can not always beinstalled aboard ship without bends and/or twists thatwould necessitate installing the line in two or moresections requiring the use of couplings. An ellipticalwaveguide run must be interfaced with electronicequipment that is designed for rectangular waveguidecompatibility and this requires transition units as well asrectangular waveguide assemblies.

Some sizes of elliptical waveguide can be fabricatedby an extrusion process in long continuous lengths (500feet) of semi-rigid material wound onto reels, permitting

5-52ORIGINAL


AN TYPE SUGGESTEDFREQUENCY

(GHz)

CUTOFFFREQUENCY

(GHz)

PEAKVSWR

AVERAGEVSWR

PEAK POWERMIDBAND

(MEGAWATTS)

AVERAGEPOWER

MIDBAND(KILOWATTS)

RG-387/U 2.7- 3.2 2.024 1.10 1.06 4.51 39.8RG-395/U 3.7- 4.2 2.779 1.10 1.06 2.53 27.6RG-381/U 4.4 - 5.0 3.433 1 06 1.03 1.66 20.6RG-379/U 5.5- 6.425 4.162 1.06 1.03 1.09 15.5RG-396/U 7.1- 8.5 5.658 1.10 1.06 0.601 9.5RG-394/U 8.5 - 10.0 6.489 1.10 1.06 0.446 6.82RG-380/U 6.0- 110 1.08 1.03 1.10 14.9

Table 5-4. Elliptical Waveguide Electrical Characteristics

B

A

DIMENSIONS MINIMUM BEND RADII(IN INCHES)

ANTYPE

A B PLANEE

PLANEH

90°TWIST

WEIGHTLB/FT

RC-387/U 4.07 2.50 20.0 42.0 180.0 4.10RC-395/U 3.00 1.99 20.0 36.0 144.0 2.76RG-379/U 2.48 1.56 18.0 30.0 96.0 1.12RG-381/U 2.10 1.31 16.0 24.0 84.0 1 81RG-396/U 1.64 1.05 12.0 18.0 48.0 0.97RG-394/U 1.38 0.85 8.0 12.0 48.0 0.59RG-380/U 1.83 1.35 36.0 48.0 120.0 1.22

Table 5-5. Elliptical Waveguide Physical Characteristics

5-5.3.1 Couplings 5-5.3.2 TransitionsCouplings are required for connecting two sections

of elliptical waveguide and should be used only when it isimpossible or impracticable to install the ellipticalwaveguide in one continuous length. These couplingscan be assembled to the elliptical waveguide at theinstallation site using hand tools with no brazing or weldingrequired. Figure 5-44 is an outline of a typical couplingfor RG-379/U, RG-380/ U, RG-381/U, RG-394/U andRG-396/U elliptical waveguide. Figure 5-45 is an outlineof a typical coupling for RG-387/U and RG-395/Uelliptical waveguide. These couplings are available fromthe manufacturer of the elliptical waveguide listed in Table5-4. To ensure the proper fit, the manufacturer'sassembly instructions should be followed.

Transitions, available from the elliptical waveguidemanufacturer, are required for interfacing with rectangularwaveguide. These transitions have a coupling on one endfor attachment to the elliptical waveguide and a MIL-F-3922 type flange on the other end for attachment to arectangular waveguide flange. The transitions can beassembled to the elliptical waveguide at the installationsite using hand tools with no brazing or welding required.Figure 5-46 is an outline of typical transitions forinterfacing rectangular waveguide to the ellipticalwaveguide listed in Table 5-4. To ensure the propermechanical connection and maintain the required systemoperational capabilities, the manufacturers' assemblyinstructions should be followed.

5-53ORIGINAL

INSTALLATION NNAVSEA SE000-00-EIM-110 WAVEGUIDES ANDSTANDARDS RIGID COAXIAL LINES

Figure 5-44. Coupling for use with Small Elliptical Waveguide

Figure 5-45. Coupling for use with Large Elliptical Waveguide

Figure 5-46. Transition for Interfacing Elliptical Waveguide to Rectangular Waveguide

5-5.3.3 Rectangular Waveguide Assembliesthat required in paragraph 5-1.3 for rectangularwaveguide.

Rectangular waveguide assemblies consisting ofbend, twist, flexible and/or straight assemblies, whenrequired for elliptical waveguide runs, shall comply withthe requirements of 5-1 and 5-2. Rectangular waveguideassemblies selected shall be compatible to the ellipticalwaveguide based on frequency of operation, materialtype, equipment interface flanges, system powerrequirements and pressurization requirements.

Elliptical waveguide shall be procured and installedin one continuous length where possible. Ellipticalwaveguide to rectangular waveguide transitions shall beinstalled on each end of the elliptical waveguide run. Iffor some valid reason the elliptical waveguide cannot beinstalled in one continuous run, elliptical waveguidecouplings must be procured and installed between eachsection of elliptical waveguide.

