department of defense standard practice -...

AMSC N/A AREA SESS

INCH-POUND MIL-STD-2003-2A(SH) 3 September 2009 SUPERSEDING DOD-STD-2003-2(SH) 24 June 1987

DEPARTMENT OF DEFENSE STANDARD PRACTICE

ELECTRIC PLANT INSTALLATION STANDARD METHODS FOR

SURFACE SHIPS AND SUBMARINES (EQUIPMENT)

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FOREWORD

1. This standard is approved for use by the Naval Sea Systems Command, Department of the Navy, and is available for use by all Departments and Agencies of the Department of Defense.

2. This standard disseminates up-to-date information detailing requirements for standard installation methods employed for submarine and surface ship electrical distribution systems.

3. These criteria apply to work on a specific ship or ships only when invoked by the Ship Specifications or similar contractual documents.

4. These criteria are for application to new construction, conversion, and alteration of existing ships.

5. Considering the magnitude of this standard, along with the changing requirements imposed on the Electric Plant, it is inevitable that changes will be required to update these criteria. Therefore, as comments arise, they should be forwarded to Naval Sea Systems Command (NAVSEA) 05Z3 to keep this standard as current as possible through subsequent revisions. Revisions will be accomplished by the issuance of additional or revised figures to be inserted in the basic standard parts. Superseded pages may be retained for reference if so desired.

6. Comments, suggestions, or questions on this document should be addressed to Commander, Naval Sea Systems Command, ATTN: SEA 05M2, 1333 Isaac Hull Avenue, SE, Stop 5160, Washington Navy Yard DC 20376-5160 or emailed to [email protected], with the subject line “Document Comment”. Since contact information can change, you may want to verify the currency of this address information using the ASSIST Online database at http://assist.daps.dla.mil.


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MIL-STD-2003-2A(SH)

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CONTENTS

PARAGRAPH PAGE

1. SCOPE......................................................................................................................................................................1 1.1 Scope.................................................................................................................................................................1 1.1.1 Application.....................................................................................................................................................1

2. APPLICABLE DOCUMENTS ................................................................................................................................1 2.1 General..............................................................................................................................................................1 2.2 Government documents ....................................................................................................................................1

2.2.1 Specifications, standards, and handbooks ................................................................................................1 2.2.2 Other Government documents, drawings, and publications.....................................................................2

2.3 Non-Government publications..........................................................................................................................2 2.4 Order of precedence..........................................................................................................................................2

3. DEFINITIONS .........................................................................................................................................................2 4. GENERAL REQUIREMENTS................................................................................................................................3

4.1 Electrical equipment mounting .........................................................................................................................3 4.1.1 Installation welding requirements ............................................................................................................3 4.1.2 Installation fasteners.................................................................................................................................3 4.1.3 Holes drilled in beams..............................................................................................................................3 4.1.4 Malleable iron castings.............................................................................................................................3

4.2 Switchboard mounting ......................................................................................................................................4 4.3 Storage batteries and servicing facilities...........................................................................................................4

4.3.1 Storage batteries – tray and rack installation............................................................................................5 4.4 Casualty power .................................................................................................................................................6 4.5 Shore power ......................................................................................................................................................6 4.6 Grounding of electrical equipment....................................................................................................................6 4.7 Tangle boxes .....................................................................................................................................................6

5. DETAILED REQUIREMENTS...............................................................................................................................6 6. NOTES .....................................................................................................................................................................6

6.1 Intended use ......................................................................................................................................................6 6.2 Acquisition requirements ..................................................................................................................................6 6.3 Designation of electric plant installation standard methods figures..................................................................7 6.4 Subject term (key word) listing.........................................................................................................................7 6.5 Changes from previous issue ............................................................................................................................7

APPENDIX A Standard Methods for Mounting Equipment .......................................................................................8 APPENDIX B Switchboard Mounting ......................................................................................................................48 APPENDIX C Battery Rack Mounting .....................................................................................................................56 APPENDIX D Casualty Power..................................................................................................................................75 APPENDIX E Shore Power ......................................................................................................................................91


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1. SCOPE

1.1 Scope. This standard covers standard installation methods for casualty power, shore power, electrical equipment, and switchboards.

1.1.1 Application. These installation methods are to be used by all installing activities. These methods do not identify ship or type, but do establish minimum standards of acceptance for Naval ships. It is the responsibility of the user activity to determine which method satisfies their requirements. It does not authorize relaxation of any requirement specifically invoked by new construction, conversion, overhaul, or refurbishment contracts. In instances where deviated design requirements (for example, ship type, ship class, and so forth) conflict with the requirements of this standard, the requirements of this standard govern. Any deviation for electric plant installation identified in this standard is to be submitted to NAVSEA 05Z3 for resolution.

2. APPLICABLE DOCUMENTS

2.1 General. The documents listed in this section are specified in sections 3, 4, or 5 of this standard. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in sections 3, 4, or 5 of this standard, whether or not they are listed.

2.2 Government documents.

2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

FEDERAL STANDARDS

FED-STD-H28 - Screw-Thread Standards for Federal Services

COMMERCIAL ITEM DESCRIPTIONS

A-A-50609 - Battery, Storage (Portable, Sealed, Maintenance-Free, Lead-Acid), 12 Volt, 15 Ampere-Hour, Type 12V-S-15 AH










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DEPARTMENT OF DEFENSE STANDARDS

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

DOD-STD-2134 - Storage Battery Arrangement for Minimum Stray Magnetic Field (Metric)

MIL-STD-3007 - Unified Facility Criteria and Unified Facility Guide Specifications

(Copies of these documents are available online at http://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

NAVAL SEA SYSTEMS COMMAND (NAVSEA) DRAWINGS

803-6983506 - Electrical Enclosures, Composite, Installation and Details

(Copies of this document are available from Commander, Portsmouth Naval Shipyard, ATTN: Code 280.1, Kittery, ME 03904.)

NAVAL SEA SYSTEMS COMMAND (NAVSEA) PUBLICATIONS

S9074-AR-GIB-010/278 - Requirements for Fabrication Welding and Inspection, and Casting Inspection and Repair for Machinery, Piping, and Pressure Vessels

(Copies of this document are available from the Naval Logistics Library, 5450 Carlisle Pike, Mechanicsburg, PA 17055 or online at http://nll.ahf.nmci.navy.mil.)

2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

3. DEFINITIONS

This section is not applicable to this standard.


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4. GENERAL REQUIREMENTS

4.1 Electrical equipment mounting. The installation of electrical equipment shall be in accordance with figures 2A1 through 2A22. Electrical equipment shall be secured in a manner that it does not come into direct contact with the outer shell plating or ballistic surfaces of the ship. A minimum clearance of 2 inches shall be maintained for inspection and painting. The mounting of electrical equipment on bulkheads subject to condensation, such as the outer surface of refrigerated space boundary bulkheads, shall be avoided. If no other location is feasible, the equipment shall be mounted at least 2 inches clear of such surfaces. Also, cable shall not be mounted in direct contact with such bulkheads, but shall use one of the wet location methods. When such surfaces are insulated, appropriate insulation methods shall be used for both equipment and cable. Where necessary to attach electrical equipment to decks or bulkheads within gun and missile blast areas, such equipment shall be mounted to provide a 2-inch minimum clearance between the structure and equipment, and, moreover, such equipment shall be located clear of areas of maximum expected deflection or whip of bulkhead and deck plating in order to prevent breakage or pulling loose of mounting feet. Composite electrical enclosures shall be mounted in accordance with NAVSEA Standard Drawing 803-6983506.

4.1.1 Installation welding requirements. Unless otherwise specified on the individual figure, the welding of studs, step hangers, tapped pads, mounting pads, extension hangers, and top bracing supports for switchboards shall be in accordance with S9074-AR-GIB-010/278. Pads, studs, and so forth shall be tapped or threaded before being welded to the ship’s structure.

4.1.2 Installation fasteners. Bolts, nuts, machine screws, and flat and lock washers shall be of commercial grade (5 or better) and material specified. One to five (1-5) threads shall project past locking nuts. Threads shall be American-National firm, coarse series Class 2, unless otherwise specified in a ship contract or ship specification. Thread fastenings shall be as specified in FED-STD-H28. Locking devices shall be used for bolts mounting electrical equipment. Through bolts and self-locking nuts shall be used to mount equipment in gun mounts and in battery compartments. When required by local QA, torque seal shall be installed on all bus connections in power panels, load centers, switchboards, and power converters upon verification of torque using a calibrated torque wrench. Switchboards and load centers shall have torque seal on bus to bus connections as well as cable connections (vendor or contractor) to bus work upon verification of torque using a calibrated torque wrench.

4.1.3 Holes drilled in beams. Location of holes drilled in beams for passing cables or securing of supports or equipment shall be on or above the neutral axis.

4.1.4 Malleable iron castings. Malleable iron castings are not approved for any install except as may be noted on the individual figure.


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4.2 Switchboard mounting. Switchboard mounting and bracing shall be in accordance with figures 2B1 through 2B6. The base of each unit shall be adequately secured to the foundation and shall be in a level plane (with reference to ship’s baseline) when secure. In order to ensure there is no warping of the switchboard framework or misalignment of component parts of the switchboard, the base of each section shall not be out-of-plane by more than ⅛ inch after installation, with all securing bolts tightened. Switchboards shall be located so that the base of the units can be bolted directly to the deck stiffeners or foundation and not bolted to a thin deck plate. Foundation bolts of the switchboard units shall be fastened to metal whose thickness in the immediate vicinity of the bolts is at least equivalent to the bolt diameter. The addition of pads may be necessary to obtain the required thickness or to compensate for the lack of flanges on the deck stiffeners. The requirements regarding rigidity of the switchboard structure, the requirements for securing the units to the foundation, and for the foundation in the ship for mounting the switchboard are intended to ensure that the switchboard units after installation in the ship will not display unsatisfactory resonant vibrations. If the horizontal vibration of deck-mounted switchboard sections or switchboards exceeds 0.040-inch double amplitude, measured on the framework near the top of the structure, top bracing shall be provided. Rigidity of the braces and their attachments shall be adequate to prevent vibration of the top of the section. Shear bolts may be employed in the braces if provision is made to prevent the brace from striking the section or bulkhead after shearing of the bolt. Horizontal braces are preferred. The angle of inclination of braces shall not exceed 45 degrees from the horizontal. The braces shall possess inherent flexibility in the vertical direction. Top bracing and installation features shall conform to the methods shown in this section. Bolts, nuts, and washers used to fasten the braces to the switchboard frame shall be held captive by suitable means. Unless other means of bracing are provided, sway bracing shall be provided front-to-back on all switchboards and side-to-side on one-section and two-section switchboards.

4.3 Storage batteries and servicing facilities. Storage batteries and service facilities shall be in accordance with figures 2C1 through 2C10, and all batteries shall be valve regulate lead acid (VRLA), unless otherwise approved by NAVSEA 05Z3. The required number of trays or cells shall be connected in series to produce the required voltage. The necessary ampere-hour capacity shall be obtained by the use of the proper size of battery. Batteries may be connected in parallel in order to obtain greater capacities than those available from the largest sized battery. In general, batteries and their applications shall be as shown in table I. Alternative VRLA batteries shall be proposed if technical and economic factors justify their use. All contractor-furnished and Government-furnished batteries shall be maintained by the contractor in accordance with the manufacturer’s instructions during construction of the ship. The contractor shall charge all batteries in accordance with manufacturer’s instructions not more than 30 days before Acceptance Trials (AT). Battery records shall be kept which indicate the battery function, the Navy type designation, the specification type, the initial charging date, and the dates of subsequent charges, and date and type of any other maintenance actions.


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TABLE I. Classes and applications of portable lead storage batteries.

Navy type designation Reference Typical uses 1/

2V-20AH-L/D-A A-A-50610 Portable floodlights 12V-15AH-L/D-A or B A-A-50609 Gyros and emergency communications

on submarines 6V-50AH-L/D-A or B A-A-50611

A-A-50612 12V-50AH-L/D-A or B A-A-50611

A-A-50612

Dial telephone systems having a capacity of 50 lines or less, interior

communications, gyrocompass emergency power

6V-100AH-L/D-A or B A-A-50613 A-A-50614

8V-100AH-L/D-A or B A-A-50613 A-A-50614

12V-100AH-L/D-A or B A-A-50613 A-A-50614

All purposes mentioned for 50-AH Type and for gun firing and sight

lighting circuits, director instrument illumination, fire control instrument

illumination, radio power, and 100 or 150 line telephone systems

6V-130AH-H/S-A or B A-A-50615 A-A-50616

8V-130AH-H/S-A or B A-A-50615 A-A-50616

12V-130AH-H/S-A or B A-A-50615 A-A-50616

Engine starting services

6V-205AH-H/S-A or B A-A-50617 8V-205AH-H/S-A or B A-A-50617

Engine starting services requiring greater capacity than 130-AH.

6V-300AH-L/D-A or B A-A-50618 8V-300AH-L/D-A or B A-A-50618

General services emergency batteries, electronic, and dial telephone systems

having a capacity of more than 150 lines

LEGEND:

V = Battery nominal voltage

AH = Ampere-hour capacity

L/D = Low rate/deep discharge cycling

H/S = High rate/shallow discharge cycling

NOTE: 1/ Typical uses of batteries shall include UPS systems in support of shipboard applications such as navigation

systems, control systems, etc.

4.3.1 Storage batteries – tray and rack installation. Trays for separately mounted batteries shall be installed to be readily accessible for testing and cleaning. Spacing of trays shall ensure effective ventilation. Clearance above trays shall be not less than 12 inches. Battery trays and racks (open and enclosed) shall be in accordance with figures 2C1 through 2C11. Where racks cannot be adequately secured to the deck and bulkhead, they shall be additionally secured by diagonal braces to the deck above, but in no case shall the vertical support extend from deck to deck. Spaces assigned for storage and service of spare batteries shall have sufficient shelf space or racks for storage of all spare batteries. On minesweepers, mine tenders, mine hunters, and similar type ships designed for low magnetic signature, where it is required to reduce to a minimum the stray magnetic field produced by the current through batteries and connections to them, arrangement and connections shall be as shown in DOD-STD-2134.


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4.4 Casualty power. The casualty power distribution system installation shall be in accordance with figures 2D1 through 2D7. These figures depict the installation requirements for horizontal bulkhead terminals, vertical risers, portable jumper cable, cable stowage racks, terminals mounted in equipment enclosures, terminal wiring, installation, and end preparation of casualty power cable. The following equipment and cable types shall be used for casualty power installments:

Bulkhead terminals Symbol 1046 and 1048

Riser terminals Symbol 1047

Plugs Symbol 1049

Cable storage racks Symbol 1040 and 1040.1

Permanent riser cable TSGU-75 (LSTSGU-75)

Portable cable THOF-42 (LSTHOF-42)

4.5 Shore power. Receptacles and cables associated with shore power facilities for surface ships shall be in accordance with the installation methods shown in figures 2E1 through 2E23. These figures depict the configuration of shore power stations inside and outside bulkheads, mounting of connection boxes, incline mounted shore power receptacles in protected areas, free standing shore power stations, details of in-line connectors on alongside power cables, portable cable jumper assemblies, termination and potting of plugs, termination and heat shrink boot requirements for in-line connectors, installation details for receptacles, typical shore power cable supports, repair and mounting of terminal boxes, and the repair and preparation of shore power cables.

4.6 Grounding of electrical equipment. The methods for grounding electrical equipment, enclosures, and supports shall be in accordance with MIL-STD-1310. Removable and hinged enclosure access panels with mounted energized components shall be grounded to the enclosure using a flexible ground strap when any voltage on the access panel exceeds 30 volts.

4.7 Tangle boxes. Tangle boxes shall be used when necessary. For instance, a tangle box shall be used if it becomes necessary to remove cable jackets from electrical cables prior to entering electrical equipment such as switchboards and load centers. Removal of cable jackets may be required to meet cable bend radius requirements or for convenience of handling due to the large number of cables involved. Conductors and cables shall be supported within the first 16 inches of coming out of the collar or transit upon entering the tangle box and every 16-32 inches thereafter. Support shall be provided using a fire resistant, non-magnetic material, such as aluminum or phenolic. Clearance of conductors and cables must maintain 1.5 inches from sides, bottom, top, and beams inside the tangle box. There shall be no duct work, piping, or any other foreign objects in the tangle boxes. Tangle boxes shall be constructed by welding and shall be painted for corrosion protection.

5. DETAILED REQUIREMENTS

(See figures.)

6. NOTES

(This section contains information of a general or explanatory nature that may be helpful, but is not mandatory.)

6.1 Intended use. This section specifies the requirements for equipment mounting, switchboard mounting, battery equipment, casualty power, and shore power methods to be employed both on surface ships and submarines. Standard methods identified for electric plant installation are intended for new construction, conversion, and alteration of existing ships.

6.2 Acquisition requirements. Acquisition documents should specify the following:

a. Title, number, and date of this standard. b. Fastener threads if other than specified in 4.1.2.


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6.3 Designation of electric plant installation standard methods figures. The electric plant installation standard method MIL-STD-2003-2 contains drawings that depict standard methods that are applicable for general electric plant installation on both surface ships and submarines. The methods shown on the figures are grouped together providing similar functions. These groups are:

MIL-STD-2003-2 (Equipment) Group A. Standard Methods for Mounting Equipment

B. Switchboard Mounting

C. Battery Rack Mounting

D. Casualty Power

E. Shore Power

The methods shown on the figures are identified by the following alphanumeric designation system:

METHOD 2A-14-2 2 A- 14- 2 Method (always the last number)

Sequential figure number

Group number

Military Standard section 2

Thus, Method 2A-14-2 identifies Method 2, figure number 14, Group A of MIL-STD-2003-2.

6.4 Subject term (key word) listing.

Battery equipment Casualty power Shore power Switchboard mounting

6.5 Changes from previous issue. Marginal notations are not used in this revision to identify changes with respect to the previous issue due to the extent of the changes.


MIL-STD-2003-2A(SH) APPENDIX A

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GROUP A - STANDARD METHODS FOR MOUNTING EQUIPMENT

A.1 SCOPE

A.1.1 Scope. This appendix describes standard methods and procedures for the installation and mounting of equipment.

A.2 APPLICABLE DOCUMENTS

A.2.1 General. The documents listed in this section are specified in this appendix. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in this appendix, whether or not they are listed.

A.2.2 Government documents.

A.2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

COMMERCIAL ITEM DESCRIPTIONS

A-A-59125 - Terminal Boards, Molded, Barrier Screw and Stud Types and Associated Accessories

DEPARTMENT OF DEFENSE SPECIFICATIONS

MIL-E-917 - Electric Power Equipment, Basic Requirements

MIL-DTL-16036 - Switchgear, Power, Low Voltage, Naval Shipboard

MIL-PRF-23236 - Coating Systems for Ship Structures

MIL-S-24149 - Studs, Welding, and Arc Shields (Ferrules), General Specification for

MIL-C-24231/1 - Connector, Plug, Type I, Molded, Three-, Four-, and Five-Conductor

MIL-C-24231/10 - Connectors, Single Cable, Type III, 14-, 24-, 30-, or 40-Conductor

MIL-C-24231/25 - Connector, Hull Inserts, Type VII

MIL-DTL-24441/20 - Paint, Epoxy-Polyamide, Green Primer, Formula 150, Type III

MIL-PRF-32273 - Battery Cells and Modules, Valve Regulated Lead-Acid, Main Storage, Submarine; General Specification for

MIL-PRF-32273/1 - Battery Cell, Valve Regulated Lead-Acid, Main Storage, Submarine, Classification Type B

MIL-PRF-32273/2 - Battery Cell, Valve Regulated Lead-Acid, Main Storage, Submarine, Classification Type C


MIL-STD-2003-3 - Electric Plant Installation Standard Methods for Surface Ships and Submarines (Penetrations)

DEPARTMENT OF DEFENSE HANDBOOKS

MIL-HDBK-2036 - Preparation of Electronic Equipment Specifications





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A.2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.


815-1853069 - Bearing Circle, Compass Holder for Portable Gyro Repeater

(Copies of this document are available from Commander, Portsmouth Naval Shipyard, ATTN: Code 280.1, Kittery, ME 03904.)

NAVAL SEA SYSTEMS COMMAND (NAVSEA) PUBLICATIONS

S9086-KC-STM-010 - NSTM Chapter 300, Electric Plant-General

(Copies of this document are available from the Naval Logistics Library, 5450 Carlisle Pike, Mechanicsburg, PA 17055 or online at http://nll.ahf.nmci.navy.mil.)

A.2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

ASTM INTERNATIONAL

ASTM A276 - Standard Specification for Stainless Steel Bars and Shapes

ASTM F1836M - Standard Specification for Stuffing Tubes, Nylon, and Packing Assemblies (Metric)

(Copies of these documents are available from ASTM International, 100 Barr Harbor Dr., P.O. Box C700, West Conshohocken, PA 19428-2959 or online at www.astm.org.)

A.2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

A.3 REQUIRED EQUIPMENT AND MATERIALS

A.3.1 Required equipment and materials. Equipment and materials for the installation and mounting of equipment shall be as specified in figures 2A1 through 2A25.

A.4 NOTES AND PROCEDURES

A.4.1 Dimensions. For figures and tables in this section, all dimensions are in inches unless otherwise noted.

A.4.2 Figures. Table 2AI provides information for the figures in this group.

TABLE 2AI. Figures for equipment mounting.

Figure number Equipment mounting Page

2A1 Equipment secured to watertight and non-watertight steel decks or bulkheads 11 2A2 Equipment mounted on insulated watertight steel deck or bulkhead 13 2A3 Bracket fans supported on steel bulkheads 15 2A4 Equipment secured to non-watertight steel decks or bulkheads 17 2A5 Equipment secured to steel stanchions 19 2A6 Equipment mounted on aluminum watertight and non-watertight decks and bulkheads 20


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TABLE 2AI. Figures for equipment mounting - Continued.

