Electronics Material Officer Course

MODULE NUMBER THREE

LESSON TOPIC ONE

ELECTRONICS MATERIAL AND MAINTENANCE

LESSON TOPIC OVERVIEW

LESSON TOPIC ONE

ELECTRONIC EQUIPMENT DESIGNATION AND MAINTENANCE

This lesson topic presents information about duties and organizational relationships, the electronics division organizational manual, and EMO relieving procedures.

The LEARNING OBJECTIVES of this LESSON TOPIC are as follow:

The student should review the "LIST OF STUDY RESOURCES" and read the Lesson Topic LEARNING OBJECTIVES before beginning the lesson topic.

LIST OF STUDY RESOURCES

ELECTRONIC EQUIPMENT DESIGNATION AND MAINTENANCE

To learn the material in this LESSON TOPIC, you will use the following study resources:

Written Lesson Topic presentations in the Module Booklet:

Additional Materials:

References:

LESSON TOPIC SUMMARY

ELECTRONIC EQUIPMENT DESIGNATION AND MAINTENANCE

This lesson topic introduces you to your material responsibilities as an EMO. You were introduced to the Maintenance Material Management (3M) System during Division Officer Course. This lesson will provide additional, electronic-specific information, provides a maintenance overview, and familiarizes you with equipment designation systems, field changes, maintenance support services, and miniature and microminiature electronic repair. The lesson narrative is organized as follows:

NARRATIVE FORM

OF

ELECTRONIC EQUIPMENT DESIGNATION AND MAINTENANCE

LESSON TOPIC 3.1

As an EMO, your primary material responsibility is to oversee the maintenance of electronic equipment. The size and complexity of this responsibility is determined by your ship's type and equipment configuration. To ensure proper maintenance, you must be aware of many factors such as past performance of equipment, modifications or alterations affecting the equipment, and sources of detailed technical information. Additionally, you must know what types and quantities of equipment are installed or planned for future installation and be able to assess how the operational condition of this equipment will affect the ship's mission. You should also be familiar with the electronics COSAL.

Training will impact maintenance, as discussed in Lesson Topic 1.3. The number and rates of the personnel on board and their capabilities directly impact your job as EMO. Your goal is to have an adequate number of well-trained personnel to maintain and repair equipment. Due to a high turnover of personnel and changing manning levels, there may be times when you will not have enough trained personnel. You must therefore, make the best use of available talent and maintenance resources and use your training program to improve the capabilities of the division.

The cleanliness of electronic equipment and spaces is also your responsibility. Most electronic spaces are air conditioned or forced-air ventilated. The circulation of air causes deposits of foreign material in and around the electronic equipment. This, coupled with dirt caused by the ship's operating environment and tobacco smoke, causes hazards to personnel and equipment. The insulating ability of matting and switch handles is diminished by an accumulation of dust and heavy dirt, which can also cause equipment failure. Conduct a weekly inspection (daily if possible) to check the cleanliness of spaces, equipment, and air filters. Then, follow up to ensure that corrective action has been taken on all discrepancies.

To fulfill your maintenance responsibilities, you must understand the terminology used to identify equipment. The navy uses six different nomenclature systems to identify electronics equipment:

As military electronic systems grew in complexity, an orderly means of identifying them and their subsystems became necessary. JETDS was adopted by all military services in 1957 and is the most used nomenclature system. The reference for JETDS is MIL-STD-196D. In JETDS, nomenclature is formatted differently, depending on whether the equipment is defined as a system, set, group, or unit. Figure 3.1-1 depicts a typical system layout.

Figure 3.1-1 Typical System Layout

A system is a combination of sets, groups, units, assemblies, subassemblies, and parts joined together to perform a complete operational function. Figure 3.1-2 is a block diagram for a typical communications system containing the necessary components (sets, groups, and units) for transmission and reception of voice and teletype signals. (Arrows indicate direction of signal flow).

Figure 3.1-2 Communications System Block Diagram

A set consists of one or more units and any additional assemblies, subassemblies, and parts necessary to perform a specific operational function (e.g., a radio transmitting set that produces and sends a radio signal. Figure 3.1-3 is an example of a set. The unshaded portion is a block diagram of a radio transmitter set which consists of a (1) radio frequency amplifier unit, (2) a radio transmitter unit, and (3) a power supply unit.

A group is a portion of a set or system that, by itself, cannot perform a complete operational function. A group may include any combination of units, assemblies or subassemblies. The antenna coupler group depicted in the shaded portion of Figure 3.1-3 is composed of two units, the antenna coupler unit and the antenna coupler control unit. To operate, it requires both power and a signal from the radio frequency amplifier unit.