5-5.4 TECHNICAL CAPABILITIES 5-5.6 BENDINGElliptical waveguide of the types shown in Tables 5-4

and 5-5 appear to be rugged, but care must be taken inhandling and assembling to prevent denting or kinkingsince this would cause a degrading effect on its electricalperformance. These elliptical waveguides (with theexception of RG-387/U) are easily unreeled and installedproviding the proper tools and techniques are used. Thecorrect hand and hydraulic bending and twisting tools areavailable from the elliptical waveguide manufacturer alongwith instructions for the proper bending, twisting, cuttingand assembling of couplings and transitions.

Elliptical waveguide may be bent in either the "E"plane or "H" plane. The bend radius shall be not lessthan that shown in Table 5-5, unless a waveguide filler isused. When bending RG-387/U elliptical waveguide withfiller (cerobend), the minimum bending radius for an "E"plane bend is 10 inches and the minimum bending radiusfor an "H" plane bend is 21 inches. The RG-387/Uelliptical waveguide shall be annealed, prior to bending, bysubmersion in water at the melting point temperature ofcerobend. The elliptical waveguide shall not be oiled.Bending of elliptical waveguide shall comply with themanufacturers' instructions for a specific size ellipticalwaveguide, utilizing the bending tools or equivalentrecommended by the manufacturer. Bends shall not beindiscriminately installed for alignment purposes or to

5-5.5 SHOP PREFABRICATION GUIDELINESThe inspection, storage, handling and layout design

for the elliptical waveguide shall be basically the same as

5-54ORIGINAL


clear objects that can be moved. Rectangular waveguidebends, when required between the elliptical transitionassembly and the associated electronic equipment, shallconform to the guidance for bends in paragraphs 5-1 and5-2.

5-5.8 SUPPORTSElliptical waveguide shall be secured to the ships

structure by supports (hangers) that comply with therequirements stated herein.

5-5.7 TWISTING 5-5.8.1 DesignElliptical waveguide supports shall be designed so

as to provide a snug fit, but shall not cause deformationto the waveguide. The inside dimension of the supportbracket shall allow for the thickness of isolation material.The support shall be adjustable in two directions foralignment to the elliptical waveguide run. Figure 5-47 is atypical elliptical waveguide support.

Elliptical waveguide may be twisted providing thetwist does not exceed 90 degrees. The twist length shallbe no less than that shown in Table 5-5 for a specific sizeelliptical waveguide. Where there is insufficient space fortwisting the elliptical waveguide, a rectangular waveguidetwist assembly in accordance with MIL-W-3970 may beinstalled between the elliptical waveguide transitionassembly and the associated electronic equipment.

Figure 5-47. Typical Elliptical Waveguide Support

5-5.8.2 Materialmethod of isolation shall comply with the appropriaterequirements of paragraph 5-2.4.9.

The support material shall be of sufficient width andthickness to support the elliptical waveguide run. It shallsupport loading due to gun and missile blast, vertical keelshock factor, ice, wave action and wind. The materialshall be compatible with the ships structure and isolatedfrom the elliptical waveguide.

5-5.8.5 HardwareFastener hardware for elliptical waveguide supports

shall comply with the requirements of paragraph 5-2.4.11.

5-5.9 PENETRATIONS

5-5.8.3 Location Deck and bulkhead penetrations for ellipticalwaveguide runs shall comply with the requirements ofparagraph 5-2.5 and the following exceptions:The elliptical waveguide supports shall be positioned

so as to prevent any stress, strain or bind on anysegment of the elliptical waveguide run. Distancebetween supports shall not exceed five feet There shallbe a minimum of two supports for each waveguidesection that exceeds two feet in length. Supports shallbe installed not closer than six inches and not furtherthan twelve inches from each side of any coupling orflange connection.

5-5.9.1 Non-Watertight PenetrationsThe clearance hole through a non-watertight

bulkhead or deck shall be of sufficient size to pass theelliptical waveguide with coupling or transition assemblyattached.

When penetrating an air/dust/fume tight bulkheadthe method of penetration shall be similar to that shownin Figure 5-10.5-5.8.4 Isolation Material5-5.9.2 Watertight PenetrationsIsolation material shall be installed between the

elliptical waveguide and the support to prevent electrolyticaction and provide a snug fit. The isolation material and

Multi-cable Transit Devices shall not be used for

5-55ORIGINAL


passing elliptical waveguide through watertight decks orbulkheads.

for passing elliptical waveguide through watertight decksand bulkheads.

Split sleeve assemblies, similar to those required inparagraph 5-2.5 and shown in Figure 5-48 shall be used

Figure 5-48. Typical Split Sleeve Assembly for Elliptical Waveguide

5-5.10 PRESERVATIONfinish is needed to assist heat dissipation generated bythe transmission line, apply one coat of formula 153-Rol.8 black epoxy-polyamide paint.Preservation of elliptical waveguide and associated

assemblies shall be as stated herein. Ensure all flange mating surfaces, coupling matingsurfaces, transition mating surfaces and threadedsurfaces are completely free of any epoxy paint.5-5.10.1 Chemical Conversion Coatings

The interior and exterior surfaces of all ellipticalwaveguide, transition assemblies including flanges,elliptical waveguide couplings and the associatedrectangular waveguide assemblies required for shipboardinstallations shall have a chemical conversion coating toprevent corrosion. Aluminum components shall have achemical conversion coating in accordance with MIL-C-5541, class 3. Copper components shall have an IriditeNo. 7P, Mixture C (or equal) chemical conversioncoating.

