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MI L-STD-454N 30 June 1992 SUPERSEDING MI L-ST D-454M 15 December

1989

MILITARY STANDARD
STANDARD GENERAL REQUIREMENTS FOR ELECTRONIC EQUIPMENT
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MIL-STD-454N 30 June 199!2

DEPARTMENT OF DEFENSE Washington DC 20360 Standard General Requirements for Electronic Equipment MIL-STD-454N 1. This Mi1itary Standard is approved for use by all Departments and Agencies of the Department of Defense. *2. Beneficial comments (recommendation, additions, deletions) and any pertinent data which may be of use in improving this document should be addressed to Defense Electronics Supply Center, ATTN: DESC-EPE, Dayton, OH 45444-5270, by using the Standardization Document Improvement Proposal (DD Form 1426) appearing at the end of this document or by letter.

ii

MIL-STD-454N 30 June 1992 *FOREWORD This standard is the technical baseline for the design and construction of electronic equipment for the Department of Defense. It captures in one document, under suitable subject headings, fundamental design requirement for eleven general electronic specifications. The opportunity to focus on a single document, afforded to contractors, results in substantial savings to the Government. This standard was prepared and is semiannually updated through the cooperative efforts of Government and industry. The following Government documents are intimately associated with tbia standard: MIL-I-983 Interior Communication Equipment, Naval Shipboard, Basic Design Requirements for (Not for New Design) Electronic Equipment, Gnound, General Specification for Electronic Equipment, Aerogpace, General Specification for Electronic Equipment, Mis8iles, Boo8ters and Allied Vehicles, General Specification for (Not for New Design) Electronic Equipment, Aero8pace, Extended Space Environment, General Specification for Parts, Materials, and Processes Used in Electronic Equipment Electronic, Electrical and Electromechanical Equipment, Guided Missile and Associated Weapon 8ystenw, Qeneral Specification for Fire Control Equipment, Naval Shipboard, Qeneral Specification for Test Equipment for Use with Ele@t~oni@ and Electrical Equipment, (feneml Specification for (Not fop New Design) Test Equipment for Use with Electrical and Electronic Equipment, General Specification for

MIL-E-4158 MIL-E-5400 MIL-E-8189

DOD-E-8983

MIL-P-1126B MIL-E-119Q1

MIL-F-18870

MIL-T-21200

MIL-T-28800

iii

MIL-STD-454N 15 December 1989 CONTENTS Paragraph 1. 1.1 1.2 1.3 1.4 ?,. 3. 4. 4.1 4.2 5. 6. SCOPE Requirements applicable to electronic equipment Revision of requirements Method of reference Interrelationship of requirements APPLICABLE DOCUMENTS DEFINITIONS GENERAL REQUIREMENTS Application Use of #election and application standards DETAIL REQUIREMENTS NOTES

Individual Requirements Requirement 1 Requirement 2 Requirement 3 Requirement 4 Requirement 5 Requirement 6 Requirement 7 Requirement 8 Requirement S Requirement 10 Requirement 11 Requirement 12 Requirement 13 Requirement 14 Requirement 15 Requirement 16 Requirement 17 Requirement 18 Requirement 19 Requi~ement 20 Requirement 21 Requirement 22 Requirement 23 Requirement 24 Requirement 25 Requirement 26 Requirement 27 Safety Design Criteria - Personnel Hazards Capacitors Flammabi1ity Fungus-Inert Matemials Soldering Bearings Interchangeability Electrical Overload Protection Workmanship Electrical Connectors Insulating Materials, Electrical Fastener Hardware Structural Welding Transformers, Inductors, and Coi1s Metals, Corrosion Resistance Dissimilar Meta18 Printed Wiring Derating of Electronic Parts and Materials Terminations Wire, Hookup, Internal Castings Pa~ts Selection and Control Adhesives Welds, Resistance, Electrical Intevconnectiona Ele@t~ical Power Arc-Resistant Materials Batte~ies

iv

MIL-STD-4S4N 15 May 1990 CONTENTS - Continued Requirement 28 Requirement 29 Requirement 30 Requirement 31 Requirement 32 Requirement 33 Requirement 34 Requirement 35 Requirement 36 Requirement 37 Requirement 38 Requirement 39 Requirement 40 Requirement 41 Requirement 42 Requirement 43 Requirement 44 Requirement 45 Requirement 46 Requirement 47 Requirement 48 Requirement 49 Requirement 50 Requirement 51 Requirement 52 Requirement 53 Requirement 54 Requirement 55 Requirement S6 Requirement 57 Requirement 68 Requi~ement 59 Requirement 60 Requirement 61 Requirement 62 Requirement 63 Requirement 64 Requirement 65 Requirement 66 Requirement 67 Requirement 68 Requirement 69 Requirement 70 Requirement 71Requirement 72 Controls Electron Tubes Semiconductor Devices Moisture Pockets Test Provisions Resistors Nomenclature Reliability Accessibility Circuit Breakers Quartz Cnystals and Oscillator Units Fuses and Fuse Holders Shunts Springs Tuning Dial Mechanisms Lubpicanta Fibrous Materials, Organic Corona and Electrical Breakdown Prevention Motors and Rotary Power Converters Encapsulation and Embedment (Potting) Gears Hydraulics Indicator Lights Meters, Electrical Indicating Thermal Design Waveguides and Related Devices Maintainability Enclosures Rotary Servo Devices Relays Switches Brazing Sockets and Aace#80ries Elect~omagnetic Inte~ference Control Human Engineering Special Tools Microelectronic Devices Cable, Coaxial (RF) Cable, Multiconductor Ma~king Readouts and Displays Internal Wiping Praati@e# Electrical Filtens Cable and Wine, Interconnection Substitutability

MIL-STD-454N 15 December 1989

Requirement Requirement Requirement Requirement

73 74 75 76

Standard Electronic Modules Grounding, Bonding, and Shielding Electrostatic Discharge Control Fiber Optics

CONTENTS - Continued

Tables Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table Table 1-1 l-II 4-I 10-1 20-1 21I 26-I 41-1 41-11 41-111 50-1 53-I 64-I 64-II 66-I 69-I 71-1 71-11 Probable effects of shock Suitable protective measures Fungi-susceptibility of materials Abbreviations for thermocouple materials Wire, electrical Qeneral comparison of metallic casting proceseeg Arc-resistant materials Materials fop electrical spring application Corrosion resisting steel for springs Carbon steel for springs Indicator lights and associated items Waveguides and related devices Digital technology progression prediction Perfomnanae chanactenistics -digital mio~oelectr.onics Cable, multiconductor Electrical clearance and leakage (areepage) distances Wire, electrical, interconnection Cable, mtilticonductor, inte~connection Indexes

Indexes Index 1-1 Index I-2 Index of Applicable Documents Subject Index

vi

MIL-STD-454N 30 June 1992

STANDARD GENERAL REC!UIREMSNTS FOR ELECTRONIC EQUIPMENT

1.1 Requirements awl icable to electronic eauiument. This standard covers the common requirements to be used in military specifications for electronic equipment. 1.2 Revision of requirements. Revisions of individual requirements ape indicated by a date below the requirement number located at the bottom of the page. A note, *Supersedes Requirement (no.) (date), is placed in the lower corner of each revised page, opposite the requirement number and date. When the basic document ia revised, those requirements not affected by change retain their existing date.
q1.2.1

Redating. Although individual requirements are reviewed and updated or validated at least once every twelve months, r@qUinementS are not redated unless technical changes are mede.

*1.3. Method of refemence. This standard shall not be invoked on a blanket basis. Rather each requirement contained herein shall be referenced in the individual specification by specifying this standard and the requirement number. 1.4 lnterrelationshi D of Feauirements. Each requirement is intended to cover some discipline in the design of equipment, such as a procedure, a process or the selection and application of parts and materials. Many of these disciplines, howaver, cannot retain a clear-cut separation on isolation from others so that when requirements of MIL-STD-454 are referenced in a specification some requirements will undoubtedly have a direct interrelationship with other requirements. This interrelationship should be taken into consideration when invoking or using these requirements. 2. APPLICABLE DOCUMSNTS 2.1 Individual Requirements. See paragraph 2 of each individual requirement for a listing of applicable documents contained therein, including those for guidance only. Doauments referenced in the individual requirements apply to the extent speaified thenein. 2 .1.1 ADDli@abl@ igsues. Unless otherwise specified, the applicable issues shall be those listed in that issue of the Department of Defense Index of Specifications and Standards (DODISS) specified in the solicitation. The applicable issue of nongovennment documents shall be the issue specified.

MIL-STD-454N 30 June 1992

2.1.2 Copies. Copies of specifications, standards, drawings, and publications required by contractors in connection with specific procurement functions should be obtained from the procuring activity or as directed by the contracting officer. *2.1.3 Industry addresses. Addreasea for obtaining documents referenced herein but not obtainable from the Government are as follows! AQhfA American Qear Manufacturers AaBo@iation 1500 King Street Suite 201 Arlington VA 22314 Society of Automotive Engineer8 (SAE) 400 Commonwealth Drive Warrendale PA 15096 American National Standards Institute 11 West 42nd Street New York NY 10036 American Society for Metals Metals Park OE 44073 American Society for Testing and Materials 1916 Race Street Philadelphia PA 19103 Ame~ican Welding Society 550 N W LeJeune Road Po Box 351040 Miami FL 33135 Electronic Industries Association 2001 Pennsylvania Ave, NW Washington DC 20006 Institute of Electrical and Electronics Engineers IEEE Service Center 445 Hoes Lane PO Box 1331 Piscataway, NJ 08S55-1331 In8titute for Interconnecting and Paakaging Electronic Circuits 73S0 Nonth Lincoln Avenue Lincolnwood IL 60646-1776

AMS

ANSI

ASM

ASTM

AWS

EIA

IEEE

IPC

MIL-STD-454N 30 June 1992

NAS

National Standards Association 1200 Quinae Onchand Boulevard Qaithersburg MD 20878 National Fire Protection Association Battery March Park Quincy MA 02269 Underwriter Laboratories, Incorporated 333 Pfingsten Road Northbrook IL 60062-2096

NFPA

UL

3. DEFINITIONS 3.1 As used in this standard, the word airborne denotes those aPPliCatiOnE PeCUliar to aircraft and missile or other systems designed for operation primarily within the earths atmosphere; space denotes application peculiar to spacecraft and systems designed for operation near or beyond the upper reaches of the earths atmosphere; and -aerospace includes both airborne and spa.seapplications. 3.2 Other terms are defined in the individual Requirements.

4. GENERAL REQUIREMENTS 4.1 Application. The Requirements contained herein are intended to provide uniform requirements applicable to electronic equipment, unless otherwise specified in the Requirement, and shal1 be incorporated by reference in genanal equipment specifications. Other doaumants may reference Requirements when applicable. 4.!2 Use of selection and application standards. When a selection and application standard is invoked in a Requirement, the devices or parts selected shall conform to the applicable military specifications refe~enced in the standard. 5. DETAIL REQUIREMENTS 5.1 Individual Requirements for electronic equipment follow

6.1 The margins of this standard are marked with asteriskg to indiaate where changes (additions , modifications, corrections, deletions) from the previous issue were made. This is done as a convenience only and the Government assumes no 1iabi1ity whatsoever for any inaccuracies in these

MIL-STD-494N 30 June 1992 notations. Bidders and contractors are cautioned to evaluate the requirements of this document based on the entire content irrespective of the marginal notations and relationship to the last previous issue. 6.2 Subject term (key word) listinE. Cable selection Corona protection Encapsulation Fasteners Flammability Fungus protection Interchangeabi 1ity of parts Marking Materiala selection Microelectronics Nomenclature Parts selection Printed wiring safety Soldering Substitutability of parts Thermal design Waveguides Wire selection Workmanship

Custodians: Army - ER Navy - AS Air Force - 11 Review activities: Army - AR, AV, CR, ME, MI, PT, TE Navy - EC, SH , OS Air Force - 17, 19, 85, 99 Other: DLA - ES FAA

Preparing activity: Air Force - 10 Agent: DLA - ES Project QDRQ-0119

MIL-STD-454N REQUIREMENT 1 SAFETY DESIGN CRITERIA - PERSONNEL HAZARDS 1. Purpose. This requirement establishes safety design criteria and provides guidelines for personnel protection. 2, Documents aDDlicable to Requirement 1: Bonding, Electrical, and Lightning Protection, for Aerospace Systems MIL-STD-131O Shipboard Bonding, Grounding, and Other Techniques for Electromagnetic Compatibility and Safety Shielding MIL-STD-1472 Human Engineering Design Criteria for Military Systems, Equipment and Facilities MIL-HDBK-600 Guidelines for Identification, Markings, Labeling, Storage, and Transportation of Radioactive Commodities ANSI C95.1-1Q82 Safety Levels with Respect to Human Exposure to Radio Frequency Electromagnetic Fields, 300 KHz to 100 GHz ANSI C95.21982 Radio Fnequency Radiation Hazard Warning Symbol ANSI N2.1-1969 Radiation Symbol ANSI 235.1-1972 Accident Prevention Signs, Specification for ANSI 235.2-1968 Accident Prevention Tags, Specification for ANSI 235.4-1973 Specification for Informational Signs Complementary to ANSI 235.1, Aacident Prevention Signs ANSI 253.1-1979 Marking Physical Hazards, Safety Color Code for NFPA 70-1990 National Electrical Code 10 CFR 20 Code of Federal Regulations, Title 10, Chapter 1, Part 20 21 CFR 1000-1050 Code of Federal Regulations, Title 21, Chapter 1, Parts 1000-1050 29 CFR 1910 Code of Federal Regulations, Title 29, Chapter KVII, Part 1910 MIL-B-5087 3. Definitions 3.1 Chassis. electrical eauiDment. The chassis is a structural item fabricated in such manner as to facilitate assemblage and interconnection of electrical or electronic items for the specific purpose of providing a basis for electrical or electronic circuits. It normally has drilled or stamped holes to accommodate the items but may include only the items necessary for its own mounting and support. 3.2 -. The frame is any construction eyetem fitted and united together, designed for mounting or supporting electrical OP electronic parts or units. 3.3 Fail-safe. The design feature of a part, unit or equipment which allows the item to fail only into a non-hazardous mode.

REQUIREMENT 1 3 May 1991 1-1

MIL-STD-454N 3.4 Interlock. An interlock is an automatic switch which eliminates all power from the equipment when an access door, cover or plate is removed. 3.4.1 BvDassable interlock. A bypassable interlock is an automatic switch with a manually operated electrical bypass device to allow equipment maintenance operations on energized equipnwnt. 3.5 Battleshort. A switch used to bypass normal interlocks in mission critical equipment (i.e., equipment which must not be shut down or the mission function will fail) during battle conditions. 4. Requirements 4.1 Fail-8afe. The design and development of all military electronic equipment shall provide fail-safe features for safety of personnel during the installation, operation, maintenance, and repair or interchanging of a complete equipment assembly or component parts thereof. 4.2 Bondin.ein hazardous areas. Electronic equipment to be installed in areas where explosive or fire hazards exist shal1 be bonded in accordance with MIL-B-5087 for aerospace systems, MIL-STD-131O for shipboand systems, and NFPA 70, Chapter !3,for gnound systems, or as otherwise specified in the detail equipment specification. 4.3 Temperature. At an ambient temperature of 25C, the operating temperature of control panels and operating controls shall not exceed 49-C. Other exposed parts subjeat to oontaat by operating personnel shall not exceed 60C. 4.4 Electrical. The design shall incorporate methods to protect personnel from inadvertent contact with voltages capable of producing shock hazards. 4.4.1 -. Means shall be provided so that power may be cut off while installing, replacing, or interchanging a complete equipm+nt, assembly, or part thereof. Interface with electrical power #our@es shall be in accordance with the applicable regulations or requirements. If a main power 8witch is provided, it shall be clearly labeled as such and shall cut off all power to the complete equipment. 4.4.2 Ground. The design and construction of equipment, excluding self-powered equipment, shall insure that all external parts, surfaces, and shieldg, exclusive of antenna and t~angmission line terminals, ape at ground potential at all times duning normal operation. The design shall include consideration o! ground cur~enta and voltage limits (possible ancing) established on a basis of hazardous location. Antenna and transmission line terminals shall be at ground potential, except for madio frequency (Pi) energy on their external surfaces

1-2

MIL-STD-454N

4.4.2.1 Self-uowered eauipment. Self-powered equipment shal1 have al1 external surfaces at the same potential 4.4.2.2 Grounding methods. Plugs for use with metal cased portable tools and equipment shall have provisions for automatically grounding the metal frame or case of tools and equipment when the plug is mated with receptacle, and the gnounding pin shall make first, break last. Q~ound connections to shields, hinges, and other mechanical partg shall not be used to complete electrical circuits. Any external or interconnecting cable, where a ground is part of the cimuit, shall carry a ground wire in the cable terminated at both ends in the same manner as the other conductors. In no case, except with coaxial cables, shall the shield be depended upon for a current-carrying ground connection. Static and safety grounds shall not be used to complete electrical circuits. A point on the electrically conductive chassis or equipment frame shall serve as the common tie point for static and safety grounding. The path from the tie point to ground shall: a. Be centinuous and permanent, b. Have ample carrying capacity to conduct safely any fault currents that ~Y be imposed upon it, c. Have impedance sufficient1y low to limit the potential above ground and to facilitate the operation of the over current devices in the circuits, and d. Have mfficient mechanical strength of the material to minimize possibility of ground disconnection. 4.4.2.3 Hinged or slide-mounted Danels and doors. Hinge8 or slides shall not be used fo~ grounding paths. Panels and doo~s containing metere, #witaheg, test points, etc, shal1 be attached or hinged in such a manner as to insure that they are at the same ground potential as the equipment in which they are mounted, whether in a closed or open position. A ground shall be aonside~ed satisfactory if the electrical connation between the door on panel and the system tie point exhibits a resistance of O.1 ohm OF less and has sufficient ampacity to insure the reliable and immediate tripping of equipment over-current protection devices. 4.4.2.4 Shieldinl. Except where a conflict with single-point shield grounding requirements would be created, shielding on wire or cable #hall be grounded to the chassis or frame. The shielding shall be secured to prevent it from contacting exposed current-carrying parts or grounding to the chassis or frame at any point other than the gnound termination. The shielding shall end at a sufficient distance from exposed conductors to prevent shorting or arcing between the conducto~ and the shielding.