A unit is an assembly or any combination of assemblies, subassemblies, and parts mounted together. Depending on its design, a unit may or may not be able to operate independently of its group or set.

Figure 3.1-3 Radio Transmitting Set

An assembly is a number of subassemblies or parts joined together to perform a specific function. Figure 3.1-4 shows a unit consisting of six assemblies. Assembly A6 is composed of six subassemblies.

Figure 3.1-4 Assemblies and Subassemblies

Table 3.1-1 Table of Equipment Indicators

The first letter "W" designates the type of installation - water. The second letter "S" designates the type of equipment - special types. The third letter "C" defines the purpose of the equipment as communications (receiving and transmitting). The equipment is a shipboard transceiver used for UHF satellite communications. A modification letter, immediately following the model number, is used to identify a set that has been modified, such as AN/SRC-16A. By referring to Figure 3.1-5, you can see that this radio has been modified once. It still retains the basic design and is functionally and electrically interchangeable with an unmodified set. A second modification is identified as AN/SRC-16B. A miscellaneous identifier may be used following the modification letter.

Equipment can be identified further by unit and group designators, such as T-916/SRC-16 (see Figure 3.1-5). The first one or two letters are called component indicators. Next are a tack (-), a model number, and a modification letter, if applicable. This is followed by a slant (/) and the indicators of the equipment or application to which the unit or group belongs (found in Table 3.1-1). Table 3.1-2 (page 3-1-12) and 3.1-3 (page 3-1-18) define unit and group indicators, respectively. An example of a unit designator is AM-3729/URT. This designator identifies a radio frequency amplifier, model number 3729, that is used with a general utility radio transmitter. All groups of equipment are identified by a two-letter indicator (e.g., OK-454(V)2/WSC).

So far, we have discussed only the notation used in equipment nomenclature. Now, we will examine the coding for major components of a set (assemblies, subassemblies, and parts). Unit and group components of a set are assigned sequential identification numbers (Unit 1, Unit 2, etc.; Group 1, Group 2, etc.) These numbers are further broken down into assembly numbers, subassembly numbers, and part numbers as shown below:

Set AN/SPS-40B

Major Unit MD-879/SPS-40B

Unit 3

Assembly 3A1

Subassembly 3A1A1

Reference Designator (Part) 3A1A1R1

Unit numbers are assigned to each designated major unit, e.g.:

AN/SPS-40B Set

MD-879/SPS-40B Unit 3

R-1788/SPS-40B Unit 5

AS-11348/SPS-40B Unit 12

Table 3.1-2 Table of Unit Indicators

LS

* Not for use by contractors.

Note 1: Not to be construed as limiting the application of the unit indicator

Table 3.1-3 Table of Group Unit Indicators

Note 1: Not to be construed as limiting the application of the group indicator

Each unit contains one or more assemblies. An example of an assembly is 12A1 Drive Assembly and 12A2 Antenna Assembly.

The assemblies may contain one or more subassemblies designated as A1, A2, A3, etc. An example of a subassembly number is 1A1A1.

The subassemblies are constructed of discrete components or parts (i.e. capacitors, resisters, terminals, sockets, transistors, tubes, etc.) An example of an electronic part is 1A1A1R1.

Sample component/part symbols:

Any of these levels (unit, assembly, or subassembly) may have parts mounted directly on their chassis. A complete list of component identifiers is too extensive to be included in this manual, but is printed in EIMB, Reference Data, NAVSEA SE000-00-EIM-140.

The Navy Model Letter System was used to assign nomenclature prior to JETDS. Although this system is no longer used, some equipment identified by this system still exist. Equipment designators in the NMLS begin with either two or three basic letters. They are followed by a tack (-), a suffix number to indicate additional purchases of the equipment (if applicable) and a

small letter to indicate modifications. Table 3.1-4 (page 3-1-23) shows the letter designations used in this system. Items in the Navy Model Letter System are designated by two or three basic letters. These letters are sometimes supplemented by prefix or suffix letters and/or numerals. Identical equipment purchased from the same contractor bears the same model designation. Additional equipment obtained for service for additional purchase is designated by a numeral following the original model letters. For example, on subsequent orders for the Model TAQ transmitting equipment, the equipment is identified by the designations TAQ-1, TAQ-2, etc.