5-5.10.3 Mating Joint ProtectionMating joints, including fastening hardware, shall be

coated with a sealer after installation and all testing iscompleted. This sealer is to prevent corrosive build-upcaused by sea water seepage into mating joints andmating hardware. Mating joints include the couplingsbetween two sections of elliptical waveguide, the couplingbetween a transition assembly and elliptical waveguide,the interface flange joint between a transition assemblyand a rectangular waveguide assembly, and the flangejoints of all associated rectangular waveguideassemblies.

5-5.10.2 Protective Paint CoatingsThe exterior surfaces of all elliptical waveguide,

transition assemblies, couplings and associatedrectangular waveguide assemblies shall have an epoxypolyamide protective paint in accordance with MIL-P-24441 and applied in accordance with the following:

An acceptable seal can be obtained with a spraycoating of clear polyurethane resin solution such asDexter Corporation's Laminar 48-C-24 or the equivalent.Using a narrow spray pattern, the polyurethane coatingshould be applied in such a manner to assure anadequate flow or run of material on the surface providinga maximum seal which will prevent seepage of salt waterinto mating surfaces and hardware.

The coating system shall consist of one coat offormula 150 primer, 2 to 4 mils thickness, and two coatsof formula 151 (Haze gray), each coat 2 to 3 mils dry filmthickness. The total minimum dry film thickness for thecoating system shall be 8.0 mils. Where a flat black

5-56ORIGINAL


5-5.11 DRY AIR REQUIREMENTSEnsure the support material, isolation material,

fastener hardware, location and alignment meets therequirements of paragraph 5-5.8.Elliptical waveguide runs should be pressurized with

dry air. The system design requirements shall complywith MIL-STD-1399, Section 102, and the following: 5-6.5 PENETRATIONS

5-5.11.1 Air ConnectionsBulkhead and deck penetrations for elliptical

waveguide shall be fabricated and installed in accordancewith paragraph 5-5.9. The deck/bulkhead sleeve part ofthe split sleeve assembly must be temporarily installedprior to pulling in the elliptical waveguide. After theelliptical waveguide has been temporarily secured inplace, the split sleeve assembly should be aligned to theelliptical waveguide and then welded to ships structure.Precautions shall be taken to prevent damage to thewaveguide during the welding process.

Dry air connections for elliptical waveguide runsshould be via the air connection that is factory installedon the elliptical to waveguide transition assembly or atthe transmitting device if applicable. Where this is notpracticable, the air connection shall comply with theapplicable requirements of 5-1.14.

5-5.11.2 PurgingProvision for purging the complete transmission line

run shall be installed. A purge valve shall be installed atthe lowest point in the transmission line adjacent toequipment it serves, where the transmission line can bepurged of moist air, or the accumulation of water. Thesource of dry air for the waveguide should be located atthe farthest point from the purge valve.

Ensure the deck or bulkhead penetration assemblymaterial, fastener hardware, protective coating andalignment to the elliptical waveguide meets therequirements of paragraph 5-5.9.

5-6.6 INSTALLATION INSTRUCTIONSThe methods and procedures required to install an

elliptical waveguide run will vary for each installationbased on the complexity of the electronic system,location of electronic equipment and the complexity ofships structure and other installed equipment between theelectronic equipment room and antenna.

5-6. ELLIPTICAL WAVEGUIDE INSTALLATIONPROCEDURES

5-6.1 GENERAL REQUIREMENTSThe installation instructions of the following

subparagraph are general in nature and are intended asguidance to assist the Installing Activity when installingelliptical waveguide aboard Naval ships.

Installation of elliptical waveguide runs shall complywith the same general requirements as those forrectangular waveguide in paragraph 5-2.1.

5-6.2 PROTECTION OF ELLIPTICALWAVEGUIDE

5-6.6.1 Site PreparationPrior to starting the shipboard assembly of elliptical

waveguide run, make a final inspection to ensure allbulkhead and deck cuts have been made, thatobstructions have been relocated where possible and thatinterfacing electronic equipments are permanentlymounted.

Protection of elliptical waveguide from time ofreceipt until completion of installation shall comply withthe applicable protective requirements listed in paragraph5-2.2 for rectangular waveguide.

5-6.3 LAYOUT OF ELLIPTICAL WAVEGUIDE The deck or bulkhead sleeve portion of split sleeveassemblies should be tack welded in place at this time.Ensure that waveguide supports have been fabricatedand are available for installation when needed.

Templates are not required for elliptical waveguideruns as they are for rectangular waveguide runs with theexception of RG-387/U. Targeting of RG-387/Uwaveguide runs shall comply with the requirements ofparagraph 5-2.3. The routing of elliptical waveguide runsshould be determined, deck and bulkhead cuts made,waveguide supports and split sleeve assembliesfabricated, and any obstructions in way of the waveguiderun relocated if possible. The deck/bulkhead sleeveportion of the split sleeve assembly should be tack-welded in place prior to removing the elliptical waveguidefrom storage.