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MIL-STD-454N

4.4.3 Accidental contact. The design shall incorporate methods to protect personnel from accidental contact with voltages in excess of 30 volts rma or dc during normal operation of a complete equipment. 4 .4.3.1 Guards and barriers. Al1 contaats, terminals and like devices having voltages between 70 and 500 volts ma or dc with respect to ground shal1 be guarded from accidental contact by personnel if such points are exposed to contact during direct support or operator maintenance. Quarda or barriers may be provided with test probe holes where maintenance testing is required. 4.4.3.2 High voltage guardin6. Assemblies operating at potentials in excess of 500 volts 8hall be completely enclosed from the remainder of the assembly and equipped with nonbypassable interlocks. 4.4.3.3 VoltaEe measurement. When the operation or maintenance of equipment employing potentials in excess of 300 volts peak could require that these voltages be measured, the equipment shall be provided with test points so that these voltage8 can be measured at a relatively low potential level. In no case shall the potential exceed 300 volts peak relative to ground Test points with voltages above 30 volts shall have the conducting material recessed a distance no less than the diameter of the probe hole and a minimum of 1.5 mm. If a voltage divider is used, the voltage divider resistance between the test point and ground shall consist of at least two resistors of equal value in parallel. 4.4.3.4 Quardinfiof r! voltafes. Transmitter output terminals, antennas and other devices that carry sufficient r! voltage to burn or injure personnel shall be protected from accidental contact in the same manner as for ac voltages in the 70to 500 volt range. 4.4.3.5 Main power switch. The power input side of the main powen switch and the incoming power line aonneotions shall be given physical protection against accidental contact. 4.4.4 Protective devices 4.4.4.1 Interlocks. Wlen a unit is provided with access doors, covers or plates, these accesg points shall be interlocked as follows: a. MO interlock= are required when all potentials in excess o! 70 volts are completely protected with guards or barrier= to prevent accidental contact under all conditions of ope~ation or any level of maintenance.

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MIL-STD-454M

b. Bypassable interlocks are required when voltages between /Oand 500 volts are exposed as the result of an access door, cover, or plate being opened. Uote that these internal voltage8 are allowed to be unguarded only if they are not exposed during direct support or operator maintenance. The bypass device shall be of such design that closing the associated door, cover or plate wi11 automatical 1y open the bypass device and leave the interloak in position to function normally. Visual means shall be provided to indicate when the interlock is bypassed. c. Nonbypa8sable interlocks are required when any voltage in exces8 of 500 volts is expoged as a result of an access door, coven OF plate being opened. 4.4.4.2 Battle short indicator. When a battle short switch Is required by the individual equipment specification, a readily visible indicator light shall be provided to indicate when the battle short switch is ON. 4.4.4.3 Safety switches. Safety switchee which will.deactivate a= Ociated mechanical drive units shall be provided for the purpose of disconnecting these units without disconnecting othen parts of the equipment. Such remotely located units and assemblies shall have provision for nonoverrideable safety switches to allow independent disconnection in the associated equipment. 4.4.5 Discharfiini? devices 4.4.5.1 Automatic discbarie devices. High voltage circuits and capacitors shall be provided with discharging devises unless they discharge to 30 volts or less within two seconds after power removal The particular discharging device that is chosen shall insure that the capacitor or high voltage circuit is discharged to 30 volts or less within two seconds. These protective devices shall be positive acting, highly reliable, and shall actuate automatically either by mechanical release on by electrical solenoid when the door or cover is opened. When resistive bleeder networks are used to discharge capacitors, the bleeder network shall consist of at least two equal valued resistons in parallel. 4.4.5.2 Shorting rods. Shorting rods shall be provided with all transmitting equipment where voltages are in excess of 70 volts rnw on dc. Where size permits, shorting rods shall be stored within the transmitting equipment, permanently attached, and readily accessible to maintenance personnel. The permanent y attached rod shal1 be connected through a flexible stranded copper wire (covered with a transparent sleeving] to the stud provided at the transmitter main frame. Where size doee not permit internal storage of the shorting rod, a grounding stud shall be provided to permit attachment of a portable shomting rod. Tbe connection to the stud shall be such that accidental loosening on high resistance to tbe ground is prevented.

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MIL-STD-4S4N 4.4.6 Connectors. Connectors used in multiple electric circuits shall be selected to preclude mismating. Where design considerations require plug and receptacles of similar configuration in close proximity, the mating plugs and receptacles shal1 be suitably coded or marked to clearly indicate the mating connectors. Plugs and receptacles shall not be of #imilar configuration if the major unit contains explosive items The design of the connector shal1 be such that the operator is not exposed to electrical shock or burns when normal disconnect methods are used. Exposed pin contacts shal1 not be energized (hot) after being disconnected from the socket contacts. 4.5 Radiation. The design of all equipment for which a federal standard exists under 21 CFR 1000 - 1050, on the Radiation Control for Health and Safety Act of 1968, shall conform to the appropriate federal standard. 4.5.1 Microwave and rf radiation. All electronic equipment or electrical device8 capable of emitting microwave or n! radiation between 300 KHz and 100 QHz shall be so designed, fabricated, shielded and operated as to avoid overexposure of personnel In areas where unintended radiation levels exist, equipment design and installation in any unrestricted area accessible to personnel shall meet the requirements of ANSI C95.1. Shields, covers, doons, etc, which when opened or removed will allow microwave and rf radiation to exceed the above, shal1 be provided with nonbypassable interlocks. 4.5.2 X ~adiation. All electronic or elect~ical devices capable of producing X radiation shall be so degigned, fabricated, shielded and operated as to keep personnel exposure as low as reasonably achievable. For equipment and installation design, shielding requirements shall be maintained at all times which limit radiation levels to not greater than 2 milliroentgens (mr) in any one hour and 100 mr in any 7 consecutive days at the operator position or within 5cm from the equipment (whichever is closer) in any ,unrestrictedarea accessible to personnel In addition, these levels shal1 be reduced whenever necessary to ensure that exposed personnel neve~ receive an absorbed dose to the whole body or any critical organ in excesE of 125 millirem per calendar quarter or 500 millirem per year. Other exposure Ehall be based on application criteria and limits as required by Nuclear Regulatory Commission Rules and Regulations, 10 CFR 20: OSHA Regulations, 29 CFR 1910.96: and FDA Regulation, 2.1CFR, Chapter 1, Subchapter J, Radiological Health. Equipment which, when shields, covers, doors, etc. are removed, will allow X radiation to exceed 2.0 mr per hour shal1 be provided with nonbypassable interlocks. 4.5.3 Laser radiation. Laser equipment and system design, installation, and operational and maintenance procedures shall conform to 21 CFR 1040. If Title 21 cannot be met because of operational ~equirementH, an exemption shall be requested from the procuring activity and applicable military laser #afety regulations shall be used as a design requirement.

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MIL-STD-454M

4.6 Mechanical. The design of the equipment shall provide personnel maximum access and safety while installing, operating, and maintaining the equipment. Equipment design shall include provisions to prevent accidental pulling out of drawers or rack mounted equipment components. Suitable protection shall be provided to prevent contact with moving mechanical pants such as gears, fans, and belts when the equipment is complete and operating. Sharp projections on cabinets, doors, and similar parts shall be avoided. Doors or hinged covers shal1 be rounded at the corners and provided with stops to hold them open. 4.6.1 Mechanical interconnection. The design shall provide positive means to prevent the inadvertent revemsing or mismating of fittings; COUP1ings; fuel, oil, hydraulic, and pneumatic lines; and mechanical 1inkage. When prevention of mismating by design consideration is not feasible, coding or marking shall be employed when approved by the procuring activity. Coding and msrking wi11 not be approved as a substitute for proper design or iterns involving explosive, emergency, or safety critical systems. 4.6.2 Power switch location. Equipment power switches shall be so selected and located that accidental contact by personnel wi11 not place equipment in operation. 4.6.3 Cathode ray tubes. Provision shall be incorporated to protect personnel from injury due to implosion of cathode ray tubes. 4.7 Eauipment safety markings. Danger, caution, etc, signs, labels and mmkings shall be used to warn of specific hazards such as voltage, current, thermal, or physical The signs, labels, and markings shal1 be as permanent as the normal 1ife expectancy of the equipment on which they are affixed. Quards, barriens, and access doors, cove~a or plates shal1 be mmked to indicate the hazard which may be be present upon removal of such devices. When possible, msrking sbal1 be located such that it is not removed when the barrier or access door is removed. Additionally, hazards internal to a unit shall be marked adjacent to hazards if they ane significantly different from those of surrounding items. Such a case would be a high voltage terminal in a group of low voltage devices. a. Physical hazards shal1 be mmked with color codes in accordance with ANSI Z53.1 where applicable to electronic equipment. b. For potentials between 70 and 500 volts, warning signs or labels shall be in accordance with ANSI Z35.1, Class II, and ANSI Z35.4, and shall read, as a minimum, Caution - (Insert maximum voltage applicable) Volts.

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MIL-STD-454N

c. For potentials in excess of 500 volts, warning signs or labels shall be in accordance with ANSI 235.1, Class I and ANSI 235.4, and shall read, as a minimum, Danger - High Voltage - (Insert maximum voltage applicable) Volta. d. Microwave or rf radiation warning signs shall be in accordance with ANSI 235.1 and ANSI C95.2. Labels shall be provided on all radiation shields to warn personnel of the radiation hazards involved upon removal thereof. Any item which can emit radiation levels in excess of those specified in paragraph 4.5.1 shall be labeled. Minimum safe clearance distances shall be clearly marked. Warning signs shall,be posted in all aneas having electronic equipment designed to operate between 300 KHz and 100 QHz with intended electromagnetic radiation levels exceeding those in paragmaph 4.5.1. e. (1) Laser labels shall be in acaondance with 21 (!FR1040. (2) Military exempt laser labels: A permanent label shall be affixed on all military laser systems that have been certified exempt from 21 CFR 1040 (Performance Standards for Light-Emitting Products), which reads: CAVTION This electronic pvoduct ha8 been exempted f~om FDA radiation safety performance ntandards, prenfribed in the Code of Federal Regulations, Title 21, Chapter 1, Subcbapte~ J, pur8uant to Ixemption No. 76 ,PL-01 DOD i88ued on 26 July 1976. This product should not be used without adequate protective devices OP p~ocedure#. f. Shields which protect personnel from X radiation shall be labeled in accordance with 10 CFR 20. g. Coding for accident prevention tags .vhal 1 be in accordance with ANSI 235.2. h. The marking or labeling of commodities containing radioactive mate~ials shal1 be in accordance wi~h 10 CFR 20. i. Ionizing radiation hazard symbols shall be in accordance with ANSI N2 1. 4.8 Hazardous and restricted mateniala

4 .8.1 Gases or fumes. The materials, as installed in tbe equipment and under serviae conditions specified in the equipment #pacification, shall not liberate gases which combine with the atmosphere to form an aoid OF aonnosive alkali, nor shall they liberate toxic or corrosive fumes which

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MIL-STD-454M

would be detrimental to the performance of the equipment or health of personnel. The materials also shall not liberate gases which will produce an explosive atmosphere. 4.8.2 Mercury. Materials and parts containing mercury shall not be used unless use of mercury is specifically required or approved by the procuring activity. 4.8.3 Radioactive materials. Use of radioactive materials shall conform to Nuclear Regulatory Commission regulations and shal1 require approval of the procuring activity. Radium shall not be used to achieve self-luminosity. 4.8.4 Glass fibers. Glass fiber materials shall not be used as the outer surface or covering on cables, wire or other items where they may cause skin imitation to operating pensonnel. This does not pmeclude the use of military specification wire and cable. When maintenance procedures require access to glass fibers, such as insulation, a proper caution note shall be provided. 5. Information for guidance only 5.1 Human engineering?. Human engineering factors affecting safety should be considered when establishing general or detailed design criteria. Rigorous detailed operational or maintenance proaedur.ea are not acceptable substitutes for an inherently safe design. Hazard and safety requirements of MIL-STD-14Y2 should be used as a guide. 5.2 Electrical. Proper instructions in accident prevention and first-aid procedures should be given to all persons engaged in electrical work to fully inform them of the hazards involved. 5.2.1 Shock hazarda Current rather than voltage is the most important vamiable in establishing the criterion for shock intensity. Three factors that detenmine the severity of electrical shock are: (1) quantity of current flowing through the body; (2) path of current thnough tbe body: and (3) duration of time that the current flows through the body. The voltage necessary to produce the fatal current is dependent upon the resistance of the body, contact aonditions, and the path through the body. See table l-I. Sufficient current passing through any part of the body will cause severe burns and hemorrhages. However, relatively small currents can be lethal if the path includes a vital part of the body, such as the heart or lungs. Electrical burns are usually of two types, those produced by heat of the arc which occurs when the body touches a high-voltage circuit, and those caused by passage of electrical current thnough the skin and tissue. While current

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MIL-sTD-45414

is the primary factor which determines shock severity, protection requirements are based upon the voltage involved to simplify their amlication. In cases where the maximum current which can flow from a uoint .. is less than the values shown in table 1-1 for reflex action, protection requirements may be relaxed.

TABLE l-I. Probable effects of shock.

Current Values (Mi1liamperes) Effects AC 25 Hz to 400 Hz o-1 1-4 4-21 21-40 40-100 Over 100 DC

0-4 4-15 15-80 80-160 160-300 Over 300

Perception Surprise Reflex action Muscular inhibition Respiratory block Usually fatal

5.2.2 Insulation of controls. All control shafts and bushings thereof should be grounded wheneven practicable. Alternatively, the control knobs or levers and all attachment screws that can be contacted duping use should be electrically insulated from the shaft. 5.2.3 Qroundinj?to chassis. Ground connection to an electrically conductive chassis or frame should be mechanically secured by soldering to a spotwelded terminal lug or to a portion of the chassis or frame that has been formed into a soldering lug, or by use of a terminal on the ground wire and then securing the terminal by a screw, nut, and lockwasher. The screw should fit in a tapped hole in the chassis or frame or it should be held in a through-hole by a nut. When the chassis or frame is made of steel, the metal around the screw hole 8hould be plated or tinned to provide a corrosion resistant connection. When aluminum alloya are used, the metal around the grounding screw or bolt hole may be oovered with a corrosion resietant surface film only if the resistance through the film is not more than 0.002 ohm. Hardware used for mounting of meters, switahes, test points, etc, should be grounded, whenever possible.

1-1o

MIL-STD-454N

5.2.4 Accidental contact. Suitable protective measures are defined in table l-II. 5.2.4.1 High current protection. Power sources capable of supplying high current can be hazardous regardless of the voltage at which they operate because of the arcing and heat generated if an accidental short circuit occurs. Al1 power buses supplying 25 amperes or over should be proteoted against accidental short circuiting by tools, jewelry or removable conductive assemblies. This may be accomplished by one or more of the following: a. Use of guards and barriers, b. Sufficient space separation to prevent short cincuits, c. Caution - warning signs. 5.2.4.2 Interlocks. Various equipment designs require different approaches to the use of interlocks. Intemlock use does not modify any other requirements of this standard and must be consistent with equipment or system specifications. Equipment sub-assemblies operating in excesg of 500 volts should be considered guamded from accidental contact only if they are completely enalosed from the remainder of the equipment and are separately protected by nonbypassable interlocks. (An example of an equipment where such compartmentalization is desirable is a display unit which utilizes a high voltage power supply for a cathode ray tube.) Modularized or sealed high voltage assemblies whiah are opened only at depot level ame exempt from interlocking requirements when approved by the procuring activity. 5.2.4.3 Permanent terminations. Terminations such as soldered connections to transformer, connectors, spliceg, etc, which are normal1y permanent and not used during routine maintenance testing, may be protected by permanent insulation such as shrink sleeving, tubing, insulating shields, etc, provided the material is rated for the potential exposed voltage. 5.3 Mechanical. Design of rack-mounted equipment should maintain the center of gravity as low as possible to minimize tipping over. 5.4 Markinf. MIL-HDBK-600 references known electronic iterm which require mmking and may be used as a guide. 5.5 Materials. Certain chemicals have been identified in the Oa@upational Safety and Health Act (OSHA) ag aancer.-p~oducing substances (carcinogens) Before using any matenials which might contain these chemicals, they should be evaluated in accordance with 29 CFR 1910.

1-11

mL-sm-454N

D8mm
,

84

..

1-12

MIL-STD-454N REQUIREMENT 2 CAPACITORS 1. PuruoSei This requirement establishes criteria for the 9election and application of capacitors. 2. Do@ument8 auplioable to Requirement 2!

MIL-C-39006/22 Capacitors, Fixed, Electrolytic (Nonsolid lllect~olyte) , Tantalum, (Polarized, Sintered Slug), 85 C (Voltage Derated to 125 C) , Established Reliability, Style CLR79 MIL-C-39006/25 Capacitors, Fixed, Electrolytic (Nonsolid Electrolyte), Tantalum, (Polarized, Sintered Slug) (Extended Range), 85 C (Voltage Derated to 125 C) , Established Reliability, Style CLRS1 MIL-STD-198 3. 4. Capacitors, Selection and Use of

Definitions. Not applicable. Requirements

4.1 Selection. Capacito~# shall be 8elected and applied in accordance with MILSTD-19S 4.2 Fixed, tantalum electrolytic. Fop Naval Air Systems Commsnd, the use of wet slug tantalum capacitors (except tantalum cased units in accordance with MIL-C39006122 and MIL-C-39006125) requires the approval of the procuring activity, and silver cased tantalum capacitors shal1 not be used. 5. Information for guidance only. Not applicable.

REQUIREMENT 2 20 September 19SS 2-1

MIL-STD-454N REQUIREMENT 3 FLAMMABILITY 1. Purpose. This requirement establishes criteria for the selection and application of materials with respect to flammability. 2. Documents aDDliCable to Requirement 3: MIL-STD-202 ASTM D568-77 ASTM D635-61 Test Methods for Electronic and Electrical Component Parts Rate of Burning andlor Extent and Time of Burning of Flexible Plastics in a Ve~tical Position, Test Method for Rate of Burning andlor Extent and Time of Burning of Self-Supporting Plastics in a Horizontal Position, Test Method for Pressure-Sensitive Adhesive Coated Tapes Used for Electrical Insulation, Methods of Testing Standard for Tests for Flammability of Plastic Materials for Parts in Devices and Appliances

ASTM D1OOO-B2 UL 94-80

3. Definition. Flammability is a complex characteristic which combines ease of ignition, surface flammability, heat contribution, smoke production, fire gasses, and fire endurance. Flammability is a function of chemical composition, physical configuration, temperature, availability of oxygen, and ~etardants or additivee. 4. Requirements. Materials used in military equipment shall, in the end item configuration, be noncombustible or fire retardant in the most hazardous conditions of atmosphe~e, pressure, and temperature to be expected in the application. Fire retardant additives may be used provided they do not adversely affect the specified performance requirements of the basic materials. Fire retardance 8hal1 not be achieved by use of nonpermanent additives to the basic material 5. Information fop guidance only. The test used to determine the flammability of material should be the test specified in the material specification. Since some materials may change state on characteristics relative to flammability during application, tests may be performed on the end item materials mixedlblendedlsatumtedl impregnatedl layered and processed to simulate the final configuration in the end equipment usage. 5.1 If the specification does not have such a test, testing should be in accondanae with ASTM D568, ASTM D635, ASTM D1OOO, or MIL-STD-202, Method 111, as applicable.

REQUIREMENT 3 10 September 1987 3-1

MIL-STD-454N

5.2 Materia18 not covered by the above test8 should be tested in accordance with a procedure approved by the pnocu~ing activity. UL 94 is a useful guide to develop teat methods and offers a comparative scale to define degree of flammability.