Figure number Equipment mounting Page

2A7 Equipment mounted on insulated aluminum decks or bulkheads 22 2A8 Equipment mounted on non-watertight aluminum bulkheads 24 2A9 Equipment mounted on aluminum stanchions 25 2A10 Equipment mounted on aluminum or steel pilaster bulkheads 26 2A11 Equipment mounted on metal joiner bulkheads 28 2A12 Equipment mounted on expanded metal or wire mesh bulkheads 29 2A13 Equipment mounted on expanded metal or wire mesh bulkhead 30 2A14 Equipment mounted on cabling racks 31 2A15 Ceiling fan support in refrigerated spaces 32 2A16 Equipment mounted in refrigerated spaces 33 2A17 Connecting adjacent cast aluminum equipment with pipe nipples 34 2A18 Connecting adjacent equipment with pipe nipples 35 2A19 Mast position indicator switches for submarines 37 2A20 Locking devices on electrical connections and installations on submarines 39 2A21 Portable ship control unit submarine bridge type 42 2A22 Electrical equipment mounting to GRP bulkheads/panels 44 2A23 Electrical equipment mounting to GRP bulkheads/panels 45 2A24 Electrical equipment mounting to GRP bulkheads/panels 45



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D (S

TEE

L) -

SIZ

E AS

REQ

UIR

ED F

OR

MO

UN

TIN

G B

RAC

KET



12

NOTES: 1. Suitable corrosion protection shall be used for dissimilar metals. 2. Methods shown are for use on interior decks or bulkheads when not subjected to moisture or high temperature

[125 °F (51.6 °C)]. Not to be used for decks or bulkheads insulated or exposed to weather. 3. CRES hardware required where equipment is brass or dissimilar metal.

FIGURE 2A1. Equipment secured to watertight and non-watertight steel decks or bulkheads - Continued.



13

FIGURE 2A2. Equipment mounted on insulated watertight steel deck or bulkhead.

DE

CK

OR

BU

LKH

EA

D

CO

LLA

R S

TUD

- M

IL-S

-241

49 S

TEE

L3/

8"-1

6 FO

R F

IXTU

RE

S O

R F

ITTI

NG

SH

AV

ING

13/

32" D

IA. M

OU

NTI

NG

HO

LES

.5/

16"-

18 F

OR

FIX

TUR

ES

OR

FIT

TIN

GS

HA

VIN

G 1

1/32

" DIA

. MO

UN

TIN

G H

OLE

S.

1/4"

-20

FOR

FIX

TUR

ES

OR

FIT

TIN

GS

HA

VIN

G 9

/32"

DIA

. MO

UN

TIN

G H

OLE

S.

EQ

UIP

ME

NTS

TEP

HA

NG

ER (S

TEEL

)

NO

TE 3

AN

D N

OTE

4H

EX H

EAD

BO

LT O

RR

OU

ND

HE

AD

MA

CH

INE

SC

REW

(STE

EL)

- S

IZE

AN

D N

UM

BE

R T

O S

UIT

SE

E 4

.1.1

INS

ULA

TIO

N

NO

TE 3

AN

D N

OTE

4

ME

THO

D 2

A-2

-3E

QU

IPM

EN

T S

EC

UR

ED

TO

EXT

EN

SIO

N H

AN

GE

R W

ITH

TH

RO

UG

H B

OLT

S(S

EE N

OTE

5)

EQ

UIP

ME

NT

INS

ULA

TIO

N

HEX

HE

AD

BO

LTS

WIT

H N

UTS

OR

RO

UN

D H

EA

D M

AC

HIN

ES

CR

EWS

WIT

H N

UTS

(STE

EL) -

SIZ

E A

ND

NU

MB

ER

TO

SU

IT

NO

TE 3

AN

D N

OTE

4

BU

LKH

EA

D

STE

P H

AN

GE

R (S

TEE

L)

SE

E 4.

1.1

TAC

K W

ELD

2 S

IDE

S O

PTI

ON

AL

1/8"

ME

THO

D 2

A-2

-4D

ECKS

OR

BU

LKH

EAD

S W

ITH

INSU

LATI

ON

EQ

UIP

ME

NT

SEC

UR

ED

WIT

H C

OLL

AR

STU

DS

(SE

E N

OTE

5)

DE

CK

OR

BU

LKH

EA

D

EQ

UIP

ME

NT

INS

ULA

TIO

N

ME

THO

D 2

A-2

-2E

QU

IPM

EN

T S

EC

UR

ED

TO

LON

G S

TUD

PA

DS

(SEE

NO

TE 2

AN

D N

OTE

5)

DE

CK

OR

BU

LKH

EA

D

EQ

UIP

ME

NT

STU

D P

AD

WIT

H H

EX

NU

T (S

TEE

L)

SE

E 4.

1.1

INS

ULA

TIO

N

NO

TE 3

AN

D N

OTE

4

MET

HO

D 2

A-2

-1E

QU

IPM

EN

T S

ECU

RE

D T

OEX

TEN

SIO

N H

ANG

ER

WIT

H T

APPE

D H

OLE

S(S

EE

NO

TE 2

AN

D N

OTE

5)



14

NOTES: 1. CRES hardware required when equipment is aluminum or brass or dissimilar metal. 2. Methods 2A-2-1 and 2A-2-2 may be used when bulkheads or decks are special treatment steel (S.T.S.). 3. CRES washers are required for aluminum or brass equipment. 4. Step hangers shall be flush with surface of insulation and threads shall extend ½" above insulation or

equipment to properly mount equipment. 5. Methods 2A2-1, 2A2-2, 2A2-3, and 2A2-4 are for use on interior decks or bulkheads not subjected to

moisture or high temperature [125 °F (51.6 °C)].

FIGURE 2A2. Equipment mounted on insulated watertight steel deck or bulkhead - Continued.



15

FIGURE 2A3. Bracket fans supported on steel bulkheads.

MET

HO

D 2

A-3

-2FA

N S

UP

POR

TED

AW

AY

FRO

M S

HIP

'S S

TRU

CTU

RE

FO

R B

ULK

HE

AD

SW

ITH

INSU

LATI

ON

OR

TO

AVO

ID A

N O

BSTR

UC

TIO

N

BR

AC

KE

T FA

N

BU

LKH

EA

DO

R F

RA

ME

SP

AC

ER

WA

SH

ER

- C

RE

S.

STU

D W

ELD

STU

DS

WIT

H N

UTS

-3/

8" D

IAM

ETE

R M

INIM

UM

LEN

GTH

AS

RE

QU

IRE

D

BU

LKH

EA

D

INS

ULA

TIO

N

SP

AC

ER

WA

SH

ER

- C

RES

.

BR

AC

KE

T FA

N

SE

E 4

.1.1

A L

IGH

TEN

ING

HO

LE M

AY

BE

CU

T IN

PLA

TE S

UP

PO

RT

TO C

ON

SE

RV

E W

EIG

HT

3/16

" PLA

TE S

UP

PO

RT

(STE

EL)

STU

D W

ELD

STU

DS

OR

HE

X H

EA

DB

OLT

S W

ITH

NU

TS -

3/8"

DIA

ME

TER

MIN

IMU

M L

EN

GTH

AS

RE

QU

IRE

D

ME

THO

D 2

A-3

-3FA

N S

UP

POR

TED

ON

A F

RAM

EFA

N S

HO

WN

SEC

UR

ED

BY

STU

D P

AD

S

BU

LKH

EA

D

FRA

ME

BR

AC

KE

T FA

N

STU

D P

AD

S W

ITH

NU

TS -

3/8"

DIA

ME

TER

MIN

IMU

M

NO

TE 1

SE

E 4

.1.1

MET

HO

D 2

A-3

-4FA

N M

OU

NT

ON

NO

N-W

ATE

RTI

GH

T B

ULK

HE

AD

FAN

SH

OW

N S

ECU

RE

D B

Y F

OU

R B

OLT

S NW

TB

ULK

HE

AD

ON

LY

NO

TE 1

MO

UN

TIN

GB

RA

CK

ET

4 - 3

/8" H

EX

HE

AD

BO

LTS

WIT

H N

UTS

LEN

GTH

AS

RE

QU

IRE

D

MET

HO

D 2

A-3

-5FA

N S

UP

POR

TED

ON

A F

RAM

EFA

N S

HO

WN

SEC

UR

ED

BY

TAP

PE

D P

AD

S

BU

LKH

EA

D

FRA

ME

BR

AC

KE

T FA

N

TAP

PE

D P

AD

S

NO

TE 1

SE

E 4

.1.1

HE

X H

EA

D B

OLT

S -

3/8

"D

IAM

ETE

R M

INIM

UM

ME

THO

D 2

A-3-

1FA

N S

UPP

OR

TED

ON

BU

LKH

EAD

SFA

N S

HO

WN

SEC

UR

ED

BY

STU

D W

ELD

STU

DS



16

NOTES: 1. CRES hardware required when material of fan brackets is aluminum or brass or dissimilar metal. 2. Methods shown are for use on interior bulkheads not subjected to moisture or high temperature [125 °F

(51.6 °C)].

FIGURE 2A3. Bracket fans supported on steel bulkheads - Continued.



17

FIGURE 2A4. Equipment secured to non-watertight steel decks or bulkheads.

ME

THO

D 2

A-4

-1E

QU

IPM

EN

T S

ECU

RE

D T

OD

EC

KS

OR

BU

LKH

EA

DS

WIT

H IN

SU

LATI

ON

(SE

E FI

GU

RE

2A2

)

SE

E 4.

1.1

HEX

HE

AD

BO

LT A

ND

NU

TO

R R

OU

ND

HE

AD

MAC

HIN

ES

CR

EW A

ND

NU

T (S

TEEL

) -N

UM

BER

AN

D S

IZE

TO

SU

IT

1/8"

TA

CK

WEL

D2

SID

ES

OPT

ION

AL

EQ

UIP

ME

NT

NO

TE 1

HEX

HE

AD

BO

LT O

R R

OU

ND

HEA

D M

ACH

INE

SCR

EW

(STE

EL) W

ITH

NU

TS -

LEN

GTH

AS

RE

QU

IRED

SEE

NO

TE 4

STR

UC

TUR

E

FOU

ND

ATI

ON

OR

MO

UN

TIN

G P

AD

NO

TE 1

BO

LT (S

TEEL

)

WAT

ER

SEA

L W

ASH

ER

EQ

UIP

MEN

T M

OU

NTI

NG

STR

AP

NO

N-W

ATE

RTI

GH

T EQ

UIP

MEN

T

DE

CK

OR

BU

LKH

EAD

EQ

UIP

ME

NTST

EP

HA

NG

ER (S

TEE

L)

NO

TE 1

HE

X H

EA

D B

OLT

OR

RO

UN

DH

EA

D M

AC

HIN

E S

CR

EW(S

TEEL

) WIT

H N

UTS

-LE

NG

TH A

S R

EQU

IRED

INS

ULA

TIO

N

ME

THO

D 2

A-4

-2E

QU

IPM

EN

T S

ECU

RE

D T

OS

TEE

L S

TRU

CTU

RE

WIT

HO

UT

INS

ULA

TIO

N

STE

EL

STR

UC

TUR

E

EQ

UIP

ME

NT

MET

HO

D 2

A-4

-3E

QU

IPM

EN

T S

EC

UR

ED

TO

DE

CKS

OR

BU

LKH

EA

DS

WIT

HO

UT

INS

ULA

TIO

N U

SIN

G E

XTE

NSI

ON

HAN

GE

R T

OC

LEA

R A

N O

BST

RU

CTI

ON

DE

CK

OR

BU

LKH

EAD

STE

P H

AN

GER

(STE

EL)

SEE

4.1

.1

MET

HO

D 2

A-4

-4M

OU

NTI

NG

NO

N-W

ATE

RTI

GH

TE

QU

IPM

EN

T W

HE

RE

EX

CE

SSIV

EM

OIS

TUR

E O

R D

RIP

IS P

RE

SEN

T

SEE

4.1.

1

NO

TE 1



18

TABLE 2A4-I. Waterseal washer table.

Mounting Metal portion – stainless steel Rubber portion - neoprene

Bolt O.D. I.D. Thickness O.D. I.D. Thickness

¼ 0.729 0.3593 0.0299 0.8125 0.1875 0.0625 to 0.0937 ⅜ 0.875 0.50 0.0299 0.9375 0.2812 0.0625 to 0.0937 ½ 1.1875 0.5468 0.0299 1.250 0.4062 0.0625 to 0.0937 ⅝ 1.5625 0.750 0.0359 1.625 0.50 0.0625 to 0.0937 ¾ 1.090625 0.962 0.0359 2.0312 0.625 0.0625 to 0.0937

NOTES:

1. CRES hardware required when equipment material is aluminum, brass, or dissimilar metal. 2. Suitable corrosion protection shall be used for dissimilar metals. 3. Methods 2A-4-1, 2A-4-2, and 2A-4-3 are for use on interior decks and bulkheads not exposed to weather,

moisture, or high temperature [125 °F+ (51.6 °C+)]. 4. This dimension shall be sufficient to clear the obstruction.

FIGURE 2A4. Equipment secured to non-watertight steel decks or bulkheads - Continued.



19

NOTES: 1. CRES hardware required when equipment material is aluminum, brass, or dissimilar metal. 2. For use in interior of ships where not exposed to weather, moisture, or high temperature [125 °F+

(51.6 °C+)].

FIGURE 2A5. Equipment secured to steel stanchions.

STA

NC

HIO

N (S

TEE

L)

EQ

UIP

ME

NT

NO

TE 1

SEC

UR

ING

BO

LTS

WIT

H C

RES

NU

TS A

ND

CR

ES

LO

CK

WA

SH

ER

S(S

EE

NO

TE 1

)

SEE

4.1

.1S

TEP

HAN

GER

(STE

EL)

MET

HO

D 2

A-5

-2E

QU

IPM

EN

T S

EC

UR

ED T

O T

WO

STE

P H

AN

GE

RS

SEE

4.1

.1ST

AN

CH

ION

(STE

EL)

EQ

UIP

ME

NT

NO

TE 1

STU

D P

AD

WIT

H N

UT

OR

STR

AIG

HT

SH

ANK

WE

LDS

TUD

WIT

H N

UT

AND

SPA

CIN

G W

ASH

ER

SEE

4.1.

1

ME

THO

D 2

A-5

-1E

QU

IPM

EN

T S

EC

UR

EDTO

STU

D P

AD

S



20

FIGURE 2A6. Equipment mounted on aluminum watertight and non-watertight decks and bulkheads.

MET

HO

D 2

A-6-

1EQ

UIP

ME

NT

SEC

UR

ED T

O T

APP

ED P

AD

SW

ELD

ED T

O B

ULK

HEA

D

DE

CK

OR

BU

LKH

EA

D

MET

HO

D 2

A-6

-3D

EC

KS O

R B

ULK

HE

ADS

WIT

HO

UT

INSU

LATI

ON

EQ

UIP

ME

NT

SEC

UR

ED W

ITH

CO

LLAR

STU

DS

EQ

UIP

ME

NT

CO

LLA

R S

TUD

- M

IL-S

-241

49 (A

LUM

INU

M)

3/8"

-16

FOR

FIX

TUR

ES

OR

FIT

TIN

GS

HA

VIN

G 1

3/32

" DIA

. MO

UN

TIN

G H

OLE

S.

5/16

"-18

FO

R F

IXTU

RE

S O

R F

ITTI

NG

SH

AV

ING

11/

32" D

IA. M

OU

NTI

NG

HO

LES

.1/

4"-2

0 FO

R F

IXTU

RE

S O

R F

ITTI

NG

SH

AV

ING

9/3

2" D

IA. M

OU

NTI

NG

HO

LES

.

NO

TE 1

ALU

MIN

UM

NU

TA

NO

DIZ

ED

SE

E 4.

1.1

BU

LKH

EAD

NO

TE 1

EQ

UIP

ME

NT

RO

UN

D H

EA

D M

AC

HIN

E S

CR

EW

OR

HE

X H

EA

D M

AC

HIN

E B

OLT

(CO

RR

OS

ION

-RE

SIST

AN

T S

TEE

L).

SIZ

E T

O F

IT M

OU

NTI

NG

HO

LES

INE

QU

IPM

EN

T. L

ENG

TH A

SR

EQ

UIR

ED

FO

R S

TUD

PA

D.

SEE

4.1

.1

NO

TE 2

ALU

MIN

UM

TA

PP

ED

PA

D -

SIZ

E T

O F

IT M

OU

NTI

NG

BO

LTS

NO

TE 1

SE

CU

RIN

G B

OLT

S O

R S

CR

EW

SW

ITH

NU

TS -

CR

ES

SIZ

E T

OS

UIT

MO

UN

TIN

G H

OLE

S

SE

E 4

.1.1

MET

HO

D 2

A-6

-2E

QU

IPM

EN

T SE

CU

RED

TO

STU

D P

AD

SB

OLT

ED

TO

BU

LKH

EAD

BU

LKH

EA

D, N

WT

NO

TE 3

EQ

UIP

ME

NT

RO

UN

D O

R H

EX

HE

AD M

ACH

INE

SC

RE

W(C

OR

RO

SIO

N-R

ES

ISTA

NT

STE

EL)

.S

IZE

TO

FIT

MO

UN

TIN

G H

OLE

S IN

EQ

UIP

ME

NT.

LE

NG

TH A

S R

EQU

IRED

FOR

TA

PP

ED

PA

D.

NO

TE 2

STA

KE

TH

RE

AD

AFT

ER

TIG

HTE

NIN

G N

UT

STU

D P

AD

S (A

LUM

INU

M O

RC

OR

RO

SIO

N-R

ESIS

TAN

T S

TEE

L)S

IZE

TO F

IT M

OU

NTI

NG

BO

LTS

HE

X N

UTS

(ALU

MIN

UM

OR

CO

RR

OS

ION

-RES

ISTA

NT

STE

EL)

SIZ

E AN

D M

ATE

RIA

L TO

SU

ITS

TUD

PA

D -

ALU

MIN

UM

NU

TSS

HA

LL B

E A

NO

DIZ

ED

WA

TER

TIG

HT

DE

CK

MET

HO

D 2

A-6-

4E

QU

IPM

EN

T S

ECU

RE

D T

O W

ATE

RTI

GH

T D

ECK

S W

ITH

OU

T IN

SU

LATI

ON

US

ING

EXT

ENSI

ON

HA

NG

ER T

O C

LEAR

AN

OB

STR

UC

TIO

N

EQ

UIP

ME

NT

EX

TEN

SIO

N H

AN

GE

R(A

LUM

INU

M)



21

NOTES: 1. CRES washers shall be used when equipment material is steel or brass or dissimilar metal. 2. CRES washers shall be used when stud pad is aluminum and equipment is steel or brass. 3. Apply gasket joint sealing packing material on watertight bulkheads.

FIGURE 2A6. Equipment mounted on aluminum watertight and non-watertight decks and bulkheads - Continued.



22

FIGURE 2A7. Equipment mounted on insulated aluminum decks or bulkheads.

EQ

UIP

ME

NT

INS

ULA

TIO

N

NO

TE 1

SE

E 4

.1.1

TAC

K W

ELD

OP

TIO

NAL

3/8"

HE

X H

EA

D B

OLT

WIT

H N

UT

LEN

GTH

AS

RE

QU

IRE

D

ALU

MIN

UM

BU

LKH

EA

DO

R D

EC

K

1/8"

2 P

LAC

ES

EXT

EN

SIO

N H

AN

GE

R(A

LUM

INU

M)

ALU

MIN

UM

DE

CK

OR

BU

LKH

EA

D

NO

TE 1

3/8"

HE

X H

EA

D B

OLT

-LE

NG

TH A

S R

EQ

UIR

ED

CR

ES

SE

E 4.

1.1

EQ

UIP

ME

NT

TAP

PE

D P

AD

S(A

LUM

INU

M)

INS

ULA

TIO

N

CO

LLA

R S

TUD

- M

IL-S

-241

49 A

LUM

INU

M3/

8"-1

6 FO

R F

IXTU

RE

S O

R F

ITTI

NG

SH

AV

ING

13/

32" D

IA. M

OU

NTI

NG

HO

LES

.5/

16"-

18 F

OR

FIX

TUR

ES

OR

FIT

TIN

GS

HA

VIN

G 1

1/32

" DIA

. MO

UN

TIN

G H

OLE

S.

1/4"

-20

FOR

FIX

TUR

ES

OR

FIT

TIN

GS

HA

VIN

G 9

/32"

DIA

. MO

UN

TIN

G H

OLE

S.

MET

HO

D 2

A-7

-3D

ECKS

OR

BU

LKH

EAD

S W

ITH

INS

ULA

TIO

NE

QU

IPM

EN

T SE

CU

RED

WIT

H C

OLL

AR S

TUD

S

DE

CK

OR

BU

LKH

EAD

EQ

UIP

ME

NT

INS

ULA

TIO

N

NO

TE 1

SE

E 4

.1.1

MET

HO

D 2

A-7-

2E

QU

IPM

EN

T S

ECU

RE

D T

O D

ECKS

OR

BU

LKH

EAD

SW

ITH

INSU

LATI

ON

USI

NG

EXT

ENSI

ON

HAN

GER

S

MET

HO

D 2

A-7

-1EQ

UIP

MEN

T SE

CU

RED

TO

DE

CK

S O

R B

ULK

HEA

DS

WIT

H IN

SU

LATI

ON

US

ING

TAP

PED

PA

DS



23

NOTES: 1. CRES hardware shall be used when equipment material is steel, brass, or dissimilar metal. 2. For use in interior of ships where not exposed to weather, moisture, or high temperature [125 °F+

(51.6 °C+)].

FIGURE 2A7. Equipment mounted on insulated aluminum decks or bulkheads - Continued.



24

NOTE: 1. CRES washers shall be used as spacers when equipment material is steel, brass, or dissimilar metal.

FIGURE 2A8. Equipment mounted on non-watertight aluminum bulkheads.

NOTE 1

EQUIPMENT

EXTENSION HANGERS (ALUMINUM)

3/8" HEX HEAD BOLTS, NUTS & LOCKWASHERS

NON-WATERTIGHT BULKHEAD(ALUMINUM)

HEX HEAD OR ROUND HEADMACHINE SCREW

BACKING WASHER (CRES)REQUIRED FOR BULKHEADS1/16" THICK OR LESS

METHOD 2A-8-1EQUIPMENT SECURED TO

BULKHEADS 3/16" THICK AND OVER

EQUIPMENT

HEX HEAD MACHINE BOLTS WITH NUTS(CRES) - SIZE TO FIT MOUNTING HOLESIN EQUIPMENT

BULKHEAD (ALUMINUM)NON-WATERTIGHT

WASHERS (CRES)SIZE TO FIT MOUNTING BOLTS0.063" MINIMUM THICKNESS

METHOD 2A-8-2EQUIPMENT SECURED TO NON-WATERTIGHT BULKHEADUSING EXTENSION HANGER TO CLEAR AN OBSTRUCTION



25

NOTE: 1. CRES washers shall be used as spacers when equipment material is steel or brass.