5-6.6.2 On Site Handling and StorageAdequate facilities must be available for handling

and transportation of elliptical waveguide and associatedcomponents from storage to the installation site.

Elliptical waveguides RG-380/U and RG-387/U willbe in straight lengths up to twenty feet long. A twentyfoot length of RG-387/U would weigh 82 pounds notincluding the shipping crate. The other ellipticalwaveguide listed in Table 5-5 will be in coils or reels up tofive hundred feet in length. A five hundred foot reel ofRG-396/U would weigh 475 pounds not including theshipping reel weight.

5-6.4 ELLIPTICAL WAVEGUIDE SUPPORTSSupports for elliptical waveguide shall be fabricated

and installed in accordance with paragraph 5-5.8. Theelliptical waveguide should be pulled-in and held in placeby temporary means before installing the permanentsupports. The supports should be installed and adjustedto the waveguide run so that no stress or strain is placedon the elliptical waveguide. The elliptical waveguideshould be protected from possible damage while weldingsupports to ships structure.

The ends of elliptical waveguide and associatedassemblies should remain sealed until actual assembly inthe waveguide run. Small assemblies such as couplings,transitions, flexible sections and bend assemblies shouldbe stored in a safe area until time of assembly in thewaveguide run.

5-57ORIGINAL


5-6.6.3 Temporary Support of Waveguide 5-6.6.7 Coupling and Transition AssemblyThe elliptical waveguide should be supported by

temporary means while the complete run is beingassembled. If possible the elliptical waveguide should bein one continuous length. Where this is not possible, thewaveguide should be installed in such a manner as tokeep the use of couplings to a minimum.

The assembly of couplings and transitions toelliptical waveguide is very similar. The transition endthat mates with elliptical waveguide is identical to one-halfof the coupling used for small size elliptical waveguide.Figure 5-49 shows a coupling in place on two sections ofsmall elliptical waveguide and identifies the couplingcomponents. Figure 5-50 shows a coupling in place ontwo sections of large elliptical waveguide and identifiesthe coupling components. Figure 5-51 provides a cut-away view and component identification of a transitioncoupling for large elliptical waveguide. Figure 5-52 is atypical assembled section showing a transition, acoupling and large elliptical waveguide. Themanufacturers' assembly instructions should be carefullyfollowed to ensure the proper mechanical and electricalfit. The completed assembly shall not have "RF" leaks orpressure leaks.

5-6.6.4 On Site Bending and TwistingBends and twists can be formed in the elliptical

waveguide (RG-387/U excepted) as it is installed aboardship. This should be kept to a minimum since theobjective is to install a transmission line as straight andas short as possible.

Bending and twisting should be accomplished onlywith tools recommended by the elliptical waveguidemanufacturer or their equivalent.

Bends and twists formed at the installation site shallshow no signs of damage to the waveguide such asdents, puckers, wrinkles or cuts and the bend or twistradius shall be no less than the minimum radius listed inTable 5-5.

Coupling faces shall be parallel to each other within0.015 inch. Prior to bolting, this alignment shall bechecked with a feeler gage. Misalignment in excess of0.015 inch shall be corrected by waveguide supportadjustment or by additional bending or twisting. Do notuse the bolts to pull the elliptical waveguide intoalignment.

5-6.6.5 Cutting of Elliptical WaveguidePreparation of the elliptical waveguide end for

couplings and transitions are the same. When cuttingelliptical waveguide, the manufacturers' instructions mustbe carefully followed. This is to ensure a square smoothcut and to prevent any intrusion of foreign matter into thewaveguide. Cutting elliptical waveguide shall not beattempted without using the manufacturers'recommended cutting jigs or the equivalent.

5-6.6.8 Split Sleeve AssemblyThe split sleeve installation and assembly

requirements and procedures of paragraph 5-2 forrectangular waveguide shall apply to the ellipticalwaveguide deck or bulkhead penetration devices. Theonly difference in the assemblies would be the shape ofthe web plate assemblies.5-6.6.6 Chemical Conversion Coating5-6.6.9 Elliptical Waveguide Support InstallationA chemical conversion coating shall be applied to

the elliptical waveguide end that has been cut inpreparation for coupling or transition attachment. Thechemical conversion coating shall be in accordance withMIL-C-5541.

The installation and assembly of elliptical waveguidesupports shall comply with the requirements andprocedures of paragraph 5-2 for rectangular waveguide.The only difference in

5-58ORIGINAL


Figure 5-49. Coupling Assembly Identification for Small Elliptical Waveguide

Figure 5-50. Coupling Assembly Identification for Large Elliptical Waveguide

5-59ORIGINAL


Figure 5-51. Transition Assembly Identification for Large Elliptical Waveguide

the waveguide supports would be the shape of the bracketthat surrounds the elliptical waveguide.

run, alignment of connections joints, alignment of splitsleeve assemblies and supports to the waveguide thatare required for rectangular waveguide runs in paragraph5-2.5-6.6.10 Installation of Rectangular Sections

An elliptical waveguide run must be interfaced withelectronic equipment with rectangular waveguideassemblies. These may be short flexible sections, bendassemblies or short straight sections. The installationand assembly of these rectangular waveguide sectionsshall comply with the applicable installation requirementsand procedures of this document for rectangularwaveguide runs.