3-2

MIL-STD-454N REQUIREMENT 4 FUNGUS-INERT MATERIALS 1. Purpose. This requirement identifies those materials which are acceptable nonnutrients of fungus and establishes conditions under which fungus nutrient materials are aaaeptable. 2. Documents auulicable to Requirement 4: MIL-T-152 Treatment, Moistu~e and Fungus Resistant, of Communications, Electronic, and Associated Electrical Equipment Varnish, Moisture and Fungus Resistant (For Treatment of Communications, Electronic, and Associated Equipment) Environmental Test Methods and Engineering Guidelines Code of Federal Regulations, Title 29, Chapter XVII, Part 1910

MIL-V-173 MIL-STD-S1O 29 CFR 1910

3. Definitions 3.1 Fungus-inert material. A material which, in all modified states and grades, is not a nutrient to fungi. 3.2 Fungicide. A subgtance that destroys or inhibits the growth of fungi

4. Requirements 4.1 Preferred materials. Fungus-inert materials listed in Qroup I of table 4-I are preferred for use. These materials need not be tested for fungus resistance prior to use. The appearance of a particular material in table 4-I does not constitute approval for its use except from the viewpoint of the resistance of the material to fungi 4.2 Acceptable materials. Those materials listed in Group II of table 4-I WY be used, provided it has been demonstrated that they meet the requirements of paragraph 4.4. When materials are compounded with a pemw.nently effective fungicide in order to meet the fungus test requirement, there shall be no loss of the original electronic or physical properties required by the basic material specification. Fungicides containing mercury shall not be used. 4.3 Hermeticallv sealed aDDlications. Fungus nutnient materials may be used untreated within hermetically sealed enclosures. 4.4 Fungus testinE. Group II materials shall be subjected to the fungus test specified in MIL-STD-81O, Method 508, for a period of 2S days. Certification by a qualified laboratory or by the material producer, based

4-1

REQUIREMENT 4 30 June 19S9

MIL-STD-454N on test data on record that the material meets Grade O or Grade 1 requirements of table 508-1, Method 508, MIL-STD-81O, is sufficient evidence of acceptability. TABLE 4-I. Funj?isusceptibility of materials.

Group I - Fun.@s-inert materials (Funflus-inert in all modified states and frades)

~1 Acrylics Acrylonitrile-styrene Acrylonitrile-vinyl-chloride copolymer Asbestos Ceramics Chlorinated polyester Fluorinated ethylenepropylene copolymer (FEP) Glass Metals Mica Plastic laminates: Silicone-glass fiber Phenolic-nylon fiber Diallyl phthalate Polyacrylonitrile

Polyamide Polycarbonate Polyester-glass fiber laminates Polyethylene, high density (above 0.940) Polyethylene terephthalate Polyimide Polymonochlorotrif luoroethylene Polypropylene Polystyrene Polysulfone Polytetrafluoroethylene Polyvinylidene chloride Silicone resin Siloxane-polyolefin polymer SiIoxane polystyrene

Grouu II - Furulusnutrient materials (May require treatment to attain fungus resistance) ABS (acrylonitri le-butadiene-sty rene) Acetal resins Cellulose acetate Cellulose acetate butyrate Epoxy-glass fiber laminates Epoxy-resin Lubricants Melamine-f ormaldehyde Organic polysulphides Phenol-formaldehyde Polydichlorosty rene Polyethylene, low and medium density (0.940 and below) Polymethyl methacrylate Polyurethane (the ester types are particularly susceptible) Polyrioinoleates Polyvinyl chloride Polyvinyl chloride-acetate Polyvinyl fluoride Rubbers, natural and synthetic Urea-formaldehyda

4-2

MIL-STD-4S4N

~/ Literature shows that unden certain aonditiong polyamides may be attacked by selective micro-organisms. However, for military applications, they are considered Group 1. 5. Information for Euidance only 5.1 Process-related materials. Processing materials to be tested for fungus resistance in accordance with paragraph 4.4, such as paint, ink, coatings, adhesives, lubricants, viscous damping fluids, silicone grease, et@, #hould be prepaned in the form of 50 mm squares or circles no more than 1.6 mm thick for testing. Liquid or paste materials should be prepared by impregnating to saturation a sterile sample of glass fabric. 5.2 Parts treatment. When treatment of parts is required to form varnish fungus-resistant materials, a moisture and fungus proofing (tAFP) conforming to MIL-V-173 may be applied in accordance with MIL-T-152 after the part is cleaned. The MPP varnish should not be applied to any part where the treatment will interfere with performance. 5.3 Carcinof!ens. Certain chemicals have been identified in the Ocaupational Safety and Health Act (OSHA) as cancer-producing substances (carcinogens) . Before using any materials which might contain these chemicals, they should be evaluated in accordance with 29 CFR 1910. Consideration of the toxicity of a substance should be given prior to material selection.

4-3

MIL-STD-454N REQUIREMENT 5 SOLDERINCi 1. Purpose. This requirement establishes the basis for soldering of electrical and electronic equipment. 2. Document applicable to Requirement 5! MIL-STD-2000 Standard Requirements for Soldered Electrical and Electronic Asaemblie6 Soldering Process, General (Non-Electrical) (Metric)

DOD-STD-1866

3. Definitions. Not applicable. 4. Requirements 4.1 Qeneral. Electrical and Electronic equipment shall be assembled, soldered, and cleaned in accordance with the requirements of MIL-STD-2000. 4.2 Structural SolderinE. Non-Electrical soldered connecting shall be in accordance with the requirements of DOD-STD-1866. 4.3 Workmanship. Workmanship of soldered assemblies shall be in accordance with MIL-STD-2000 or DOD-STD-1866 as appropriate. Information for guidance only. 5.1 Application. MIL-STD-2000 expresses the minimum requirements appropriate tO the ~nufa@tuFe Of electrical and electronic equipment. It may be necessary to supplement the requirements of MIL-STD-2000 in order to achieve higher reliability requirements associated with critical equipment applications (space, nuclear ordnance, command/control, etc.).

REQUIREMENT 5 30 Octoben 1991 5-1

MIL-STD-454N REQUIREMENT 6 BEARIMQS 1. PurDOse This requirement establishes criteria for the selection and application of bearings. 2. Documents aDDliCable to Requirement 6: Bearings, Bal1, Annular (General Purpose) Bearings, Roller, Cylindrical; and Bearings, Roller, SelfAligning Bearing, Roller, Tapered Bearings, Sleeve, (Bronze, Plain or Flanged) Bearing, Roller, Needle, Airframe, Anti-Fni@tion, Inch Bearing, Sleeve, Washers, Thrust, Sintered, Metal Powder Oil Impregnated, General Specification for Bearings, Plain, TFE Lined, Self-Aligning Bearings, Journal-Plain and Flanged, TFE Lined Bearing, Plain Rod End, TFE Lined, Self-Aligning Bearing, Sleeve (Steel Backed) Bearing, Roller, Thrust Barrier Coating Solution, Lubnicant Migration Deterring Bearing, Ball, Annular, for Instruments and Precision Rotating Components Bearing, Sleeve, Plain and Flanged, Self-Lubricating Bearing, Plain, Self-Aligning (BeCu, CRES Race) Process for Barrier Coating cf Anti-Friction Bearings

FF-B-171 FF-B-185 FF-B-187 FF-B-195 MIL-B-3990 MIL-B-5687 MIL-B-8942 MIL-B-8943 MIL-B-8948 MIL-B-13506 MIL-B-17380 MIL-B-81744 MIL-B-81793 MIL-B-81934 MIL-B-61936 MIL-STD-1334

3. 4.

Definitions. Not applicable. Reaui~ements

4.1 Selection and application. Bearings best suited to meet the physical, functional, environmental and service life requirements of the application shall be selected from those conforming to one or mope cf tbe specifications listed below. Replacement of the bearing shall be possible without uge of special tools unless such provisions would adversely affect the proper functioning on service life of the bearing. FF-B-lfl FF-B-1S5 FF-B-1S7 FF-B-195 MIL-B-3990 MIL-B-56S7 MIL-B-8E142 MIL-B-S943 MIL-B-S948 MIL-B-13506 MIL-B-17380 MIL-B-B17Q3 MIL-B-81E134 MIL-B-B1936

REQUIREMENT 6 30 June 1989 6-1

MIL-STD-454N

4.2 Lubricant. Adequate lubricant shall be provided either within the bearing or externally in the form of oil reservoirs or g~ease FelUbFiCatiOn facilities except as noted in 4.3. Where lubricant replenishment is required, precaution shall be taken to prevent purged or lost lubricant from entering and adversely affecting the operation of the electronic equipment. Where bearings coated with preservative are installed in closed housings, the preservatives shall be compatible with the lubricant used in the assembly. 4.3 Unlubricated bearings. Unlubricated bearings or bushings may be used only in applications where the presence of a lubricant would be undesirable or detrimental and the functional, environmental and se~vice life requirements can be met in this condition. 4.4 Barrier coating. Bearings requiring a barrier coating shall be coated in accordance with MIL-STD-1334. Barrier coating material shall conform to MIL-B-81744. 4.5 Seals and shields. All rolling element bearings shall be adequately protectad by seals or shields on the bearing or installed in housings which provide adequate shielding to prevent foreign matter from entering the bearing. 4.6 Electrical grounding. Ball and noller bearings used for rotating an electrically anergized equipment shall be electrically shunted to avoid current flow through the bearings. 4.7. Alifinment. Bearings shall be located to ensure proper shaft alignment and support. 5. Information for guidance only

6.1 Self-lubricating bearings. Permanently lubricated bearings on bushings of plastic, metallic-plastic combinations, or all metallic materiala with or without d~y film lubricant may be used pnovided wear products produced during operation will not cause or contribute to failuxw of the elec!t~onic equipment or bearings. 5.2 Unlubricated bearings. For selection of low f~iction, long life, unlubricated bearings refer to MIL-B-BQ42, MIL-B-S943, and MIL-B-6948.

6-2

MIL-STD-454N REQUIREMENT 7 INTERCHANQEABI LITY 1. Purpose. This requirement establishes design criteria to aesure the interchangeability of parts , subassemblies, and assemblies. 2. Documents aml icable to Requirement 7: Definitions of Items Levels, Item Exchangeability, Models, and Related Terms Electronic Parts, Materials, and Processes for Space and Launch Vehicles

MIL-STD-!280

MIL-STD-154Y

3.

Definitions.

3.1 Assembly, interchangeable item. part. subassembly and substitute item. The terms assembly, interchangeable item, part, subassembly and substitute item are defined in MIL-STD-280. 3.2 Standard Darts. For Air Force space and launch vehicles, standand parts are as described in MIL-STD-1547. For al1 other equipments, standard parts are defined in the applicable general specification or contract. 4. Requirements

4.1 Design tolerances. Design tolerances shall permit parts, subassemblies and assemblies to be used in thein parent assemblies without regard to the source of supply or manufacturer. Parts, subassemblies and and assemblies having the full range of dimensions and characteristics permitted by the specification governing the part, subassembly or assembly shall be usable as replacement items without selection and without from tbe specified performance requirements of the parent items. 4.2 Parts and materialg. When permission is granted to use a nonstandard pant or matenial because the existing standard part or material is not available, the equipment shal1 be so designed that the nonstandard part or material and the standard part or material are interchangeable. When the specification for the part or material contains substitutability or supersession information, the design shall permit the #ubstitute or superseding parts or materials to be used interchangeably. 5. Information for guidance only. Not applicable

REQUIREMENT 7 15 December 1989 7-1

MIL-STD-454N REQUIREA4SMT 8 ELECTRICAL OVERLOAD PROTECTION 1. PurDOae. This requirement establishes the criteria and philosophy for electrical overload protection. 2. Documents aDDliCable to Requirement 8: Definitions of Item Levels, Item Exchangeability, Models, and Related Terms Electrical Power, Direct Current, Space Vehicle Design Requirements National Electrical Code

MIL-STD-280 MIL-STD-1539 NFPA 70-1990

3.

Definitions

3.1 Class 1 eauipment: Ground and shipboard, including test and checkout g~ound equipment 3.2 3.3 Class 2 eauiument: Manned aerospace equipment Clas8 3 eauipment: Unmanned aeroapace equipment

4. Requirements. The requirements specified herein shall apply only to equipment and systems as defined in MIL-STD-2S0 for class 1 and class 2 equipment and MIL-STD-1539 for class 3 equipment. 4.) Protection for class 1 eauiDment

4.1.1 Current overload Protection. Current ovenload protection shall be provided for primary circuits. Devices such as fuses, circuit breakers, time delays, cutouts, or solid-state current-interruptiondevices shall be used to open a circuit whenever an overload condition OCCUIIS. No overcurrent protective device shall be connected in series with any conductor which is grounded at the power sounce unlees the device simultaneously opens all load conductors in the cimcuit and no pole operates independent y, or as otherwise allowed by the National Ele@t~ical Code, NFPA 70. Protective devices for wired-in equipment #hal1 be connected to the load side of the equipment power #witch (main circuit powem disconnect] For portable equipment a separable connector or the attachment plug and receptacle shall serve ag the main circuit power disconnect and the protective device may be on either the line Bide or the load side of the equipment on-off switch.

REQUIREMENT S 30 April 1991 s-1

MIL-STD-454N

Fuses. Where fuses are used, at least one extra fuse of each type 4.1.2 and rating used shall be supplied and attached to the applicable units of the equipment. Panel-mounted fuse posts shall be such as to permit renewal of fuses without use of tools. 4.1.3 Ci~@uit breakers. Circuit breakers shall give a visual indication when tripped. Holding the switching device closed on an overload shall not prevent tripping of the breaker. Multi-pole circuit breakers shall be used for three-phase equipment and shall disconnect all phases if an overload occurs in any one phase. Circuit breakers shal1 not be used as switches unless such breakers have been specifically designed and tested for that type 8ervice. 4.2 Protection for class 2 eauipment

4.!2. 1 Current overload protection. Current overload protection for the equipment shall be provided by fuses or circuit breakers. Circuit breakers shall not be used as switches unless such breakers have been specifically designed and tested for that type service. 4.2.2 SDar@ fU13eS When fuses are used, a minimum of one spare fuse for each size and rating but a quantity of not less than 10 percent of the total shal1 be inco~porated in the equipment and shall be contained in the same compartment. 4.3 PPOtectiOn for class 3 eauimnent. Electrical overload protection shall not be provided in individual boxeg or systems receiving power.

5.1 Location. Overload protection for the equipment should be provided therein. For class 1 and claas 2 equipment, all protective devices employed in the equipment should be in a readily accessible, safe location. 5.2 Resettable circuit !motectors. Circuit breakers or othen resettable devices should be used to protect critical circuits, or where predictable overloadn 011surges occur because of peculiar equipment functions or operator effects which are unavoidable.

8-2

MIL-STD-454N REQUIREMENT 9 WORKMANSHIP 1. Puruose. This requirement establishes the acceptable workmanship criteria for electronic equipment. This requirement will define those workmanship requirements not normslly covered in subsidiary specifications OF drawinge. 2. 3. 4. Documents applicable to Requirement Q: Definitions. Not applicable Reauiremente Not applicable.

4.1 Cleaning. After fabrication, parts and assembled equipment shall be cleaned of emudgen: loose, spattered, or exaenn solde~; weld metal; metal chips and mold release agents; or any other foreign msterial which might detract from the intended operation, function, or appearance of the equipment. 4.2 Threaded Da~ts or devices. Screws, nuts and bolts shall show no evidence of cross threading, mutilation, or detrimental or hazardous burrs, and shall be firmly secured. 4.3 Rearing assemblies. Bearing assemblies shall be fnee of ~ust, discoloration, and imperfections of ground, honed, or lapped surfaces. Contacting surfaces shall be free of tool msrks, gouge msrks, nicks, or other surface-type defects. There shall be no detrimental interference, binding, or galling. 4.4 Wirinj?. Wires and cables shall be positioned or protected to avoid contact with rough on ir~egular surfaces and sharp edges and to avoid damsge to conductors or adjacent parts. 4.5 Shielding. Shielding on wires and cables shall be secured in a manner that will pnevent it fnom contacting or shorting exposed current-carrying parts. The ends of the shielding or braid shall be secured to prevent fraying. 5. Information for guidance only

5.1 Containment. The harness and cable form containment means should be neat in appearance, uniformly applied, and positioned to retain critical form factors and breakout locations. The containment means (lacing, ties, tiedown straps, etc) should not cause the wire or cable insulation to deform so that pe~fomnsnce characteristics are adver.saly affected.

REQUIREMENT 9 12 February 198B Q-1

MIL-STD-454N

5.2 Insulation. There should be no evidence of burns, abrading, or pinch marks in the insulation that could cause short circuits or leakage. 5.3 Clearance. The clearance between wires or cables and heat generating parts should be .eufficient to minimize deterioration of the wires or cables

9-2

MIL-STD-454N REQUIREMENT 10 ELECTRICAL CONNECTORS 1. PurDo8e. This requirement establishes criteria fon the selection and application of electrical connectors. *2.. Documents aDDliCable to Requirement 10 : MIL-J-641 MIL-P-642 MIL-C-10544 MIL-C-12520 MIL-C-29600 Jack, Telephone, General Specification for Plug, Telephone, and Acce8aory ScFewE, General Specification for Connector, Plug and Receptacle (Electrical , Audio, Waterproof, Ten Contact, Polarized) Connector, Plug and Receptacle (Electrical, Waterproof), and AcceasorieB, Qeneral Specification for Connector, Electrical, Circular, Miniature, Composite, High Density, Quick Coupling, Environment Resistant, Removable Crimp Contacts Connectors, Electrical, Circular, Miniature, High Density, Quick Disconnect (Bayonet, Threaded, and Breech Coupling) Environment Resistant, Removable Crimp and Hermetic Solder contacts, General Specifications for Connectors, Miniature, Audio, Five-Pin and Six-Pin Connectors, Plug and Receptacle, Intermediate Power (Electrical) (Waterproof)Type Mw, Qeneral Spe@ificatiOn fOr Adapters, Connector, Coaxial, Radio Frequency (Between Series and Within Series) Connectors, Electrical, Flat Cable, and/on Printed Wining Board, Nonenvironmental, General Specification for Electrical Connectors, Plug-In Sockets and Associated Hardware, Selection and Use of Se~vicing Tool= fop Electric Contacta and Connecticrm, Selection and Use of Connectors, Electromagnetic Interference (EMI) Filter Cable Connectors for Audio Facilities fom Radio Broadcasting

MIL-C-38999

MIL-C-55116 MIL-C-551S1 MIL-A-5S339 MIL-C-83503 MIL-STD-1353 MIL-STD-1646 MIL-STD-2120 Contact EIA-2QV-A 3. 4.

Definitions. Not applicable. Requirements

4.1 Selection. Selection and use of electrical connectors shall be in accordance with MIL-STD-1353 and as specified herein. Intended use information contained in the individual connector specifications shall be considered prior to making connector selections. Contact crimp, installing REQUIREMENT 10 30 June 1992 1o-1

MIL-STD-454N

and removal tools shall be in accordance with MIL-STD-1646 or as specified in the individual connector specifications. However, contractors may use tooling as recommended by the contact or tooling manufacturer provided that the finished crimp meets all of the performance requirements of the contact and connector specification. The variety of these tools required within a Eygtem shall be kept to a minimum. Maintenance instructions and other data supplied by the contractor shall list the military standard tools and contacta. 4.2 Audio freauency and communication connectors, special puruose. Connectors conforming to MIL-C-10544 or MIL-C-55116 shall be used in audio frequency applications, such as head sets and chest sets, excluding pilots helmets. For low level, three wire and audio input circuits in fixed plant nontactical sound equipment, connectors conforming to EIA-297-A shall be used. 4.3 Connectors with th@rmOdOUDle contacts. All connectors used in conjunction with thermocouples shall have theim contact materials identified by one of the following methods: a. Nameplate securely attached to each connector half or mounted on the panel-mounted receptacles. b. InmJlation sleeving or other markers designed for attachment around wire bundles. Markers shall be attached adjacent to the plug. Contact materials shall be identified with abbreviations in accordance with table 10-1. TABLE 10-1. Abbreviations for thermocouple materials.