FIGURE 2A9. Equipment mounted on aluminum stanchions.

METHOD 2A-9-1EQUIPMENT SECURED TO ALUMINUM STANCHIONS

AND BULKHEADS LESS THAN 3/16" THICK

EQUIPMENT

NOTE 1

HEX HEAD MACHINE BOLT ORROUND HEAD MACHINE SCREWWITH NUT (CRES) - SIZE TO SUITMOUNTING HOLESLENGTH AS REQUIRED

DISTANCE ASREQUIRED

ALUMINUM

SEE 4.1.1

MINIMUM DISTANCEAS REQUIRED

STANCHION



26

FIGURE 2A10. Equipment mounted on aluminum or steel pilaster bulkheads.

SE

E N

OTE

4

EQ

UIP

ME

NT

STU

D P

AD

(STE

EL O

RA

LUM

INU

M) S

IZE

ASR

EQU

IRE

D F

OR

MO

UN

TIN

GE

QU

IPM

EN

T

BU

LKH

EAD

(ALU

MIN

UM

OR

STE

EL)

RE

MO

VE E

XIS

TIN

G R

IVET

SIN

WA

Y O

F PL

ATE

SU

PPO

RT

DR

ILL

HO

LES

IN P

LATE

TO

MAT

CH

HO

LES

IN B

ULK

HE

ADA

ND

RIV

ET

IN P

LAC

E

FOR

WE

LD S

IZE

SEE

4.1

.1

PIL

AST

ER(A

LUM

INU

M O

R S

TEE

L)

PLA

TE S

UP

POR

T (S

TEEL

OR

ALU

MIN

UM

)A

TTAC

H T

O B

ULK

HEA

D A

T PI

LAS

TER

S(S

EE N

OTE

S 1,

2, A

ND

3)

NO

TE 5

HEX

NU

TS -

MA

TER

IAL

AN

DS

IZE

TO

SU

IT S

TUD

PA

DS

MET

HO

D 2

A-1

0-1

EQ

UIP

ME

NT

SE

CU

RE

D T

O B

ULK

HE

AD

ON

PIL

AST

ER S

IDE

(NO

T FO

R N

EW

CO

NS

TRU

CTI

ON

)



27

NOTES: 1. Plate support is not required except when equipment to be mounted is greater than 6" by 9" or weighs 15

pounds or more. 2. Steel plate supports shall be used when attaching brass equipment. 3. Aluminum plate supports may be used when attaching aluminum or steel equipment. 4. Apply two coats of primer in accordance with MIL-PRF-23236 or MIL-DTL-24441/20, F150 between faying

surface of bulkhead and plate support. 5. CRES washers shall be used as spacers when stud pad and equipment are of dissimilar metal.

FIGURE 2A10. Equipment mounted on aluminum or steel pilaster bulkheads - Continued.



28

NOTES: 1. Location of mounting holes to be templated from unit being installed. 2. All faying surfaces of aluminum to dissimilar metal to be protected with one layer of scotch wrapped no. 22

tape, Minnesota Mining and Mfg. Co. or equal.

FIGURE 2A11. Equipment mounted on metal joiner bulkheads.

METHOD 2A-11-1

A

3/16" DIAMETER (MIN.)CRES BLIND RIVETLENGTH TO SUIT(NOTE 1)

A

MAXIMUM WEIGHT 5 LBS.

SECTION A-A

EQUIPMENT

NOTE 2

METHOD 2A-11-2MOUNTING PLATE

(ALUMINUM, STEEL OR CRES)

SECTION B-B

WELD STUDSIZE AND MATERIAL TO SUIT

NOTE 2

STUD WELD

B

B6" MAX

CLEQUIPMENT

1/2"

1/8" THICK (MIN.)NOTE 1

DRILL FOR 3/16" DIAMETER (MIN.)CRES BLIND RIVETLENGTH TO SUIT



29

NOTES: 1. Method shown is for components up to 10 pounds. 2. Method for appliances over 10 pounds and up to 30 pounds use backing plates extended to angle support for

mesh. Backing plates to be ⅛" steel. 3. No appliances are to be mounted on portable sections of expanded metal bulkheads except small fixtures

which may easily be moved and which must be attached thereto for efficient operation. 4. CRES washers shall be used as a spacer when enclosure material is aluminum and angles are steel.

FIGURE 2A12. Equipment mounted on expanded metal or wire mesh bulkheads.

SECTION A-ASEE NOTE 1

ANGLENOTE 4

BACKINGWASHER

SPACER WASHER (CRES)

ROUND HEAD MACHINESCREW OR HEX HEADBOLT WITH NUT - STEELAND CRES LOCKWASHER

SECTION A-ASEE NOTE 2

SUPPORTING PLATE(STEEL)


ROUND HEAD MACHINESCREW OR HEX HEADBOLT WITH NUT - STEELAND CRES LOCKWASHER

ANGLENOTE 4

ENCLOSURES

NOTE 4

EXPANDEDMETALBULKHEAD

BACKINGWASHER

AA

DECK

METHOD 2A-12-1EQUIPMENT SECURED TO EXPANDED METAL OR

WIRE MESH BULKHEADS USING ANGLE SUPPORTS

DECK



30

FIGURE 2A13. Equipment mounted on expanded metal or wire mesh bulkhead.

EQUIPMENT

STRENGTHENING PLATES(CORROSION-RESISTANT STEEL)TO SUIT EQUIPMENT

BULKHEAD (EXPANDED METAL)

METHOD 2A-13-1EQUIPMENT SECURED TO EXPANDEDMETAL OR WIRE MESH BULKHEADS

BULKHEAD(WIRE MESH) HEX HEAD BOLT AND NUT

(CRES) - LENGTH ANDSIZE TO SUIT EQUIPMENT



31

NOTES: 1. The weight of any particular piece or group of electrical equipment secured to cable rack will be limited to 25

pounds maximum on steel and 10 pounds maximum on aluminum racks. 2. Location of equipment to be so arranged that it will not interfere with inspection and painting. 3. This method is intended for use in isolated cases only.

FIGURE 2A14. Equipment mounted on cabling racks.

BRACKET (STEEL OR ALUMINUM)

SEE 4.1.1

STRAP SUPPORT (STEEL OR ALUMINUM)SEE 4.1.1

SPACER WASHER(CRES)

EQUIPMENT SECURED TO HANGER STRAPSWITH THROUGH BOLTS, NUTS, ANDLOCKWASHERS (CRES)SIZE AND LENGTH TO SUIT EQUIPMENT

A

AHANGER STRAP (STEEL OR ALUMINUM)LENGTH TO SUIT

SEE 4.1.1

HANGER STRAP (STEEL OR ALUMINUM)SIZE TO SUIT

MOUNT EQUIPMENT WITH HEX HEAD BOLTS ORROUND HEAD MACHINE SCREWS, NUTS, ANDLOCKWASHERS (CRES)SIZE AND LENGTH TO SUIT EQUIPMENT

3/8" HEX HEAD BOLTS3/4" LONG WITH NUTSAND LOCKWASHERS(STEEL OR ALUMINUM)

ELEVATIONSECTION "A-A"

METHOD 2A-14-1EQUIPMENT MOUNTED ON CABLE RACKS

APPLICABLE TO BULKHEAD RUNS IN MAIN CABLEWAYS, INMACHINERY SPACES, AND PASSAGES



32

FIGURE 2A15. Ceiling fan support in refrigerated spaces.

MET

HO

D 2

A-1

5-1

FAN

SU

PP

OR

TED

FR

OM

OV

ER

HE

AD

SH

EA

THIN

G S

UP

PO

RT

AN

GLE

S

CAB

LE

BU

LKH

EAD

FOR

PE

NE

TRA

TIO

NS

SE

E M

IL-S

TD-2

003-

3

SPA

CE

R W

AS

HE

RS

(CR

ES)

STU

D W

ELD

STU

DS

WIT

HN

UTS

(CR

ES) -

LE

NG

TH A

SR

EQ

UIR

ED

ME

TAL

SH

EAT

HIN

G(C

OR

RO

SIO

N-R

ES

ISTA

NT

STEE

L)

SH

EA

THIN

G S

UP

POR

TA

NG

LE (S

TEEL

)

SHE

ATH

ING

SU

PPO

RT

CEI

LIN

G A

NG

LE (S

TEEL

)



33

FIGURE 2A16. Equipment mounted in refrigerated spaces.

METHOD 2A-16-1EQUIPMENT SECURED TO SHEATHING SUPPORTS

SHEATHING SUPPORT ANGLE


EQUIPMENT

SHEATHING SUPPORTCEILING ANGLE

METAL SHEATHING(CORROSION-RESISTANT STEEL)

STUD WELD STUDS WITH NUTS (CRES)SIZE AS REQUIRED

ADDED SHELF (STEEL)

FOR WELD SIZE SEE 4.1.1



34

FIGURE 2A17. Connecting adjacent cast aluminum equipment with pipe nipples.

METHOD 2A-17-1CAST EQUIPMENT CONNECTIONSUSING THREADED PIPE NIPPLES

BULKHEAD

EQUIPMENT(ALUMINUM)

EQUIPMENT(ALUMINUM)

THREADED PIPE NIPPLE (ALUMINUM)

UNION (ALUMINUM)OPTIONAL

METHOD 2A-17-2CAST EQUIPMENT CONNECTIONS

USING ALUMINUM TUBING

BULKHEAD

EQUIPMENT(ALUMINUM)

EQUIPMENT(ALUMINUM)

TUBING (ALUMINUM)

12" MAX.



35

FIGURE 2A18. Connecting adjacent equipment with pipe nipples.

MET

HO

D 2

A-1

8-1

SHE

ET

ME

TAL

EQU

IPM

ENT

CO

NN

ECTE

DW

ITH

PIP

E O

R T

UBE

NIP

PLES

ME

TAL

OR

MO

LDE

DP

LAS

TIC

EQ

UIP

ME

NT

"O" R

ING

GA

SK

ET

SLI

P W

AS

HE

RS

ME

TAL

OR

MO

LDE

DP

LAS

TIC

EQ

UIP

MEN

T

NY

LON

TU

BE

AS

TM F

1836

M

CAP

GR

OM

MET

LOC

KN

UT

BOTT

OM

WAS

HER

CO

NN

EC

TIN

G N

IPPL

E - A

LUM

INU

M O

RP

LAS

TIC

TU

BIN

G O

F FI

RE

RE

SIS

TAN

CE

EQ

UA

L TO

NY

LON

OR

NY

LON

TU

BIN

GIN

CLU

DIN

G Z

YTEL

(NO

TE 1

)



36

NOTE: 1. Plastic and composite equipment enclosures shall be connected with plastic or composite tubing only.

FIGURE 2A18. Connecting adjacent equipment with pipe nipples - Continued.



37

NOTES: 1. Typical methods shown here are for information and guidance to installing activities for mounting indicator

switches and associated magnets. 2. Switches and magnets shall be mounted in such a manner as to facilitate their adjustment in the direction of

mast travel.

FIGURE 2A19. Mast position indicator switches for submarines.

METHOD 2A-19-1

METHOD 2A-19-2SURFACE MOUNTED

SW2SW1

TRAVELOF MAST

MAGNET

LOCATE SWITCH ANDMAGNET TO SUIT UPPOSITION

MOLDED PLUG ASSEMBLYMIL-C-24231/1 SYM 713

LOCATE MAGNET TOSUIT DOWN POSITION

MASTS

MAST FARING

MAGNET

SWITCH - SYM 2652.1A A

SWITCH MTGFOUNDATION

2 1/4"

1 1/8"

3/16" TO 1/4" (MAX.) AIR GAPBETWEEN MAGNET AND SWITCH(SEE NOTE 3)

VIEW A-A

5/16"-18 CRES MOUNTING BOLTSAND LOCKWASHERS

PROVIDE SLOTTED HOLES FORADJUSTING SWITCH ASSEMBLY

1/4" STEEL SWITCH MOUNTING FOUNDATIONAND/OR BRACKET AS REQUIRED TO SUITSWITCH LOCATION

METHOD 2A-19-3RECESS MOUNTED

PROVIDE ELONGATEDHOLES IN MOUNTING CLIPFOR RECESS MOUNTING

1/4" - 20 CRES RHSCREWS ANDLOCKWASHERS

MAGNETIC ASSEMBLY,AS REQUIRED

AFTER FINAL ADJUSTMENT OF MAGNET,FILL CAVITY WITH EMBEDDING COMPOUNDCOMPATIBLE WITH EXISTING MATERIALAND/OR COATING ON THE MAST

1/4" - 20 CRES MOUNTINGBOLTS AND LOCKWASHERS

MAGNETIC ASSEMBLY,AS REQUIRED



38

NOTES (continued): 3. If magnets other than those furnished with switch assembly are required, the following precautions shall be

taken: a. Air gap between switch and magnet must be set to ensure that the coercive force of the magnet is

sufficient to operate the switch at an ambient of -40 °F (-40 °C). b. The coercive force must be limited to operate only the switch for which it is intended.

4. All welding shall be in accordance with approved methods. 5. Magnet assemblies other than those furnished with switch shall have a thin coating of epoxy resin compound

PR-610-TCF (chockfast orange) of ITW Philadelphia Resins Corp. or equal.

FIGURE 2A19. Mast position indicator switches for submarines.



39

Locking devices Method 2A-20-1

A – Electrical connections 1. Motors and generators

a. Use lock nuts, lock washers, or other means to lock connections which tend to become loose because of vibration (see Method 1B-10-1). Refer to Naval Ships’ Technical Manual S9086-KC-STM-010, Chapter 300.

2. Control and instrument circuits a. Unless otherwise specified in the individual equipment specification, locking devices shall be provided

on the following basis for electrical connections in all equipment: all nuts, bolts, studs, and screws used for electrical connections shall be secured by means of a locking device in accordance with acceptable locking devices such as nut and locknut, self-locking nut, external tooth lock washers, internal tooth lock washers except that a locking device need not be provided where lug terminals are used for conductors below 4000 circular mils (CM) (14AWG). Terminal boards shall be in accordance with A-A-59125, except that lock washers are not required under terminal nuts. Refer to MIL-E-917.

3. Propulsion control cubicle (other than bus bar joints) a. Locking devices shall be provided on the following basis for electrical assemblies in all switchgear units

and in all equipment unless otherwise specified in the individual equipment specifications. All nuts, bolts, studs, and screws used for electrical connections shall be secured by means of an acceptable locking device except that a locking device need not be provided where solderless type connectors are used for conductors below 4000 circular mils (CM) (14AWG). Terminal boards shall be in accordance with A-A-59125 or equivalent, except that lock washers are not required under terminal nuts. Refer to MIL-E-917 and MIL-DTL-16036.

4. Bus bar joints (main and auxiliary power) a. In securing bus joints, bolts shall be fitted with a securing nut and a lock nut, or may be fitted with nuts

of special design which have been specifically approved by NAVSEA. Flat washers shall be used under all bolt heads and nuts adjacent to the conductor.

b. Intercell connectors in battery compartments shall be secured with stainless steel bolts, flat washers, and nuts conforming to ASTM A276, Type 316. Refer to MIL-PRF-32273, MIL-PRF-32273/1, and MIL-PRF-32273/2.

5. Interior communication (I.C.) and fire control (F.C.) equipment a. Lock washers shall be employed with bolts or machine screws and nuts in all cables used to secure

electrical connections. Refer to MIL-HDBK-2036. 6. Switchboards and control equipment

a. Use locking devices such as check nuts or lock washers where necessary to keep connections tight. Refer to S9086-KC-STM-010, NSTM Chapter 300.

FIGURE 2A20. Locking devices on electrical connections and installations on submarines.



40

Locking devices Method 2A-20-2

B – Electrical installations 1. In general, locking devices should be employed under the following conditions:

a. For mounting rotating equipment and/or mounting equipment in steering gear compartments. b. For securing electrical equipment in the battery compartment and in and about the propulsion controls.

Refer to S9086-KC-STM-010, NSTM Chapter 300. 2. Parts subject to vibration

a. Nuts used on moving parts or subject to vibration during operation shall be secured by star washers, cotter pins, or other approved form of locking device.

b. Equipment attached directly to hull foundations, and which is subject to severe self-generated vibration, shall be attached with through bolts and self-locking nuts or castellated nuts and cotter pins or wire.

3. Interior parts of machinery a. Nuts or bolts used on interior parts of machinery must be wired, cottered, or otherwise locked.

4. Switchboard and control equipment a. Use locking devices such as lock nuts and lock washers to keep mechanical connections tight. Refer to

S9086-KC-STM-010, NSTM Chapter 300. b. Equipment mounted in the battery compartment above the levels of the lowest cell tops shall be attached

with through bolts and self-locking nuts of castellated nuts with cotter pins or wire. 5. Enclosures (fitting and fixtures)

a. Locking devices are not required for mounting non-rotating electrical equipment unless subject to excessive vibration (see 2.a above).

6. Open equipment (exposed wiring, bus bars, switches, etc.) a. Nuts, bolts, and screws used for structural purposes above exposed electrical equipment shall be secured

with acceptable locking devices where holding nut, screw, bolt, or component part could fall into the equipment. Refer to MIL-DTL-16036.

NOTES: 1. This figure is for guidance only and does not take precedence over any specification mentioned herein nor

any individual equipment specification. 2. Referenced documents contained herein are those in effect on issue date of this standard. Amendments and/or

revisions to referenced documents bearing a later date than the issue date of this standard take precedence. 3. Self-locking nuts of the elastic stop nut type, with nylon (or equivalent) insert locking rings shall not be used

at temperatures in excess of 250 °F (121.1 °C). 4. For #10 screws and below, use of tooth lock washers in lieu of split type lock washers is preferred. 5. Internal tooth lock washers shall not be used for new construction.

FIGURE 2A20. Locking devices on electrical connections and installations on submarines - Continued.



41

TABLE 2A20-I. Locking devices on electrical connections and installations on submarines.

Locking device required (numbers indicate order of preference)

Application Paragraph number Jam or lock nut

Tooth lock washer

Split ring lock

washer

Approved self-locking

nut 1/

Remarks

Main motor & generator Mounting Terminal

B-1-A, B-3-A, B-6-A A-1-A

3 3/

2

1 1

Auxiliary motor & generator Mounting Terminal

B-1-A, B-3-A, B-6-A A-1-A

3 3/

2 3/

4

1 1

This includes all MG sets and all AC and DC motors used in aux power ckts

Distribution switchboards Mounting Mech connection Elec connection

B-2-A, B-2-B, B-6-A B-4-A A-6-A

3 3/

2 3/, 4/

4

1 3 1

Approved self-locking nut preferred for bus bar joints, tooth lock washers preferred for terminal studs

A.C. switchboards Mounting Mech connection Electrical connectino

B-2-A, B-2-B, B-6-A B-4-A A-6-A

3 3/

2 3/, 4/

4

1 3 1

Approved self-locking nut preferred for bus bar joints, tooth lock washers preferred for terminal studs

Prop cont cubicle Mounting Electrical connection

B-1-B, B-6-A A-1-A

3 2/

2 3/, 4/

4

1 1

Control panel Mounting Wiring

B-2-A, B-2-B, B-6-A A-2-A

2 3/

1 3/, 4/

4

1 3

Locking devices not generally used for cont pnl mtg except for condition B-2-A & B-2-B. This includes small motor controllers.

Bus bar joints A-4-A 2 1 I.C. & F.C. equipment

Installation Wiring

B-4-A, B-5-A B-5-A

2 2/, 3/

1 3/, 4/

3 3

4 4

General wiring connections

B-2-A 2 2/, 3/ 1 3/, 4/ 3 4

Bus bar joints in battery tanks

A-4-A 2 1

Battery cell connectors A-4-B None required

NOTES: 1/ Elastic stop nuts are generally procured for this application. 2/ This includes the wiring of connection boxes, distribution boxes, rotary snap switches, push-button switches, receptacles, terminal connection of

fractional HP motors, LTG fixtures, etc. 3/ Where spring lock-washers and tooth lock-washers are used on electrical connections, they shall be employed in connection with flat washers for

bolts and screws larger than ¼ diameter. 4/ Tooth lock-washers shall be used under the bearing surface of screw heads or nuts whichever (if both, place under nut) comes in contact with

plastic material.

FIGURE 2A20. Locking devices on electrical connections and installations on submarines - Continued.



42

FIGURE 2A21. Portable ship control unit submarine bridge type.

ME

THO

D 2

A-2

1-1

FOU

ND

ATIO

N

SUB

MAR

INE

BR

IDG

E A

REA

EXT

EN

SIO

N C

ABLE

FO

RD

OC

KSID

E U

SE

1853

085-

79

PR

ESS

UR

EP

RO

OF

CAP

1853

085-

104

FOU

ND

ATI

ON

PLA

TE

PLU

G A

ND

FOU

ND

ATIO

N P

LATE

TO B

E F

ASTE

NED

TOG

ETH

ER

ME

TAL

TO M

ETAL

POR

TAB

LE S

HIP

CO

NTR

OL

UN

IT S

YM

294

5 O

R S

YM

294

5.1

BEA

RIN

G C

IRC

LE A

ND

CO

MPA

SSH

OLD

ER D

WG

815

-185

3069

CO

NN

BO

X

AC

O S

WIT

CH

TES

T C

ABLE

1853

085-

80

INB

OA

RD

CAB

LE T

OC

ON

NEC

TIO

N B

OX

(PA

RT

OF

HU

LL F

TG)

PRE

SSU

RE

HU

LL

HU

LL F

TG IN

SER

TM

IL-C

-242

31/2

5-00

2

P.P

. HU

LL F

ITTI

NG

MIL

-C-2

4231

/10-

005

SH

IPB

UIL

DER

FU

RN

ISH

ED

90 D

EGR

EE O

R S

TRAI

GH

T PL

UG

ASS

EM

BLY

(PR

ESSU

RE

PRO

OF)

1853

085-

78 A

ND

77

RE

SPE

CTI

VEL

Y



43

TABLE 2A21-I. Portable ship control unit submarine bridge type and NSN.