Figure 5-53 shows the relationship of ellipticalwaveguide components and rectangular waveguidecomponents in an overall transmission line run. Figure 5-53 is not intended to be representative of a typicalinstallation.

5-6.7 PURGING AND PRESSURIZATION(SHIPBOARD)

5-6.6.11 Overall Elliptical Waveguide Run The elliptical waveguide run, after completion ofinstallation, should be purged, tested for leaks andpressurized in accordance with the requirements ofparagraph 5-2.

The overall elliptical waveguide run; after finalassembly of couplings, transitions, rectangular waveguidesections, structural penetrations, waveguide supports;shall meet the same requirements for straightness of

5-60ORIGINAL


Figure 5-52. Typical Assembly Showing Transition, Coupling and Large Elliptical Waveguide

Figure 5-53. Typical Relationship of Elliptical to Rectangular Waveguide Components

5-61ORIGINAL


5-6.8 GROUNDING OF ELLIPTICALWAVEGUIDE RUNS

5-6.10 QUALITY CONTROL INSPECTIONQuality control inspections shall be conducted

during the installation process and after completion of allwork to ensure the elliptical waveguide run conforms tothe ships installation drawings and this document.

Grounding of elliptical waveguide runs, when requiredby Electromagnetic Interference Tests, shall comply withthe requirements and methods of MIL-STD-1310.

Quality control inspection shall comply with theguidelines of paragraph 5-2.10 and the following.5-6.9 PRESERVATION OF ELLIPTICAL

WAVEGUIDE RUNS 5-6.10.1 Couplings and TransitionsThe preservation of elliptical waveguide runs to

prevent corrosion and contamination shall comply withthe applicable requirements, methods and proceduresthat apply to rectangular waveguide in paragraph 5-2.9and the following:

Ensure couplings and transitions for ellipticalwaveguide have been assembled and fastening boltstorqued according to manufacturers' instructions. Ensurealignment of coupling faces is in accordance withparagraph 5-6.6.7.

5-6.9.1 Coupling and Transition Sealing5-6.11 ELECTRICAL REQUIREMENTS ANDTESTS

After satisfactory completion of the ellipticalwaveguide run, coupling and transition joints includingfastening hardware shall be spray coated with a narrowspray pattern using a polyurethane coating such asLaminar 48-C-24 or equivalent. This polyurethanecoating shall be applied in such a manner to assure anadequate flow or run of material on the surface providinga maximum seal which will prevent seepage of sea waterinto mating surfaces and hardware.

After satisfactory completion of installation, visualinspections, tightness tests, and prior to initial equipmentturn-on, the transmission line shall be electrically testedin accordance with the requirements and tests ofparagraph 5-2.11.

5-62ORIGINAL

INSTALLATION NAVSEA SE000-00-EIM-110 CONTENTSSTANDARDS APPENDIX 5A

APPENDIX 5-ATABLE OF CONTENTS

Military Documentation for Waveguide selection, requirements, design data and specifications are to be filed byuser in the following sequence.

Document No. Brief Description

MIL-STD-242, Part 1, SEC-501 Selection of Waveguides

MIL-STD-242, Part 1, SEC-503 Summary of Factors Effecting Waveguide Failure

MIL-HDBK-216, SEC-6 Waveguide Theory, Calculations, Frequencies, andDimensions

MIL-STD-1358 Selection of Rigid Rectangular, Rigid and CircularWaveguide

MIL-W-85 Rectangular Waveguide Specifications

MIL-W-23351 Rigid Waveguide Specifications

5-63ORIGINAL

INSTALLATION NAVSEA SE000-00-EIM-110 CONTENTSSTANDARDS APPENDIX 5B

APPENDIX 5-BTABLE OF CONTENTS

Military Documentation for Rigid Coaxial Transmission Line selection, requirements, design data and specificationsare to be filed by user in the following sequence.


MIL-STD-242, Part 1, SEC-701 Selection of Rigid Coaxial Transmission Lines

MIL-HDBK-216, SEC-6 Rigid Coaxial Transmission Line Theory, Calculations,Frequencies, and Dimensions

MIL-L-3890 Rigid Coaxial Transmission Line Specifications

MIL-L-28796 Rigid Coaxial Transmission Line AssembliesSpecification

5-64ORIGINAL

INSTALLATION NAVSEA SE000-00-EIM-110 CONTENTSSTANDARDS APPENDIX 5C

APPENDIX 5-CTABLE OF CONTENTS

Military Documentation for Transmission Line Flange selection, requirements, design data and specifications are tobe filed by user in the following sequence.