Chromel Alumel Iron Constantan Copper Platinum Platinum Rhodium Rhenium

CR AL FE CN Cu PT PT RH RE

Cobalt Tungsten Rhenium Tungsten Iridium Rhodium Iridium Rhodium Mo1ybdenum Gold

co W RE w IR RH IR MO AU RI+

4.4

Heavy dut.vconnectors

10-2

MIL-STD-454N

4.4.1 Power connectors (40-200 amDeres). Al1 powe~ connectors for any ground application shall confcrm tc Section 102 of MIL-STD-1353 and shall be used with heavy duty jacketed @able as specified on the insert standards.

*4.4.2 General Durpose and shipboard. Connectors for general purpcse heavy duty applications and shipboard power applications shall conform to Section 102 of MIL-STD-1353. Connectors used for external applications shall be pressurized and waterproof in the mated and unmated condition in accordance with the mqui~ements of Classes C or L. Connectors used internally (within a protective enclcsure such as a shelter) may be in accordance with Class R pnovided watemprocfing OF pressurization is not a requirement for the application. 4.4.3 Right angle power and control (Army only). In application where right angle bend is required, center lock screw multicontact connector# shall conform to MIL-C-12520 or MIL-C-55181, as applicable. 4.5 Qeneral utility connectors. Polanized connectors me the preferred Etylee.and shall be used where automatic grcunding must be provided to insure safety to equipment and personnel. Connectors fan genenal utility power applications shall aonform to Section 106 of MIL-STD-1353. 4.6 Plugs and jacks (teleDhOne t.vDe) . Telephone type jacks and plugs shal1 conform to MIL-J-641 and MIL-P-642. 4.7 Test jacks. Test jacks shall conform to Section 10S of MIL-STD-1353. Jacks or receptacles for use as rf test points shall be selected in accordance with paragraph 4.8. 4.8 Rf connectors. Rf connectors shall conform to Section 200 of MIL-STD-1353. Adapters used with rf connectors shall conform to MIL-A-55339. 4.9 Connectors for Drinted WirinE. Printed circuit connectors shall conform to Section 104 of MIL-STD-1353. 4.10 Connecter wiring. Multiple conductors may terminate in a contact p~ovided the sum of the cross 8ectional areas of the conductors does not exceed the maximum cross sectional mea for which the contact is rated. Not more than one wire shall be routed through any hole in the grommet of an environmentally sealed connector. 4.11 Extra contacts. The following requirements are applicable to all articles of equipment, except those in which it is unlikely that additional circuits will be required.

10-3

MIL-STD-4S4N

4.11.1 Quantity and location. Unused connector contacte or contact positions for external circuits shall be provided for future use, and shall be located on the periphery (outer contacts) of the connector. The minimum quantity shall be as specified below:

Total number of used contacta in connecto~ 1 thru 3 4 thru 25 26 thru 100 101 or over

Unused contacts or contact positions reauired [rein) 1 (optional) a 4 6

4.11.2 An extra connector shall not be used to meet this requirement without the approval of the procuring activity. 4.11.3 Size and nating of extna contacts. The size and rating of extra contacts shall be compatible with other contacts within the connectors. 4 .11.4 CnimD contact connector. e. When crimp contaat environmentally sealed connectors are used, all contact positions shall be filled with contacts. 4.11.5 SealinE DIUfi# . Sealing plugs shall be inserted in the grommet holes of unused contacts in environmentally sealed connector. 4.11.6 Potted connectors. For potted connecto~a, each unused contact shal1 have a maximum gauge wire of 150 mm minimum length attached and identified with the contact designation for future use. For connectors external to the unit, the wire end shall be suitably capped to prevent moisture from entering the connector. 4.12 Protective measures. All unmated connectors shall be protected with metal or plastic caps or otherwise suitably protected during maintenance, etorage and shipment. Protective caps 6pecified by military specifications or militamy standards and designed fon mating with specific connectors shall be used. Unmated connectors which may contain electrically hot circuits while in environmentally hazardous areas shall be aovered with moistureproof and vapo~proof caps. Conne@ton# on enclosed cabinet mounted equipment need not be provided with protective caps unless an environmental hazard exists. 4.13 Connecto~a fov pound conductor flat cable. Connectors for use with flexible nound conductor flat cable shall conform to bfIL-C-B3503.

10-4

MIL-STD-454N

4.14 Fireproof connectors. Fireproof and firewall connector shall be class K and shall conform to Section 101 of MIL-STD-1353. Where it is nece88amy to maintain electrical continuity for a limited time under continuous flame, both the receptacle and mating plug shall be class K. If flame integrity only is necessary without the need for electrical continuity, a class K neaeptacle shall be used, but the mating plug may be of any type and class. In all cases, the plug and receptacle shall be environment resisting. 4.15 Filter pin connectors. Electrical connecters incorporating filter pins shall be considered for use only when conventional electrical filtens are not acceptable. When used, filter pin ccnnectore shall conform to MIL-STD-2120. *4.16 Comnosite Connectcra. Miniatu~e aomposite environment resisting connectors shall conform to MIL-C-29600 or MIL-C-3S999. 5. Information for guidance only. Not applicable.

10-5

MIL-STD-454N REQUIREMENT 11 INSULATING MATERIALS, ELECTRICAL

1. Purpose. This requirement establishes criteria for the selection and application of electrical insulating materials. Insulating materials used for encapsulation and embedment (potting) and for conformal coating are excluded from this requirement. 2. Documentg armlicable to Requirement 11: Plagtic Sheet and Plastic Rod, Thermosetting, Cast Insulation Tape, Electrical (Rubber, Natural and Synthetic) Insulating Compound, Electrical, Ceramic, Class L Molding Plastica and Molded Plastic Parts, Thermosetting Plastic Rods and Tubes, Thermosetting, Laminated Insulation, Electrical, Synthetic-Resin Composition, Nonrigid Plastia Material, Laminated, Thermosetting, Electrical Insulation, Sheets, Glass Cloth, Silicone Resin Insulation Tape, Electrical, Glass-Fiber (Re8in-Filled) , and Cord, Fibrous-Glass Insulation Sleeving, Electrical, Flexible, Coated, General Specification for Insulation Tape, Electrical, Self-Fusing: For Use in Electroniaa, Communications, and Al1ied Equipment Insulation Sleeving, Electrical, Flexible Tape, Rubber, Unvulcanized, Splicing and Molding (Tapes TL-317/U and TL-318/U) Plastic Sheet, Laminated, Thermosetting, Qlass-Cloth, Melamine-Resin Pla8ti@ Sheets, Laminated, Thermosetting, Nylon Fabric Base, Phenolic-resin Insulation Tape, Electrical, Pressure Sensitive Adhesive and Pressure Seneitlve Thermosetting Adhenive Insulation Cloth and Tape, Electrical, Glass Fiber, Varnished Plastic Sheet, Laminated, Thermosetting, Glass Fiber Base, Epoxy-Resin Insulation Tape, Nonadhering, Glass Fabric, Polytetrafluoroethy lene Coated Plastic Sheet, Laminated, Glass Cloth Polytetrafluoroethylene Resin Insulation Tape, Electrical, High-Temperature, Glass Fiber, Pressure Sensitive

L-P-516 HH-I-553 MIL-I-1O MIL-M-14 MIL-P-79 MIL-I-631 MIL-P-Q97 MIL-I-3158 MIL-I-3190 MIL-I-3S25 MIL-I-7444 MIL-T-13020 MIL-P-15037 MIL-P-15047 MIL-I-15126 MIL-I-17205 MIL-P-18177 MIL-I-18746 MIL-P-19161 MIL-I-19166

BEQUIREMSNT 11 15 December 1989 11-1

MIL-STD-454N

MIL-I-22076 MIL-I-22129 MIL-I-23053 MIL-I-23264 MIL-I-23594 MIL-I-24092 MIL-I-24204 MIL-I-24391 MIL-I-46852 MIL-I-49456 MIL-I-81765 MIL-I-8S080 AMB 3638E

AMS 3653D AMB 3654B

AMS 3635A ASTM D32Q5-81 29 CFR 1910

Insulation Tubing, Electrical, Nonrigid, Vinyl, Very Low Temperature Grade Insulation Tubing, Electrical, Polytetrafluoroethylene Resin, Nonrigid Insulation Sleeving, Electrical, Heat-Shrinkable, General Specification for Insulator, Ceramic, Electrical and Electronic, General Specification for Insulation Tape, Electrical; High Temperature Polytetrafluoroethylene, Pressure-Sensitive Insulating Varmish, Electrical, Impregnating, Solvent Containing Insulation, Electrical, High Temperature, Bonded, Synthetic Fiben Paper Insulation Tape, Electrical, Plastic, Pressure Sensitive Insulation Tape, Electrical, Self-Adhering, Unsupported Si1icone Rubber Insulation 8heet, Electrical, Silicone Rubber, Thermally Conductive, Fiberglass Reinforced Insulating Components, Molded, Electrical, Heat Shrinkable, General Specification for Insulation Sleeving, Electrical, Shrinkable Without Heat, General Specification for Plastic tubing, Electrical Insulation, Irradiated Polyolefin, Pigmented, Semi-rigid, Heat-Shrinkable 2 to 1 Shrink Ratio Tubing, Electrical Insulation, Standard Wall, Extruded Polytetrafluoroethylene (PTFE) Tubing, Electrical Insulation, Light Wall, Extruded Polytetrafluoroethylene (PTFE) Tubing, Eleatmical Insulation, Thin Wall, Extruded Polytetnafluonoethylene (PTFE) PTFE Tubing, Specification for Code of Federal Regulations, Title 29, Chapter XVII, Part 1910

3. 4.

Definitions. Not applicable. Requirements

4.1 Ceramics. Ceramic compounds shal1 confarm to MIL-I-10. Ceramic insulators shall conform to MIL-I-23264. 4.2 Electrical taDe. Tape shall be selected from the types included in MIL-I-3158, MIL-I-3825, MIL-T-13020, MIL-I-15126, MIL-I-17205, MIL-I-18746, MIL-I-19166, MIL-I-23594, MIL-I-24391, and MIL-I-46852.

11-2

MIL-STD-454N

4.3 Sleevinfi and tubin.4. Sleeving and tubing shall aonform to MIL-I-631, MIL-I-3190, MIL-I-7444, MIL-I-22076, MIL-I-2212!3, MIL-I-23053, MIL-I-85080, AMS 3638, Ahf33653, Ahf23654, Ahf3365S, otIASTM D3295. MIL-I-631 shall also apply to film, film tape, sheet and sheet tape forma of insulation. 4,4 Plastic, thermo$etting, cast. When used for electrical insulation, parts fabricated from cast tbermosetting plastic materials shall be in accordance with L-P-516. 4.5 Plastic, thermosettinr?. laminated. Materials selected shall conform to MIL-P-79, MIL-P-997, MIL-P-15037, MIL-P-15047, MIL-P-18177, MIL-P-19161, or MIL-I-24204. The preferred base is glass cloth. Electrical in#ulator8 fabricated from laminated thermosetting-plas tic sheets, plates, rods and tubeg (except transparent plastics) shall be treated after all mecbining and punching operations with a suitable moisture barrier unless the plastic has a moisture absorption of 1.0 percent or less or is used in a hermetically sealed container. 4.6 Plaetic. thermoaettin~, molded. Materials used to mold electrical insulators shall conform to MIL-M-14. Molded parts which undergo subsequent machining shall be vacuum impregnated with a suitable moistune barrier material and dried after all sunface-br.caking operations have been completed. Cotton and linen shall not be used as filler material in any electrical insulator. kfete~ials having moisture absorption of 1.0 percent or less, and those ueed in hermetically sealed containers, need not be impregnated. 4.7 Varnish, insulating?. Insulating varnieh shall confonm to MIL-I-24092.

4.8 Heat shrinkable insulations. For applications requiring heat shrinkable insulators other than sleeving, such as strain relief boots or enclosure feed throughs, the material shall conform to MIL-I-81765. 4.9 Thermally conductive insulators. Applicatione which require a thermal1y conductive insulator between heat generating parts and their heat sinks shall use a material in accordance with MIL-I-49456 if silicone grease is not suitable. *4.10 Polyvinyl ahloride. Polyvinyl chloride insulating materials shall not be used in aerospace applications. Their use in other applications requires procuring activity appmoval. 5. Information for Euidance only

11-3

MIL-STD-4.54M

*5.1 Selection criteria. Insulating materials should be #elected based upon meeting or exceeding application requirements, such as: a. Temperature endurance b. Moigture absorption and penetration c. Fungus resistance d. Dielectric strength e. Dielectric constant Carcinogens. Certain chemicals have been identified in the 5.2 Occupational Safety and Health A@t (OSHA) as aancer. -producing substances (carcinogens) . Before using any materials which might contain these chemicals, they should be evaluated in accordance with 29 CFR 1910. Consideration of the toxicity of a substance should be given prior to material selection. f. Mechanical strength g. Dissipation factor b. Ozone resistance i. Flammability

11-4

MIL-STD-454N REQUIREMENT 12 FASTENER HARDWARE 1. Purpose. This requirement establishes criteria for the selection and application of fastener hardware. 2. Documents aDDlicable to Requirement 12: FF-B-575 FF-N-836 FF-R-556 FF-S-85 FF-S-86 FF-S-92 FF-S-200 FF-S-21O FF-W-84 FF-W-92 FF-W-1OO TT-S-1732 FED-sTD-H2a MIL-S-1222 MIL-F-5591 MIL-R-5674 MIL-B-6812 MIL-S-7742 MIL-B-Y838 MIL-R-7885 MIL-R-8a14 MIL-B-8831 MIL-S-8879 MIL-F-18240 MIL-T-22361 MIL-S-22473 MIL-R-22978 MIL-R-24243 Bolts, Hexagon and Square Nut, Square, Hexagon, Cap, Slotted, Castle Knurled, Welding and Single Ball Seat Rivet, Solid, Small; Rivet, Split, Small; Rivet Tubular, Small; Flat Washer (Burr); and Cap, Rivet, General Purpose Screw, Cap, Slotted and Hexagon-Head Screw, Cap, Socket-Head Screw, Machine; Slotted, Cross Recessed or Hexagon Head Setscrews; Hexagon Socket and Spline Socket, Headless Setscrews, Square Head and Slotted Headless Washers, Lock (Spring) Washer, Metal, Flat (Plain) Washer, Lock (Tooth) Sealing Compound, Pipe Joint and Thread, Lead Free, General Purpose Screw-Thread Standards for Federal Services Studs, Bolts, Hex Cap Screws, Socket Head Cap Screws and Nuts Fasteners, Panel: Nonstructural Rivets, Structural, Aluminum Alloy, Titanium Columbium Alloy, General Specification for Bolts, Aircraft Screw Threads, Standard, Optimum Selected Series; General Specification for Bolt, Internal Wenching, 160 KSI FTU Rivets; Blind, Structural, Pull-Stem and Chemically Expanded Rivet=, B1ind, Nonstructural Type Bolt, Tensile, Steel, 180 KSI FTU, 450F, External Wrenching, Flanged Head Screw Threads, Controlled Radius Root with Increased Minor Diameter, General Specification for Fastener, Externally Threaded 250F, Self-Locking, Element for Thread Compound, Antiseize, Zinc Dust-petrolatum Sealing, Locking and Retaining Compounds! (Single-Component) Fastener, Rotary, Quick-Operating, High Strength Rivet, Blind, Nonstructural, Retained Mandrel, Open-end, Domed Head, Aluminum Alloy, Carbon Steel

REQUIREMENT 12 16 February 1989 12-1

MIL-STD-454N

MIL-N-25027 MIL-R-21384 MIL-S-46163 MS33522

MS33540 MS33557 NAS498 NAS547 NAS16S6 NAS16S7

Nut, Self-Locking 2500F, 450F, and 800F Rivet, Blind, Drive Type Sealing, Lubricating, and Wicking Compounds: Thread Locking, Anaerobic, Single Component Rivets, Blind, Structural, Mechanically Locked and Friction Retainer Spindle, (Reliability and Maintainability, Design and Construction Requirements for) Safety Wiring, and Cotter Pinning, General Practices for Nonstructural Rivets for B1ind Attachment, Limitations for Design and Usage Rolts, Shear, 95 KSI FSU Fa8tener, Rotary, Quick-Operating, High Strength Rivet, Blind, Aluminum Sleeve, Mechanically Locked, Spindle, Bulbed Rivet. Blind. Monel and Inconel Sleeve. Mechanically Locked Spindie, Bulbed

3. 4. 4.1

Definitions. Not applicable. Reauirementa Threaded fasteners and related Darts

4.1.1 S@~ew tb~eads. Screw thread selection shall be based on the using applications in accordance with the following. a. Screw threads shal1 be in accordance with FED-STD-H28 in applieations where the thmeaded fasteners are required to mate with or mount threaded commercial equipment or devices. b. Screw threads shall be in accordance with MIL-S-S879 for applications requiring high strength or high fatigue life. (Caution shall be exercised where a MIL-S-SS79 UNJ external thread fastener i8 used due to its incompatibi 1ity with the commonly used UNC, UNF or UNEF threaded nut or tapped hcle.). c. Screw thread sizes and series for general usage shall be selected in accordance with MIL-S-7742. 4.1.2 screws. Screws shall confcrm to the specifications listed below. a. b. Machine screws shall confcrm to FF-S-92. Cap screws shall conform to FF-S-8S cr FF-S-86.

12-2

MIL-STD-454N

c.

Setscrews shall conform to FF-S-200 or FF-S-21O.

d. Self-locking screws shall conform to MIL-F-18240. Fiber inserts shall not be used as the locking device. 4.1.3 Bolts. a. b. c. d. e. f. Bolts .ehallconfo~m to the specifications listed below.

Hex bolts shall conform to FF-B-575. Bolt studs shall conform to MIL-S-1222. Aircraft bolts shall conform to MIL-S-6812. Internal wrenching bolts shall conform to MIL-B-7838 High tensile strength bolts shall conform to MIL-B-8831. Shear bolts shall confonm to NAS498. Nuts shall conform to the specifications listed below

4.1.4 N= a. b. c.

General purpose nuts shall confonm to FF-N-836. High temperature nuts shall conform to MIL-S-1222. Self-locking nuts shall conform to MIL-N-25027.

4.1.4.1 Sheet sr.rin~nuts. Sheet spring nuts shall not be used without specific approval of the procuring agency. 4.1.5 Safety wi~ing and cotter pins. Application of #afety wiring and cotter pins shall conform to MS33540. 4.1.6 Quarter turn fastenens. Quarter turn fasteners shal1 conform to MIL-F-6591. 4.1.1 Rotary auick oDeratini4 hi~h strength fasteners. Rotary quick operating high strength fasteners shall conform to MIL-F-229YB or NAS547. 4.1.8. Lockwashers. Lockwashers shall conform to the specifications listed below. a. b. Spring lockwashers shall conform to FF-W-84. Tooth lockwashers shall confonm to FF-W-1OO.