Name Sym PC no. NSN

Cont unit 2945

2945.1

2945.2 77

78 1H6150-00-590-0863

2945.4 79 1H6150-00-590-3453

Cable assy

2945.5 80 1H6150-00-590-3454

FIGURE 2A21. Portable ship control unit submarine bridge type - Continued.



44

NOTES: 1. Location of mounting holes to be templated from unit being installed. 2. Small holes can be drilled into GRP panels with a sharp, twist-type drill bit. Prick punch to center drill bit.

Larger holes can be drilled with a hole cutter. When drilling holes for “blind fasteners”, a drill stop should be utilized to prevent drilling through the entire panel. When using a hole cutter, first drill through one face sheet, and from the opposite side of the panel, use the pilot hole from the first cut to drill the second face sheet. This method will help avoid panel delamination and high pressure plastic laminate (HPPL) chipping.

3. When cutting and drilling GRP panels, care must be taken to provide adequate ventilation and dust collection. Eye and ear protection and the use of a dust mask is recommended. Caution: if any signs of allergic reaction appear when working with GRP panels, work should stop immediately.

4. Some chipping and cracking of the HPPL may occur when cutting or drilling GRP panels. This degradation of the panel, while unavoidable, must be kept to a minimum so as not to degrade the holding capacity of fasteners or take away from the finished appearance of the panel. In many cases, keeping the drill bits and blades sharp, and using masking tape over the area to be cut or drilled, will keep degradation of the panel at a minimum. If chips and cracks propagate out beyond where the mounting hardware ends, the damage will be noticeable and will require cosmetic repair. In some cases, through-type fasteners may dimple the panel. This condition is acceptable as long as there is no cracking of the panel face.

5. GRP panels are easily scratched, punctured, and scorched by hot work. Care should be taken when working on or close to these panels.

6. For weight limitation of equipment installed on GRP panels, see figure 2A24.

FIGURE 2A22. Electrical equipment mounting to GRP bulkheads/panels.

FLAT WASHER

HEX HEAD BOLTSELF LOCKING

EQUIPMENT ORFOUNDATION

GRP BULKHEAD/PANEL

TEE NUT

FINISHING CAP


GRP BULKHEAD/PANEL

METHOD 2A-22-1RIVET MTG

RIVET

THIS METHOD IS TO BE USED WHEN THE DISTANCEFROM THE BULKHEAD TO THE C G OF THE EQUIPMENTIS LESS THAN 4 INCHES.

METHOD 2A-22-2TEE NUT



45


METHOD 2A-23-2TEE BOLT

NUT PLATE

FLAT WASHER

LOCKNUT


GRP BULKHEAD/PANEL

PAN HEAD TEE BOLT(HI SHEAR)

METHOD 2A-23-1TEE NUT WITH WASHER

FLAT WASHER

HEX HEAD BOLTSELF LOCKING


GRP BULKHEAD/PANEL

TEE NUT

FINISHING CAP

FLAT WASHER

GRP BULKHEAD/PANEL

METHOD 2A-23-3NUT PLATE

WASHER

EQUIPMENT/FOUNDATIONMOUNTING BOLT SHOULDNOT PENETRATE PANEL

EQUIPMENT OR FOUNDATION

RIVET 3/16" (TYP)

NUT PLATE



46

Fastener selection (size) for installation of electrical equipment/foundations to GRP bulkheads/panels Procedure for selecting fastener size and type:

1. Establish correct E, H, L, and Wp per pair of bolts: E = Horizontal distance (inches) from BHD to equipment CG (taken from vendors drawings) H = Vertical distance (inches) between the pair of bolts Wp = Weight (pounds) of equipment acting through each pair of bolts (Wt ÷ number of bolt pairs) L = Horizontal distance between the extreme pair of fasteners

2. Locate correct “E” and “H” values on the “E” and “H” scales shown in table 2A25-I. 3. Make a straight line connecting these points. 4. Where the line made in step 3 crosses the “K” scale shown in table 2A25-I, make a horizontal line all the way

to the right side of the chart. 5. The vertical lines located under each detail represent different ranges of weight that the vertical pair of

fasteners can support. If the horizontal line made in step 4 crosses these vertical lines at values greater then the Wp found in step 1, the fastener detail can be used. In the event that the Wp required exceeds the Wp available on the chart, a pedestal foundation should be considered.

6. If more than one detail will work, the final choice will depend on such factors as available inventory, size of existing mounting holes on equipment, type of space where the equipment is located, and the required finish on the opposite face of the bulkhead.

7. “L” is a function of the number of pairs as shown: No. of pairs “L” 2 0.5H 3 0.75H 4 1.0H

Example Equipment: Feeder distribution box weight Wt = 20 lbs., Height = 14", Width = 13", Depth = 8" Mounting data: Four holes – 17⁄32" dia, 10" (vertical), 9" (horizontal) 1. E = 4 (vendor data), H = 10, Wp = Wt ÷ number of bolt pairs = 20 ÷ 2 = 10 lbs. 2. A straight line connection of E = 4 and H = 10 results in a “K” value of 0.4. 3. A horizontal line drawn from a 0.4 “K” value to the right end of the chart shows that Method 2A-24-1 meets

the requirement.


Wt = total weight

H

LE



47

TAB

LE 2

A24

-I.

Fast

ener

size

and

type

sele

ctio

n.

FIGURE 2A24. Electrical equipment mounting to GRP bulkheads/panels - Continued.

017

.324

.528

.415

.518

.424

.4

1/4

1/4

5/16 3/8

1/2

3/8

1/2

3/16

(WIT

HW

AS

HE

R)

1/2

3/8

H S

CAL

E01020304048

4 8 12 16 20 24

E S

CAL

E

0.05 0.

1

0.2

0.3 0.

4 0.5 1

2

48

K S

CA

LE

ME

THO

D2A

231

CH

ER

RY

-MA

TE

ME

THO

D2A

232

T-N

UT

ME

THO

D2A

241

T-N

UT

ME

THO

D2A

242

T-B

OLT

MET

HO

D2A

243

NU

TP

LATE

1234567899.

2

12345678910121415161724 22 20 18 16 15 14 12 10 9 8 7 6 5 4 3 2 1

124681012141618202224262815 14 12 10 8 6 5 4 3 2 1

123456810121415161824 22 20 18 16 14 12 10 8 7 6 5 4 3 2 1


MIL-STD-2003-2A(SH) APPENDIX B

48

GROUP B – SWITCHBOARD MOUNTING

B.1 SCOPE

B.1.1 Scope. This section describes procedures for the proper installation and mounting of switchboards.

B.2 APPLICABLE DOCUMENTS

B.2.1 General. The documents listed in this section are specified in this appendix. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in this appendix, whether or not they are listed.

B.2.2 Government documents.

B.2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.



(Copies of this document are available online at http://assist.daps.dla.mil/quicksearch/ or from the Standardization Document Order Desk, 700 Robbins Avenue, Building 4D, Philadelphia, PA 19111-5094.)

B.2.3 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

B.3 REQUIRED EQUIPMENT AND MATERIALS

B.3.1 Required equipment and materials. The equipment and materials required for the proper installation and mounting of switchboards are specified in figures 2B1 through 2B6.

B.4 NOTES AND PROCEDURES

B.4.1 Dimensions. For figures and tables in this section, all dimensions are in inches unless otherwise noted.

B.4.2 Figures. Table 2BI provides information for the figures in this group.

TABLE 2BI. Figures for the installation and mounting of switchboards.

Figure number Switchboard installation Page

2B1 Switchboard foundation bolting 49 2B2 Switchboard bracing 50 2B3 Switchboard bracing 51 2B4 Switchboard bracing 52 2B5 Switchboard bracing 53 2B6 Switchboard bracing 55




49

NOTES: 1. Base channel web strengthening pieces located on each side of foundation bolts shall be provided when base

pads are not used. Weld webs in place on underside of base channel to form a square with foundation bolt in center.

2. CRES washers shall be used when switchboard framing is aluminum and base pad is steel. 3. Switchboard base channel shall be Class B bonded to foundation base pad in accordance with

MIL-STD-1310.

FIGURE 2B1. Switchboard foundation bolting.

STEEL CHANNEL

STEEL GUSSET

STEEL ANGLE

CONTINUOUS WELD

HOLES FOR FOUNDATION BOLTS AREPROVIDED IN SWITCHBOARD UNITS BYSWITCHBOARD MANUFACTURERS IAW MIL-DTL-16036

METHOD 2B-1-1SECTION THROUGH BASE CHANNEL SHOWING

BASE PAD(SEE NOTE 1)

HEX HEAD BOLT (STEEL)

METHOD 2B-1-3BOTTOM CORNER CONSTRUCTION

LOCKWASHER (CRES)

BASE CHANNEL

NOTE 2BASE PAD DECK PLATE

FOR WELD SIZESEE 4.1.1

BASE CHANNEL

HOLES FOR FOUNDATION BOLTSARE PROVIDED IN SWITCHBOARD UNITS BYSWITCHBOARD MANUFACTURERS IAW MIL-DTL-16036

METHOD 2B-1-2TYPICAL FLOOR PLAN FOR SWITCHBOARD

UNIT



50

NOTE: 1. Dimensions marked “A” must be less than 45 degrees.

FIGURE 2B2. Switchboard bracing.

METHOD 2B-2-1TYPICAL METHOD USING SHEAR BOLTS WITH TOP

BRACING ATTACHED TO BULKHEADREINFORCING ANGLEWELDED TO BULKHEAD


SHEAR BOLTS


METHOD 2B-2-2

ALTERNATE

BRACING ATTACHMENTSHALL BE IAW FIGURE 2B6

A



51



SHEAR BOLTS

BRACING ATTACHMENTSHALL BE IAW FIGURE 2B6

TEE BAR

METHOD 2B-3-1TYPICAL METHOD USING INITIAL DEFLECTING BRACE

REINFORCING ANGLEWELDED TO BULKHEAD



52

NOTES: 1. Where the length of switchboard section is less than the height, lengthwise bracing shall be provided. 2. Dimensions marked “A” must be less than 45 degrees.


FOR

WE

LD S

IZE

SEE

4.1

.1

MET

HO

D 2

B-4-

3

BR

AC

ING

ATT

AC

HM

EN

T S

HAL

L B

E IA

W F

IGU

RE

2B

6

FOR

WE

LD S

IZE

SE

E 4

.1.1

FOR

WEL

D S

IZE

SE

E 4.

1.1

OV

ER

HE

AD

BE

AM

MET

HO

D 2

B-4-

2TY

PIC

AL M

ETH

OD

USI

NG

SH

EAR

BO

LTS

WIT

H T

OP

BR

AC

ING

ATT

ACH

ED T

O B

ULK

HEA

D S

TIFF

ENE

RS

FOR

WE

LD S

IZE

SE

E 4

.1.1

SH

EA

R B

OLT

S

SH

EA

R B

OLT

S

SH

EA

R B

OLT

S

FOR

WE

LD S

IZE

SE

E 4.

1.1

FOR

WEL

D S

IZE

SE

E 4.

1.1

SA

ME

SIZ

EB

RA

CE

A

BU

LKH

EA

D

MET

HO

D 2

B-4-

1M

ETH

OD

S O

F LE

NG

THW

ISE

BR

ACIN

G

AA

A



53


FOR

WEL

D S

IZE

SEE

4.1

.1

SHE

AR B

OLT

S

ME

THO

D 2

B-5

-3

TYP

ICAL

ME

THO

D U

SIN

G S

HEA

R B

OLT

S W

HER

EFL

EXIB

ILIT

Y IS

PR

OVI

DED

IN B

OTH

HO

RIZ

ON

TAL

& V

ERTI

CA

L PL

ANE

OV

ERH

EAD

BEA

M

FOR

WEL

D S

IZE

SE

E 4

.1.1

STR

AP

THIS

ME

MBE

R S

HAL

L BE

AT

LEA

ST

12" L

ON

G T

OAL

LOW

FLE

XIBI

LITY

INTH

E VE

RTI

CAL

DIR

ECTI

ON

A

ME

THO

D 2

B-5

-1FR

ON

T B

RA

CIN

G

BRAC

ING

ATT

ACH

MEN

T SH

ALL

BE IA

W F

IGU

RE

2B6

(TYP

)

FOR

WEL

D S

IZE

SEE

4.1

.1

A

SHEA

R B

OLT

S

TYP

ICAL

ME

THO

D U

SIN

G S

HE

AR

BO

LTS

WIT

H T

OP

BR

ACIN

G A

TTAC

HED

TO

OV

ER

HE

AD B

EAM

FOR

WEL

DSI

ZE S

EE 4

.1.1

SH

EAR

BO

LTS

MET

HO

D 2

B-5

-2R

EA

R B

RAC

ING

OVE

RH

EAD

BEA

M



54

NOTE: 1. Dimensions marked “A” must be less than 45 degrees.

FIGURE 2B5. Switchboard bracing - Continued.



55

NOTE: 1. Shear bolts, nuts, and washers in switchboard frameworks shall be made captive.


BOLT THREADED INTOSWITCHBOARD FRAMETO MAKE IT CAPTIVE

TYPICAL METHODS OF RETAINING SHEAR BOLTS,NUTS, AND WASHERS

METHOD 2B-6-1

METHOD 2B-6-3METHOD OF ATTACHING BRACE TO SWITCHBOARD

HAVING DRIPSHIELD

METHOD 2B-6-2

BOLT HEAD WELDED TOSWITCHBOARD FRAMETO MAKE IT CAPTIVE

SHEAR BOLTSBOLTS THREADED INTOSWITCHBOARD FRAMETO MAKE IT CAPTIVE

LOCKWASHER (CRES)

DRIPSHIELD



MIL-STD-2003-2A(SH) APPENDIX C

56

GROUP C – BATTERY RACK MOUNTING

C.1 SCOPE

C.1.1 Scope. This section describes procedures for the proper installation and mounting of battery racks.

C.2 APPLICABLE DOCUMENTS

C.2.1 General. The documents listed in this section are specified in this appendix. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in this appendix, whether or not they are listed.

C.2.2 Government documents.

C.2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

FEDERAL SPECIFICATIONS

FF-S-92 - Screw, Machine: Slotted, Cross-Recessed or Hexagon Head

MM-L-736 - Lumber; Hardwood


MIL-E-917 - Electric Power Equipment, Basic Requirements

MIL-W-21157 - Weldment, Steel, Carbon and Low Alloy (Yield Strength 30,000-60,000 PSI)

MIL-S-22698 - Steel Plate, Shapes and Bars, Weldable Ordinary Strength and Higher Strength: Structural

MIL-DTL-24441 - Paint, Epoxy-Polyamide, General Specification for


C.2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

ASTM INTERNATIONAL

ASTM A36/A36M - Standard Specification for Carbon Structural Steel

ASTM A1008/A1008M - Standard Specification for Steel, Sheet, Cold-Rolled, Carbon, Structural, High-Strength Low-Alloy, High-Strength Low-Alloy with Improved Formability, Solution Hardened, and Bake Hardenable

ASTM F1145 - Standard Specification for Turnbuckles, Swaged, Welded, Forged

ASTM F1267 Standard Specification for Metal, Expanded, Steel






57

NATIONAL AEROSPACE STANDARDS COMMITTEE (NA/NAS)

NASM 25027 - Nut, Self-Locking, 250 Deg F, 450 Deg F, and 800 Deg F

(Copies of this document are available from Aerospace Industries Association, 1250 Eye Street NW, Washington, DC 20005-3924 or online at www.aia-aerospace.org.)

C.2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

C.3 REQUIRED EQUIPMENT AND MATERIALS

C.3.1 Required equipment and materials. The equipment and materials required for the proper installation and mounting of battery racks are specified in figures 2C1 through 2C4.

C.4 NOTES AND PROCEDURES

C.4.1 Dimensions. For figures and tables in this section, all dimensions are in inches unless otherwise noted.

C.4.2 Figures. Table 2CI provides information for the figures in this group.

TABLE 2CI. Figures for the installation and mounting of battery racks.

Figure number Battery rack installation Page

2C1 Open battery racks 58 2C2 Open battery rack details 62 2C3 Enclosed battery racks 66 2C4 Enclosed battery rack details 67 2C5 Details of wood spacer blocks for battery racks 69 2C6 Battery clamp details 70 2C7 Battery clamp details 71 2C8 Battery clamp details 73


http://www.aia-aerospace.org/�


58

FIGURE 2C1. Open battery racks.

2.50

00 x

2.5

000

x 0.

188

L, T

YP

BU

LKH

EAD

27.1

87

TYP

0.18

8

TYP

0.18

8

0.25

0 M

OU

NTI

NG

PLA

TE

4.30

0

5.30

00.

250

MO

UN

TIN

G P

LATE

4X (0

.375

) 3/8

-16

UN

C1.

25 IN

. LG

. TYP

0.12

5

DE

TAIL

OF

SH

OC

K IS

OLA

TOR

(DE

CK

MO

UN

T)

5.30

0

4.30

0TY

P0.

125

4.81

2

44.2

5018.0

0

20.5

00 1.00

0

BB

AA

1.00

0

SH

OC

K IS

OLA

TOR

DEC

K M

OU

NT

DEC

K

1.50

2.00

0 X

2.0

00 X

0.1

88 L

, TYP

2.50

0 X

2.5

00 X

0.1

88 L

, TYP

TYP

0.12

5

1.00

X 0

.188

FB

,0.

50 R

AD

, TYP

C L

0.25

0 M

OU

NTI

NG

PLA

TE, T

YP

10.5

00 T

YP

1.00

0

35.0

00

SHO

CK

ISO

LATO

R

SH

OC

K IS

OLA

TOR

BU

LKH

EAD

MO

UN

T

HO

LD-D

OW

NR

ETAI

NE

R B

LOC

K

TUR

NBU

CKL

E

BU

LKH

EAD

TYP

0.12

5

TYP

0.12

5

TYP

4.50

0 TY

P

1.00

0

0.12

5

TYP

0.12

5 2.50

0 X

2.50

0 X

0.18

8

10.5

00

DE

CK

0.25

0 M

OU

NTI

NG

PLA

TE

8.50

0

BULK

HEA

D

DET

AIL

OF

SH

OC

K IS

OLA

TOR

(BU

LKH

EAD

MO

UN

T)



59

NOTES: 1. L-angles and plate steel shall be in accordance with MIL-S-22698, Grade A. 2. Battery racks shall be painted prior to assembly with black acid-resistant paint, NAVSEA paint formula no.

28. 3. Turnbuckles shall be in accordance with ASTM F1145, Class 7. 4. Retainer blocks shall be clean hard maple in accordance with MM-L-736. 5. Machine screws shall be corrosion-resistant steel in accordance with FF-S-92. Self-locking nuts shall be

corrosion-resistant steel in accordance with NASM 25027. 6. All welding shall conform to MIL-W-21157. 7. Horizontal spacing shall be such as to provide equal space on sides and between adjacent batteries. 8. This battery rack is intended to accommodate sealed, lead-acid batteries having a length of 16.6", width of

6.8", case height of 8.6", and terminals located on the battery top near the battery corners. If batteries having other dimensions are used, battery rack dimensions shall be adjusted accordingly.

Shock isolator shall be Aeroflex isolator part no. CB1500-20-C2 with the following characteristics: A. Helical 0.625" wire rope shock mount. B. Height 4.30", width 5.30", length 10.50". C. Compression average, K=1800 pounds/inch, shear average, K=1300 pounds/inch, roll average, K=1300

pounds/inch. D. Max. rated dynamic travel = 1.80" for compression and shear, 2.80" for 45-degree compression roll. E. Max. rated shock load = 3200 pounds compression, and 2400 pounds for shear or roll. F. Damping factor = 0.15. G. Lateral stiffness (percent of vertical) = 0.60. H. Oil, grease, ozone, salt spray, organic solvents, and fatigue resistant. I. Allows movement in any direction. J. Operating temperature range is -40 to +212 °F (-40 to +100 °C).

FIGURE 2C1. Open battery racks - Continued.



60


1.00

0

CO

UP

LIN

G (0

.562

5)9/

16" H

EX

BA

RD

RIL

L &

TA

P (0

.312

5) 5

/16-

18 U

NC

28

2.00

0

0.75

0 R

H

8.60

0

JAW

AN

D J

AWTU

RN

BU

CK

LE

Ø .2

50 H

EX

BO

LT &

NU

T,LE

NG

TH A

S N

EED

ED(2

RE

QU

IRE

D)

Ø .1

87

0.75

0 LH

0.18

811.7

50

45°

SN

IPE

, TY

P2.

000

x 2.

000

x 0.

188

L,10

.750

DE

TAIL

C

BA

TTE

RY

CLA

MP

11.7

50

16.5

00

SEC

UR

ING

SC

REW

ASS

Y

TUR

NB

UC

KLE

TYP

0.18

8TY

PB

ATTE

RY

CLA

MP

0.18

8

DET

AIL

A-A

1.00

02.

500

X 2.

500

X 0

.188

L,

0.18

80.

500

Ø.3

125

0.25

0 P

L

0.50

0 R

BA

TTE

RY

CLA

MP

2.50

0 X

2.5

00 X

0.1

88 L

1.25

00.

5313

DR

ILL

THR

UFO

R 0

.500

HEX

HD

BO

LD

1.00

01.

500 (0

.500

) 1/2

-13

HE

X H

D B

OLD

5 IN

LO

NG

GR

AD

E 5

FULL

TH

REA

D

TAC

K W

ELD

AT

TWO

OP

P F

LATS

WIT

H

VA

RIE

S

(0.5

00) 1

/2-1

3 H

EX H

D B

OLD

2 R

EQ

'D P

ER

ASS

Y2.

00 X

3.5

0 X

0.1

88 L

1.25

0

DE

TAIL

C (S

EC

UR

ING

SC

REW

AS

SY)

9.01

5 6.86

5

3.63

5 1.48

55.

3125

10.5

00

MO

UN

TIN

G P

LATE

(0.2

50 P

LATE

TH

ICK

NES

S)

4X Ø

(.37

5) 3

/8 X

16-U

NC

10.6

25

5.31

25

0.18

8TY

P

0.18

8TY

P0.

188

TYP

0.05

001.

000

TYP

0.18

80.

500

TYP

DE

TAIL

B-B

BAT

TER

Y C

LAM

P

1.12

5

1.62

5 1.12

5

0.50

00.

500

1.00

0

RET

AIN

ER B

LOC

KS0.