If, after acceptance by the Navy Department, NAVSEA authorizes a modification of

the equipment, a lower case alteration letter is assigned to follow the model letters. For example, if a Model TAB-1 transmitter is modified after delivery by the addition of a harmonic suppressing circuit or unit, the model designation will be changed to TAB-1a. An additional modification of the TAB-1a or a modification of the TAB-1 differing from the "a" modification, will be indicated by a "b" and the equipment will be designated as TAB-1b. Experimental equipment assigned model letters beginning with an "X" if it is manufactured by a Naval organization (e.g., XA, XB, etc), or with a "C" when manufactured by a commercial company (e.g., CXA, CXB, CXAA, CXAB, etc). Preliminary models of equipment to be purchased by the U.S. Navy are given an "X" prefix letter, separated from the basic designation by a dash. The preliminary (test) model of "Model TBU" was therefore designated "Model X-TBU." MIL-HBK-140, which is no longer in effect, is the reference for NMLS.

Under the NTDS, there are two methods for assigning nomenclature: numerically, which consists of five digits, and alphanumerically, which consists of two digits and three letters. Examples are the 66047 (35-foot whip antenna) and 30AAP (voltage regulator). In both systems, the first two digits indicate the class of material and are defined in Table 3.1-5 (page 3-1-26). Navy type designations are assigned to denote major units and also to most component parts likely to require replacement during the normal life of the equipment involved. There are two systems of type designations: the Numerical System of Navy Type Designations and Alphabetical System of Navy Type Designations.

In the numerical system the designation is composed of a Navy type (e.g., 21426), a group of prefix letters to indicate the manufacturer of the item (e.g., CZZ) and, when necessary, a suffix letter. The prefix letters, and the Navy type number, are separated by a dash to form the complete Navy type designation (e.g., CZZ-21426). Once prefix letters are assigned to a manufacturer, they remain the permanent identification of the company and precede the Navy type numbers of all material manufactured by that manufacturer. Preliminary models of major units are identified by a special description consisting of the Navy type number assigned for the corresponding unit of the production equipment, prefixed by the letter "X". An example is CRV-X52041. The suffix letter is assigned to differentiate units of improved or different manufacture which are entirely interchangeable as units but, due to difference in construction, are not necessarily interchangeable with respect to their integral parts. The suffix letter is separated from the numerical portion by a dash. For example:

The alphabetical system, used for radar equipment units and special apparatus, is similar to the numerical system, but the last three or four numbers are replaced with alphabetical letters starting with AAA and progressing alphabetically; such as AAA, AAB, AAC...AAZ, ABA, ABB...etc. Also, the suffix letter is replaced by a suffix number; the first modification being indicated by the number "1," etc. An example of this system is CZZ-21AAA. The fundamental principles governing the application of both systems of Navy type designations are the same. This nomenclature may be prefixed with "NT-" which indicates Navy type. This prefix is still widely used for antennas (i.e., NT-66047, which is a 35-foot whip antenna.) Any prefix other than NT is a manufacturer's designating symbol. NTDS Material class numbers are provided in Table 3.1-5 (page 3-1-26).

The MARK-MOD nomenclature consists of the name of the equipment and a sequence of "MK-MOD" letters and numbers (e.g., Ship's Inertial Navigation System or SINS, MK2

MOD 1). Unlike in the JETDS designation system, the item name must always be included with the MK-MOD designation to specifically identify the equipment. The MK-MOD designations are assigned in numeric sequence within each equipment type. The item name may be spelled out, but the accepted letter group abbreviation (e.g., SINS, DRAI, MSR, WDE, WDS, etc.) is preferred for lengthy names. This system is used primarily for weapons systems, but you will also see it used for other equipment.

The TSEC system is similar to JETDS and is assigned to all Communications Security (COMSEC) equipment and materials. This nomenclature is approved by the Director of the National Security Agency (NSA), as set forth in CSP-1, Annex D. The format for equipment is: "TSEC," followed by a slant (/), three letters (called function designators), and the item number. An example is the TSEC/KWR-37, which is a Cryptographic Teletypewriter Receiver, Model Number 37. Assemblies, as described in JETDS, have their own format. Listed first are the item function designators, followed by a tack (-), the item number, and the suffix "/TSEC". For example, a KYB-6/TSEC is a cryptographic speech cabinet. See Table 3.1-6 (page 3-1-28). There are also COMSEC AIDS, which will always have the letter "A" as a second character, for example, KAM. This directs you to use the COMSEC AIDS column of Table 3.1-6.