12-3

MIL-STD-454N

4.1.9 Flat washers. Flat washers shall conform to FF-W-92. 4.1.10 Thread-1ocking and retaining comuounds. Thread-locking and retaining compounds shall conform to MIL-S-22473 or MIL-S-46163. 4.1.11 Antiseize compounds. Antiseize compounds shall conform to MIL-T-22361 Or TT-S-1732. 4.2 RivetE

4.2.1 Nonstructural nivets. Nonstructural rivets shall conform to the following. a, Small solid, split, tubular and general purpose ~ivets shall conform to FF-R-556. b. Nonstructural blind rivets shall conform to MIL-R-SS14

Blind, nonstructural, retained mandrel type rivets shall confonm to ;IL-R-24243. 4.2.2 Structural rivets. Stmmtural rivets shall conform to the following! a. Aluminum and aluminum alloy rivets shall conform to MIL-R-5674.

b. Structural, blind, pull-stem rivets shall conform to MIL-R-7885, NAS1686 or NAS 1687. c. 5. 5.1 Blind, drive type rivets shall conform to MIL-R-27384 Information for guidance only Threaded fasteners

5.1.1 FasteninE of soft materials to soft materials. The mounting or assembly of parts made of soft materials to soft materials should be accomplished by one of the following methods: a. A through-screw or bolt secured by a self-locking nut or plain nut with a lockwasher. b. A through-screw or bolt secured by a plain nut with a thread locking compound applied to the threads of the screw or bolt and nut. c. A screw or bolt in a threaded device such as a threaded bushing: a =taked, clinched OF pressed-in nut; or a threaded insert. The bushing, nut,

12-4

MIL-STD-454N or insert shall be secured to, or should be ingtalled in, the parent structure in accordance with the applicable procedures. The engaged length of threaded inserts in the parent material should be at least 1.5 times the nominal diameter of the internal thread. Where the matenial thickness is insufficient to accommodate a 1.5 times thread diameter insert, a shorter insert may be used in application where maximum st~ength is not of primary importance; or a solid threaded bushing (which provides equal strength with leas length because of the greater outside diameter of the bushing) should be used. When the screw or bolt is to be installed in an aluminum alloy part, the aluminum al10Y part should be p~ovided with threaded inserts of corrosion resistant steel or othe~ suitable materials. When the sorew or bolt is to be installed in a plastic material part, the plastic part should be provided with threaded inserts. If lockwashers or self-locking threaded inserts are not used, a thread-locking compound in accordance with 4.1.10 should be applied tO the threads of the screw or bolt. d. A screw or bolt in a tapped hole, with a thnead-locking compound in accordance with 4.1.10 applied to the threads of the screw or bolt. e. A stud in a tapped hole. Self-locking nuts should be avoided on stud-mounted components, unless the stud material is compatible with the strength and material of tbe nut used. 5.1.2 Fastening of hard materiala to soft materials. In addition to the methods outlined in 5.1.1, a screw or bolt with a lockwasher may be used in a threaded bushing, staked, clinched or pressed-in nut, threaded insert or tapped hole. 5.1.3 FasteninE of soft materials to hard materials. In addition to the methods outlined in 5.1.1, a self-locking screw or bolt may be used in a hole tapped into the hard material Self-locking screws or bolts with nonmetallic locking devices should not be used where the specified service conditions or p~oceesing, such as baking of paints or soldering, might deteriorate the locking device. 5.1.4 Fastening of hard materials to hard materials. Any of the methods outlined in 5.1.1 through 5.1.3 may be used. 5.1.5 Fastening of brittle materials. Bnittle castinga on parts made of ceramic or othen brittle materials should be properly cushioned when necessary to prevent breakaga. Washers or gaskets of suitable material and compressibility should be used betwean the facing surfaces of the brittle part and other brittle or metal parts , when practicable, to prevent breakage OF damage to the protected parts during assembly or f~om 6evere shock, vibration or temperature changes encounte~ed under the specified service

12-5

MIL-STD-454N

conditions. Lead washers should not be used. Parts that are secured with threaded devices and pliable washers should not use lockwashers as the locking device, and other approp~iate locking devices should be considered. !i. 1.6 FasteninE with aluminum alloy or magnesium fastenera. The use of threaded fasteners made of aluminum al10Y or magnesium to mate with threaded parts of aluminum alloy or magnesium should be avoided wherever possible. Where such i8 required, an antiseize compound in acco~dance with 4.1.11 should be used to prevent seizing of the thneadg. 5.1.7 Flat washers. Flat washers should be used for the following applications: a. Between screw heads and soft materials, unless a washer head gcrew, or similar type that provides a bearing surface equivalent to the bearing surface of the appropriate flat washer, is being used. b. Between a nut or lockwasher and a soft material

c. Where lockwashers are used for securing a soft material, a flat washer should be provided to prevent marring or chipping of the material or the applied protective coating, except in areas where an electrical ground ia required. d. Except where it conflicts with electromagnetic interference considerations, a flat washe~ should be used between an organically finished material and lock-washers, bolt and screw heads, or nuts. *5.1.8. Thread engagement. The length of the screws and bolts installed with nuts should be such that the exposed portion is a minimum lenght equivalent to 1.5 thread pitches plus the chamber. Maximum length should be 1imited by the nea~est la~ge~ #tandar.d BcFew length. For highly stressed applications, screws OP bolts should have a minimum thread engagement of 1.5 timee their nominal diameter in tapped parts other than nuts. In normal applications, screws 011bolts should have a minimum engagement length equal to their nominal diameter in tapped parts other than nuts. When the assembly is not frequently disassembled and where maximum strength is not required, less thread engagement may be used. S.2 Rivets. Rivets should be used in preference to other hardware for securing parts not requi~ing nemoval. Wherever the thickness of metal which accepts the heads of flush rivets is lese than the height of the mivet heads, the material should be dimpled rather than countersunk. The distance from the center of rivet holes to the edges of the material in which the rivets are placed shall not be legs than 1.5 times the rivet diameter. Design and limitations of rivets should be in accordance with MR33522 and MB335S7.

12-6

MIL-STD-454N

Rivets for joining magnesium parts should be composition 5056 anodized aluminum alloy or an aluminum alloy having equal galvanic compatibility with the magnesium being used. 5.3 Other fastening methods

5.3.1 Set screws. One set screw may be used on a flatted shaft. Two set screws at 90- to 120 displacement should be used when the shaft is not flatted. Cone-point set screws should not be used, except when the opposing metal has been properly countersunk to receive the cone-point. 5.3.2 Accens devices. Fasteners for uEe with access devices should be readi1y removable for replacement purposes without damaging the attached panel or access door. 5.3.2.1 Nonstructural aDolicati0n8. Quarter-turn fastenars should be used only to retain nonstructural access to devices where quick access is required. 3.3.2.2 Structural aDDlications. Rotary, quick-operating, high strength panel fasteners should be used to retain structural aacess deviceg where quick acceas is required. 5.3.2.3 Thneaded fasteners. Threaded fasteners used with acceas devices should be self-aligning, captive type handwane. 5.3.3 Sanew threaded device armliaations 5.3.3.1 Screws or bolte without nuts. Applications requiring the use of screws or bolts without nuts should use one of the following screw locking methods: a. b. 0. Lockwashers under the heads of the screws or bolts Self-locking screws Self-locking threaded inserts

d. A locking or retaining compound in accordance with 4.1.10 applied to the threads e. Safety wire through drilled heads in accordance with 4.1.5.

5.3.3.2 Countersunk head screws. Countersunk head screws, when not secured by other locking means, should be secured by the application of a thread-

12-7

bfIL-sTD-454N

locking compound in accordance with 4.1.10. Staking by means of upsetting metal is acceptable for permanent assemblies when other means are impracticable or unsatisfactory for de8ign reasons. thread-cutting, and drive screws. Thread forming, 5.3.3.3 Thread-forminfi, thread-cutting, and drive screws should not be used except for attaching identification plates. 5.3.3.4 Safety wiring and cotter Dins. Safety wiring and cotter pins should not be used on termina18 such as screws and threaded studs that are required to function as electrical terminals. !3.3.3. 5 Thread-locking? and retaining COMDOUndS. Thread-locking and retaining compounds should not be used where required electrical conductivity is impaired or failure of the compound would endange~ personnel or damage the equipment.

12-8

MIL-STD-454N REQUIREMENT 13 STRUCTURAL WELDING 1. PurDose. This requirement establishes criteria for structural welds. Welded electrical connections are excluded from this requirement. 2. Documentn applicable to Requirement 13:

Welding, Resistance, Spot and Seam Welding, Fusion, Electron Beam, Process fon Welded Joint Design Welding and Brazing Procedure and Performance Qualification Arc Welding Procedures for Constructional Steels Qualification of Aincraft, Missile, and Aerospace Fusion Welde~s Fusion Welding for Aerospace Applications MIL-STD-2219 Metallic Materials and Elements fcn Aerospace Vehicle MIL-HDBK-5 Structures MIL-HDBK-730 Materials Joining ANSI/AWS A2.4-86 Standard Symbols for Welding, Brazing and Nondestructive Examination ANSI/AWS A3.O-85 Standard Welding Terms and Definitions, Including Terms for Brazing, Soldering, Thermal Spraying and Thermal Cutting MIL-W-6858 MIL-W-46132 MIL-STD-22 MIL-STD-248 MIL-STD-1261 MIL-STD-1S95 3. 4. Definitions. Not applicable. Reauirementn

4.1 Arc and gas welding. Welding by arc and gas methcds ahal1 be performed by operators who have passed the applicable certification tests and have a certificate of proficiency in accordance with MIL-STD-248 or MIL-STD-1595. Welding of aluminum, magnesium, and steel alloys shall conform to MIL-STD-2219. Resistance welding. Resistance welding of joints shall conform to 4.2 MIL-W-685FI 5. Information for guidance onlv -S. 1 Qeneral. The joint aneas of all parts to be welded should be @leaned of contaminants and materiale which may be detrimental to obtaining satisfactory welds. Degnadatio of material properties in the heat affected zone cauged by welding should be considered. Weldments should be stress relieved when induced stress resulting from welding, design ccnfigu~ation, or materials welded may be harmful. See ANSI/AWS 2.4 fop welding symbols, ANSI/AWS A3.O REQUIREMENT 13 9 May 1991 13-1

MIL-STD-454N

for welding terms and definitions, and MIL-STD-22 for welded joint designs. MIL-HDBK-730 provides guidance in this field of materials joining and its related processes. 5.2 Resistance welding. MIL-HDBK-5 may be used as a guide for spot-to-sheet edge distances and allowable strengths. 5.3 Noncritical applications. In ground equipment applications, welding procedures in accordance with MIL-STD-1261 may be used where, if the weld should fail, it will not compromise personnel or equipment safety or prevent completion of the mission. 5.4 Other methods. Other welding methods, such aa the electron beam process of MIL-W-46132, may be used provided approval is obtained from the procuring activity.

13-2

MIL-STD-454N REQUIREMENT 14 TRANSFORMERS, INDUCTORS, AND COILS 1. PuPDose. This requirement establisbeg criteria for the selection and application of transformers, inductors, and coils. 2. Documents aDDliCable to Requirement 14: MIL-T-55631 MIL-T-83721 MIL-STD-9S1 MIL-STD-12S6 Transformers, Intermediate Frequency, Radio Frequency and Discriminator, General Specification for Transformer, Variable, Power, General Specification for DesiAn, ManufacturinE and Quality Standards for Custom Elec~romagnetic Devi~es for Spac~ Applications Transformers, Inductors, and Coils, Selection nd Use of

3. Definitions. Not applicable 4. Requirements 4.1 Selection. Selection of transformers, inductors, and coi s shall be in accordance with MIL-STD-1286 and the following paragraphs. 4.1.1 Intermediate, radio freauency and digcriminatov transformers. Inte~meadiate, radio frequency and discriminator transformers shal1 conform to Grade 1, 2, or 4 of MIL-T-55631. The use of Grade 3 transformers shall be limited to hermetically sealed or encapsulated assemblies. 4.1.2 Variable transformers. Variable transformers shall conform to MIL-T-a3r21. 4.1.3 Custom electromagnetic devices for sDa@e aDDlications. Custom electromagnetic devices for space applications shall confo~m to MIL-STD-981 5. Information fon guidance only. Not applicable

REQUIREMSIIT14 20 September 19SS 14-1

MIL-STD-454N REQUIREMENT 15 METALS, CORROSION RESISTANCE 1. PurDose. This requirement establishes cniteria for tbe seleotion and treatment of metals as related to their ability to resist corrosion. 2. Documents armlicable to Requirement 15: Dissimilar Metals Unified Code for Coatings and Finishes for DOD Materiel

MIL-STD-889 MIL-STD-1516

3. Definitions. Not applicable 4. Requirements. Metals shall be corrosion resistant or aoated or metallurgically processed to resist corrosion. processes for metallic parts shall conform to applicable MIL-STD-889 and MIL-STD-1516. Coatings shall be eelected shall be Materials and requirements in from MIL-STD-1516.

5. Information for guidance only. The environmental severity to which the equipment will be exposed should be considered in selection of metals. The use of non-corrosion resistant steel alloys, except whene specifically required for electronic purposes, should be kept to a minimum.

REQUIREMENT 15 10 September 1987 15-1

MIL-STD-454N REQUIREMENT 16 DISSIMILAR MSTALS 1. PurDose. This requirement establishes criteria for the selection and protection of dissimilar metal combinations and other significant corrosion behavior factors. 2. Document applicable to Requirement 16: MIL-STD-889 Dissimilar hfetalg

3. Definitions. Not applicable 4. Reauirement6. Selection of meta18 for use in electronic equipment shall be made in accordance with the requirements of MIL-STD-889. 5. Information for i?uidance only. Where electronic design requirements preclude the insulation of incompatible metal combinations as identified in MIL-STD-889 from one another, specific! attention should be paid to isolating the combination from exte~ior. environments.

REQUIREMENT 16 10 September 1967 16-1

MIL-STD-454N REQUIREMENT 17 PRINTED WIRING 1. Puruose. This requirement established criteria for the design and treatment of printed wiring assemblies. 2.Documents aDDlicable to Reauinement 17: MIL-P-46843 MIL-STD-1861 ANSI/IPC-D-322 Printed Wiring Assemblies Electrical and Electronic Assemblies, Boards, Cards, and Associated Eandware, Selection and Use of Guidelines for Selecting Printed Wiring Beard Sizes Using Standard Panel Sizes

3. Definitions. Not applicable 4. Requirements 4.1 Rigid Drinted wirinj?and DFinted wiring boards. Rigid printed wiring and printed wiring boards for single-sided, double-sided, and multilayer printed wiring shall conform to MIL-STD-1861. The materials uged for single-sided, double-sided, and multilayer printed wiring boards shall conform to MIL-STD-1S61. 4.2 Rii?idminted wiring assemblies. Rigid printed wiring assemblies consisting of rigid printed wiring boards on which separately manufactured parts have been added shall conform to MIL-STD-1S61. For Army missile weapon systemz, MIL-P-46S43 shall apply only for replacement purposes 4.3 Conformal coatinfi. When conformal coating is required, rigid printing wiring assemblies shall be confonmally coated with a coating material which conforms to MIL-STD-1S61. 4.4 Flexible and rij?id-flex wiring. Flexible and rigid-flex printed wiring shall conform to MIL-STD-1S61 and shall be designed in accordance with MIL-STD-1S61. *4.5 Discrete wiring bcamds. Digcrete wiring boardg with plated-through holes shall be in accordance with MIL-STD-1861. 4.6 Baakulane asgemblieg. Drinted wiring. Electrical baakplane printed wiring assemblies shall conform to MIL-STD-1861 and shall be designed in accordance with MIL-STD-1S61.

REQUIREMENT 17 30 June 1992 17-1

MIL-STD-454N 5. Information for guidance only 5.1 Printed wiring board size. Guidelines for the selection of printed wiring board eizeg are delineated in ANSI/IPC-D-322.

17-2

MIL-STD-434N REQUIREMENT 18 DERATING OF ELECTRONIC PARTS AND MATERIALS 1. Purpose. This requirement establishes criteria for derating of electronic parts and materials. 2. Document auDlicable to Requirement 18: MIL-STD-1547 Parts, Materials, and Processes for Space and Launch Vehicles, Technical Requirements for

3. Definitions. Not applicable 4. Requirements 4.1 Derating. In the application of electronic parts and materials, the parts and materials selected shall be used within their electrical ratings and environmental capabilities (e.g., any ambient or hot spot temperatures, voltage, current, or power dissipation). Derating shall be accomplished as necessary to a8sure the required equipment reliability within the specified operating conditions. 4.2 Derating for launch vehicles and space systems Electronic parts and materials used in launch vehicles or space systems shall be derated in accordance with the requirements of MIL-STD-154Y. 5. Information for guidance only. Not applicable.

REQUIREMENT 18 12 February 1988 18-1

MIL-STD-454N REQUIREMENT 19 TERMINATIONS 1. Purpose. This requirement established criteria for the selection and application of terminati0n8. 2. Documents aDDlicable to Requirement 19: MIL-T-7928 MIL-T-15659 MIL-T-55156 MIL-T-55164 MIL-STD-1277 MS 27212 Terminals, Lug and Splice, Crimp-Style, Copper Terminal, Lug, Solder, Copper and Phosphor Bronze Terminals, Lug, Splices, Conductor; Screw Type, General Specification for Terminal Boards, Molded, Barrier, Screw Type, and Associated Terminal Board Lugs, General Specification for Splices, Terminals, Terminal Boards, Binding Posts, Terminal Junction Systems, Wire Caps; Electrical Terminal Boards, Assembly, Molded-in Stud, Electric

3. Definitions. Not applicable. 4. Requirements 4.1 Termina18

4.1.1 Lug terminals. Lug tenminals shall conform to one of the following specificationg, and wherever possible shall be selected from MIL-STD-1277. MIL-T-792S MIL-T-15659 MIL-T-55156 Crimp, Insulated and Noninsulated Solder Screw

4.1.2 Stud terminals. feed-through terminals. and binding rmste Stud terminals, feed-through terminals and binding posts shall be selected from MIL-STD-1277. 4 .1.3 Number of wires per terminal or lug. The number of wireg terminated in an individual tenminal or lug shall not be greater than three. Multisection turret, bifurcated, or multi-hole lug terminals shall have not more than three wires per section, tong, or hole. In no case shall the total cro8s sectional area of the terminated wires exceed the cross sectional area capacity of the terminal or lug. If a greater number of wires is required than those specified berein, approval of the procuring activity shall be obtained. 4.2 Terminal boards. Terminal boards shall be gelected from MIL-STD-1277

REQUIREMENT 19 30 June 1989 19-1

MIL-STD-454N

4.2.1 Number of lUAS uer terminal The maximum number of lugs to be connected to any one terminal on a terminal board shal1 be two for screw-type terminal boards covered by MIL-T-55164 and as specified in the detail specification sheets for stud-type terminal boards. Not more than four lugs shall be connected to any one terminal of a board covered by M227212. Aacesso~Ien such an stud connectors, 8traddle plates, jumpers and terminal board lugs shall be counted as lugs for this purpose. 4.3 Terminal junction systems. Terminal junction systems shall be selected from MIL-STD-1277. 5. Information for i?uidance only. Crimping of terminal lugs should he so accomplished that the connections will meet the resistance (voltage drop) and tensile strength requirements and tests of MIL-T-7Q28.