812

0.81

2

0.56

2

2.75

0

0.56

2

0.25

0

19.0

00

3.87

5

4X Ø

.250

MAC

HIN

E S

CR

EWW

ITH

FLA

T W

AS

HE

R A

ND

SE

LF-

LOC

KIN

G N

UT.

LEN

GTH

AS

NE

EDE

D

SEA

TIN

G W

AS

HE

R F

OR

0.37

5 B

OLT

, STE

EL

CO

ML.

TAC

K W

ELD

TO

CH

ANN

EL

CH

AN

NEL

, STE

EL,

AS

TM A

36/A

36M

, TYP

E I,

SIZE

- 2.

000

X 1

.000

X 0

.188

L GR

AIN

1.00

0

3.00

0

0.37

5 ST

EEL

RO

D, B

EN

D A

ND

WEL

DTO

CH

AN

NE

L AS

SH

OW

N0.62

5 C

BO

RE

1.25

0

0.37

5



61




6.8", case height of 8.6", and terminals located on the battery top near the battery corners. If batteries having other dimensions are used, battery rack dimensions shall be adjusted accordingly.




62

FIGURE 2C2. Open battery rack details.

3.75

40.7

516.5

0

19.0

0

BB

SH

OC

K IS

OLA

TOR

DE

CK

MO

UN

TD

EC

K

1.50

2.00

0 X

2.00

0 X

0.1

88 L

, TY

P

2.50

0 X

2.5

00 X

0.1

88 L

, TY

P

TYP

0.12

5

1.00

X 0

.187

5 FB

,0.

50 R

AD

, TYP

1.00

1.00

(EA

CH

MO

UN

TIN

G P

LATE

)S

CR

EW

, CA

P-S

OC

KET

HE

AD,

FLA

T C

OU

NTE

R S

UN

K, 8

2°A

LLO

Y S

TEE

L (M

S246

67-5

3)

C L 2.50

00 x

2.5

000

x 0.

188

L, T

YP

BU

LKH

EAD

TYP

0.18

8

TYP

0.18

8

0.25

0 M

OU

NTI

NG

PLA

TE

3.25

0

4.00

00.

25 M

OU

NTI

NG

PLA

TE

4X (0

.375

) 3/8

-16

UN

C 3

A X

1.2

5 IN

. LG

.

DE

TAIL

OF

SH

OC

K IS

OLA

TOR

(DE

CK

MO

UN

T)

4.00

0

3.25

0TY

P0.

125

TYP

0.12

5

TYP

8.50

0 TY

P

1.00

0

4.00

.50

0.12

50.

250

MO

UN

TIN

G P

LATE

, TYP

TYP

0.12

5 2.50

0 X

2.50

0 X

0.1

88L

8.50

0

DE

CK

0.25

0 M

OU

NTI

NG

PLA

TE

BU

LKH

EAD

DE

TAIL

OF

SH

OC

K IS

OLA

TOR

(BU

LKH

EA

D M

OU

NT)

35.6

3

SH

OC

K IS

OLA

TOR

SH

OC

K IS

OLA

TOR

BU

LKH

EAD

MO

UN

T

HO

LD-D

OW

NR

ETA

INE

R B

LOC

K

TUR

NB

UC

KLE

BU

LKH

EAD

15.0

036

.325

63.6

25

2.50

X 2

.50

X 0

.188

L, T

YP

MO

UN

T FO

R T

UR

NBU

CKL

EEN

D P

ULL

AA

6.31

312

.00

12.0

012

.00

6.31

3



63


28. 3. Turnbuckles shall be in accordance with ASTM F1145, Class 7. 4. Retainer blocks shall be material that is electrically non-conductive. Melamine or clean hard maple in

accordance with MM-L-736 is recommended. Alternate material is permitted when approved by NAVSEA. 5. Machine screws shall be corrosion-resistant steel in accordance with FF-S-92. Self-locking nuts shall be


10.1", height of 8.1", and terminals located on the battery top near the battery diagonal corners. If batteries having other dimensions are used, battery rack dimensions shall be adjusted accordingly.

9. Assemble isolators to mounting plates before welding mounting plates. Shock isolator shall be Aeroflex isolator part no. CB1400-15-T2 or equivalent with the following characteristics:

A. Helical 0.50" wire rope shock mount. B. Height 3.25", width 4.00", length 8.50". C. Compression average, K=1670 pounds/inch, shear average, K=1500 pounds/inch, roll average, K=720

pounds/inch. D. Max. rated dynamic travel = 2.50" for 45 for compression roll, 1.50" for compression, and 1.20" for shear. E. Max. rated shock load = 2500 pounds compression, and 1800 pounds for shear or roll. F. Oil, ozone, grease, salt spray, organic solvents, and fatigue resistant. G. Operating temperature range is -40 to +212 °F (-40 to +100 °C) or greater inclusive range.

FIGURE 2C2. Open battery rack details - Continued.



64


2.00

X 2

.00

X 0

.188

L

1.25

0

DE

TAIL

C (S

ECU

RIN

G S

CR

EW A

SSY

)

7.31

0 5.56

0

2.93

0 1.18

04.

000

8.50

0

MO

UN

TIN

G P

LATE

4X Ø

0.4

06 T

HR

U

Ø

0.7

62 X

82°

10.6

25

5.31

3

2.50

0 X

2.50

0 X

0.1

88 L

0.18

8TY

P0.

188

TYP

0.05

001.

000

TYP

0.18

80.

500

TYP

DE

TAIL

B-B

0.18

811.7

50

45°

SN

IPE,

TYP

2.00

0 x

2.00

0 x

0.18

8 L,

10.7

50

DET

AIL

C

BAT

TER

YC

LAM

P

11.7

50

16.5

00

SEC

UR

ING

SCR

EW A

SSY

TUR

NB

UC

KLE

TYP

0.18

8TY

P

MO

UN

T FO

RTU

RN

BUC

KLE

EN

DP

ULL

0.18

8

DET

AIL

A-A

1.00

02.

500

X 2.

500

X 0

.188

L

0.18

80.

500

Ø 0

.312

5

0.25

0 PL

0.50

0 R

MO

UN

T FO

R T

UR

NB

UC

KLE

EN

DPU

LL

2.50

0 X

2.50

0 X

0.1

88 L

1.25

0Ø

0.5

31 D

RIL

L TH

RU

FOR

0.5

00 H

EX H

D B

OLD

1.00

01.

500 (0

.500

) 1/2

-13

HEX

HD

BO

LT3.

5 IN

LO

NG

GR

ADE

5FU

LL T

HR

EAD

TAC

K W

ELD

AT

TWO

OP

P FL

ATS

VAR

IES

(0.5

00) 1

/2-1

3 H

EX H

D N

UT

2 R

EQ

'D P

ER

ASS

Y

BAT

TER

Y C

LAM

P

1.12

5

1.62

5

1.12

5

.500

.500

1.00

0

RET

AIN

ER

BLO

CKS

0.81

2 0.81

2

0.56

2

2.75

0

0.56

2

0.25

0

13.5

00

3.87

5

4X Ø

0.2

50 M

AC

HIN

E S

CR

EWW

ITH

FLA

T W

ASH

ER A

ND

SE

LF-

LOC

KIN

G N

UT.

LEN

GTH

AS

NE

EDE

D

SEA

TIN

G W

ASH

ER F

OR

0.37

5 B

OLT

, STE

EL C

OM

L.TA

CK

WE

LD T

O C

HAN

NEL

CH

AN

NE

L, S

TEE

L, A

STM

A36

/A36

M, T

YPE

I,S

IZE

- 2.

000

X 1

.000

X 0

.188

L GR

AIN

1.00

0

3.00

0

0.37

5 S

TEEL

RO

D, B

EN

D A

ND

WEL

DTO

CH

ANN

EL A

S S

HO

WN0.

625

CBO

RE

1.25

0

0.37

5

TYP

CH

AN

NE

L

EN

DPU

LL J

AW R

H

EN

DPU

LL J

AW L

H

1.00

0

CO

UPL

ING

(0.6

875)

11/1

6" H

EX B

AR

DR

ILL

& T

AP (0

.312

5) 5

/16-

18 U

NC

28

2.00

0

0.75

0 R

H

7.50

0 B

EFO

RE

TAK

E U

P

JAW

AN

D J

AW

TUR

NB

UC

KLE

0.25

0 H

EX

BO

LT &

SE

LF-L

OC

KIN

G N

UT,

LEN

GTH

AS

NEE

DED

(2 R

EQ

UIR

ED)

Ø 0

.187

0.75

0 LH

0.25

0



65




10.1", height of 8.1", and terminals located on the battery top near the battery diagonal corners. If batteries having other dimensions are used, battery rack dimensions shall be adjusted accordingly.




66

NOTES: 1. Maximum width of cabinet doors shall be not more than 32". 2. Interior of closed cabinets shall be coated with an epoxy conforming to MIL-DTL-24441 and applied in

accordance with note 3 of figure 2C2. 3. Exterior shall be finished in accordance with MIL-E-917. 4. Enclosure is designed to accommodate open racks shown on figure 2C1 and 2C2. 5. Material shall be steel in accordance with ASTM A1008/A1008M, Class 1, Fin Matte. 6. Ventilation exhaust shall be discharged overboard or into a non-recirculating duct. 7. Section details are shown on figure 2C4.

FIGURE 2C3. Enclosed battery racks.

3"

3"

3 HINGESEQUALLY SPACED

MAINTAIN 3-INCH CLEARANCEBETWEEN ADJACENT FITTINGSIN AREA OF VENT

LOUVERS

SEE NOTE 1

HANDLE/LOCK

A A C CB B

E

E

D

D

BULKHEAD

SECURINGANGLE

STIFFENING ANGLENUMBER AS REQD.

2" 2"

WELD TO INSIDE1/2 OVERLAP

5" MAX.

2" APPROX.

FLATTEN EXPANDED METALSIZE 1/2, NO. 13, TYPE II, CL. 1,ASTM F1267VENT BOTH ENDS

METHOD 2C-3-1

DECK

FORCED DRAFT VENTILATION STACKSEE NOTE 6

PROVIDE RODS AND GUIDESFOR TOP AND BOTTOMBOLTS TO SUIT LATCH



67

FIGURE 2C4. Enclosed battery rack details.

ME

THO

D 2

C-4

-1D

ETA

ILS

FO

R F

IGU

RE

2C

3

BU

LKH

EAD

OPE

N R

ACK

- S

EEFI

GU

RES

2C

1 &

2C2

FOR

DET

AILS

SE

CU

RIN

G A

NG

LE (S

TEEL

)1"

x 3

/4" x

3/1

6", 4

1/2

" LO

NG

STIF

FEN

ING

AN

GLE

(STE

EL)

1" x

1" x

3/1

6", L

EN

GTH

TO

SU

IT

SEE

NO

TE 1

SE

E N

OTE

1

0.07

8"

1/16

"

0.07

8"

1"

1 3/

4"D

OO

R

1/8"

x 3

" x 2

" FU

LL S

UR

FAC

E H

ING

E(S

TEE

L) W

ITH

NO

N-R

EM

OVA

BLE

BR

ASS

PIN

. CO

M.,

WEL

D

WA

SH

ER

1 1/

4" x

5/8

" x 0

.109

" TH

ICK

2 1/

4"

1 3/

4"

1/8" HA

ND

LE, T

RIP

LEFL

EX

, 3 P

OIN

T LA

TCH

CO

MM

CA

BIN

ET

LOC

K D

IV. O

R E

QU

AL

1/16

"

0.07

8"

1 3/

8"

JAM

AN

GLE

, ON

E SI

DE

ON

LY3/

8" x

3/8

" x 1

/16"

, SPO

T W

ELD

1 3/

8"

1 3/

4"

1/8"

CA

BIN

ETD

OO

RS

EC

TIO

N D

-D

SEC

TIO

N E

-E

SEC

TIO

N A

-AS

EC

TIO

N B

-BS

ECTI

ON

C-C

DE

CK

0.07

8"1

1/2"

1/16

"

0.07

8"

2 1/

4"

1/16

"

2"

60°



68

NOTES: 1. For weld size, see 4.1.1. 2. These details are for figure 2C3.

FIGURE 2C4. Enclosed battery rack details - Continued.



69

NOTES: 1. All components shall be coated with epoxy before assembly in accordance with note 3 of figure 2C2. 2. Retainer blocks to be clear hard maple in accordance with MM-L-736.

FIGURE 2C5. Details of wood spacer blocks for battery racks.

1 5/

8"

1 5/

8"

4 27

/32"

GR

AIN

1"

1 5/

8"

1 5/

8"

7 1/

4"

GR

AIN

17°

3 1/

8"

7/16

"

2 13

/32"

4 13

/16"

7/16

"7/

16"

ME

THO

D 2

C-5

-1

2 3/

16"

3/16

"

4"

2 3/

16"

5 3/

4"5

3/4"

4"4"

3/16

"

1 3/

4"1

3/4"

17°

MET

HO

D 2

C-5

-27/

16"

3 11

/16"

1" D

IA.

3 H

OLE

S

9/32

" DIA

. 4 H

OLE

S

8 1/

16"

3 7/

8"3

7/8"

3/16

"

3/16

"

15 1

3/16

"

1 1/

16"3/

8"

GR

AIN

MET

HO

D 2

C-5

-3

3 1/

4"

3 1/

4"

1 1/

2"

9/32

" DIA

., 2

HO

LES

9/32

" DIA

., 2

HO

LES



70

NOTES: 1. All components shall be coated with epoxy before assembly in accordance with note 3 of figure 2C2. 2. Rivet shall be ¼ brazier head, high tensile steel. 3. Channel shall be steel, ASTM A36/A36M, Type 1, Size 2 by 1 by 3⁄16. 4. Retainer blocks to be clear hard maple in accordance with MM-L-736.

FIGURE 2C6. Battery clamp details.

1/4"

RIVET-SEE NOTE 2LENGTH TO SUIT

METHOD 2C-6-2

SEATING WASHER FOR3/8" BOLT (STEEL, COML)

5/8"

1 3/4" 3/8"

METHOD 2C-6-1

4 3/4" 5 3/4" 5 3/4" 2 7/16"18 11/16"

EYE BOLTHOLDER

1/2" DIA., 3 HOLES

STEEL WASHER FOR 3/8" BOLT(STEEL, COML)

1 1/8"

1/8" BRAZIER HD. RIVETLENGTH TO SUIT

1/8" BRAZIER HD. RIVETLENGTH TO SUIT

9/32" DRILL1/2" R.

1"

1" 5/8"

3/16"

1/4"

3/16"

3/8"

1/16"

RETAINER BLOCK

GRAIN

1/4"1/4"

1"1/8"

3/8"

PIVOT PLATE (STEEL) 1"

7/8" 1"

1/4"

1"

3"

3/8" STEEL RODBEND & WELD TOCHANNEL AS SHOWN

GRAIN

CBORE4 HOLES

1.0 INCH

3/8"

WASHER FOR1/4" RIVET (STEEL, COML)

1 5/8"

1 1/8"

1 1/8"

1/2"

1/2"

1"

RETAINER BLOCKS

1 1/4"

15 5/16"

CHANNELSEE NOTE 3

SEENOTE 4

2 3/4"

13/16"

13/16"3 7/8"

9/16"

9/16"



71


4 3/

8"

SEA

TIN

G W

ASH

ER

FO

R3/

8" B

OLT

(STE

EL, C

OM

L)(S

EE N

OTE

5)

9/16

" R.

1/2"

1/2"

1"

1 1/

4"

1 1/

4"1 7/

8"15

/16"

15/1

6"

13/3

2"3

13/3

2"

1/4"

5 13

/32"

13/3

2"9/16

" R.

2 1/

4"

18 1

3/16

"

3 3/

8"

3"

30°

30°

RE

TAIN

ER B

LOC

KS

WAS

HE

R F

OR

1/4

" RIV

ET

(STE

EL,

CO

ML)

RIV

ET-H

EAD

OV

ER(S

EE N

OTE

2)

METH

OD 2C

-7-3

GR

AIN

3/8"

STE

EL

RO

D B

END

AN

DW

ELD

TO

CH

ANN

EL A

SSH

OW

N

SEA

TIN

G W

ASH

ERFO

R 3

/8" B

OLT

(STE

EL, C

OM

L)

4 11

/16"

3"

30°

1 7/

8"

RET

AIN

ER

BLO

CK

S

RIV

ET-

HEA

D O

VER

(SEE

NO

TE 2

)

WAS

HER

1/4"

11 7

/8"

30°

1"

ME

THO

D 2

C-7

-1

3/8"

STE

EL R

OD

BEN

D A

ND

WEL

D T

O C

HAN

NE

L AS

SH

OW

N

3 1/

4"5

9/16

"

3/4"

2 3/

4"

1/2"

1/2"

1"

1 1/

2"

1 1/

2"

3"

1"

1"

30°

7 9/

16"

2"30

°

CH

ANN

EL

(SEE

NO

TE 3

)

5/8"

3 3/

4"

5/8"

RE

TAIN

ER

BLO

CKS

GR

AIN

1"27

7/8

"

5"

SEA

TIN

G W

ASH

ER F

OR

3/8"

BO

LT (S

TEEL

, CO

ML)

(SE

E N

OTE

5)

WA

SH

ER F

OR

1/4

" RIV

ET(S

TEEL

, CO

ML)

RIV

ET

- HEA

D O

VER

(SE

E N

OTE

2)

ME

THO

D 2

C-7

-2

GR

AIN

3 3/

8"

3/8"

STE

EL

RO

D B

END

AN

DW

ELD

TO

CH

ANN

EL A

SSH

OW

N

1"1

1/4"

1"1

7/16

"

3 13

/32"

CH

AN

NE

L (S

EE

NO

TE 3

)

9/16

"

9/16

"

3 1/

4"

1"

2 11

/16"

1 13

/16"

30°

30°

3 1/

8"

CH

AN

NEL

(SEE

NO

TE 3

)1/

2"1/

2"1"

1" 1"

2 1/

4"

1/2"

1 1/

8"3

1/4" 4

1/4"

1 1/

8"



72

NOTES: 1. All components shall be coated with epoxy before assembly in accordance with note 3 of figure 2C2. 2. Rivet shall be ¼ brazier head, high tensile steel. 3. Channel shall be steel, ASTM A36/A36M, Type 1, Size 2 by 1 by 3⁄16. 4. Retainer blocks to be clear hard maple in accordance with MM-L-736. 5. For weld size, see 4.1.1.

FIGURE 2C7. Battery clamp details - Continued.



73


6 1/16" 6 15/16" 6 1/16"

RIVET - HEAD OVER(SEE NOTE 2)

30° 30°30° 30°

30° 30°30°5 5/16"7 11/16"5 5/16"

RETAINER BLOCKS

CHANNEL (SEE NOTE 3)

1 1/2"

2 1/2"

1 1/4"

1 1/4"

RETAINER BLOCKS

METHOD 2C-8-3

3/8" STEEL ROD BENDAND WELD TO CHANNELAS SHOWN

3 1/8"2 11/16"

2 3/4"

1/2"1/2" 1"

1"

3"

1 1/8"

4 11/16"1 7/8"

30°

1/2"

3 1/4"

1/2"

GRAIN

1"24 7/8"

4 1/4"


WASHER

2 1/4"

1 1/4"

1 1/8"



1"

2"

METHOD 2C-8-13/8" STEEL ROD BEND ANDWELD TO CHANNEL ASSHOWN

4 3/4"2 1/4"

3/4"2 3/4"

1/2"1/2" 1"

1 1/2"

3"

7/8"

30°3" 2 3/4"

30°

5/8"

3 1/2"

5/8"

RETAINER BLOCKS

GRAIN

1"22 5/8"

4 3/4"

SEATING WASHER FOR3/8" BOLT (STEEL, COML)(SEE NOTE 5)

WASHER FOR 1/4" RIVET(STEEL,COML)

RIVET - HEAD OVER (SEE NOTE 2)

7/8"

1 1/2"

1 3/4"

1 1/4"

METHOD 2C-8-23/8" STEEL ROD BEND ANDWELD TO CHANNEL ASSHOWN

4 3/4"2 1/4"

3/4"2 3/4"

1/2"1/2" 1"

1 1/2"

3"

1 1/4"

30°3" 2 3/4"

30°

5/8"

4 1/4"

5/8"

GRAIN

1"22 5/8"

5 1/2"


WASHER FOR 1/4" RIVET(STEEL, COML)



74

NOTES: 1. All components shall be coated with epoxy before assembly in accordance with note 3 of figure 2C2. 2. Rivet shall be ¼ brazier head, high tensile steel. 3. Channel shall be steel, ASTM A36/A36M, Type 1, size 2 by 1 by 3⁄16. 4. Retainer blocks to be clear hard maple in accordance with MM-L-736. 5. For weld size, see 4.1.1.

FIGURE 2C8. Battery clamp details - Continued.


MIL-STD-2003-2A(SH) APPENDIX D

75

GROUP D – CASUALTY POWER

D.1 SCOPE

D.1.1 Scope. This section describes procedures for the proper installation of casualty power.

D.2 APPLICABLE DOCUMENTS

D.2.1 General. The documents listed in this section are specified in this appendix. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in this appendix, whether or not they are listed.

D.2.2 Government documents.

D.2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.