The commercial nomenclature system is only assigned to equipment used by the military. This system is most predominantly used in identifying test equipment. However, it is also used to identify a variety of other special types of equipment. Commercial nomenclature consists of a

Table 3.1-4 Navy Model Letter System

Table 3.1-5 Navy Type Designation System (NTDS)

Class No. Material

Class No. Material

Table 3.1-6 Telecommunications Security (TSEC) Nomenclature System

model number assigned by the manufacturer (Federal Supply Code for Manufacturer), preceded by a code that identifies the manufacturer. Figure 3.1-6 (page 3-1-30) shows the basic structure of the Commercial Nomenclature System.

A field change is any modification or alteration made to electronic equipment after delivery to the government. Field changes are developed to improve performance, operational characteristics, maintenance, reliability, and safety features of equipment. Some field changes require minor wiring or mechanical changes to equipment and consist only of instructions for making the change. Other field changes are more extensive, requiring circuit changes and the removal or substitution of parts. The nature of each field change is indicated by a type and classification designation, operational category, and an installation priority.

Field Changes are designated as Type I, Type II, Type III, or Type IV. The type designator indicates the general contents of the change kit (publications package only, publications package and parts, etc.) Not included in the package are Planned Maintenance System (PMS) documentation, Allowance Parts List (APL) documentation, or other documentation not controlled by NAVSEA or SPAWAR. Corrections and revisions to these documents, as a result of field changes, are issued by the activities that have control over them. Type definitions are described in the following paragraphs.

A Type I field change requires parts that are provided in the change kit. The kit also contains a publications package, materials, and special tools required to install the field change and revise equipment nameplates, publications, and charts.

A Type II field change requires parts that are not provided in the field change kit. A Type II field change may either be a kit consisting of only the publications package, instructions published in an Electronics Information Bulletin (EIB), or other official instructions. When the change is published in the EIB, complete instructions for making the field change and for correcting related publications are included. The parts, tools, and test equipment required to make a Type II field change are either standard shipboard items (e.g., wire, terminal lugs, soldering irons) or readily available from stock supplies (e.g., repair parts stocked for the equipment).

A Type III field change requires parts. However, not all of the parts are included in the kit. The kit consists of materials and special tools required to make the field change to one piece of

Figure 3.1-6 Commercial Nomenclature System

POWER METER MODEL 431A HEWLETT PACKARD

POWER METER CAQ1 OR 28480 431A

equipment and to revise the equipment's nameplates, publications, and charts. The parts, tools, and test equipment not included in the kit are either standard shipboard items (e.g., wire, terminal lugs, soldering irons), or readily available from stock supplies (e.g., on board repair parts).

A Type IV field change does not require parts or the use of special tools. This type of field change may either be a kit consisting of only the publications package, instructions published in the EIB, or other official instructions. When the change is published in the EIB, complete instructions for making the field change and correcting related publications are included.

There are three class designations (A, B, and C) for field changes, one of which is assigned to each field change. The class designator indicates who is responsible for funding the change and who is responsible for installing it.

Class A field changes are approved for installation by forces afloat or shore station personnel. No installation funding is required.

Class B field changes to shipboard equipment are approved for installation by naval shipyards, tenders, or repair facilities under the conditions stated in the field change bulletin, when authorized by type commanders. Fleet installation funding is required. Class B field changes to equipment at training activities are approved for installation and funded by the appropriate systems command. Except for Class B field changes presently under procurement, in the supply system, or in the fleet installation planning stage, this type of field change is no longer issued.

Class C field changes normally require industrial assistance for installation and require the appropriate systems command to fund installation.

Two operational categories describe the effect the changes will have on the operating characteristics of the equipment. These categories are operational and non-operational. An operational field change affects the military characteristics of the equipment (e.g., a radar range increase or the addition of an electronic countermeasures capability). A non-operational field change does not effect the military characteristics of the equipment. This kind of change pertains

to equipment maintenance, reliability improvements, safety of personnel and equipment, equipment performance.

The emergency priority is assigned to field changes for the following reasons:

The urgent priority is assigned to changes for the following reasons:

The routine priority is assigned to proposed changes when "emergency" or "urgent" does not apply.

Electronic field changes are developed to improve equipment performance, operational characteristics, maintenance, reliability, and safety features. Therefore, field changes are approved only after they have been determined to be warranted by the results. Approval of field changes is given by the systems command that has control over the equipment to be modified. The controlling systems commands for shipboard electronic equipment are NAVSEA and SPAWAR.