19-2

MIL-STD-454N REQUIREMENT 20 WIRE, HOOKUP, INTERNAL 1. Purpose. This requirement establishes criteria for the selection and application Of electrical internal hookup wire. 2. Documents aDDliCable to Requirement 20: QQ-W-343 MIL-W-76 MIL-w-5oa6 hlIL-W-6845 MIL-W-5E46 MIL-W-5908 MIL-W-16878 MIL-W-19150 MIL-W-22759 MIL-W-81044 Wire, Electrical, Coppen (Uninsulated) Wire and Cable, Hookup, Elect~ical, Insulated Wire, Electric, Polyvinyl Chloride Insulated, Copper or Copper Al10Y Wire, Electrical, Iron and Constantan, Thermocouple Wire, Electrical, Chromel and/or Alumel, Thermocouple Wire, Electrical, Copper and Constantan, Thermocouple Wine, Electrical, Insulated, General Spe@ification for Wire, Insulated, Hard Drawn Copper Wire, Electric, Fluonopolymer-Insulated,Copper or Copper Alloy Wine, Electric, Crosslinked Polyalkene, Cros81inked Alkane-Imide Polymer, or Polyarylene Insulated, Copper or Copper Al10Y Wire, Elect~i@, Polyimide Insulated, Copper or Copper Alloy Wire, Electrical, Solderless Wrap, Insulated and Uninsulated, General Specification for Identification Coding and Application of Hook-Up and Lead wire

MIL-W-81381 MIL-W-81822 MIL-STD-681

3. Definitions. Not applicable, 4. Reauirementa 4.1 Selection. Internal hookup wire shall be selected from the types and classes specified by the documents listed in table 20-1. For solderless map applications, wires shall be selected which are in accordance with MIL-w-sla22. 4.1.1 MIL-W-76 shall be used for Army applications only 4.1.2 MIL-W-16878 shall not be used for Air Force or Navy aerospace applications.

REQUIREMENT 20 30 June 1992 20-1

MILrsTc-454N

I
M A.u_L
20-2

MIJrSTC-454N

4AI=14=I=
Ill

rarrsw454N

20-4

MIL-STD-454N

20-5

MIL-STD-454N

9 g

-.,

20-6

MIL-sTD-45411

4.1.3 MIL-W-22759 wire with only single polytetrafluoroethylene insulation used in Air Force space and missile applications shall require the approval of the procuring activity. 4.1.4 Wires with polyvinyl chloride insulation shall not be used in aerospace applications. Use of these wires in any other application requires prior approval of the procuring activity. 4.1.5 Silver plated copper wire shall not be used in applications involving APmy missile ayatenw. 4.2 Identification. Hookup wires in the equipment shall be, insofar as practicable, distinctly coded in color or numbered. Short hookup wire, 150 mm or less between termination points, need not be marked if the path of the short wine can be cagily and visually traaed. The unmsrked wire must be specified on the drawing. Codes, when used, shal1 be in accordance with MIL-STD-681 or ag otherwise agreed upon with the procuring activity. Numbers shall not be used where they would be difficult to read on trace, such as in aompact aesemblie=. *4.3 Bare wire. Bare hookup wire shall be type H class S, soft or drawn and annealed, and coated, and shall conform to QQ-W-343. Bare hookup wire shall not be used unless insulated wire is impractical because of circuit characteristics or shortness of wire run. 5. Information for F,uidance only S.1 Solid or stranded. Stranded wire should be used for conductors and cables which are normslly flexed in use and servicing of the equipment, such as cables attached to the movable half of detachable connectors and hanging cables attached to removable or movable doors and shields Leads 150 mm or less in length may be run as solid wires unless they form interconnections between shock isolation mounted parts and nonshock isolation mounted parts. There are come other inatancee, such as wire wrapping, where a solid conductor msy be required regardless of length. 5.2 Cold flow. Certain insulating materials exhibit a cold flow characteristic. Caution should be used in the selection of these materials in applications requining restrictive clamping or tying, eta, whe~e this feature may result in exposed or shorted conductors. 5.3 Thermocouple wipe. Selection of thermocouple wire shall be in accordance with MIL-W-5845, MIL-W-5846, or MIL-W-5908.

20-7

MIL-STD-454N REQUIREMENT 21 CASTINGS 1. PurDose. This requirement establi8he8 criteria for the design, classification, inspection, and repair of castings. 2. Documents aDDliCable to Requirement 21: MIL-STD-2Y6 MIL-STD-2175 Impregnation of Porous Nonferrous Metal Castings Castings, Classification and Inspection of

3. Definitions. Not applicable. 4. Requirements 4.1 Die castings. Die castings shall not be used where the casting might be subject to impact. Zinc alloy die castings shall not be used where dimensional changes of the casting could affect use of equipment. 4.2 Porous castings. When required, castings shall be impregnated in accordance with MIL-STD-276. 4.3 Classification and inspection. Castings shall be classified and inspected in accordance with MIL-STD-2175. 4.4 Inserts. Inserts which are intended to be cast in place shall be knu~led, grooved, or otberwiae prepared to secure satisfactory keying of the insert to the casting. Inserts shall be fabricated from a material which is not adversely affected by exposure to the molten casting alloy. When inserts are located near a casting edge, sufficient edge distance shall be allowed in order to develop the required resistance to insert pull-out, and to avoid cracking of the casting. Casting defects resulting from use of inserts, such as partial alloying, peon bonds, porosity, and cracks shall not be present. 5. Information for i?uidance only 5.1 Selection and aDDlication. In any design utilizing metallic castings, consideration should be given to intended application, the availability of molding and ca6ting alleys, the choice of a suitable cagting process (see table 21-1), and the use of ribs and fins.

REQUIREMENT 21 10 September 1987 21-1

MIL-STD-454N

TABLE 21-1. General comparison of metallic castin~ processes.

ype of :astings

limen Iional mcuracy

Lbilityto citability ,eproduce 001 or volume ninedetail !Ost reduction 3 1 1 2 2 1 1 3 3 3 3 1 3 1 2 1 1 3

urface moothess

;uitabilitj :or large Iized :aatinga

Sand Die Inve#tmen Shell mold Permanent mold Plaster mold

3 1 1 2 2 2

3 1 1 2 2 2

1 3 3 3 2 3

Legend!

1 = Very gooa; 2 = good; 3 = fair

5.2 Repair of unmachined castings. Repair of minor discontinuities or defects in unmachined or raw castings should be permitted only when specific aPP~OVal has been granted by the cO~tFactOp ~te~ial Review Board (m) , Or 18 specified on the engineering documentation. Weld repair should be limited to clasa 3 and class 4 castings .(class1 and class 2 repair should require procuring activity approval) and to areas where no severe stress will be encountered. Heat treatable alloys must be ful1y reheat treated afte~ welding to meet drawing requirements. 5.3 Reuair of machined castings. Repair of defects in machined castings should be permitted for class 3 and class 4 castings based on the contractors MRB decision. Class 1 and class 2 casting repain should require procuring activity approval Reheat treatment should be required unless engineering analysis during bfBBaction can demonstrate it is unnecessary.

21-2

MIL-STD-454N REQUIREMENT 22 PARTS SELECTION AND CONTROL 1. PurDose. This requirement offers guidance as to parts seleation and control which must be considered when preparing contractual documents. IT DOES NOT ESTABLISH REQUIREMENTS AND MUST NOT BE REFERENCED IN CONTRACTUAL DOCUMENTS. Parts selection and control must be directly specified in the contract or the system/equipment specification, as appropriate. 2. Documents aDD1iCable to Requirement 22: MIL-STD-965 MIL-STD-1546 Parts Control Program Parts, Materials, and Processes Standardization Control and Management Pnognam for Spacecraft and Launch Vehicles

3. Definitions. Not applicable 4. Requirements. Not applicable 5. Information for guidance only 5.1 Parts control rmog~am. MIL-STD-Q65 establishes two pnocedumes covening the submission, review, and approval of Prognam Parts Selection List8 and changes thereto. The objective is to achieve life cycle cost savings and cost avoidance8 by: (1) assisting equipment or system managers and their contractors in the selection of parts commensurate with contractual requirements, (2) minimizing the variety of parts used in new design, (31 enhancing nterchangeability, reliability, and maintainability of military equipment and supplies, and (4) conserving re80urce8 and (5) assuring long term availability of parts. MIL-STD-965 mu8t be tailored when applied; application guidance i8 offered in the document. 5.2 Part8 control DroEram for 8Dacecraft and launc!h Vehi@le8. (Not applicable to NASA program8) MIL-STD-1546 establishes the criteria and requirement for the preparation and implementation of a Parts, Materials, and Proce88e8 Standardization Control and Management Program for u8e during the design, development, fabrication, and te8t of spacecraft and launch vehicles. The implementation of thi8 8tandard i8 intended to: (1) assure total, integrated, and coordinated management of the selection, application, procurement, control and standardization of part8, materials and pmocesses (PMP), (2) reduce program C08t8, (3) improve the standardization and reliability of program parts, materials, and proce88e8 and (4) a88ure long term availability of parts.

REQUIREfdSNT 22 12 February 198S 22-1

MIL-STD-454N REQUIREMENT 23 ADHESIVES 1. Purpose. This requirement establishes guidance for the selection and application of adhesives. 2.Documents aDDliCable to Requirement 23: MMM-A-121 W-A- 130 MMM-A-132 W-A- 134 W-A-138 W-A-181 MMM-A-189 MMM-A-1617 MMM-A-1931 MIL-A-3E120 MIL-A-5540 MIL-A-8576 MIL-A-22397 MIL-A-24179 MIL-A-2S463 MIL-A-46050 MIL-A-46146 MIL-A-47089 MIL-A-47315 MIL-A-47317 MIL-A-47318 MIL-A-48611 MIL-A-52194 MIL-A-81236 MIL-A-81253 MIL-A-83377 MIL-A-87135 MIL-HDBK-691 29 CFR 1910 Adhesive, Bonding, Vulcanized Synthetic Rubber to Steel Adhesive, Contact Adhesive, Heat Resistant, Airframe Structural, Metal to Metal Adhesive, Epoxy Resin, Metal to Metal Structural Bonding Adhesive, Metal to Wood, Structural Adhesive, Phenol, Reaomcinol, or Melamine Base Adhesive, Synthetic-Rubber, Thermoplastic, General Purpose Adhe#ive, Rubber Base, (lene~alPurpose Adhesive, Epoxy, Silver Filled, Conductive Adhesive, Optical, Thermosetting Adhe6ive, Polychloroprene Adhesive, Acrylic Base, for Acrylic Plastic Adhesive, Phenol and Resorcinol Resin Base (for Marine Sexwice Use) Adhesive, Flexible Unicellular-Plastic Thermal Insulation Adhesive, Film Form, Metallic Structural Sandwich Construction Adhesive, Cyanoacrylate, Rapid Room-Temperature Curing, Solventles8 Adhesive-Sealants, Silicone, RTV, Non-Corrosive (for Use With Sensitive Metals and Equipment) Adhesive, Metal Filled, Conductive, Electrical and Thermal Adhesive, Polyurethane Adhesive, Air Drying, Silicone Rubber Adhesive, Copolymer Polyurethane Adhesive System, Epoxy-Elastomeric, for Glass-To-Metal Adhesive, Epoxy (for Bonding Glass Reinforced Polyester) Adhesive, Epoxy Resin With Polyamide Curing Agent Adhesive, Modified Epoxy Resin With Polyamine Curing Agent Adhesive Bonding (Structural ) for Aerospace and Other Syetema, Requi~ementa fop Adhesives, Non-Conductive, for Electronics Application Adhesive Bonding Code of Federal Regulations, Title 29, Chapter XVII, Part 1910

REQUIREMENT 23 15 December 1989 23-1

MIL-STD-454N

3. Definitions 3.1 Adhesives. Adhesives are substances capable of holding materials together by surface attachment. Adhesive is a general term and includes, among otherg, cement, glue, mucilage and paste. All of these terms ape loosely used interchangeably. 4. Requirements. Not applicable. 5. Information fOIIguidance onlX 5.1 Design of joint. The joint should be designed to minimize concentrations of stress. The basic stress should be in shear. The weakest design is where the basic stress is in cleavage or peel and non-axial loading in tension produces cleavage. 5.!2 Deleterious effects. The user should ascertain that the formulation of the adhesive selected will have no deleterious effects on the bonded assembly or nearby items when the bonded assembly is in storage, transit or use under the environmental conditions for which it was designed. Deleterious effects may be caused by the slow release of trapped solvents which can damage many types of rubber and plastic, or cause other harmful results degrading operation of the equipment. 5.3 &mlication. Cane ghould be taken to avoid starved joints which are the result of either absorption of adhesive by a porous material, poor application, inadequate coverage, or exceaaive pre#nure. Where one or both of the adherends are porous, successive thin coats of adhesive should be applied to completely seal the surface, and each coat should be dry before the next @oat is applied. This procedure should be used instead of the application of one thick adhesive coat to the porous surface, except in the caee of silicone adhesives. In general, the thicker the adhesive layer, the lower the shea~ resistance, but the higher the strength to impact and peeling. 5.4 Structural Compatibility. Adhesives which are not compatible structurally should be avoided. FOP example, a brittle adheaive should not be used ton glass bonding because excessive shrinkage during setting or cuming will load the glass in tension. For assemblies which may be flexed or subject to impact, a bnittle adhesive should not be used. 5.5 Carcinogens. Certain chemicals have been identified in Safety and Health Act (OSHA) as cancer producing substances Befo~e using any materials which might contain carcinogens, evaluated in accordance with 29 CFR 1910. Consideration of substance should be given pnior to matenial selection. the Occupational (carcinogens) they should be the toxicity of a

23-2

MIL-STD-454N

5.6 Thermoplastic. All thermoplastic adhesives have a tendency to creep under load, especial1y at elevated temperature, and should not be used in critical structural applications. Many thermoplastic adhee. ives have limited or poop Penintance to certain solvents. 5.7 Materials to be bonded. The materials to be bonded assume critical importance as there are some materials, such as fluorocarbon, polyethylene, and nylon that cannot be bonded satisfactorily without prior treatment, special adhesives, or both. 5.8 Quide for selection and application. The following, although not a complete list, may be used as a guide in selecting adhesives and bonding procedures to meet design requirements in electronic equipment. MMM-A-121 MMM-A-130 MMM-A-132 MMfd-A-134 MMM-A-138 W-A-181 W-A-189 MMM-A-1617 W-A-1931 MIL-A-3920 MIL-A-5540 MIL-A-8576 MIL-A-22397 MIL-A-24179 MIL-A-2S463 MIL-A-46050 MIL-A-46146 MIL-A-47089 MIL-A-47315 MIL-A-47317 MIL-A-47316 MIL-A-48611 MIL-A-52194 MIL-A-81236 MIL-A-81253 MIL-A-83377 MIL-A-87135 MIL-HDBK-691

Many of these specifications have no requirements pertaining to electrical properties. Where electrical properties are important, the suitability of the material for the application should be established.

23-3

MIL-STD-454N REQUIREMENT 24 WELDS, RESISTANCE, ELECTRICAL INTERCONNECTIONS 1. Purpose. This requirement establishes criteria for resistance welds of electrical and electronic interconnections and part leads. This requirement does not include structural welds. !2.Documents applicable to Requirement 24: MIL-W-8939 Welding, Resistance, Electronic Circuit Modules

3. Definitions. Not applicable. 4. Requirements. Weld8 and welding processes shall be in accordance with MIL-W-8939 5. Information fon Euidanae onl~ 5.1 Contaminants. All surfaces of leads or parts to be welded should be free of contaminants which would adversely affect fo~ming of the welded joint. 5.2 Electrical connections. Except where needed to meet electromagnetic interference or system compatibility requirements, welded electrical connections should not be used where it may be neceeaa~y to diaaonnect, IIepla@e, or ~econnect a part or module during se~vicing. 5.3 Excess conductor wire. Excess conductor wipe should be trimmed sufficiently close to provide adequate clearance to prevent possible elect~ical shorting but not so close as to cause damage to the welded joint. 5.4 Strain relief Each pant lead terminating at a connection point should have allowance for strain relief to minimize tensile or shear st~ess.

REQUIREMENT 24 12 February 1988 24-1

MIL-STD-454N REQUIREMENT 25 ELECTRICAL POWRR 1. PurDose. This requirement establishes criteria for electrical power. 2. Documents aDDlicable to Requirement 25: Frequencies for Electric Power Electric Voltages, Alternating and Direct Current Aircnaft Electric Power Characteristics Characteristics of 28 Volt DC Electrical Systems in Military Vehioles Interface Standard for Shipboard Systems Electrical Power, Direct Current, Space Vehicle Design Requirements

MIL-STD-205 MIL-STD-255 MIL-STD-704 MIL-STD-1275 MIL-STD-13QQ MIL-STD-1539

3. Definitions. Not applicable 4. Requirements 4.1 General. Except as specified below, the electrical power source required for electronic equipment and associated equipment and fop portions of systems employing electronic equipment shall be in accordance with MIL-STD-205 and MIL-STD-255. 4.2 Airborne. The electrical power requirements for airborne and associated equipment shall be in accordance with MIL-STD-704. 4.3 ShiDboard. The electrical power requirements for shipboard and associated equipment ahal1 be in accordance with Type I or Type II of Section 300 of MIL-STD-1399. 4.4 SDace. The electrical power requirements for space equipment shall be in accordance with MIL-STD-1539. 4.5 Ground vehicles. The electrical power requirements for military ground vehicles shall be in acco~dance with MIL-STD-1275. 5. Information for Euidance onlv. Not applicable.

REQUIREMENT 25 15 December 1989 25-1

MIL-STD-454N REQUIREMENT 26 ARC-RSSISTANT MATERIALS 1. Purpose. This requirement establishes criteria for the selection and application of arc-resistant materials used for insulation of electrical power circuits. 2. Documents aDDliCable to Requirement 26: Plastic Sheet and Plastic Rod, Thermosetting, Cast Rubber, Si1icone Insulating Compound, Electrical, Ce~amic, Class L Molding Plastics and Molded Plastic Parte, Thermosetting Plastic Rod and Tube, Thermoeetting, Laminated Plastic Material, Laminated, Thermosetting, Electrical Insulation, Sheets, Glass Cloth, Silicone Resin Plastic Sheet, Laminated, Thermosetting, Glass-Cloth, Melamine-Resin Plastia Sheet, Laminated, Glass Cloth, Polytetrafluoroethylene Resin Molding Material, Plastic, Epoxy Compounds, Thermosetting Plastic Material, Silicone Resin, Glass Fiber Base, Low-Pressure Laminated Plastic Sheet and Strip, Polyimide Plastics: Methods of Testing Standard Method of Test for High-Voltage, Low-Current Dry Arc Resistance of Solid Electrical Insulation Materials Code of Federal Regulations, Title 29, Chapter XVII, Part 1910

L-P-516 22-R-765 MIL-I-1O MIL-M-14 MIL-P-79 MIL-P-997 MIL-P-15037 MIL-P-1Q161 MIL-M-24325 MIL-P-2551B MIL-P-46112 FED-STD-406 ASTM D495-73 29 CFR 1Q1O

3.