MIL-STD-242, Part 1, SEC-601 Selection of Flanges for Rigid Rectangular Waveguide

MIL-STD-242, Part 1, SEC-602 Selection of Flanges for Rigid Waveguide

MIL-STD-242, Part 1, SEC-603 Selection of Flanges for Rigid Coaxial TransmissionLines

MIL-STD-1327 Selection of Flanges for Transmission Lines

MIL-HDBK-216, SEC 7 & 11 Flange Theory, Calculations, Frequencies, andDimensions

MIL-F-3922 Rectangular Rigid Waveguide Flange Specifications

MIL-F-39000 Rigid Waveguide Flange Specifications

MIL-F-24044 Rigid Coaxial Transmission Line Flange Specifications

MIL-C-39004 Quick-Disconnect Specifications for Sub-MiniatureWaveguide Flanges

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INSTALLATION NAVSEA SE000-00-EIM-110 CONTENTSSTANDARDS APPENDIX 5D

APPENDIX 5-DTABLE OF CONTENTS

Military Documentation for Rigid Coaxial Transmission Line selection, requirements, design data and specificationsare to be filed by user in the following sequence.


MIL-HDBK-660 Fabrication of Bends, Twists, and Flange Assemblies

MIL-B-7883 Fabrication Requirements for Assemblies Producedby Brazing Processes

MIL-C-5541 Chemical Conversion Specifications

MIL-R-46846 Heat Shrinkable Rubber

Cold Shrinkable Rubber

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INSTALLATION NAVSEA SE000-00-EIM-110 CONTENTSSTANDARDS APPENDIX 5E

APPENDIX 5-ETABLE OF CONTENTS

Military Documentation for Transmission Line Assemblies and Components are to be filed by user in the followingsequence.


MIL-STD-242, Part 1, SEC-502 Selection of Flexible Waveguide Assemblies

MIL-HDBK-216, SEC-8 Waveguide Assemblies Theory and Data Tables

MIL-W-287 Flexible Waveguide Assemblies Specifications

MIL-W-3970 Rigid Waveguide Assemblies Specifications

MIL-STD-242, Part 1, SEC-702 Selection of Adapters (Waveguide and Coaxial)

MIL-HDBK-216, SEC-3A AND 9A Waveguide to Coaxial Cable Adapters, Theory andData Tables

MIL-A-22641 Waveguide to Coaxial Cable Adapters Specifications

MIL-A-24211 Waveguide Flange Gasket Specifications

MIL-STD-242, Part 1, SEC-802 Selection of Dummy Loads

MIL-HDBK-216, SEC-13 Dummy Load Calculations, Frequencies, PowerRatings and Terminations

MIL-D-3954 Dummy Load Specifications

MIL-STD-242, Part 1, SEC-1200 Selection of Directional Couplers

MIL-HDBK-216, SEC-12 Directional Coupler Data Tables

MIL-STD-1328 Selection of Directional Couplers

MIL-C-15370 Directional Coupler Specifications

MIL-HDBK-216, SEC-4 & 10 Waveguide Switch Data Tables

MIL-S-55041 Waveguide Switch Specifications

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SECTION 6EQUIPMENT INSTALLATION

INSTALLATION NAVSEA SE000-00-EIM-110 EQUIPMENTSTANDARDS INSTALLATION

SECTION 6EQUIPMENT INSTALLATION

6-1 INTRODUCTIONcomponents may be listed as individual units or as asystem by the contract documents. The InstallingActivity shall ensure the equipment or componentinstalled aboard ship is the same equipment orcomponent supplied by the Government for that specificfunction.

The installation of electronic equipment enclosuresaboard Navy ships is much more complicated than theinstalling of equipment in a land based installation.Some of the more critical factors that must beconsidered are; limited space, sea and battleconditions, normal ship reactions to sea conditions,effect of equipment weight and location on shipsoperational characteristics, habitability, accessibility,equipment reliability under severe sea conditions orbattle conditions, RF interference interaction betweenequipments, and the interface compatibility with otherequipments comprising a complex shipboard system. Itbecomes apparent from these factors that the Navymust and should expect the Installing Activity to useonly the best in materials, methods and workmanshipwhen installing electronic equipments aboard Navalships.

6-4.2 EQUIPMENT SUPPLIED BY THEINSTALLING ACTIVITY

Installing Activity furnished equipment is definedas any equipment, system or system component that isprocured and installed by the Installing Activity inaccordance with the government referenced documentsfor a specific installation. The Installing Activity shallensure the equipment or component procured andinstalled aboard ship is in compliance with MIL-E-46400and is the same equipment or component requested bythe Government for a specific installation.

6-4.3 EQUIPMENT FABRICATED BYINSTALLING ACTIVITY

6-2 PURPOSE Installing Activity fabricated equipment is definedas any equipment, system or system component that isfabricated by, or under the direction of, the InstallingActivity for shipboard installation in accordance with thegovernment referenced documents for a specificinstallation.

The purpose of this section is to make the Installeraware of the limitations and constraints placed upon theindividual equipment unit as well as the overall electronicsystem installed aboard Navy ships, and the InstallingActivity's responsibility to ensure each unit ofequipment in electronic spaces is located and installedin accordance with the latest approved documentsreferenced by a specific ship's specification of ShipAlt.

Enclosures for electrical fittings and fixtures shallcomply with the requirements of MIL-E-24142.

6-5 INSTALLATION REQUIREMENTS6-3 SCOPE The Installing Activity shall ensure electronic

equipment, systems and components are installedaboard Navy Ships in accordance with the methods,materials, procedures, and requirements stated and/orreferenced herein.