MIL-S-901 - Shock Tests, H.I. (High-Impact) Shipboard Machinery, Equipment, and Systems, Requirements for

MIL-DTL-5516 - Packing, Preformed, Petroleum Hydraulic, Fluid Resistant, 160 °F (71 °C)

MIL-DTL-15024 - Plates, Tags, and Bands for Identification of Equipment, General Specification for

MIL-I-15265 - Insulation, Electrical, Plastic (Submarine Bus Bar Covering)

MIL-DTL-16878/8 - Wire, Electrical, Silicone Rubber Insulated, 200 Deg. C, 1000 Volts

MIL-S-24235 - Stuffing Tubes, Metal, and Packing Assemblies For Electric Cables, General Specification for

MIL-DTL-24552 - Terminals and Seals, Plugs and Switch, Casualty Power Systems, Receptacle Type, General Specification for

MIL-DTL-24552/1 - Terminals and Seals, Plugs and Switch, Casualty Power, Receptacle Type, Back Connected 200 Ampere, 450-Volt, Alternating Current, Three-Phase, Symbol No. 1046

MIL-DTL-24552/2 - Terminals and Seals, Plugs and Switch, Casualty Power, Receptacle Type, Upper and Lower Riser, 200-Ampere, 450-Volt, Alternating Current, Three-Phase, Symbol No. 1047

MIL-DTL-24552/3 - Terminals and Seals, Plugs and Switch, Casualty Power, Seal, Symbol No. 1048

MIL-DTL-24552/4 - Terminals and Seals, Plugs and Switch, Casualty Power, Plug, 100-Ampere, 450-Volt, Alternating Current, Three-Phase, Symbol No. 1049

MIL-DTL-24643/3 - Cable, Electrical, 600 Volts, Types LSSHOF, LSDHOF, LSTHOF, and LSFHOF

MIL-DTL-24643/16 - Cable, Electrical, 1000 Volts, Type LSTSGU (Including Variation LSTSGA)





76

D.2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

ASTM INTERNATIONAL

ASTM A36/A36M - Standard Specification for Carbon Structural Steel

ASTM B209 - Standard Specification for Aluminum and Aluminum-Alloy Sheet and Plate

ASTM B211 - Standard Specification for Aluminum and Aluminum-Alloy Bar, Rod, and Wire

ASTM B633 - Standard Specification for Electrodeposited Coatings of Zinc on Iron and Steel

ASTM F1836M - Standard Specification for Stuffing Tubes, Nylon, and Packing Assemblies (Metric)


NATIONAL ELECTRICAL MANUFACTURERS ASSOCIATION (NEMA)

NEMA HP 6 - Electrical and Electronic Silicone and Silicone-Braided Insulated Hook-Up Wire Types S (600 V), ZHS (600 V), SS (1000 V), ZHSS (1000 V) and SSB Braided (1000 V)

(Copies of this document are available from the National Electrical Manufacturers Association, 1300 North 17th Street, Suite 1847, Rosslyn, VA 22209 or online at www.nema.org.)

SAE INTERNATIONAL

SAE-AMS-DTL-23053/5 - Insulation Sleeving, Electrical, Heat Shrinkable, Polyolefin, Flexible Crosslinked

SAE-AMS-DTL-23053/18 - Insulation Sleeving, Electrical, Heat Shrinkable, Modified Fluoroploymer, Crosslinked

SAE-AMS-QQ-A-250/8 - Aluminum Alloy 6061, Bar, Rod, Wire, and Special Shapes; Rolled, Drawn, or Cold Finished

(Copies of these documents are available from SAE World Headquarters, 400 Commonwealth Drive, Warrendale, PA 15096-0001 or online at www.sae.org.)

D.2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

D.3 REQUIRED EQUIPMENT AND MATERIALS

D.3.1 Required equipment and materials. The equipment and materials required for the proper installation of casualty power component are specified in figures 2D1 through 2D7.

D.4 NOTES AND PROCEDURES

D.4.1 Dimensions. For figures and tables in this section, all dimensions are in inches unless otherwise noted.

D.4.2 Figures. Table 2DI provides information for the figures in this group.



http://www.nema.org/�

http://www.sae.org/�


77

TABLE 2DI. Figures for the installation casualty power components.

Figure number Casualty power installation Page

2D1 Casualty power distribution system 78 2D2 Casualty power riser terminal 80 2D3 Casualty power bulkhead terminal 82 2D4 Casualty power cable stowage rack 84 2D5 Casualty power jumper cable assembly 86 2D6 Casualty power terminal preparation 88 2D7 Identification and end preparation of casualty power cables used with equipment in

accordance with MIL-DTL-24552 89



78

FIGURE 2D1. Casualty power distribution system.

RIS

ER

OR

LO

WE

R T

ER

MIN

AL

(SE

E N

OTE

2)

PRO

TEC

TIVE

CO

VER

S (3

) TO

BE

INST

ALLE

D A

T AL

L TI

MES

EXC

EPT

WH

EN

IN U

SE

BULK

HEA

D

CA

BLE

ASSE

MBL

IES

(SEE

NO

TE 3

)

A B C

EQ

UIP

ME

NT

ENC

LOSU

RE

(SEE

NO

TE 7

)(S

WBR

D, P

NL,

XFR

MR

, ETC

.)

EN

CLO

SUR

E T

ERM

INAL

(S

EE N

OTE

5)

CA

BLE

STO

RAG

E R

ACK

(S

EE N

OTE

4)

WA

TER

TIG

HT

BULK

HEA

D

SEAL

SEAL

BULK

HEA

D T

ERM

INAL

S

(

SEE

NO

TE 6

)



79

NOTES: 1. The casualty power distribution system shall be arranged to provide temporary transmission of power to span

damaged areas in accordance with section 320 of the ship specifications. 2. Vertical risers for transmission of power to a deck above or below shall be installed in accordance with

figure 2D2. 3. Portable jumper cable assemblies shall be provided for connecting riser terminals to horizontal run bulkhead

terminals and to terminals on switchboards, panels, and controllers in accordance with figure 2D5. 4. Cable storage racks shall be installed to stow the portable jumper cable assemblies in compartments where the

cable is used in accordance with figure 2D4. 5. Equipment terminals shall be mounted on equipment enclosures in accordance with Method 2D-3-2. 6. Bulkhead terminals for horizontal fore-and-aft casualty power runs shall be installed in accordance with

Methods 2D-3-1 and 2D-3-3. 7. When equipment enclosure is watertight, the seal MIL-DTL-24552/2 shall be used.

FIGURE 2D1. Casualty power distribution system - Continued.



80

FIGURE 2D2. Casualty power riser terminal.

1/4"

1/4"

2 1/

4"

2 3/

4"

5 1/

2"

5/16

" DR

ILL,

4 H

OLE

S

CA

SU

ALT

Y P

OW

ER

SU

PP

LY S

YS

TEM

RIS

ER

TE

RM

INA

L C

ON

NE

CTE

D T

O R

ISE

R T

ER

MIN

AL

IN C

OM

PAR

TME

NT

17/3

2"

3/16

"

5/16

"

6"

MA

RKI

NG

SH

OW

N IN

DO

TTED

IS T

YPIC

AL O

NLY

AN

D

SH

OU

LD IN

DIC

ATE

TH

E A

CTU

AL

LOC

ATI

ON

IN T

HE

VES

SEL

17/3

2"

3/16

"

4'-6

" TO

6'

4'-6

" TO

6'

BU

LKH

EAD

BU

LKH

EAD

9"

DEC

K

DEC

K

DEC

K

MIN

IMU

M R

EQU

IRE

D F

OR

INS

TALL

ATI

ON

ALLO

W S

LAC

K B

ETW

EEN

SU

PPO

RT

AN

D T

ERM

INAL

3

2" M

AX.

BET

WEE

N S

UP

POR

TS

2

1

72

SEE

NO

TE 3

SEE

NO

TE 2

MIL

-S-2

4235

CAB

LE A

SSY'

SAS

REQ

UIR

ED(S

EE

FIG

UR

E 2

D5)

WH

EN T

HE

RIS

ER T

ERM

INAL

ISIN

STA

LLE

D O

UTS

IDE

ON

A W

EATH

ERD

EC

K, T

HIS

LIN

E S

HA

LL B

E C

HA

NG

ED T

O:

78

SEE

NO

TE 4



81

TABLE 2D2-I. List of materials for casualty power.

9 -- Wire NEMA HP 6, Type FF-2 8 As required Nameplate - BHD Brass See note 4 7 2 Nameplate –Riser Brass See note 4 6 -- Cable, LSTHOF-42 -- MIL-DTL-24643/3 5 -- Terminals, Casualty Power,

Plug, Sym. No. 1049 -- MIL-DTL-24552/4

4 -- Terminals, Casualty Power, Seal, Sym. No. 1048

-- MIL-DTL-24552/3

3 -- Terminals, Casualty Power. Receptacle Type, Back Connected, Sym. No. 1046

-- MIL-DTL-24552/1

2 -- Terminals, Casualty Power. Receptacle Type, Upper and Lower Riser, Sym. No. 1047

-- MIL-DTL-24552/2

1 -- Cable, LSTSGU-75 -- MIL-DTL-24643/16

Part no.

Quantity Casualty power component

Material Material specification or reference

NOTES:

1. The riser shall be installed as shown or in accordance with specifically approved deviations. 2. Stuffing tube shall be of the type required for the particular deck construction where installed. 3. A 12" radius minimum handling clearance shall be maintained about center of riser terminals as shown. 4. Nameplates shall comply with MIL-DTL-15024, Type B, and marked as shown. PC 8 is the same as PC 7

except marked “bulkhead terminal” in lieu of “riser terminal”. 5. See figure 2D6 for wiring and installation of terminals.

FIGURE 2D2. Casualty power riser terminal - Continued.



82

NOTES: 1. Part no. are shown on figure 2D2. 2. Method 2D-3-2 is shown for NWT installations. Seal PC. 4 on figure 2D2 shall be used for all other

installations. 3. A 2" diameter opening in equipment enclosure or bulkhead is required. 4. See figure 2D6 for wiring and installation of terminals.

FIGURE 2D3. Casualty power bulkhead terminal.

METHOD 2D-3-1

PROTECTIVE COVERREMOVED

22

DECKDECK

8

BLKHD

STUFFING TUBE

1

ALTERNATE BULKHEADTERMINAL ASSEMBLY

NOTE: TERMINAL BLOCK SHOULD BELOCATED ON TOP OF CASUALTY POWERTERMINAL IN LIEU OF THE BOTTOM

8 8

4

SEE NOTE 3BULKHEAD

33

TYPICAL CASUALTY POWER,BULKHEAD TERMINAL ASSEMBLY

8

3

METHOD 2D-3-2(SEE NOTE 2)

NEED HEIGHTDIMENSION

SEE NOTE 3

EQUIPMENTENCLOSURE(SEE NOTE 7)

1/4"

1/4"

1 3/4"

2 1/4"

5 1/2"

5/16" DRILL, 4 HOLES

DANGER SHOCK HAZARD THIS TERMINAL IS

17/32"

6"

WARNING PLATE(SEE NOTE 5)

5/16"

NORMALLY ENERGIZED17/32"

3/16"

METHOD 2D-3-4

WARNING PLATE

TYPICAL CASUALTY POWERTERMINAL MOUNTED ONEQUIPMENT ENCLOSURE

METHOD 2D-3-3



83

NOTES (continued): 5. Normally energized casualty power terminals (those connected to transformers, power panels, or motor

controllers) shall have a warning plate installed inscribed as shown in Method 2D-3-4. Plate shall be Type B (brass) of MIL-DTL-15024.

6. A 12" radius minimum handling clearance shall be maintained center of bulkhead terminal. 7. When equipment enclosure is watertight, then seal MIL-DTL-24552/3 shall be used.

FIGURE 2D3. Casualty power bulkhead terminal - Continued.



84

FIGURE 2D4. Casualty power cable stowage rack.

1/2"

1 7/

8"

3 1/

2"7/

16" -

3 P

LAC

ES

3/16

"

3/16

"

4 1/

2"

SPO

OL

- 7/1

6" D

IA.

TAP

TH

RU

1/4"

-20

UN

C-2

B

3"

1/2

"

1/4"

1/2"

3.00

6"2.

996"

3/4"

1/4"

R. T

YP

TRIM

PLA

STI

SOL

CO

VER

ING

EVE

N W

ITH

TO

P O

F SP

OO

L.C

LEAN

TH

REA

DS.

DIP

IN P

LAST

ISO

L,TY

PE P

. MIL

-I-15

265.

APP

LY C

OAT

ING

APP

RO

X. 3

/32"

TH

ICK.

4" 8" B 10"

36" M

AX.

O

F C

ABL

E ST

OW

AGE

RAC

K

C L

3/16

" ON

AL.

1/8"

ON

STE

EL.

18" (

ABT)

4

1

5

CAB

LEAS

SY'S

SEE

SH

T20

5

QTY

AS

REQ

'DFO

R N

O. O

FC

ABLE

ASS

Y'S

TOBE

STO

WED

6

PLU

G R

ETAI

NER

6

3/16

" ON

AL.

1/8"

ON

STE

EL.

BH

D

CA

BLE

3/8"

ON

AL.

1/4"

ON

STE

EL. 3

3

INST

ALLA

TIO

N A

RR

ANG

EMEN

T

NO

T TO

SC

ALE

1"

1/2"

DIA

.

1/2"

R.

LASH

ING

HO

OK

3

5"5"

9" R

.3"

A

1/4"

R. (

2 PL

ACES

)

SAD

DLE

2

1/2"

AS

REQ

UIR

ED

1/4"

R.

3"

1/4"

R. (

4 PL

ACES

)

RE

TAIN

ING

CLI

P

1/4"

1/4"

1 3/

4"

2 1/

4"

5 1/

2"

5/16

" DR

ILL,

4 H

OLE

S

CA

SU

ALT

Y P

OW

ER

SU

PPLY

SY

STE

M

CA

BLE

RA

CK

FO

R S

TOW

AG

E O

F

CA

BLE

S F

T LO

NG

9/32

"

3/16

"

5/16

"

6"D

OTT

ED M

ARKI

NG

IS O

NLY

AN

EXA

MPL

E A

ND

SH

OU

LD IN

DIC

ATE

THE

ACTU

AL

LOC

ATIO

N IN

TH

EV

ESS

ELN

AM

E PL

ATE

4

DEC

K

2

9/32

"

3/16

"



85

TABLE 2D4-I. Table of dimensions.

Length of cable stowed A B

Up to 150' 6" 26" 150' to 325' 9" 40"

TABLE 2D4-II. List of materials – quantities for one rack.

6 As required Plug retainer Steel -- 5 1 Lashing 36" long, ¼" thick Hemp T-R-650; see note 7 4 1 Name plate Brass See note 9 3 2 Lashing hook Note 10 See notes 8 & 10. 2 1 Saddle Note 1 See notes 1 & 8 1 1 Retaining clip Note 1 See notes 1 & 10

Part no.

Quantity Name Material Material specification or reference

NOTES:

1. Saddle and retaining clip to be mild steel of weldable and drawable quality for steel bulkheads and aluminum alloy SAE-AMS-QQ-A-250/8 (or if applicable, ASTM B209) for aluminum bulkheads.

2. Depth of saddle and location of lashing hooks to be determined by amount of cable stowed. 3. Brackets shall not be welded on aluminum bulkheads less than ⅛" thick without proper reinforcement. 4. After installation, the entire fixture shall be painted to match surrounding structure. 5. All steel or aluminum parts shall be assembled by welding as specified. 6. All sharp corners shall be slightly rounded. 7. Both ends of lashing shall be served. Lashing not furnished. 8. When rack assembly is mounted on steel ends, all steel parts should be zinc-plated to conform to the

requirements of ASTM B633, Type I, Class 2. 9. Identification plates shall be Type B (brass) of MIL-DTL-15024 and shall be marked as shown. 10 Lashing hook to be ½" diameter mild steel KSM J welding pin or ½" diameter rod ASTM A36/A36M on steel

bulkheads and ½" diameter aluminum alloy KSM J welding pin or ½" diameter aluminum alloy ASTM B211 on aluminum bulkheads.

11. Stowage rack shall pass hi-shock test in accordance with MIL-S-901 while supporting coil of 75' of LSTHOF-42 cable or 72-pound equivalent dummy weight.

FIGURE 2D4. Casualty power cable stowage rack - Continued.



86

FIGURE 2D5. Casualty power jumper cable assembly.

5.25

"

CA

BLE

, LS

THO

F-42

PC

6 (F

IGU

RE

2D

2)

75' M

AX

.(S

EE

NO

TE 1

)1.

82"

4.27

"

SE

E D

ETA

IL "A

"S

EE

DE

TAIL

"A"

BLAC

K

WH

ITE

RED

PLU

G B

OO

T 3.00

"0.

50"

A B C

A B C

CR

IMP

WIT

H T

& B

HY

DR

AU

LIC

DIE

NO

.29

OR

EQ

UA

L

DE

TAIL

"A"

SID

E V

IEW

SE

CTI

ON

TRA

NS

PA

RE

NT

HE

AT

SH

RIN

KA

BLE

TU

BIN

GS

AE

AM

S-D

TL-2

3053

/18.

1 1

/2" I

.D.

CA

BLE

IDE

NTI

FIC

ATI

ON

TA

G(S

EE

NO

TE 2

)

MA

RK

ING

SH

OW

N IN

DO

TTE

D IS

AN

EX

AM

PLE

ON

LY A

ND

SH

OU

LD IN

DIC

ATE

TH

E A

CTU

AL

LEN

GTH

AN

D R

AC

K N

O. W

HE

RE

STO

WE

D.

RAC

K N

O.

KE

Y

PLU

G H

OU

SIN

G

PH

AS

E A

PH

AS

E B

PH

AS

E C

ME

THO

D 2

D-5

-1P

LUG

, MIL

-DTL

-245

52/4

SY

M 1

049



87

NOTES: 1. Cable length shall not exceed 75' in length unless approved by NAVSEA. 2. Each cable end shall be marked as shown. 3. See list of material on figure 2D4.

FIGURE 2D5. Casualty power jumper cable assembly - Continued.



88

NOTE: 1. Packing assembly ASTM F1836M, NSN 5975-00-202-2607 for size 5 stuffing tube to be furnished by

installing activity, sym. 1047 only.

FIGURE 2D6. Casualty power terminal preparation.

1/2"-20 NUT

LOCKWASHER

FLAT WASHER

4.70"

0.62"

BULKHEAD

BULKHEAD RUBBER SEAL MIL-DTL-24552/3, SYM 1048

0.75"

0.75"

4.875"

SYM 1047

CABLE TSGU-75

PACKING ASSEMBLY(SEE NOTE 1)

0.527" DIA.3 MTGHOLES

0.75"

1/4"-20 NUT

LOCKWASHER

FLAT WASHER

0.75"

5.125"

LUG CRIMPTO CABLE

BUS BAR

UPPER OR LOWER RISERTERMINAL, MIL-DTL-24552/2, SYM 1047

METHOD 2D-6-2

FURNISHEDWITH TERMINAL

CABLE TYPE FF-2 OFMIL-DTL-18878/8. CRIMPTO LUG. NOTE-FISH ONEEND OF CABLE THROUGHHOLES OF SEAL WHEREA SEAL IS REQUIRED.BEFORE CRIMPINGOTHER END, CONNECTOTHER END TO TERMINALON OTHER SIDE OFBULKHEAD OR TOEQUIPMENT BUS ASREQUIRED.

SYM 1046

LUG

BULKHEAD TERMINALMIL-DTL-24552/1, SYM 1046

(SAME AS SYM 1047 EXCEPT AS SHOWN)

1.875" DIA.

INSTALL THISFACE TOWARDTERMINAL

1.00"

SYM 1048

METHOD 2D-6-3



89

FIGURE 2D7. Identification and end preparation of casualty power cables used with equipment in accordance with

MIL-DTL-24552.

HE

AT

SH

RIN

KA

BLE

TU

BIN

G(T

RA

NS

PA

RE

NT

TYP

E) S

EE

NO

TES

6 A

ND

7

SE

E N

OTE

3H

EA

T S

HR

INK

ABLE

TU

BIN

G(S

EE

NO

TES

5, 6

, AN

D 7

)

14" M

INIM

UM

3/4"

3/4"

2 3/

4"

"O" R

ING

, (N

OM

INA

L 3/

8" I.

D. x

3/3

2" C

.S.)

(SE

E N

OTE

5)

SE

E N

OTE

9 CO

PP

ER

FE

RR

ULE

(SE

E N

OTE

S 4

AN

D 8

)

CA

BLE

IDE

NTI

FIC

ATI

ON

TA

GC

AB

LE, T

HO

F 42

(I I/

4" O

.D.)

MET

HO

D "A

"

BE

FOR

E F

OR

MIN

G

ME

THO

D "B

"(S

AM

E A

S M

ETH

OD

"A" E

XCE

PT

FOR

LEA

VIN

G F

LAR

ED

RAD

IUS

AT

END

)

AFT

ER F

OR

MIN

G

RAD

IUS

(FER

RU

LE)

BA

RE

CO

ND

UC

TOR

CLO

SE

D E

ND

CA

BLE

0.28

0" 0.27

9" +

0.0

02"

0.34

3" +

0.0

02"

7/8"

1/8"

MA

X. B

AR

E C

ON

DU

CTO

R

75 F

T R

AC

K N

O. 2

-73-

2

AFT

ER

FO

RM

ING

CLO

SE

D E

ND

FER

RU

LE

HE

X F

LAT

TO B

E 0

.286

" + 0

.005

"A

CR

OS

S F

LATS

- A

FTER

CO

MP

RE

SSIO

N

2 3/

4"

1"

1/2"

1" 1" 1"1/

4"

1/2"

1/2"

SP

RIN

G

GU

IDE

PIN

FOR

MIN

G D

IETY

PE

A (S

TEE

L)(S

EE

NO

TES

1 A

ND

2)

STO

CK

NU

MB

ERS

DIE

- H

3456

-00-

024-

1501

FER

RU

LE -

H59

40-0

0-19

4-73

94

TYP

ICA

L M

ETH

OD

OF

SEC

UR

ING

CO

PP

ER

FE

RR

ULE

TO

CO

ND

UC

TOR

PR

ES

S

FOR

MIN

G D

IE

C L

C L

1"

CA

BLE



90

NOTES: 1. Forming die shall be so constructed as to prevent disassembly while handling. 2. Springs shall be of a type and design that will hold the die halves normally in the open position. 3. Exposed end of cable sheath insulation at crotch shall be made effectively watertight by use of heat shrinkable

boot. 4. Place round copper ferrule on conductor and secure by forming as shown in detail by method “A” or “B”. 5. For phase identification by touch-install, heat shrink tubing. See notes 6 and 7 and non-metallic “O” rings,

NSN 5330-00-050-1211, MIL-DTL-5516 or equivalent black wire. Black wire (“A” phase) 1 “O” ring, black H.S. tube White wire (“B” phase) 2 “O” rings, white H.S. tube Red wire (“C” phase) 3 “O” rings, red H.S. tube

6. Phase and cable identification: Heat shrinkable tubing for phase identification shall be flexible type, SAE-AMS-DTL-23053/5, Class 1, and for cable identification shall be transparent SAE-AMS-DTL-23053/18.