Definitions. Not applicable.

4. Reauiremente. Materials shall conform to table 26-I. The materials listed have passed the minimum requirements of 115 Becondn when subjected to the arc-resistance test of ASTM D495 or Method 4011 of FED-STD-406, and are listed in approximate order of arc resistance. 5. Information for $!uidance only

5.1 ADDliCati0n8. Materials may be masked, if necessary, during any treatment of the equipment in which they are used which might result in degradation of the arc-resistant properties of the material. Fop parts which may be exposed to other than high-voltage, low-current arcing, the materials should be evaluated fon overall thermal and electrical characteristics. Suitability fon the specific application and the potential for satisfactory

REQUIREMENT 26 30 June 1989 26-1

MIL-STD-454N performance in elevated humidity, as defined in the detail equipment specification, Ehould also be considered. 5.2 Carcinogens. Certain chemicals have been identified in the Occupational Safety and Health A@t (OSHA) as cancer-pnoducing substance (carcinogens) . Before using any materials which might contain these chemicals, they should be evaluated in accordance with 29CFR 1910. Consideration of the toxicity of a substance should be given prior to material selection. TABLE 26-I. Arc-resistant materials.

Materials Ceramic Pla#tic(s), thermosetting, Molding

.%ecification MIL-I-1O MIL-M-14 Al1

CMI-5, GDI-30, GDI-30F, MAG, MAI-30, MAI-60, MAI-1OO, MAT-30, MDG, MME, MMI-5, MMI-30, fASG MSI-30, SDG, SDG-F, SDI-30 MEE GMG

Molding, epoxy compounds Laminated rods and tubes Laminated sheets Glass cloth, melamine resin Glass cloth, polytetrafluoroethylene resin Glass cloth, silicone resin Low pressure laminate, silicone resin, glass fiber base Sheet and rod, cast Sheet and strip, polyimide Silicone rubber

MIL-M-24325 MIL-P-79

MIL-P-15037

GMS

MIL-P-19161

GTE

MIL-P-997

GSG

MIL-P-25518

All

L-P-516 MIL-P-46112 ZZ-R-765

E-2 Al1 All

26-2

MIL-STD-454N REQUIREMENT 27 BATTERIES 1. Purpose. This requirement establishes the criteria for the selection and aPPli@atiOn of batteries, including installation and marking criteria. !t2.Documents applicable to Requirement 27: MIL-B-18 MIL-B-10154 MIL-B-11188 DOD-B-15072 Batteries, Non-Rechargeable, Dry Batteries, Prima~y, Waten-Activated (Dunk Type) Batteries, Storage, Lead-Acid Batteries, Storage, Lead-Acid, Portable, General Specification for (Metric) Batteries, Dry (Alkaline) MIL-B-49030 Batteries, Non-Rechargeable, Lithium Sulfun Dioxide MIL-B-49430 Battenies, Rechargeable, Nickel-Cadmium, Sealed MIL-B-49436 Batteries, Non-Rechargeable, Lithium Manganese Dioxide MIL-B-49458 Batterie8, Non-Rechargeable, Lithium Thionyl Chloride MIL-B-49461 Batteries, Storage, (Cells), Vented, Nickel-Cadmium MIL-B-55118 Batteries, Rechargeable, Nickel-Cadmium, Sealed MIL-B-55130 Drv Battenies. lda~nesium. MIL-B-55252 Batteriesand-Cells, Sto~age, Mickel-Cadmium, Aircraft, MIL-B-817E7 General Specification for Batteries, Stonage, Lead-Acid, Qeneml Specifiaation for MIL-B-B3769 Nickel-Cadmium Battery Usage Practices for Space Vehicles DOD-STD-1578 Regulation 700-83, Army Materiel Command 3. Definitions. Not applicable 4. Reauir.ement8 Batteries shall not be used unless approved by the procuring 4.1 ~ activity. 4.1.1 ArmY applications. Battery power fon Amy equipment (development and non-development type) and other-service-developedequipment adopted by the Army shal1 be selected in accordance with Army Materiel Command Regulation 700-83. 4.1.2 Suace applications. Batteries for space applications shall be selected and applied in accordance with DOD-STD-1578. 4.1.3 Lithium batteries. When lithium batteries are to be used in an equipment, direction on their use, transportation, storage, and disposal

REQUIREMENT 27 30 June 1892 27-1

MIL-STD-454N

should be requested through the procuring activity from the following sources: FOP Army: US Army Laboratory Command Electronics Technology and Devices Laboratory ATTN: SLCET-P Ft Monmouth NJ 07703-5302 Department of the Navy Naval Sea Systems Command ATTN: NAVSEA 652 Washington DC 20362 Sacramento Air Logistics Center ATTN: MMIEC McClellan AFB CA 95652

For ?Javy :

For Air Force:

4.2 Rechargeable batteries. Rechargeable batteries shall conform to MIL-B-11188, DOD-B-15072, MIL-B-49436, MIL-B-55118, MIL-B-55130, MIL-B-81757, MIL-B-83f69, or DOD-STD-1578. 4.3 NonrecharEeable batteries. Nonrechargeable batteries shall conform to MIL-B-18, MIL-B-10154, MIL-B-49030, MIL-B-49430, MIL-B-494SS, MIL-B-49461, or MIL-B-55252 4.4 Installation marking. Connections, polarity, minimum acceptable voltage for equipmant operation, nominal voltage, and type(s) of batteries required shall be mmked as applicable in a prominent place on or adjaaent to the battery compartment. 4.5 Warninfilabel. Battery-powened equipment, with the exception of equipment requiring permanent battery installation, shall be labeled externally as follows: WASNIUQ RS~VS BATTERIES BEFOES SEIPMSIiT OR IIIACTIVS Si03AQK OF 30 DAYS OR M3BB Examples of equipment requiming permanent battery installation are soncbuoys, mi88ilea, and fuses. 5. Information for Euidance cnly. The battery compartment should be provided with devicee to firmly secure the batteries. Adequate room should be provided

27-2

MIL-STD-454N

for battery installation, maintenance, testing, and removal without disassembly of the equipment. The battery compartment should prevent pressure build-up from heat, gases, liquids, or chemicals released during battery operation, charging, deterioration, or rupture, and should also prevent such materials from entering the electronic compartment. When magnesium dry batteries are uged, extra precautions should be obsenved e.indethese batteries give off heat at high rates of discharge (less than 10 hours) and evolve hydrogen.

27-3

MIL-STD-4S4N REQUIREMENT 28 CONTROLS 1. Purpose. This requirement establishes criteria for the selection and application of controls. 2. Documents applicable to Requirement 28: MIL-K-3926 MIL-K-25049 MIL-D-2.S728 3. Definitions 3.1 Ouenatinf control. Operating controls are controls that may be required for use during the normal operation of the equipment. 3.2 Adjustment controls. Adjustment controls are controls that are used fon alignment and calibration of the equipment and are not used during normal operation of the equipment. 4. Reauiremente 4.1 Qeneral. All controls shall be marked, indexed, sized, and located 80 that the control position can be readily identified. Controls shall have fixed guide ma~ks if pre-setting of the controls is required. Contnols located adjacent to their associated displays shall be so positioned that operation of the control will not obscure the display. Controls shall be so connected in the circuit that tbe controlled characteristics (e.g., sensitivity, volume, or voltage) increase with clockwise rotation of the control as seen from the operating position. In general, movement of a control forwand, clockwise, to the right, or up, shal1 turn the equipment on, cause the quantity to increase or cause the equipment to move forward, clockwise, to the right or up. 4.2 Accessibility Knobs, Control (For Use with Electronic, Communications, and Al1ied Equipment) Knob, Cont~ol, Equipment, Aircraft Dial, Control, Multitum Counters, QenePal SpeCifi@atiOn for

4.2,1 ODeratinflcontrols. Controls necessary for the operation of the equipment shall be neadily accessible, and unless otherwise specified shall be located on the front panel of the unit. 4.2.2 Adjustment controls. Adjustment controls that are required for periodic alignment or calibration shall be mounted bebind covered openings,

REQUIREMENT 28 10 September 1EJ87 28-1

MIL-STD-454N

such as access doors, on the surfaces of the equipment accessible when installed. When not adjustable by hand, controls shall be designed to accept a common screwdriver blade tip. Controls which infrequently require adjustment need not be accessible from the operating panel, but shall be readily accessible for servicing when the equipment is opened for maintenance pu~poaes. 4.3 Mechanical characteristics

4.3.1 w Mechanical stops shall be pmovided for all adjustable controls, except controls designed for unlimited rotation. Where flexible control shafts are employed, or where stops integral to the adjustable control on the mechanism could be damaged by excessive torque, stops shall be provided on the driving end of the ehaft. 4.3.2 Locking devices. Control locking devices shall be capable of retaining the controls in any given setting within the range of control The locking and unlocking action shall be easily and quickly accomplished, and shall not affect the getting of the control. When in the unlocked position, the locking devices shall not interfere with the normal operation of the control Wheve vernier controls are used, the locking devices shall openate on both main and vernier controls if necessary to prevent damage. 4 .3.3 Nonturn devices. All nonturning cont~ols and bodies or cases of turning controls shall be equipped with a positive device to prevent their turning in the panel or assembly on which they are mounted. 4.3.4 Shafts and couplinfis. Coupling between or to #hafts shall be accomplished by means of metallic or insulated couplings rigidly secuned. 4.3.5 Control knobs and handles. Control knobs conforming to MIL-K-3926 or MIL-K-25O49 shall be uged wherever suitable. For knobs not covered by a military specification, color, tactile information, and flammability requirements shall be in accordance with MIL-K-3926. Control knobs and handles shall have high impact stnength and shall be firmly gecu~ed to the control shafts by use of setscrews wherever that type of fastener is applicable. Plasti@ knobe and handles shall have metal inserts for setscrews and Bhall not warp or crack. 4.3.6 Multitu~n counte~s control dials. Manual1y operated multiturn counters control dials shall conform to MIL-D-28728. 4.3.7 Stabilit.v. All controls shall be so designed that the setting, pogition, or adjustment of any control shall not be altered when the equipment is subjected to the service conditions #pe@ified in the detail equipment 6pecificati0n.

28-2

MIL-STD-454N

4.3.8 Factory adjustment controls. The design of equipment shall not include factory- or sealed adjustment controls, unless specifically approved by the detail equipment specification. 5. Information for guidance only 5.1 Arrangement and location. Controls should be anranged to facilitate smooth and rapid operation. All controls which have sequential relations, which are related to a particular function or operation, or which are operated togethen should be grouped together along with their associated displays. Controls should be conveniently located with respect to associated visual displays. Controls should be of such size and so spaced that the manipulation ofa given control does not interfere with the setting of an adjacent control. Adjustment controls with required test points should be grouped and so marked as to pnovide for simplicity and ease of maintenance. 5.2 Mechanical operation. Infrequently required controls should be screwdriver adjusted. Play and backlash in controls should be held to a minimum commensurate with intended operational functions and should not cause poor contact or inaccurate Betting. Controls should operate freely and smoothly without binding, scraping, or cutting. Controls msy be lubricated when lubrication does not interfere with operation and is specified in the detail equipment specification. 5.3 Shafts and couDlings. Shafts subject to removal may have their couplings seauned by two set screws 90 to 120 degnees apart. Flexible couplings msy be used for controls where the use of rigid couplings would interfere with the satisfactory operation OXImounting of such aontrols.

2.9-3

MIL-STD-454N REQUIREMENT 29 ELECTRON TUBES 1. PUPDOSR. This requirement establishes criteria for the selection and application of electron tubes. 2. Document aDDlicable to Requirement 29: Electron Tubes, Selection and Use of

MIL-STD-200 3.

Definitions. Not applicable.

4. Requirements. Electron tubes shall be selected and applied in accordance with MIL-STD-200. 5. Information for fiuidance only. Not applicable.

REQUIREMENT 29 20 Septemben 1988 29-1

MIL-STD-454N REQUIREMENT 30 SEMICONDUCTOR DEVICES 1. PuPDOBe. This requirement establishes criteria for the selection and application of semiconductor devices. 2. Documents ADP1icable to Requirement 30. MIL-S-19500 MIL-STD-701 MIL-STD-750 MIL-STD-134Y Semiconductor Devices, General Specification for Lists of Standand Semiconductor Devices Test Methods forSemiconducto~ Devices Parts, Materials, and Proceeaee for Space and Launch Vehicles, Technical Requirements for

3. 4.

Definitions. Not applicable. Requirements.

4.1 Selection and application. Semiconductor devices shall be selected and applied in accordance with MIL-STD-701 and, for Space Division, AFSC (SD), MIL-STD-1S47. 4.1.1 Reliability. Discrete semiconductor devices in military systems during full scale development and production shall, as a minimum, conform to MIL-S-19S00, product assurance JANTX level JANS level shal1 be used for space applications. 4.1.2 Order of Precedence. Unless otherwise specified, the order of precedence shall be as follows: 4.1.2.1 For Packaged Devices: a. MIL-S-19500 - Qualified semiconductors listed in MIL-STD-701

b. Other MIL-S-19500 - Other qualified semiconductors subject to procuring activity approvals. c. Active DESC drawings subject to procuring activity approval

d. Other semiconductor documents (see 4.1.3) subject to procu~ing All devices shall be screened and tested in accordance activity approval with 4.1.3.4. 4 .1.2.2 For Dice:

REQUIREMENT 30 6 May 1991 30-1

MIL-STD-45N a. MIL-S-19500 JAN C program (See paragraph 1.2.1.2, Appendix H, and detailed specifications). b. approval. Other semiconductor documents subject to procuring activity

4.1.3 Qualified Devices. When the contract fom a design specifies the use of TX equivalent quality level or higher on DESC drawings, and there is a JANTX, JANTXV, or JANS device available, the qualified JANTX, JANTXV, or JANS .eemiconducto~ shall be the only device authorized for use. 4.1.3.1 JANS Level. JANS level devices shall be used in space flight, and aritical applications for Spaae Division, AFSC (SD). When JANS level parts, in accordance with MIL-S-19500, are not available on cannot be qualified by the manufacturer, the requirements of MIL-STD-1547 shall apply in accordance with p~ocuring activity direction. 4 .1.3.2 JANTX. JANTXV. and JANS Levels. JANTX, JANTXV, or JANS level devices shall be used in Amy Missile Command, Amy Laboratory Command, Naval Air Systeme Command and Air Force applications other than SD space, launch, and reentry equipment. When a qualified JANTX, JANTXV device does not exist and an active DESC drawing device of the required generic chip and package type or case outline does exist, the DESC drawing device ahal1 be the preferred device authorized for that degign. 4.1.3.3 JAN Level. JAN level is no longer authorized for new designs. When JAN level does not exist or is not available (for old design), the aPPrOPpiate substitutions shall be JAMTX, JANTXV, or JANS when available. When JANTX, JANTXV, or JANS level devices are not available, JAN level may be used subject to the procuring activity approval provided the devices are gcreened per JANTX requirements of table II and be tested in accordance with requirements of table III (group A) and table IV (group B) of MIL-S-19500. 4 .1.3.4 Other Semiconductors. When MIL-S-19500 qualified devices are not available, other semiconductors may be used subject to procuring activity approval. All devices shall be screened and tested as in 4.1.3.3 above. 4.2 Sealinj?-. All semiconductor devices used in equipment shal1 be hermetically sealed in glass, metal, metal oxide, ceramic, OP a combination of these. Use of plastic (organic or polymeric) encapsulated or sealed devices nequires the approval of the proauring activity. 5. Information for fuidance only. Semiconductor devices are susceptible to electrostatic dfscha~ge damage. Appropriate discharge procedures should be observed prio~ to handling these parts, and deeign selection of deeired devices should include a consideration of the effectiveness of the input or other protective elements included in the device deeign.

30-2

MIL-STD-454M REQUIREMENT 31 MOISTURE POCKETS 1. PurDose. This requirement establishes criteria for the treatment and drainage of moisture pockets. 2. 3. Documents aDDli@abl@ to Requirement 31. Mot applicable. Definitions. Mot applicable.

4. Requirements. Where moistune pockets are unavoidable in unsealed equipment, provision shall be made for drainage of such pockets Desiccants or moisture-absorbent materials shall not be used within moisture pockets. 5. Information for guidance only

5.1 Pockets, wells, and traDs. Pocket#, wells, traps, and the like in which water or condensate could collect when the equipment i8 in normal position should be avoided. 5.2 Sealed eauiDment. In sealed equipment or assemblies such as waveguides, the use of desiccants or other methods, such as ga# purging, is permitted.

REQUIREMENT 31 10 September 1987 31-1

MIL-STD-454N REQUIREMENT 32 TEST PROVISIONS 1. Purpose. This requirement establishes criteria for test provisions. 2. Documents anDlicable to Requirement 32: MIL-STD-415 MIL-STD-2165 Test Provisions for Electronic Systems and Associated Equipment, Design Critenia for Testability Program for Electronic Systems and Equipment

3. Definitions. Not applicable. 4. Requirements 4.1 Built-in test devices. Built-in test deviceg shall maintain their accuracy under all operating conditions requined by the equipment under test. These devices shall be provided with connections OF access for their operational checkout on calibration. 4.2 External test Doints. Protection shall be provided in the test point circuitry to prevent equipment damage caused by the external grounding of test points. 4.3 Failure effect. Unless otherwise specified, provisions for testing shall be so designed that any failure of built-in test devices will not degrade equipment operation or cause equipment shut down. 4.4 Test Drovieion8 Test provisions to provide means for monitoring performance, calibration, and fault isolation shall be in accordance with MIL-STD-41S. 5. Information fop guidance onlv 5.1 Testability program. When specified by the procuring activity, a testability program should be implemented in accordance with MIL-STD-2165

REQUIREMENT 32 12 Februany 1988 32-1

MIL-STD-454N REQUIREMENT 33 RESISTORS 1. PurDose. This requirement establishes criteria for the selection and application of resistors. 2. Documents aDKtl ica.bleto Requirement 33: MIL-T-23648 MIL-STD-199 Thermistor (The~mally Sensitive Reai8tor), Insulated, General Specification for Resistors, Selection and Use of

3. Definitions. Not applicable. 4. Requirements 4.1 Selection. Rasistors shall be #elected and applied in accordance with MIL-STD-199. 4.2 Thermistors. Thermistors shall conform to MIL-T-23648.

5. Information for fuidance only. Not applicable.

REQUIREMENT 33 20 September 1988 33-1

MIL-STD-454N REQUIREMENT 34 NOMENCLATURE 1. PurDose. This requirement establishes criteria for nomenclature (item name and type designation). 2. Document apDlicable to Requirement 34: MIL-STD-196 Joint Electronics Type Designation System

3. Definition. Not applicable. 4. Requirements. Item names and type designations for electronic equipment shall be established in accordance with MIL-STD-196. 5. Information for guidance only. The assignment of type designations does not constitute approval of equipment or the uge of a particular item in a specific set and does not waive any requirements of the contract involved, nor does the app~oval of the equipment constitute approval of the type designation assignment.