The intent of this section is to assist the InstallingActivity in obtaining the optimum equipment installationthrough the referencing of appropriate documentationand general requirements. Where conflict arises therequirements of NAVSEA 0910-LP-432-5900 GeneralSpecifications for Ships of the U.S. Navy (S9AA0-AA-SPN-010/GEN-SPEC) shall take precedence over allother documents referenced or requirements statedherein.

6-5.1 LOCATIONElectronic equipment shall be located in

accordance with Government Arrangement guidancedrawings, Installation Control Drawings and as statedherein:

6-4 SELECTION REQUIREMENTS(a) The location of a unit or system shall be so

that the added weight and movement does notadversely affect the ship's characteristics.The selection of electronic equipments for ship

installations is determined by the cognizant Governmentactivity based on the type ship and its function in thefleet. The Government either provides the equipment tothe Installing Activity or provides sufficient parametersfor procurement and/ or fabrication by the InstallingActivity through guidance documents such as ShipAltsand Standard Drawings.

(b) Units shall be so located that the designambient temperature is not exceeded. Particularattention should be given to the location of intake andexhaust vents with respect to adjacent units, so as notto dump exhaust heat from one unit into the intake ofanother.

(c) Units shall be raised above decks topreclude entry of water or dirt.

6-4.1 EQUIPMENT SUPPLIED BY THEGOVERNMENT

(d) Locating units with excessive noise levels inor near living or control spaces shall be avoided.

(e) Equipment located within the surface shipshull or superstructure shall be mounted by one of thefollowing methods, listed in order of preference:

Government furnished equipment is defined as anyequipment, system or system component that isprovided by the Government to the Installing Activity fora specific installation. These equipments or 1. Deck mounted

2. Overhead (accessory items such as

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indicators, speakers and junction boxes).6-6.1 UNIT IDENTITY3. Structural bulkheads only

4. Deck-mounted and braced to structuralbulkheads.

Identification plates for electronic equipment shallidentify each unit by functional name and signednumber.5. Overhead and braced to structural

bulkheads.6-6.2 ANTENNA IDENTIFICATION PLATES

6-5.2 FOUNDATIONS Identification plates for antennas shall include theantenna location in the assigned number.Installation Control Drawings, Navy Standard and

Type Drawings, the methods of DoD-STD-2003-1(NAVY) and Equipment Technical Manuals shall beused to obtain electrical, mechanical, and dimensionaldata including specific installation requirements andrestraints required for the design, fabrication andinstallation of equipment foundations and supports.

6-6.3 ABBREVIATIONSAbbreviations in accordance with MIL-STD-12 may

be used on identification plates requiring longinscriptions.

6-6.4 ATTACHED COMPONENTIDENTIFICATION6-5.3 FASTENERS

Installation Control Drawings, Navy Standard andType Drawings, the methods of DoD-STD-2003-1(NAVY) and Equipment Technical Manuals shall beused to obtain fastener data for the attachment ofelectronic equipment to foundations, supports or ship'sstructure.

Where an attached part of a component needsfurther identification, and the manufacturer has notprovided an identification plate, the Installing Activityshall provide and install the necessary identificationplate.

6-7 OPERATING INSTRUCTION CHARTS6-5.4 HABITABILITYElectronic equipment, associated cabling and other

devices shall be located to present a neat appearancewithout unnecessarily obstructing passage or reducingheadroom. Where practicable clear headroom in walkingareas shall be six feet, three inches minimum, and theminimum clear width of passageways through livingspaces shall be 36 inches.

Operating Instructions supplied with the equipmentshall be mounted as stated herein. OperatingInstructions provided by the Installing Activity shallcomply with the following requirements and mountinginstructions.

6-7.1 MATERIAL EXCEPTIONS

6-5.5 ACCESSIBILITYType GCP-H plastic sheeting used for lithographed

and laminated charts shall conform to FederalSpecification L-P-387.Electronic Equipment, associated cabling and

other devices shall be located to provide space foroperation, maintenance and repair. Equipment such asfuse boxes and panels shall be accessible forreplacement of fuses, switching and testing. Handoperated devices such as switches and pushbuttonsshall be located at least 1 foot and not more than 6 feetabove the deck.

Clear transparent vinyl resin sheets used forlaminating printed paper charts shall conform to FederalSpecifications L-P-535.

6-7.2 FINISHOperating Instruction Charts shall have a matte

finish.Permanently installed equipment shall be kept

clear of routes required for removal of equipment ormachinery.

6-7.3 LETTERINGOperating Instruction Charts shall have black

lettering printed in a clear and simple form withproportionally larger print for titles and paragraphheadings.

6-5.6 GROUNDING AND BONDINGElectronic Equipment, associated cabling and

other devices shall be electrically grounded and/orbonded in accordance with the requirements of MIL-STD-1310.

6-7.4 SIZEChart size shall be 8 inches by 10.5 inches overall,

where practicable. Smaller or larger sizes, preferable5.25 inches by 8 inches or 10.5 inches by 16 inches,shall be used where more suitable for the proper displayof the material.