An approved field change implies authority for making the change, but only on the systems and equipment specified by the approving activity (the controlling systems command). The applicability of field changes to specified installations, systems, and equipment is presented in each Electronic Field Change Bulletin and distributed in advance by publication in the EIB or, in special cases, by letter or message from the controlling systems command or project office. Installation of approved and applicable field changes is mandatory when they are available, and must be made at the earliest opportunity according to the assigned accomplishment priorities.

The final procedure in the installation of a field change is an important one, and must be performed even if it was not included in the field change bulletin. This procedure includes stamping the field change accomplishment plate and submitting documentation. If the equipment ot which the field change bulletin applies has a field change accomplishment plate attached, the field change number is stamped on the plate. The plate should belong to the equipment or unit whose type designation exactly matches the type designation (e.g., AN/SPS-10D) of the field change bulletin. If the equipment or unit does not have a plate, they can be requisitioned from the supply system. Finally, the change is reported by submitting an OPNAV 4790/CK.

No matter how proficient a maintenance division/work center becomes, there will always be a time when outside assistance is required. This assistance may be in the form of technical assistance from FTSC, NAVSEA, SPAWAR, or a commercial vendor. The navy must possess a capability to maintain and assess the operational status of shipboard equipment and systems, with minimum reliance on outside activities. Maintenance actions are to be taken at the lowest level capable of handling them. When help outside the command is needed, use navy resources first. If help cannot be obtained reasonably or appropriately from these sources, get outside assistance. This lesson topic identifies navy non-industrial technical assistance activities.

Non-industrial technical and material support are available to units from:

When technical experts from these activities are aboard, ensure that appropriate technicians and supervisors are also aboard to provide manpower, material, tools, and test equipment. Shipboard technicians and supervisors can take advantage of technical assistance by treating it as a training evolution. Diagnostics and repair should be accomplished by ship's technicians to the greatest possible extent. Outside technical assistance should be over-the-shoulder advice and

guidance, unless the situation dictates otherwise. Additionally, the ship must provide required technical documentation, tools, and test equipment. The assistance personnel are aboard at your request, so make their visit pleasant, informative, and productive in terms of repair and training. This will generally be noted in their post-assistance report.

DIRECT FLEET SUPPORT (DFS)

DFS consists of engineering and technical assistance that is beyond assistance available from fleet activities and includes:

This assistance is provided by civilian electronic field engineers under contract with the Naval Sea Systems Command. You may request DFS assistance at any time except when your ship is in a shipyard. However, your first call for assistance must be to a FTSC and the TYCOM RSG. Navy policy dictates that fleet and shore activities be self-sufficient. DFS is available for technical problems that are beyond the capability of the fleet but do not require industrial services. The primary objective of DFS is to provide technical assistance and to promote self-sufficiency by providing instruction and guidance to ship's force. The FLTCINCs may request DFS from the systems commands or their designated representatives. Some of the major DFS programs are listed below:

A secondary objective of DFS is to provide training to ship's force and IMAs.

FTSC are fleet controlled support detachments located in areas of major fleet concentration. Their mission is to improve fleet combat system readiness by helping ship's force achieve technical self-sufficiency. They do this by providing OJT in the maintenance and operation of combat system equipment. FTSC training is provided in a classroom and aboard ship in the form of technical assistance. FTSC training may also consist of reviews, tests, or trials of system performance. FTSCs also certify fleet miniature/microminiature (2M) repair stations and 2M technicians. FTSCs detachment are located at the following ports:

Pearl Harbor, HA

Norfolk, VA

Groton, CT

San Diego, CA

Naples, Italy

Yokosuka, Japan

San Francisco, CA

Mayport, FL

Kings Bay, GA

Seattle, WA

FTSCs provide the following services, as their technical capability and manning permits:

FTSCs will accept requests for technical assistance only after repair attempts by ship's force have failed or ship force needs technical assistance in troubleshooting the problem. If you need FTSC assistance, request it in time to permit completion of the work during normal working hours. Overtime is not normally authorized except for emergency services to meet operational commitments, which require a CASREP or message request for technical assistance. When a FTSC provides on board services, the enlisted technicians regularly assigned to the equipment must be present and available. Ship's technicians do the work with the advice and assistance of FTSC personnel. The EMO must also be present to coordinate details and keep the chain of command informed. Your ship must provide test equipment (calibrated), technical manuals, repair parts, MRCs, and adequate working facilities so that FTSC personnel may carry out their assignment promptly and efficiently. Whenever FTSC personnel are embarked outside the local FTSC area, the ship they are working in is required to report their initial arrival and final departure times by message. This message keeps other commands advised of work status and the availability of FTSC personnel for reassignment. FTSCs will give first priority to CASREPs and situations that affect primary mission readiness. They will schedule routine checks and inspections as resources allow. FTSCs do not provide numerical "grades" for inspections, but rather a report of material conditions found and recommended corrective action.