7. Tubing size as supplied: a. For cable identification - 1½ I.D. b. For phase identification - ¾ I.D. c. ½" and 2¾" lengths

8. Pull out strength of ferrule shall be at least 150 pounds. If this cannot be accomplished by forming of ferrule directly over conductor, add a few copper strands in space between conductor and ferrule before forming. After the ferrules are formed on the conductors, remove any sharp fins and edges, replace ferrules cracked in forming.

9. Heat shrink tubing shall extend over the ferrule approximately ⅛" for watertight effectiveness. For repair only; not for new construction.

FIGURE 2D7. Identification and end preparation of casualty power cables used with equipment in accordance with MIL-DTL-24552 - Continued.


MIL-STD-2003-2A(SH) APPENDIX E

91

GROUP E – SHORE POWER

E.1 SCOPE

E.1.1 Scope. This section describes procedures for the proper installation of shore power.

E.2 APPLICABLE DOCUMENTS

E.2.1 General. The documents listed in this section are specified in this appendix. This section does not include documents cited in other sections of this standard or recommended for additional information or as examples. While every effort has been made to ensure the completeness of this list, document users are cautioned that they must meet all specified requirements of documents cited in this appendix, whether or not they are listed.

E.2.2 Government documents.

E.2.2.1 Specifications, standards, and handbooks. The following specifications, standards, and handbooks form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

A-A-59296 - Insulating Compound, Electrical (for Field Splicing Applications)


MIL-DTL-915/6 - Cable, Power Electrical, 600 Volts, for Outboard Use Only (Not for Inboard Use), Type THOF


MIL-T-16366 - Terminals, Electrical Lug and Conductor Splices, Crimp-Style

MIL-S-24235 - Stuffing Tubes, Metal, and Packing Assemblies for Electric Cables, General Specification for

MIL-C-24368/1 - Connector Assemblies; Plug, Power Transfer, Shore to Ship and Ship to Ship, 500 Volts, 500 Amperes, 60 Hertz, Symbol Number 1160

MIL-C-24368/2 - Connector Assemblies; Receptacle, and Receptacle - Cabled, Power Transfer, Shore to Ship and Ship to Ship, 500 Volts, 500 Amperes, 60 Hertz, Symbol Number 1161

MIL-C-24368/4 - Connector Assemblies; Plugs and Receptacles, Electric, Power Transfer, Shore to Ship and Ship to Ship, 500 Volts, 500 Amperes, 60 Hertz, Symbol Numbers 1162.1, 1162.2 and 1162.3

MIL-C-24368/5 - Connector Assemblies; Plug, Submarine Shore Power Transfer, Shore to Ship and Ship to Ship, 500 Volts, 400 Amperes, 60 Hertz, Three-Phase, Symbol Number 1149

MIL-C-24368/6 - Connector Assemblies; Dual Purpose, Submarine Shore Power Transfer (AC) and DSRV Battery Charging (DC), 500 Volts, 400 Amperes, 60 Hertz, Three-Phase, Symbols 1150 and 1150.1

MIL-I-24768/1 - Insulation, Plastic, Laminated, Thermosetting, Glass-Cloth, Melamine-Resin (GME)


MIL-STD-2003-1 - Electric Plant Installation Standard Methods for Surface Ships and Submarines (Cable)

MIL-STD-2003-3 - Electric Plant Installation Standard Methods for Surface Ships and Submarines (Penetrations)



92

MIL-STD-2003-4 - Electric Plant Installation Standard Methods for Surface Ships and Submarines (Cableways)

MIL-STD-3007 - Unified Facilities Criteria and Unified Facilities Guide Specifications


E.2.2.2 Other Government documents, drawings, and publications. The following other Government documents, drawings, and publications form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

NAVAL SEA SYSTEMS COMMAND (NAVSEA) DESIGN DATA SHEETS

DDS 100-1 - Reinforcement of Openings in Structure of Surface Ships Other than in Protective Planting

(Copies of this document are available from Commander, Naval Sea Systems Command, ATTN: SEA 05M2, 1333 Isaac Hull Avenue, SE, Stop 5160, Washington Navy Yard DC 20376-5160, or by email at [email protected] with the subject line “DDS request”.)


815-1197055 - Connection Box, Wt for Ship to Ship Power, Sym 490

815-1197056 - Cable Assembly, Sym 762,762.1

815-1197071 - Shore Terminal Box, 492.3,492.4

815-1197074 - Connector, Plug, Sym 761.1

815-1197217 - Shore Terminal Box-SBM15,493.3-493.4

(Copies of these documents are available from Commander, Portsmouth Naval Shipyard, ATTN: Code 280.1, Kittery, ME 03904.)

E.2.3 Non-Government publications. The following documents form a part of this document to the extent specified herein. Unless otherwise specified, the issues of these documents are those cited in the solicitation or contract.

SAE INTERNATIONAL

SAE-AMS-DTL-23053/4 - Insulation Sleeving, Electrical, Heat Shrinkable, Polyolefin, Dual-Wall, Outer Wall Crosslinked

SAE-AMS-DTL-23053/15 - Insulation Sleeving, Electrical, Heat Shrinkable, Polyolefin, Heavy-Wall, Coated, Flexible, Outer Wall Crosslinked

SAE-AS81765/1 - Insulating Components, Molded, Electrical, Heat Shrinkable Polyolefin, Crosslinked, Semi-Rigid and Flexible

(Copies of these documents are available from SAE World Headquarters, 400 Commonwealth Drive, Warrendale, PA 15096-0001 or online at www.sae.org.)

E.2.4 Order of precedence. Unless otherwise noted herein or in the contract, in the event of a conflict between the text of this document and the references cited herein, the text of this document takes precedence. Nothing in this document, however, supersedes applicable laws and regulations unless a specific exemption has been obtained.

E.3 REQUIRED EQUIPMENT AND MATERIALS

E.3.1 Required equipment and materials. The equipment and materials required for the proper installation of shore power component are specified in figures 2E1 through 2E23.



mailto:[email protected]�

http://www.sae.org/�


93

E.4 NOTES AND PROCEDURES

E.4.1 Dimensions. For figures and tables in this section, all dimensions are in inches unless otherwise noted.

E.4.2 Figures. Table 2EI provides information for the figures in this group.

TABLE 2EI. Figures for the installation of casualty power components.

Figure number Shore power installation Page

2E1 Shore power installations 94 2E2 Shore power installations 96 2E3 Mounting shore receptacles with 90-degree potting inside of bulkhead 98 2E4 Mounting shore power receptacles inside of bulkhead 100 2E5 Stagger mounting of shore power receptacles with 90-degree potting inside of bulkhead 102 2E6 Mounting shore power receptacles outside of bulkhead 104 2E7 Mounting shore power receptacles outside of bulkhead 106 2E8 Incline mounted shore power receptacles in protected areas 108 2E9 Free standing multiple shore power station 110

2E10 In-line connectors on alongside power cables (destroyer tenders and repair ships only) 112 2E11 In-line connectors on alongside power cables (for submarine tenders only) 114 2E12 Protection of shore power cable when exiting trunks (submarines) 116 2E13 Portable shore power cable jumper assemblies 118 2E14 Shore power installation for submarines 120 2E15 Termination and potting ship-or-shore power plug MIL-C-24368/1 122 2E16 Termination and potting ship-or-shore power receptacle MIL-C-24368/2 125 2E17 Alongside power in-line connectors MIL-C-24368/4 (tenders and repair ships) 128 2E18 Installation details for shore power receptacle MIL-C-24368/2 130 2E19 Typical shore power cable supports 132



94

FIGURE 2E1. Shore power installations.

PLU

G A

SSEM

BLY

CAB

LE A

SSE

MBL

Y

SEE

NO

TE 1

SEE

NO

TE 3

SEE

NO

TE 4

SEE

NO

TE 2

RP

RP

RP



95

LEGEND: P - Plugs R - Receptacles

(See figures 2E13 and 2E17)

NOTES: 1. Typical shore power installations for submarines are shown on figures 2E13 and 2E14. 2. Reference should be made to MIL-STD-3007 for typical shore power installations for shore activities. 3. In-line connector installations in accordance with figure 2E17 are used to connect cable assemblies to shore

power plugs. For ease of handling, approximately 10' of THOF-500 cable (15' of THOF-500 cable for submarines) is used for each plug assembly and approximately 150' of THOF-500 for each cable assembly. In-line connectors shall not be used in lieu of a splice of short run cables. Further, in-line connectors may be omitted in favor of a continuous length of cable.

4. Typical shore power installations for surface ships are shown on figures 2E1 through 2E13. 5. Portable shore-to-ship power cables are the responsibility of the shore activity. Portable ship-to-ship or ship-

to-shore cables onboard ship (tenders, repair ships, etc.) are the responsibility of the ship. Splicing of shore power cables is not recommended. If they cannot be avoided, splices and cable jacket repair should be in accordance with the hot splice vulcanized neoprene method described in the Civil Engineering (Naval Construction and Battalion Center, Port Hueneme, CA 93043) Technical Note TN No. N-1503.

6. Provide ungrounded electrical power at the ship’s shore power connection. Power shall be ungrounded from a dedicated transformer secondary serving only the ship and no industrial grounded type loads. The transformer amphere rating is not to be demanded or have a diversity factor applied.

7. Voltage shall not exceed the steady state voltage, ±5 percent, as measured at the ship’s main switchboard, i.e., for a 450-volt nominal ship system the allowable range is 427.5 to 472.5 volts.

8. Current rating requirement shall be achieved via multiple 400-amp shore power cabling circuits. 9. Install safety devices at dockside capable of automatically maintaining services during power surges and

equipped with circuit breakers to de-energize the electrical power during overloads. A 400-amp circuit breaker (100 KAIC rating) shall be provided for each portable shore power cable circuit serving ship. Ensure circuit breaker KAIC rating equals or exceeds (450 volt) transformer and cabling system capability.

10. Portable shore power cabling and connectors serving ship shall have a total current carrying capacity equal to or exceeding the specified shore power current requirements.

11. Type and condition of portable cabling and connectors shall be in accordance with (MIL-STD-2003-2) figure 2E1.

12. Spliced portable cabling is not to be used. 13. All portable cable circuits are to be of equal lengths (within 10 percent). 14. Cabling shall not be allowed to droop into river/sea. 15. Route excess lengths of portable cabling along length of pier and not in coils. 16. Post safety barriers at ship and shore connections. 17. Connect the portable shore power cabling and connectors to the ship. 18. Comply with the ship's polarity requirements. 19. Shore power cables shall be wrapped with protective covering at locations where chafing may occur. 20. PE-stamped power system one-line diagram shall be reviewed/accepted by government electrical engineer

prior to award of contract or connection of ships power to commercial facilities. The drawing is to show both permanent and portable conductors (size/type), switchgear bus ratings, other disconnects, pier connections, circuit breaker ratings, or other features from utility (source) to ships terminals.

FIGURE 2E1. Shore power installations - Continued.



96

FIGURE 2E2. Shore power installations.

3.75

" CLE

AR

AN

CE

FOR

HA

ND

LE

STU

FFIN

G T

UB

ES

2.0"

MIN

. (TY

PIC

AL)

MIL

-C-2

4368

/2R

EC

EP

TAC

LE

WA

TER

TIG

HT

BULK

HE

AD

4"

IND

ICA

TOR

LT.

SY

M N

O. 2

815.

2(W

HIT

E)

SH

OR

E P

OW

ER S

TATI

ON

5"

40" -

44"

OP

TIM

UM

CO

NN

EC

TIO

N B

OX

12"

MIN

.

18" M

IN.

42" M

IN.

(3) 4

00 M

CM

CA

BLE

S

PR

OTE

CTI

VE

DE

CK

SH

IPS

CA

BLE

ME

THO

D 2

E-2-

1

SP

LIC

ES

CA

BLE

CO

ND

UC

TOR

S



97

NOTES: 1. See figures 2E16 and 2E18 for installation details of receptacles. 2. Configuration of shore power station as shown hereon is optimum and should be followed to the greatest

extent possible.

FIGURE 2E2. Shore power installations - Continued.



98

FIGURE 2E3. Mounting shore receptacles with 90-degree potting inside of bulkhead.

3.75

" CLE

ARAN

CE

FOR

HA

ND

LE

STU

FFIN

G T

UB

ES

2.0"

MIN

. (TY

PIC

AL)

WA

TER

TIG

HT

BU

LKH

EAD

4"

IND

ICA

TOR

LIG

HT

SYM

NO

. 281

5.2

(WH

ITE

)

SH

OR

E P

OW

ER

STA

TIO

N

MET

HO

D 2

E-3-

1

5"

40" -

44"

OP

TIM

UM

CO

NN

EC

TIO

N B

OX

14"

MIN

.

18" M

IN.

42" M

IN.

PR

OTE

CTI

VE

DE

CK

LSTS

GA

-400

OR

LSTS

GU

-400

RE

CE

PTA

CLE

MIL

-C-2

4368

/2



99


extent possible.

FIGURE 2E3. Mounting shore receptacles with 90-degree potting inside of bulkhead - Continued.



100

FIGURE 2E4. Mounting shore power receptacles inside of bulkhead.

TAC

K W

ELD

(ALL

)

AC

CE

SS

PLA

TE -

NO

TE 3

19" X

40"

AC

CE

SS

15" X

36"

3.5"

MA

X.S

PAC

ING

MET

HO

D 2

E-4

-1

5"

40" -

44"

OPT

IMU

M

CO

NN

. BO

X

24"

60"

MIN

.

PR

OTE

CTI

VE

DEC

K

LSTS

GA

-400

OR

LSTS

GU

-400

CO

MPA

RTM

EN

T S

IDE

6"

CA

BLE

SU

PPO

RT

3.75

" CLE

ARA

NC

EFO

R H

AN

DLE

STU

FFIN

G T

UBE

S

2.0"

MIN

. (TY

PIC

AL)

RE

CE

PTA

CLE

MIL

-C-2

4368

/2

WA

TER

TIG

HT

BU

LKH

EAD

4"

IND

ICA

TOR

LIG

HT

SYM

NO

. 281

5.2

(WH

ITE)

SH

OR

E PO

WE

R S

TATI

ON



101


extent possible. 3. Strength of access plate shall be equivalent to bulkhead. Front access shall be provided only when access

from the compartment side cannot be provided.

FIGURE 2E4. Mounting shore power receptacles inside of bulkhead - Continued.



102

FIGURE 2E5. Stagger mounting of shore power receptacles with 90-degree potting inside of bulkhead.

WA

TER

TIG

HT

BULK

HEA

D

CO

NN

. BO

X(T

YPIC

AL)

RE

CEP

TAC

LEM

IL-C

-243

68/2

TAC

K W

ELD

(ALL

)

CAB

LE S

UPP

OR

T

LSTS

GA

-400

OR

LSTS

GU

-400

ME

THO

D 2

E-5

-1

STU

FFIN

G T

UBE

(TYP

ICA

L)

14"

MIN

.

1

9"TY

PIC

AL

1

9"

19"

1

9"

18.

25"

8.7

5"

8.7

5"

8

4"AP

PR

OX

.

3.7

5"C

LEA

RAN

CE

FOR

HAN

DLE

1

2"

MIN

.

1

6"

MIN

.

1

2"

MIN

.

3

2"

ACC

ESS

12" X

12"

(TYP

ICAL

)AC

CES

S P

LATE

16" X

16"

(TY

PIC

AL)

IND

ICAT

OR

LIG

HT

SYM

NO

. 281

5.2

(WH

ITE)

SH

OR

E P

OW

ER S

TATI

ON



103


extent possible.

FIGURE 2E5. Stagger mounting of shore power receptacles with 90-degree potting inside of bulkhead - Continued.



104

FIGURE 2E6. Mounting shore power receptacles outside of bulkhead.

ACC

ESS

15" x

36"

AC

CES

SPL

ATE

19" x

40"

3.5"

MAX

.S

PAC

ING

CAB

LES

CO

NN

. BO

X

TAC

K W

ELD

(ALL

)

24"

WA

TER

TIG

HT

ENC

LOSU

RE

W.T

. BU

LKH

EA

D

3.75

" CLE

ARAN

CE

FOR

HAN

DLE

4"

4"

2.0"

MIN

. (TY

PIC

AL)

12"

8"

6"

49" 8"

KIC

KPIP

ES

CAB

LE S

UPP

OR

T

IND

ICAT

OR

LIG

HT

SY

M N

O. 2

815.

2(W

HIT

E)

SH

OR

E P

OW

ER

STA

TIO

N

LSTS

GA-

400

OR

LSTS

GU

-400

14"

REC

EPTA

CLE

SM

IL-C

-243

68/2

ME

THO

D 2

E-6

2

12"

ME

THO

D 2

E-6

3

REC

EPTA

CLE

WIT

H90

° P

OTT

ING

WIT

HLS

TSG

A-40

0 O

RLS

TSG

U-4

00

RE

CE

PTA

CLE

WIT

HS

TRA

IGH

T P

OTT

ING

W

ITH

(3) M

CM

-400

CAB

LE

ME

THO

D 2

E-6

1



105


extent possible.

FIGURE 2E6. Mounting shore power receptacles outside of bulkhead - Continued.



106

FIGURE 2E7. Mounting shore power receptacles outside of bulkhead.

SH

OR

E P

OW

ER S

TATI

ON

CAB

LE S

UPP

OR

TS

TAC

K W

ELD

(ALL

)

2.0"

MIN

. (TY

PIC

AL)

12" M

IN.

MET

HO

D 2

E-7

-1

16"

ME

THO

D 2

E-7

-2

14"

ME

THO

D 2

E-7

-3

REC

EPTA

CLE

WIT

H90

° P

OTT

ING

FO

RLS

TSG

A-40

0 O

RLS

TSG

U-4

00 C

ABLE

REC

EPTA

CLE

WIT

HS

TRAI

GH

T PO

TTIN

G

FO

R(3

) MC

M-4

00 C

AB

LES

8° A

PPR

OX.

15°

APPR

OX.

WAT

ERTI

GH

T BH

D.

TO B

E E

QU

AL T

OBU

LKH

EAD

24" M

IN.

(1) C

ON

N.

BO

X

LSTS

GU

-400

TYP

WA

TER

TIG

HT

ENC

LOSU

RE

6" O

PEN

ING

- TW

O C

ABLE

S2.

5" O

PEN

ING

- O

NE

CAB

LE

PR

OTE

CTI

VE D

ECK

1.5"

CLE

ARAN

CE

FOR

PLU

G H

AND

LE

40" -

FO

UR

RC

PT.

36.5

" - T

HR

EE

RC

PT.

23" -

TW

O R

CP

T.

18" -

ON

E R

CP

T.

IND

ICA

TOR

LT.

SYM

NO

. 281

5.2

(WH

ITE

)

REC

EPT

ACLE

MIL

-C-2

4368

/2

3.75

" APP

RO

X.C

LEA

RAN

CE

FOR

HA

ND

LE

ACC

ESS

12" x

12"

PO

RTA

BLE

PLAT

E16

" x 1

6"

3.5"

MA

X.

SPA

CIN

G

RE

INFO

RC

ED

PIP

E S

IZE

PRES

CR

IBED

IN D

DS

100

-1



107


extent possible.

FIGURE 2E7. Mounting shore power receptacles outside of bulkhead - Continued.



108

FIGURE 2E8. Incline mounted shore power receptacles in protected areas.

PASS

AG

EWAY

SU

PPLY

CA

BLES

FRO

M T

HE

OV

ERH

EAD

SH

OR

E P

OW

ER

STA

TIO

N

ME

THO

D 2

E-8

-1

15°

APP

RO

X.3"

MIN

.

24" M

IN.

12" M

IN.

12 1

/2"

MIN

.

CO

NN

. BO

X

CAB

LE S

UP

POR

T

PR

OTE

CTI

VE D

ECK

WA

TER

TIG

HT

BULK

HEA

D

66" -

FO

UR

RE

CE

PTAC

LES

(MAX

.)50

1/2

" - T

HR

EE R

EC

EPTA

CLE

S

36" -

TW

O R

ECEP

TAC

LES

19 1

/2" -

ON

E R

ECEP

TAC

LE

4"4"

4"4"

4"

IND

ICA

TOR

LIG

HT

SY

M N

O. 2

815.

4(W

HIT

E)

REC

EPTA

CLE

(TYP

)M

IL-C

-243

68/2

STU

FFIN

G T

UBE

SH

OR

E P

OW

ER S

TATI

ON

12 1

/2"

MET

HO

D 2

E-8

-2



109


extent possible. 3. This method shall be used only in protected areas such as passageways, storerooms, and similar

compartments not exposed to the weather.

FIGURE 2E8. Incline mounted shore power receptacles in protected areas - Continued.



110

FIGURE 2E9. Free standing multiple shore power station.

LSTS

GA-

400

OR

LSTS

GU

-400

12"

MIN

.

MET

HO

D 2

E-9

-1M

ETH

OD

2E

-9-2

ME

THO

D 2

E-9

-3

14"

MIN

.24

"M

IN.

(3)M

CM

-400

CAB

LE

IND

ICA

TOR

LIG

HT

SYM

. NO

. 281

5.4

(WH

ITE)

DE

CK

60" F

OR

2 R

OW

S52

" FO

R1

RO

W O

FR

ECEP

TAC

LES

5" R

.(T

YP)

3" (T

YP)

4" (T

YP)

ACC

ESS

PLA

TE 2

0" X

36"

(TYP

)AC

CE

SS 1

8" X

32"

(TY

P)

3" R

.(T

YP)

6" (T

YP)

14"

(TYP

) SEC

TIO

N B

-B

ENC

LOSU

RE

RU

BBE

RG

ASKE

T

SYM

. 281

5.4

DET

AIL

"A"

FLU

SH M

OU

NTI

NG

OF

SYM

. 281

5.4

SEE

DET

AIL

"A"

SEC

TIO

N A

-A

BB

CO

NN

ECTI

ON

BO

X

7 1/

4"7

1/4"

13 1

/2"

13 1

/2"

13 1

/2"

MIL

-C-2

4368

/2S

HO

RE

PW

R R

CPT

(TY

P)

RE

CEP

TAC

LE C

UTO

UT

(TY

P)

4 3/

4" 9 3/

4"

9 3/

4"

11 3

/4"

AA2"

(TYP

)

2" (T

YP)



111


extent possible.

FIGURE 2E9. Free standing multiple shore power station - Continued.



112

NOTES: 1. Cable assembly Method 2E-10-1 is permitted on destroyer tender and repair ships to join two lengths of cable

together. Every effort should be made to install the required length of cable in lieu of using in-line connections.