6-5.7 SAFETYThe equipment installation shall meet the safety

requirements of MIL-STD-454, Requirement 1,necessary to protect the personnel installing, servicingand operating the equipment. 6-7.5 LOCATION

6-6 EQUIPMENT IDENTIFICATIONOperating Instruction Charts shall be mounted in a

conspicuous place on or near the equipment, or on ornear the equipment control point by one of the followingmethods listed in order of preferenceUnits of electronic equipment (including antennas)

shall be identified and labeled as stated herein: (a) Direct mounting on the subject equipment oron the adjacent structure providing they can be easily

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read from an advantageous position or operatingstation.

material and tools.(f) Flammable materials shall not be stored in

areas containing electrical and electronic equipments.(b) Standard card holders that comply withNAVSEA drawing 805-1639213. (g) Electrical and electronic equipment shall be

suitably covered to prevent damage from weldingsplatter, dust, flying particles, falling objects, spillage'sand other sources of possible damage.

(c) Visible index file frames and brackets thatcomply with NAVSEA drawing 805-1749000. These areto be used for holding operating instructions and safetyprecaution cards in spaces where it would be impracticalto make separate displays.

(h) Tools and installation materials such asfastener hardware, tape, sleeving and lugs shall not beplaced on ledges within equipment where they may beinadvertently left to fall into the equipment circuitry.6-8 EQUIPMENT PROTECTION

(i) Ventilation air filters to equipment shall becleaned or replaced as appropriate prior to initialenergizing of the equipment.

The protection of electronic equipment againstdamage of any type shall be the responsibility of theInstalling Activity from time of receipt through theinstallation process and until the equipment or systemis turned over to the Navy. The methods andprocedures used by the Installing Activity for electronicequipment protection shall comply with the requirementsstated herein.

(j) Equipment surfaces and finish shall beprotected from scarring, bending, denting and otherdamages.

(k) Work areas shall be adequately lighted tofurther ensure good workmanship.

6-8.3 DAMAGED EQUIPMENT REPAIR ORREPLACEMENT6-8.1 PROTECTION FROM RODENTS AND

INSECTS The Installing Activity shall be responsible for therepair or replacement of equipment or equipmentcomponents damaged between the time of receipt andtime of turn over to the Navy as stated herein.

During the installation period suitable precautionssuch as, but not limited to, the following shall be takento prevent equipment damage by rodents and insects.

(a) Cable openings and access doors onelectric and electronic enclosures shall be kept closedor fitted with temporary covers at all times except duringperiods involving actual work on a specificenclosure/equipment.

(a) Replaced equipment or components shall bethe same as the original.

(b) Workmanship of fabricated replacementcomponents shall be comparable to the originalcomponent workmanship.

(b) Unused openings in equipment shall befitted with metal covers on completion of the installation.

(c) Painting or refinishing of electrical andelectronic equipment shall be comparable to the originalfinish.(c) Cables shall be installed so as to avoid

inaccessible pockets or ledges of sufficient size toharbor rodents and insects. 6-8.4 PROTECTION FROM VANDALISM

(d) Where practicable, the installation shall becompletely accessible for inspection and cleaning.

The Installing Activity shall be responsible for theprotection of electronic equipment from vandalism andpossible damage from knob twisters during theinstallation period as stated herein.

(e) Where cables enter open ducts or trunks,the duct or trunk opening shall be fitted with metallicguards or screens. (a) Prior to installation aboard ship, electronic

equipment shall be stored in controlled areas withaccess by authorized personnel only.

(f) Where a choice exists between horizontaland vertical cable runs, the latter shall be selected whenpracticable. (b) Electronic equipment in transit from point of

receipt and/or storage area to the shipboard installationsite shall not be left unattended.6-8.2 CLEANLINESS--A FORM OF

PROTECTION (c) During the shipboard installation period,spaces containing electronic equipment shall becontrolled by suitable means that will prevent access byunauthorized personnel during unmanned conditions.

During the installation period suitable precautionssuch as, but not limited to, the following shall be takento prevent the damaging effects of dirt, grime and otherforeign matter to electrical and electronic equipment. (d) When electronic equipment installers are

working in spaces containing electronic equipment, itshall be their responsibility to prevent vandalism orequipment damage by unauthorized personnel.

(a) Equipment interior and exterior shall bevacuum cleaned only. Compressed air shall not beused.

(b) Areas where electrical and electronicequipments are being installed shall be kept clean andfree of debris.

6-9 SECURE EQUIPMENT

The installation of secure equipment, including thespaces in which they are located, shall comply with therequirements of MIL-STD-1680.

(c) Appropriate receptacles shall be provided forlitter and scrap disposal.

(d) Tops of electrical and electronic equipmentenclosures shall be kept free of all foreign objects.

(e) Tops of electrical and electronic equipmentenclosures shall not be used as storage for installation

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6-10 INTERFACE COMPATIBILITY

The interface compatibility of shipboard installedelectronic equipments between units of the samesystem, units of other electronic systems and withancillary equipment/systems shall comply with theapplicable requirements of MIL-STD-1399 for a specificinstallation.

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NIMB Installation Standards (SE000-00-EIM-110)

Documents

Transcript of NIMB Installation Standards (SE000-00-EIM-110)