Ordinarily, electronics work assigned to NAVSEA, NAVAIR, or SPAWAR field activities is done by naval military and civilian personnel. However, when necessary, the Naval Sea Systems Command or the Space and Naval Warfare Systems Command will provide the professional services of electronic field engineers. These engineers provide technical information to naval personnel on unusual design, planning, installation, and maintenance problems associated with the introduction of new equipment. The major justification for their use, however, is their contribution in helping navy personnel to perform their duties more efficiently through training. At naval shipyards, for instance, they train and instruct shipyard personnel in the installation, checkout, and adjustment of equipment. Shop personnel are given detailed information on the fine points of equipment maintenance techniques. Aboard ships, electronic field engineers

familiarize the ship's force with the adjustment, maintenance, and operation of installed electronic equipment. Additionally, electronic field engineers provide classroom instruction for

U.S. Navy personnel on newly developed equipment. You can obtain field engineering services by submitting a request to your operational or type commander. The appropriate systems command will arrange on-call engineering services if not already available through the FTSC.

The Space and Naval Warfare (SPAWAR) Systems Command was created to deal with the increasing problems associated with shipboard equipment maintenance (maintainability, reliability, and availability). SPAWAR detachments provide a direct line of communication with

shipboard personnel responsible for electronic maintenance, with industrial activities which

support the fleet and the manufacturers who design and build the equipment. The detachments are not maintenance activities, but rather engineering management arms of the systems command, organized to resolve maintenance problems by taking or recommending remedial action. They are concerned with maintenance in its fullest sense: design, installation, training, logistics, and technical information. Each detachment has the following major divisions: ASW, radar and tactical data systems, engineering and logistic support, and combatant craft engineering. Each division is subdivided into branches with project engineers and technicians assigned to exercise engineering maintenance management over each piece of assigned equipment. The routine duties of SPAWAR detachments include:

Information gained from shipboard experience is furnished to the systems command for consideration when designing or updating equipment. Casualty reports and maintenance reports are investigated for corrective measures. Field changes are studied and released as developed. Articles and maintenance tips appear in the Electronics Information Bulletin (EIB). For assigned equipment, maintenance requirement cards receive final engineering approval. Experience and information gathered from maintenance reports, casualty reports, and shipboard interviews are applied to the research and development program and manufacturing stages to prevent future maintenance problems.

Forces afloat are the highest priority customers of SPAWAR. SPAWAR technical logistic support capability is maintained to ensure quick response to fleet requests for assistance. The implementation of the Fleet Liaison Program established direct lines of communication and provided "one-stop shopping" for support necessary to meet fleet operational requirements. A primary goal of the Fleet Liaison Program is to provide a single point-of-contact for the fleet in electronic matters by receiving, investigating, and evaluating problem areas. After investigating a problem, a fleet liaison team will recommend, initiate, and coordinate corrective actions. Additionally, the Fleet Liaison Office provides advice and consultation in the following areas:

There are six SPAWAR Field Activities with Fleet Liaison Offices: NAVELEXSECCEN Washington, DC; NAVELEXCEN Charleston, SC; NAVELEXCEN Portsmouth, VA; NAVELEXCEN San Diego, CA; Vallejo, CA; and NAVELEXACT St. Inigoes, MD., SPAWAR DET Mayport, FL. Note that, as the navy continues to "right-size", SPAWAR organization continues to change. On January 2, 1992, the navy established four major warfare centers by consolidating seven naval research and development centers with twenty-nine engineering and fleet support activities. One of these new centers is the Naval Command, Control, and Ocean Surveillance Center (NCCOSC), SPAWAR 90. NCCOSC's mission is to be the navy's full spectrum research, development, test and evaluation, engineering, and fleet support center for C³ systems and ocean surveillance. One of the subordinate commands of NCCOSC is NCCOSC In-Service Engineering (NISE). NISE is absorbing NAVELEX field activities mentioned in the previous paragraph however, many personnel in the fleet are as yet unaware of this process. Note that some NAVELEX field activities have not yet adopted the "NISE" designation. Currently, NISE West is the old NAVELEX San Diego. Its mission is to provide electronics material support for assigned systems and equipment. NISE West has two subordinate commands, NAVELEX Vallejo (a NISE West detachment) and NISE West Pearl Harbor (a NISE West activity). NISE West Activity Pearl Harbor has two facilities in Guam and Japan. These facilities extend NISE West Activity customer service to deployed units. NISE East includes the Naval Electronic System Engineering Center, Portsmouth (NESEC Portsmouth); the Naval Electronics Engineering Center, Charleston (NESEC Charleston); the Naval Electronic Systems Engineering Activity, St. Inigoes (NESEA St. Inigoes) and the Naval Electronic Systems Security Engineering Center (NESSEC) in Washington, DC. NISE assignments are as follow:

It is CNO policy that maintenance be accomplished at the lowest practical level for shipboard electronic equipment. Technological advances in equipment design had changed the Navy's repair philosophy from one of component replacement to one of module replacement for a number of modern systems. These modules (PCBs, CCAs, and EMs) are characterized by increased packaging complexity, multi-layer construction, and the extensive use of microminiature devices and subminiature components. Replacement of such modules is expensive. To repair PCBs/CCAs/EMs to the component level, the U.S. Navy instituted the Support and Test Equipment Engineering Program (STEEP), currently known as the 2M (Miniature/Microminiature)/ATE (Automatic Test Equipment) Repair Program. The 2M/ATE program allows the repair of complex modules at the organizational and intermediate maintenance levels. Using ATE and 2M Repair Stations to screen, fault isolate, and repair PCBs/ CCAs/EMs increases the availability of shipboard electronic equipment by reducing logistic delays and precluding turn-in of operational modules to supply.

Faulty PCBs/CCAs/EMs are usually DLR and as such are returned to the supply system in exchange for replacements. The damaged modules are processed for contractor repair, repaired within the navy establishment, or discarded. A recent study of various ships found that 35% of all PCBs/CCAs/EMs turned in for depot level repair showed no evidence of failure. In some specific systems, the figure was as high as 65%. Many of these modules could have been easily repaired aboard a ship with a 2M/ATE capability. This does not occur because the SM&R (Source, Maintenance, and Recoverability) code assigned by the supply system indicates that the

module is DLR (5G, 5S cog) or consumable (1N cog) and units are often unaware of 2M/ATE capabilities in their area. Progressive Depot Level Repair (PDLR) (OPNAVINST 4700.7J of

4 Dec 92) permits repair of DLRs at organizational and intermediate maintenance levels. When repair is beyond organizational level capability, the faulty component is forwarded to a Module Test and Repair (MTR) Facility for intermediate level repair. Do not allow your personnel to turn in faulty components without first ascertaining local 2M/ATE capabilities by checking the Master TPS Index List.

Miniature electronic repair is the repair of single-sided and double-sided PCBs, including the removal and installation of dual-in-line packages (DIP) and other microelectronic packages; the repair of PCB laminate and printed wiring; and the removal and application of conformal coating. Microminiature electronic repair is the repair of multi-layer PCBs. This usually requires sophisticated equipment, such as stereo microscopes. Microminiature electronic repair includes repair of multi-layer modules and small "daughter" boards that are too complex or dense for miniature electronic repair. Microminiature repair also includes the repair of flexible PCBs, printed circuit cables, optical encoders, and edgelighted panels; the removal and installation of special connectors, eyelets, and terminals; electroplating; microsoldering; and complete rebuilding. These repairs are only authorized under the NAVSEA 2M Repair Program in commands that have certified facilities. The 2M program provides the tools, test equipment, documentation, and training required for 2M repair. A typical 2M station is shown in Figure

3.1-7.

Figure 3.1-7 2M Repair Station

The 2M program excludes internal repairs to microelectronic components, but their removal or replacement is acceptable. Other exclusions include internal repairs to critically sensitive components, such as miniature radio frequency balanced mixers. Categories of 2M repair are:

NAVSEA and NAVSUP have authorized the use of the 2M Piece Parts Kit to facilitate 2M repair. The kit provides an inventory of generic electronic components ranging from 1,000 to 3,000 individual resistors, capacitors, transistors, semi-conductors, and microcircuits that cross-reference to approximately 43,000 part numbers. An inventory and cross-reference retrieval system is provided in floppy disk format. 2M Piece Parts Kits are logistically supported by a series of AELs and are tailored to ship classes and shore sites. The kits support a wide range of radar, communications, sonar, fire control, GPETE, and Commercial Off-The-Shelf (COTS) systems and equipment. Kits are assembled in Modular Drawer Storage Cabinets protected by Electrostatic Discharge (ESD) sensitive paint. A grounding strap is provided as an additional protective measure.