FIGURE 2E10. In-line connectors on alongside power cables (destroyer tenders and repair ships only).

10' ±4"THOF-500CABLE

PLUGMIL-C-24368/1SEE FIGURE 2E16

PLUGS

RECEPTACLES

IN -LINECONNECTORSMIL-C-24368/4

THOF-500CABLE

ASSEMBLE IAWFIGURE 2E17

METHOD 2E-10-1DESTROYER

TENDERS



113

NOTES (continued): 2. Shore facilities may utilize available commercial single-phase or three-phase in-line connectors to facilitate

shore power connection to ship. The type of connector used shall be determined by responsible shore facility. For non-MIL-Spec in-line connectors, installation methods shall be in accordance with manufacturers’ instructions.

FIGURE 2E10. In-line connectors on alongside power cables (destroyer tenders and repair ships only) - Continued.



114

NOTES: 1. Cable assembly Method 2E-11-1 is permitted on submarine tenders when it is necessary to replace a damaged

MIL-C-24368/5 or /6 type plug connector. The tender may purchase a 15' length of cable with a MIL-C-24368/5 or /6 type plug connector at one end. This cable may be connected to the alongside power cable via in-line connectors.

FIGURE 2E11. In-line connectors on alongside power cables (for submarine tenders only).

METHOD 2E-11-1SUBMARINE

TENDERS

15' ±4"THOF-500CABLE

PLUGS

RECEPTACLES

IN -LINECONNECTORSMIL-C-24368/4

THOF-500CABLE

ASSEMBLE IAWFIGURE 2E17

OUTBOARD CONNECTOR(PLUG)

MIL-C-24368/5 AND /6SEE FIGURE 2E14



115

NOTES (continued): 2. Shore facilities may utilize available commercial single-phase or three-phase in-line connectors to facilitate

shore power connection to ship. The type of connector used shall be determined by responsible shore facility, for non-MIL-Spec in-line connector, installation shall be in accordance with manufacturers’ instructions.

FIGURE 2E11. In-line connectors on alongside power cables (for submarine tenders only) - Continued.



116

FIGURE 2E12. Protection of shore power cable when exiting trunks (submarines).

WIT

H C

OFF

ERD

AMW

ITH

OU

TC

OFF

ERD

AM

TYP

ICAL

EX

IT O

F S

HO

RE

POW

ER C

ABLE

SFR

OM

SER

VIC

E O

R E

SCAP

E TR

UN

KS

ME

THO

D 2

E-12

-3

SID

E H

ATC

HCO

VER

AN

DG

ASKE

T

CO

FFER

DAM

(FA

BRIC

ATE

TO S

UIT

)

6" x

13"

OP

ENIN

G18

SQ

.

BR

AC

KET

SEE

DET

AIL

A-A

(SEE

NO

TE 2

)

LAC

E

TOPS

IDE

SH

OR

E PO

WER

CAB

LE A

RR

ANG

EMEN

T

LIFE

LIN

ESM

ETH

OD

2E

-12-

2M

ETH

OD

2E

-12-

1

7"AP

PRO

X.

DET

AIL

A-A

TYPI

CA

L C

ABLE

PR

OTE

CTI

ON

BR

ACKE

T(F

ABR

ICAT

E TO

SU

IT T

RU

NK)

MA

TER

IAL:

STAI

NLE

SS S

TEE

L

3'-2

"AP

PRO

X.1/

2"-1

3 BO

LT(2

RE

QU

IRED

)

30.2

" PLT10

.2" P

LT

CAB

LE O

.D.

THO

F-50

0-3"

SEC

TIO

N B

-B

B B



117

NOTES: 1. Location and arrangement of cables in trunks must facilitate their exit. 2. Cables must be protected against cuts resulting of personnel traffic through the trunk, and of cable resting

against sharp edges. Sharp bend radius of cables shall be avoided.

FIGURE 2E12. Protection of shore power cable when exiting trunks (submarines) - Continued.



118

FIGURE 2E13. Portable shore power cable jumper assemblies.

METHOD 2E-13-1SURFACE SHIPS

30±2"

NOTE 3

NOTE 3

30±2"

12 1/2' ±2"THOF-500CABLE

DETAIL "A"

REFER TO DRAWING NUMBER 185787FOR LUGS WITH ONE MOUNTING HOLE

MIL-C-24368/5 AND MIL-C-24368/6SEE FIGURE 2E14

METHOD 2E-13-2SUBMARINES

PLUGMIL-C-24368/1SEE FIGURE 2E15

7 1/2' ±2"THOF-500CABLE

FOR SUBMARINE APPLICATIONS,THOF-400 CABLE SHALL NOT BESUBSTITUTED FOR THOF-500CABLE.

OUTBOARD CONNECTOR (PLUG)



119

TABLE 2E13-I. Crimp lugs.

Cable type Nominal diameter of conductor (inch) Lug size*

Crimp lug (MIL-T-16366)

Thomas & Betts or equivalent

500 MCM 256-30695-555 THOF-500 0.960

600 MCM 54289 400 MCM 256-30695-535

THOF-400 0.850 500 MCM 256-30695-555

Equivalent crimp lugs may be substituted for the ones specified above. Order lugs (silver-plated) with blank tongue and drill (two holes) as shown in Detail A. * Flexible cable, such as THOF (MIL-DTL-915/6), may require the next larger size lug due to the larger outside diameter of the flexible conductors (see MIL-T-16366).

NOTES:

1. Portable shore power cable jumper assemblies are a NATO requirement. They are furnished onboard ships to connect to shore cable assemblies in foreign ports or in places where the proper plugs are not available. Normally, the supply activity provides both the cable assembly and the appropriate plugs.

2. Stowage facilities shall be furnished for these assemblies. 3. Install a crotch boot and tubing in accordance with figure 2E17. 4. The NATO required adapter cables should not include in-line connectors. 5. Jumper cables for in-service vessels may be Type THOF-400. However, there shall be no mixing of jumper

cable sizes for each installation. For submarine applications, THOF-400 cable shall not be substituted for THOF-500 cable.

FIGURE 2E13. Portable shore power cable jumper assemblies - Continued.

9/16" DIA.(2 HOLES)

1 3/4" 13/16" MAXIMUM

COPPER CRIMP LUG (SILVER - PLATED),TYPE CLC, MIL-T-16366. CRIMP LUG TOCABLE. SEE CRIMP LUG TABLE.

DETAIL "A"



120

FIGURE 2E14. Shore power installation for submarines.

90°

SEE

FIG

UR

E 2

E13

FO

R O

NB

OA

RD

JUM

PE

R C

AB

LE A

SS

EMB

LIE

SW

HE

N R

EQ

UIR

ED

.

CA

BLE

THO

F-50

0LE

NG

TH A

S R

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121

NOTES:

1. Protective caps are not necessary inboard unless required by the installing activity. 2. Housing shall be made of steel matching that of the submarine hull by the supplier in accordance with

MIL-C-24368/5. 3. A spanner is required for the installation of connectors of protective caps. Spanner wrench shall be J.H.

Williams & Co. 3" face spanner wrench part no. 434 or equivalent. 4. Hardware shown hereon is in accordance with MIL-C-24368/5.

FIGURE 2E14. Shore power installation for submarines - Continued.



122

Step 1 – Plug disassembly: If plug is received partially assembled, remove insert retaining screws and remove insert, by pushing from rear. Remove sleeve retaining plates, sleeves, pins, and bus lugs.

Step 2 – Cable end preparation: Remove abrasion jacket and insulation as shown in illustrations 2A, 2B, or 2C as applicable.

Step 3 – Cable termination: Prior to crimping, position bus lugs on conductors as shown in illustration 3. Note position of index keys. Insert cable into bus lugs and crimp as shown in illustration 4. Crimp using Thomas & Betts (T&B) hydraulic power crimp and die set, or equivalent.

FIGURE 2E15. Termination and potting ship-or-shore power plug MIL-C-24368/1.

CABLECABLE SIZE REDUCER (SEE NOTE 2)CABLE INSERTION

OBSERVATION HOLE

BUS LUG ILLUSTRATION 4 - CRIMP CONFIGURATION

INDEX KEY

PHASE C(RED)

PHASE A(BLACK)

PHASE B(WHITE)

ILLUSTRATION 3 - FRONT VIEW BUS LUG AND CABLECONDUCTOR ORIENTATION

BLACK PHASE A

WHITE PHASE B

RED PHASE C

FOLD BACK JACKET ANDREMOVE FILLER AND REFOLDFORWARD PRIOR TO POTTING.- FOR PLUG ONLY -

3 SLITS 1 3/4" THROUGHABRASION JACKET 120° APART

FIGURE 2C: TO BE USED WHENCABLE LAY IS OUT OF PHASE WITHBUS BAR ORIENTATION. (ILLUS. 3)

ILLUSTRATION 2C - 3 CONDUCTOR CABLE

2 1/8±1/16"

THREE CONDUCTORCABLE THOF-500

4 1/2±1/8"

ILLUSTRATION 2B - 3 CONDUCTOR CABLE

RED PHASE C

BLACK PHASE A

WHITE PHASE B

ILLUSTRATION 2A - SINGLE CONDUCTOR CABLE - FOR RECEPTACLE ONLY - FIGURE 2E16

2 1/8±1/16"

ILLUSTRATION 1 - PLUG DISASSEMBLY

FLAT WASHERLOCK WASHERSCREW,INSERTRETAININGSCREW

FLAT WASHERLOCK WASHERPINSLEEVESLEEVE RETAINER PLATE

INSERT

BUS LUG



123

Step 4 – Cable scraping and cleaning: Thoroughly scrape and roughen the outside insulation at the conductors and cable jacket with a scraper. Coarse file or emery cloth for a length to be potted to ensure adhesion with the potting compound. Abrade the rear face of the insert (bus lug side) and the inside surface of the plug in the same manner. Clean abraded area with a lint-free cloth wetted with acetone or methyl ethyl ketone, and allow to dry. Note: Avoid touching or handling of roughened area to eliminate any contamination of surface.

Step 5 – Potting: Slide plug housing over cable and assemble as follows (see illustration 7):

a. Position insert on the bus lugs so index keys fit in their respective slots. b. Apply a light coat of non-insulated lubricant (not silicone grease) to the threads of the 21 pins and install

through the insert so lugs and insert are “locked” together. Lockwashers and flat washers are used with each pin. Flat washers are installed next to the insert. NOTE: Do not over-tighten pins (30 inch-pounds maximum) as they are copper.

c. Install 21 sleeves, chamfer facing out, by snapping them onto the ball-tipped pins (see note 4). d. Install sleeve retainer plates (4 screws each). e. Attach insert to plug housing with eight screws, the index pin, and hole pattern. Assure proper position.

Assure that the eight screws are tight prior to potting. FIGURE 2E15. Termination and potting ship-or-shore power plug MIL-C-24368/1 - Continued.

FLAT WASHERLOCK WASHERSCREWS

FLAT WASHERLOCK WASHERPINSLEEVE (CHAMFER OUT)SLEEVE RETAINER PLATE

INSERT

BUS LUG

INDEX PIN

INDEX HOLE

INDEX KEY

ILLUSTRATION 7 - PLUG ASSEMBLY

ILLUSTRATION 6 - CABLE INSULATION CLEANINGILLUSTRATION 5 - CABLE INSULATION SCRAPING



124

f. Set plug on end and secure the cable to a suitable overhead support. Position plug so that the cable is

centered in hole at rear of the housing (illustration 8). g. Weigh out the specified ratio of the stycast 2741 potting compound and the catalyst 16 hardener and mix

thoroughly (see note 3). Pour the mixed compound slowly from one side of the plug housing until the void area is filled. Allow the compound to cure eight hours at room temperature.

h. Assemble. Step 6 – The plug is now ready for use.

NOTES: 1. When the plug MIL-C-24368/1 is furnished without cable, it shall be prepared for use as shown hereon. 2. Unless otherwise specified in the contract or order, bus lugs are furnished for 500 MCM cable. Cable size

reducers, Part M24368/4-033 of MIL-C-24368/4, shall be used if 400 MCM cable is used. 3. Potting compound shall be 100 parts by weight of stycast 2741 cured with 50 parts by weight of catalyst 16 as

manufactured by Emerson Cuming, Inc., Canton, Massachusetts 02021. No other compound shall be used without prior approval of NAVSEA. To fill the plug, ¾ of a gallon (5 pounds) is required. NOTE: Verify that manufacturer’s potting compound expiration date is still current.

4. Caution: If sleeve chamfer is not facing out, a hazardous condition will exist.

FIGURE 2E15. Termination and potting ship-or-shore power plug MIL-C-24368/1 - Continued.

FILL UPTO THE TOP

ILLUSTRATION 8



125

Step 1: If receptacle is received partially assembled, remove insert retaining screws and remove insert by pushing from rear. If crimping of cable to bus lugs cannot be done while bus lugs are still assembled in the insert, remove them by removing the pins.

Step 2: Prepare and terminate cable same as steps 2, 3 (modified as shown hereon), and 4 of figure 2E15. Prior to crimping, position bus lugs on conductors as shown in illustration 2A. Note position of index keys. Position insert on the bus lugs so index keys fit in their respective slots. Apply a light coat of non-insulating lubricant (not silicone grease) to threads of the 21 pins and install through the insert so lugs and insert are “locked” together as shown in illustration 2B. If cable is long or installed in ship, slide mounting plate over cable first. NOTE: Do not over-tighten pins (30 inch-pounds maximum) as they are copper.

FIGURE 2E16. Termination and potting ship-or-shore power receptacle MIL-C-24368/2.

ILLUSTRATION 1 - RECEPTACLE ASSEMBLY

FLAT WASHERLOCK WASHERPIN

SCREW, INSERTRETAINING

INSERT

BUS LUG(FOR 90°RECEPTACLE)

BUS LUG(FOR STRAIGHTRECEPTACLE)

THREE CONDUCTORCABLE 400 OR 500MCM AS APPLICABLE

STRAIGHTRECEPTACLE

(3) SINGLE CONDUCTOR CABLES400 OR 500 MCM AS APPLICABLE

FLAT WASHERLOCK WASHERPIN

INSERT

90°RECEPTACLE

ILLUSTRATION 2B - INSERT AND CABLE ASSEMBLY

INDEX KEY

PHASE A(BLACK)

PHASE C(RED)

PHASE B(WHITE)

ILLUSTRATION 2A - FRONT VIEW BUS BAR ANDCONDUCTOR ORIENTATION



126

FIGURE 2E16. Termination and potting ship-or-shore power receptacle MIL-C-24368/2 - Continued.

5.08 I.D.

TAPE

12 3/4"

FOR 90° RECEPTACLE

ILLUSTRATION 4 - MOLD FOR 90° RECEPTACLE

INSERT AND CABLEASSEMBLY(ILLUS. 2B)

10 1/4"

TAPE5.08 I.D.

TAPE

INSERT AND CABLEASSEMBLY(ILLUS. 2B)

FILL UPTO THE TOP

ILLUSTRATION 3B - MOLD FOR STRAIGHT RECEPTACLE

4 5/8±1/4" FOR 3 SINGLE CONDUCTORS - 1/2 GALLON6 7/8±1/4" FOR 3 CONDUCTOR CABLE - 3/4 GALLON

FORM IN A CYLINDRICAL SHAPE ANDSECURELY TAPE. AS SHOWN IN ILLUS. 3B.

15 1/2"

- 1 3/4 GALLONS

ILLUSTRATION 3A



127

Step 3 – Potting: a. Fabricate a mold to the dimensions shown in illustrations 3 and 4 from a material such as 0.03 thick

plastic sheet. A cellulose acetate material has been shown to be satisfactory. Center and secure mold to insert with tape.

b. Position insert and secure cable to a suitable overhead support. Center cable in mold. c. Weigh out the specified ratio of the stycast 2741 potting compound and the catalyst 15 hardener and mix

thoroughly (see note 3). Pour the mixed compound slowly from one side of the receptacle housing until the void area is filled. Allow the compound to cure eight hours at room temperature.

d. Remove tape holding mold to insert. The mold may be removed if desired. e. Slide cable through the hole (see illustration 5) in the receptacle mounting plate and attach insert with

eight screws and nuts. The index pin and hole pattern will assure proper position. Step 4 – The receptacle is now ready for use.

NOTES: 1. When the receptacle MIL-C-24368/2 is furnished without cable, it shall be prepared for use as shown hereon. 2. Unless otherwise specified in the contract or order, bus lugs are furnished for 400 MCM cable. 3. Potting compound shall be 100 parts by weight of stycast 2741 cured with 50 parts by weight of catalyst 15 as

manufactured by Emerson Cuming, Inc., Canton, Massachusetts 02021. No other compound shall be used without prior approval of NAVSEA. The material required to fill the mold is shown next to illustration 3A.

FIGURE 2E16. Termination and potting ship-or-shore power receptacle MIL-C-24368/2 - Continued.

SCREW, INSERT RETAINING

INSERT

RECEPTACLE MOUNTING PLATE

INDEX PIN

POTTING

INDEX HOLE

FLAT WASHER

LOCK WASHER

NUT

ILLUSTRATION 5 - RECEPTACLE ASSEMBLY



128

FIGURE 2E17. Alongside power in-line connectors MIL-C-24368/4 (tenders and repair ships).

SH

OR

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OR

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AP

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RED



129

Notes and installation instructions: 1. Clean cable jacket and conductor insulation. First slide tubing over individual conductors and shrink in place

(prior to removal of insulation for crimping). Next slide crotch boot over cable conductors and cable jacket. Press firmly into crotch of conductors and shrink on place (Method 1A-6-1).

2. Shrink on the materials shall be as follows: 2E171-1 Crotch boot Part 1A62-II of Section 1, Group A 2E171-2 Tubing (27" long) M23053/15-104-0 of SAE-AMS-DTL-23053/15 2E171-3 Boot 1/

2E171-4 Kit 2/

1/ Boot, Part 2E171-3 shall be either a heavy duty tubing or a molded boot as shown below. Either part shall have adhesive on the internal wall which meets the adhesive requirements described in Section 1, Group A. Material for the tubing shall meet the performance requirements of SAE-AMS-DTL-23053/15 Class 1. Material for the molded boot shall meet the performance requirements of SAE-AS81765/1.

Expanded Recovered

2/ A kit shall contain: 1 crotch boot (2E171-1), 3 tubing (2E171-2), 3 boots (2E171-3), 1 abrasion device, and pertinent installation instructions.

3. Shrink part by applying heat, using a hot air blower or other heat source. Minimum recovery temperature is 350 °F. As heat is applied, move heat source back and forth over part to be shrunk. For crotch boot and tubing, shrink from center to ends to avoid trapping air. When part has recovered enough to assume the configuration of the item covered and excess adhesive appears at the ends, discontinue heating. Additional heat will not make the part shrink more tightly.

4. Crimp using T&B die no. 94H or equivalent. 5. Shore facilities may utilize available commercial single- or three-phase in-line connectors to facilitate the

shore power connection to ship. Type of connectors used shall be determined by the responsible shore facility. For non-MIL-Spec in-line connectors, installation methods shall be in accordance with manufacturer’s instructions.

FIGURE 2E17. Alongside power in-line connectors MIL-C-24368/4 (tenders and repair ships) - Continued.

0.155

0.50"

RECOVERED

6.25"

2.34"

3.60" 1.65"

1.72"

2.7"

1"9"

•

1.75"

0.82"

0.22"0.18"



130

FIGURE 2E18. Installation details for shore power receptacle MIL-C-24368/2.

11 1

/2"10

1/2

"6 1/

2"4

1/2"

8"9 1/

2"

4"

MIL

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4368

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131

NOTES: 1. Where receptacles are potted by a manufacturer to a short length of cable, splice shall be in accordance with

MIL-STD-2003-1. For greater accessibility, splice may be located below deck. Ship’s cable may be terminated and potted directly onto the receptacle as shown on figure 2E16 by the installing activity.

2. For suitable cable support, see MIL-STD-2003-4. 3. Access to terminal, boxes, and receptacles shall be provided. 4. Protective enclosure is required to provide protection and personnel safety and shall be of a tightness required

per compartment location. Proper gasketing and drainage for condensation shall be provided for watertight enclosures.

5. Six no. 20 AWG wire leads, 36" long are provided with each switch marked with circuit identification and wire size (1-20, 2-20, etc.). A heat shrinkable tubing (in accordance with SAE-AMS-DTL-23053/4, Class 2) shall be installed over the wire leads between the switch and connection box.

6. Opening of cover or unlatching of plug activates the shunt trip of circuit breaker, opening the breaker to “trip” position. Cover must be closed or plug latched before circuit breaker can be closed.

7. See MIL-DTL-16036 for wiring of the indicator lights. The alternate connection of the indicator lights as shown in MIL-DTL-16036 can be made when crimping the conductors at the cable splice. Flush mounting of indicator lights is preferred for greater protection (see detail “A”, figure 2E9).

8. A handle locking bracket shall be installed when receptacles are furnished without brackets. 9. Deck or bulkhead cable penetrations shall be in accordance with MIL-STD-2003-3.

FIGURE 2E18. Installation details for shore power receptacle MIL-C-24368/2 - Continued.



132

FIGURE 2E19. Typical shore power cable supports.

SHO

RE

PO

WE

R S

TATI

ON

YO

KE

SOC

KET

SFI

XE

D

DET

AIL

B -

B

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SAG

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AY

(SEE

NO

TE 1

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UP

ERST

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RE

PO

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BLE

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C -

C

DE

CK

CLI

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S1

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3"



133

NOTES:

1. The location of the shore power station shall be determined with respect to the lay of the portable shore power cables over the ship with due consideration given to securing of cables away from personnel traffic on deck.

2. Surface of cable contact to brackets shall be smooth to minimize cable damage. 3. A cable securing clamp assembly in accordance with detail “A-A” shall be installed on a suitable location to

provide cable strain relief on the plugs. 4. Rollers may be added to the intermediate bulkhead and portable yokes to improve cable handling capabilities.

FIGURE 2E19. Typical shore power cable supports - Continued.


MIL-STD-2003-2A(SH)

134

Preparing activity:

Navy – SH (Project SESS-2008-003)

NOTE: The activities listed above were interested in this document as of the date of this document. Since organizations and responsibilities can change, you should verify the currency of the information above using the ASSIST Online database at http://assist.daps.dla.mil.


http://assist.daps.dla.mil/�

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