The Integrated Workstation provides the technician aboard ship with a work environment that simplifies transition from a stowed condition to an up and running workstation. This workstation provides stowage for all required tools and makes them readily available for assembly, connection, and use. Heavy equipment is secured to the work surface or in drawers and small hand tools are conveniently stored in foam cutouts within comfortable reach. The storage drawers are equipped with locking bars and are tested in accordance with military standards for shock resistance. Cabinet interiors and exteriors are protected with ESD-sensitive paint. Installation plans call for the 2M Piece Parts Kit and interface devices to be collocated with the workstation and standards required for scope and meter calibration located on a riser shelf above the work surface.

Technicians who repair electronic assemblies and subassemblies must receive formal training in miniature or microminiature repair and be certified 2M technicians; OJT is not acceptable for certification. Activities must maintain at least two certified repair technicians for each level of 2M repair station on board. Activities that have a single 2M station are authorized to train up to

three 2M technicians, and activities having multiple 2M stations are authorized to train two 2M technicians per station. 2M is not a primary NEC assignment. A secondary 2M NEC coupled with an existing billet is identified in the U.S. Navy's Master Billet File and the Enlisted Distribution Verification Report (EDVR) for the ratings ST, FC, ET, DS, CTM, GM, IC, GSE, EW, WT, and OTM. There is no NEC requirement for ATE however, ATE training is available. With suitable proficiency and 2M training, personnel may be awarded one of the following 2M NECs:

Prospective 2M repair technicians must satisfy the following requirements: have at least twelve months obligated service remaining on board upon completion of 2M training, fulfill all CANTRAC requirements, be a graduate of the Basic Shipboard Soldering Course, and be recommended for 2M training. Qualified technicians are issued cards that certify them as 2M repair technicians. The card is serialized, signed, and indicates the level of certification and date of expiration. Continued NEC qualification requires annual recertification by a qualified 2M inspector, instructor, or certification agent. The Manual of Navy Enlisted Manpower and Personnel Classifications and Occupational Standards (NAVPERS 18068E) lists guidelines for revising and deleting NECs when technicians no longer meet certification requirements or are no longer working in the 2M program. Direct quota requests for 2M training to detailers.

Maintenance activities performing 2M repair must meet the technical criteria of NAVSEA. Certifications are conducted periodically by FTSCs. Only certified repair stations may perform 2M repairs. Additionally:

Activities are required to have their 2M repair stations certified every 18 months. Certification inspections are conducted by FTSC 2M inspectors. When the 2M/ATE audit is finished, the FTSC inspector will issue a letter to your activity, IUC, ISIC, and the In Service Engineering Agent (ISEA). This letter will specify the status of your 2M repair capability, noting specific deficiencies and recommendations for corrective action. Ensure that your ship's recertification inspections (both station and personnel) are conducted before you deploy if current certifications will lapse during the deployment. Table 3.1-7 (page 3-1-44) shows the number of 2M/ATE stations authorized for various types of ships and craft.

The MTR program was created to provide short distance, quick turn around repair of PCBs/CCAs/EMs that cannot be repaired at the organizational level by providing an electronic repair facility aboard one of the larger units of a task force. For example, many ships have a electronic repair bench fitted with an AN/USM-465 (ATE) and Huntron Tracker 5100DS integrated with a desktop computer. If you were the EMO aboard a smaller ship and had a PCB that your technicians could not fix, you could send the board to the MTR facility by helicopter. Technicians in the facility would identify the faulty component and draw it from repair parts inventory. 2M technicians would then repair the PCB and return it by helicopter. If a PCB/CCA/EM cannot be repaired by an MTR facility, it will be forwarded for depot level repair. When your ship is assigned to a task force, find out which ships are carrying MTR facilities. SIMAs and tenders also have MTR facilities. By taking a short walk with the board and a 2K, you will have your equipment operational sooner than if you had sent the board to higher level facilities. You will also save money.

PROCEED TO ASSIGNMENT SHEET 3-1-1A IN THE ASSIGNMENT BOOKLET. UPON COMPLETION, TAKE THE ASSIGNMENT BOOKLET TO THE LEARNING CENTER INSTRUCTOR.

Figure 3.1-7 Authorized 2M/ATE Deployments