REQUIREMENT 34 12 February 1988 34-1

MIL-STD-454N REQUIREMENT 35 RELIABILITY 1. Purpose. This requirement offers guidance as to meltability requirements which must be considered when preparing contractual documents. IT DOES NOT ESTABLISH REQUIREMENTS, AND MUST NOT BE REFERENCED IN CONTRACTUAL DOCUMSNTS Reliability program tasks, quantitative requirements, and verification or demonstration requirements must be dinectly specified in the contract or the 8yatem/equipment specification, as appropriate. ~. D0CUitIent8 aDDliCable to Requirement 35. Definitions of Terms for Reliability and Maintainability Reliability Modeling and Prediction Reliability Design Qualification and Produat Acceptance Te8tS: Exponential Distribution Reliabi1ity Program for Sy8tems and Equipment Development and Production Procedures for Performing a Failure Mode, Effects and Criticality Analysis Reliability Prediction of Electronic Equipment

MIL-STD-721 MIL-STD-756 MIL-STD-761 MIL-STD-785 MIL-STD-1629 MIL-HDBK-217 3. 4. 5.

Definitions. Not applicable Requirement. Not applicable

Information for fuidance only.

5.1 Reliability r.mogram. Reliability engineering and accounting tasks aimed at preventing, detecting, and connecting reliability design deficiencies, weak parts, and workmanship defects and providing reliability related information e88ential to acquisition, operation, and support management should be included in contract requirements with the objective of establishing and maintaining an efficient reliability prognam according to life CyCle pha8e. MIL-STD-785 ie the overal1 p!wgram document fo~ the area. It is sectionalized into individual task 8tatements and require8 exten8ive tailoring when it i8 applied. Detailed application guidance a8 to the nature of the ta8k8 and when they 8hould be imposed is provided. Other reliability documents which may be invoked through MIL-STD-785 on which may be cited directly as a baSi8 for contract requirement include MIL-STD-721, MIL-STD-756, MIL-STD-7E1, MIL-STD-1629, and MIL-HDBK-217. 5.2 Quantitative ~eauirements. Quantitative ~eliability requirements and verification or demonstrate ion requirements should be established appropriate to p~ogram phase.

REQUIREMENT 35 3 May 1991 35-1

MIL-STD-454N REQUIREMENT 36 ACCESSIBILITY 1. Purpose. This requirement establishes criteria for accessibility. 2. Documents aDDliCable to Requirement 36: Definition of Item Levels, Item Exchangeability, Mcdels, and Related Terms Definitions of Terms for Reliability and Maintainability Human Engineering Design Criteria for Military Systems, Equipment and Faci1ities

hfIL-sTD-280 MIL-STD-721 MIL-STD-1472

3. 3.1

Definitions Accessibility. Accessibility is as defined in MIL-STD-721

3.2 Part, subassembly, and assembly. Part, subassembly, and agsembly are as defined in MIL-STD-280. 4. Reauinements

4.1 Access. Each article of equipment and each major subassembly forming a pa~t thereof shall provide for tbe necesRa~y access to its interior parts, terminals, and wiring for adju=tmentm, required circuit checking, and the removal and replacement of maintenance parte. Accessibility for testing and replacement does not apply to parts located in nonrepair.able subassemblies or assemblies. For routine serviaing and maintenance, unsoldering of wires, wire harnesses, parts or subassemblies shall not be required in order to gain accesa to terminala, solde~ed connections, mounting screws and the like. Inspection windows shall be provided whe~e necessany. Sizes of openings, maximum reach requirements, and allowable sizes and weights of replaceable assemblies shall confcrm to limits established in MIL-STD-1472. 4.2 Connections. Connections to parts inside a removable container shall be arranged to permit removal of the container without threading connection leads through the container. 4.3 ~ Parts which are identified as replaceable parts shall not be
uounted hy means or rivets, spot welding, or hard curing compounds. No

unsoldering or soldering of connections shall be necessary when the fnont panel or any subchassis is ~emoved for maintenance purposes. Design shall be such that where plug-in modules or assemblies are used, they can be eaaily inserted in the proper location when correctly oriented without damage to equipment CYIparta being engaged.

REQUIREMENT 36 12 February 1988 36-1

MIL-STD-454N

4.4 Enclosures. Accessibility to chassis, assemblies, or parts contained within cabinets, consoles or other enclomnes shall be provided from outside the basic equipment through the use of access doors, by mounting such items on withdrawal slides, swinging doors, through cable extenders and cable retractors, provisions for circuit card extenders which will allow part on module operation in the open position, or other arrangements to permit adequate access for properly servicing the equipment. Automatic or manual1y operated locks shall be provided to lock the chassis in the servicing position. When withdrawal slides are used they shall be of guided sectional construction with tracks and rolle~s Complete removal and access for servicing of electronic equipment contained within cabinets, consoles or other enclosures shall be pnovided from either the front or near of the equipment. Guide pins or locating pins, or the equivalent, shall be provided fon mechanical alignment during mounting. Shipboard equipment shal1 have complete access for maintenance and servicing from the front of the equipment. 4.5 Bolt-together racks and enclosures. For Navy ship and shore applications, when bolt-together racks are nequired, fastening shall be provided to bolt adjacent racks together at the top with external brackets and through the bottom of the rack to a base or foundation. Bottom mounting shall be accessible fnom the front with minimum disassembly of internal pa~ts or subassemblies. 5. Information for guidance only 5.1 COmDatibillt.V. Equipment should be designed for optimum accessibility compatible with openating, maintenance, electromagnetic compatibility, and enclonu~e ~equirements. 5.2 Parts. If, in order to check or remove a part, it is necessary to displace some other part, the latter part should be so wired and mounted that it can be moved without being disconnected and without causing circuit detuning on instability.

36-2

MIL-STD-454N REQUIREMENT 37 CIRCUIT BREAKERS 1. PurDose. This requirement establishes criteria for tbe selection and application of circuit breakers. 2. Do@umenta armlioable to Requirement 37: Circuit Breakers, Selection and Use of

MIL-STD-149S 3. 4.

Definitions. Not applicable Requirements

4.1 Selection and aDDli@ation. Circuit breakers shall be selected from hfIL-STD-1498. Trip-free circuit breakens shall be used. Nontrip-free circuit breakers shall be used only when the application requires ovemiding of the tripping mechanism for emergency use. 4.2 Manual operation. Circuit breakers shall be capable of being manually operated to the ON and OFF positions. Circuit bneakers shall not be used as ON-OFF switches unless such b~eakers have been specifically designed and tested for that type of service. 4.3 Position identification. Circuit breakers shall have easily identified ON, OFF and TRIPPED positions except that the TRIPPED position may be the same as the OFF position with no differentiation between OFF and TRIPPED being required. 4.4 Orientation. Cin@uit breakens shal1 opemate when pe~manent1y inclined in any direction up to 30 degrees from the normal vertical or normal horizontal position. The trip point of an inclined unit shall not vary mone than + 5 percent of the current specified for nommal position mounting. Circuit breakers used on flight equipment and portable test equipment shall operate within the limits of the detail specification when the equipment is in any position or ~otation about its th~ee principal axes. 5. Information fcr guidance only. Not applicable.

REQUIREMENT 37 20 September 1988 37-1

MIL-STD-454N REQUIREMENT 38 QUARTZ CRYSTALS AND OSCILLATOR UNITS 1. Purpose. This requirement establishes criteria for the selection of quartz crystal units and crystal oscillators. 2. Documents aDDlicable to Requirement 38: 08ci1lators, Crystal Crystal Units, Quartz; and Holders, Crystal

MIL-O-5531O MIL-STD-683 3. 4.

Definitions. Mot applicable. Requirements

4.1 Quartz cr.vstals. Quartz @rystal units shall be selected in accordance with MIL-STD-683. 4.2 Crystal oscillator units. Crystal oscillator units shall conform to MIL-O-S331O. 5. Information fop duidance only. Mot applicable

REQUIREMENT 38 20 September 1988 30-1

MIL-STD-454M REQUIREMENT 39 FUSES AND FUSE HOLDERS 1. Purpose. This requirement establishes criteria for the selection and application Of fUSeS, fuseholders, and associated hardware. 2. Document aDDlicable to Requirement 39: Fuses, Fu8eholders, and Associated Hardware, Selection and Use of

MIL-STD-1360

3. 4.

Definitions. Not applicable. Reauirementa

4.1 Selection and aDnli@ation. Fuses, fuseho~ders, and associated hardware shall be selected fnom MIL-STD-1360. 4.2 Extractor post type fuseholders. The load shal1 be connected to the fuseholder terminal that terminates in the removable cap assembly. 5. Information for guidance only

5.1 Branch circuits. Fusing should be so applied that fuses in branch circuits will open before the fuses in the main circuit. 5.2 Thermal considerations. Fuses are thermally activated devices. In general, time delay fuses are most susceptible to ambient temperature extremes; current limiter.8 the least. 5.3 Load current considerations. Fuse ratings are in temns of RMS, not average, 1ine currents measured using true RMB neading instruments. Direct current lines having a pulRating component should be measuned using a true RMS reading instrument.

REQUIREMIWT 39 20 September 1988 39-1

MIL-STD-454N REQUIREMENT 40 SHUNTS 1. PurDose. This requirement establishes criteria for the selection of external meter shunts. 2. Documents applicable to Requirement 40: MIL-S-61 MIL-I-1361 Shunt, Instmwnent, External, 50 millivolt (Lightweight Type) Instrument Auxiliaries, Electrical Measuring; Shunts, Re8iators, and Transformers

3. Definitions. Not applicable. 4. Requirements. External meter shunts shall aonfomn to MIL-S-61 or MIL-I-1361, as applicable. only. Not applicable. 5. Information for fiuidanoe

REQUIREMENT 40 20 September 19S8 40-1

MIL-STD-454N REQUIREMENT 41 SPRINGS 1. Purpose. This requirement establishes criteria for the design, selection, and application of springs. *2. Documents aDDlicable to Requirement 41: Steel, Stainless and Heat Re8isting, Alloys, Plate, Sheet, and Strip Wire, Copper Alloy Steel, Sheet and Strip (1095) Aircraft Quality Silver and Silver Alloy Spring, Helical, Compression and Extension Copper-Chromium Al10Y Forgings, Wrought Rod, Bar and Strip (Copper Alloy Numbers 182, 184 and 185) Strip, Metal, Carbon Steel, Cold rolled, Hardened and Tempe~ed, Spring Ouality Copper-Beryllium Alloy (Copper Alloy Numbers C17500 and C1751O), strip

QQ-S-766

QQ-W-321 MIL-S-7947 MIL-S-13!282 MIL-S-13572 MIL-C-19311

MIL-S-46049

MIL-C-81021

ASTM A29/A29M- Steel Bars, Carbon and Alloy, Hot Wrought and Cold Finished, General Requirements for 88 ASTM A22Q/ A22SM-83 ASTM A313-8Y Steel Wire, bfu8icSpming Quality

Chromium-Nickel Stainless and Heat Resisting Steel Spring wipe Steel, Strip, High Carbon, Cold Rolled, Spring Quality, General Requirements for Steel, Strip, High Carbon, Cold Rolled

ASTM A682-79

ASTM A6841 A684M-86 ASTM B122-86

Plate, Sheet, Strip and Roller Bar, Copper Nickel Tin Alloy, Copper Nickezinc (Nickel Silver), and Coppen Nickel Alloy

REQUIREMENT 41 30 June 1992 41-1

MIL-STD-454N

ASTM B139/ B139M-90 ASTM B151/ B151-11.89 ASTM B194-8B ASTM B196/ B196M-88 ASTM B197/ B197M-89 ASTM B206-B6A ASTM B206M-87

Bronze, Rod, Bar

Alloy (Nickel Silver) Copper Nickel Zink and Copper Nickel Rod and Bar Copper-Bemyllium Alloy Plate, Sheet, Strip, and Balled Ban Copper-Beryllium Alloy Rod and Bar

Copper-Beryllium Alloy Wire

Copper Nickel Zinc Alloy Wire and Copper Nickel Alloy Wire Copper Nickel Zinc Alloy Wire and Copper Nickel Alloy Wire Metric Gold-Silver-Platinum Electrical Contact Alloy, Specification for

ASTM B522-BO

Metals Handbook, Vol I (1978), American Society for Metals 3. 4. 4.1 Definitions. Not applicable. Requirements Helical sDrinEs. Helical springs shall conform to MIL-S-13572.

4.2 Electrical contact sDring#. Electrical contact springs shall use materials selected from table 41-1. 4.3 Carbon steel springs Carbon steel springs shall be suitably plated or finished to resist corrosion. 5. Information for guidance only

5.1 Corrosion resistinf steel. Corrosion reeiating steel 8pring6 are preferred where electrical conductivity is not a consideration and where they are adequate for the purpose intended. 5.2 Fatii?uelimits. Fatigue limits of the springs 8hould not be advemsely affected by corvosion, ope~ating temperature, and other environmental

41-2

MIL-STD-454N

conditions in service. Fatigue limits should be consistent with the maximum specified operating cycles fan the respective part or equipment or, if such is not specified, with the maximum duty cycle to be expected during the equipment service life. 5.3 Electrical conductivit!f. Electrical conductivity of contact #pninge should not be adversely affected by corrosion, operating temperature and other environmental conditions in service. 5.4 Enclosure. Where practicable, springs should be enclosed in housings or otherwise captivated in order to prevent broken pieces from entering and advereely atfecting the equipment. 5.5 Heat treatment. Springs made of materials that achieve their desired properties by heat treatment, such as copper-beryllium alloys, annealed carbon steels, CRES steels, or heat nesisting alloys, ghould be heat treated to the specified temper after forming. 5.6 Grain orientation. Flexure and forming of springs should be designed to OCCUP perpendicular to the grain of tbe material. Deviation fnom the perpendicular should not exceed 45 degrees. 5.7 Documents for specifying materials. When the materials listed in tables 41-1, 41-11, and 41-111 me used, they Bhould aonform to the specifications listed for each material.

41-3

MIL-STD-454N *TABLE 41-1. Materials for electrical spring application.

Material

Form

fdaterial Specification

Copper-nickel-zinc alloy

Plate, sheet, strip and rolled bar Rod, shapes and flat products with finished edges (flat wire, strip and bar)

ASTM B122

CIQ-C-586 ASTM B122 ASTM B151 ASTM B206 ASTM B196 ASTM B197 ASTM B194 QQ-W-321 MIL-C-81021

Copper-beryl1ium alloy

Bars and rod Wire Strip

Copper al10Y Copper-cobalt-beryllium alloy Oopper-chromium al10Y Phosphor bronze

Wire, spring Strip

Bar, rod, and strip

MIL-C-19311

Bar, rod, plate, sheet, strip, ASTM B139 and flat wire Strip ASTM B522

Platinum-iridiumalloy Silver-copper alloy

Bar, rod, plate, sheet, strip, MIL-S-13282 and wire Metals Handbook, Vol I

?alladium-copper al10Y

41-4

MIL-STD-454

TABLE 41-11. Corrosion resisting steel for sDrings.

Material

Form

Material Specification

7 Steel, CRES

Wire Strip

ASTM A313 QQ-S-766

TABLE 41-111. Carbon steel fan sD~ings.

Material

Form

Material Specification

Steel, high carbon Steel, carbon and al10Y (for springs)

Wire, spring, music Strip, cold rolled untempered spring

ASTM A228 ASTM A6S2 ASTM A684

Steel, carbon and alloy (for springs) Steal, carbon, strip

Bars, round, square and flat Cold rolled, hardened and tempered spring Sheet and strip A-annealed (condition 1) II-hardtemper (condition 3) cold finished

ASTM A29

MIL-S-46049

Steel, carbon (1095)

MIL-S-7947

41-5

MIL-STD-454N REQUIREMENT 42 TUNING DIAL MECHANISMS 1. Purpose. This requirement establishes criteria for the design of tuning dial mechanism. 2. Documents e.DPliCableto Requirement 42: MIL-S-3644 MS33558 Shaft Assembly, Flexible Numerals and Letters, Aircraft Instrument Dial, Standard Form of

3. Definitions. Not applicable. 4. Requirements 4.1 DA The division marking and lettering on tuning dials shall be suitably etched or printed with characters of style MS33558. Dial markings shall be legible at a distance of 0.6 meter fnom any point within a solid angle of 60 degrees defined by a surface of revolution about a line through the center of the dial and perpendicular to the panel. Minimum space between characters shall be one stroke width. The width of the lubber line or pointer tip shall not exceed the width of the graduation marks. Except for digital tuning indicators, for which only one calibration number will be seen, dials shal1 be marked so that at least two ml ibration numbers on each band can be seen at any dial setting. 4.2 Ralance and friction. Weighted tuning knobs shall be counterbalanced. Friction in tuning dial mechanism shall allow smooth and easy adjustment of the operating knob over the enti~e operating range of the mechaninm, but #hall have sufficient resistance or shall incorporate a positive locking device to maintain the setting under all specified service conditions. Friction shall be achieved through dry or elastic resistance nather than by fluid resistance. 4.3 Flexible control shafts. Flexible #haft assemblies conforming to MIL-S-3644 shall be used when a flexible mechanical connection is nequimd between the tuning knob and the tuned device. 5. Information for guidance only 5.1 Tuning ratio. The tuning ratio used should be the optimum which will permit both rapid and precise setting.

REQUIREMENT 42 30 June 1989 42-1

MIL-STD-4541J REQUIREMENT 43 LUBRICANTS 1. PurP0se8. This requirement establishes criteria for the selection and application of lubricants. 2. Documents aDDlicable to ReaUi~@M@nt 43! Lubricating Oil, General Purpose, Preservative (WaterDisplacing, Low-Temperature) Petrolatum, Technical Lubricating Oil , Gear, Multi-Purpose Lubricating Oil, Preservative, Medium Lub~icating Oil, Instrument, Jewel Beaning Lubricating Oil, In8tmment, Aincmaft, Low Volatility Lubricating Oil, Gear, Petroleum Base Lubricating Qrea8e(High-Temperature,Ele@tric Motor, Ball Rollen Bea~ings) MIL-L-17331 MIL-H-17672 MIL-L-23398 Lubricating Oil , Steam Turbine (N0nC0rr08i V@) Hydraulia Fluid, Petroleum, Inhibited Lubricant, Solid Film, Air Cuned, Corrosion Inhibiting, NATO Code Number S-749 Qrease, Airc~aft and In8t~ument, Qear and Actuator Screw Gnea6e, Multi-Purpose, Quiet Service Grease, High Performance, MUlti-PUrp08e (Metric) Lubricant, Cleaner, and Preservative Orease, Aircraft, General Purpose, Wide Temperature Range

VV-L-800

VV-P-236 MIL-L-2105 MIL-L-3150 MIL-L-3918 MIL-L-6085 MIL-L-60S6 MIL-L-15719 and

MIL-G-23827 MIL-Q-24139 DOD-Q-24508 MIL-L-4601O MIL-G-81322

REQUIREMENT 43 15 August 1990 43-1

MIL-STD-454N

MIL-L-8132Q

Lubricant, Solid Film, Extreme Environment, NATO Code Number s-1737 Code of Federal Regulations, Title 29, Chapter XVII, Part 1910

29 CFR 1910

3. 4. 4.1

Definitions. Not applicable. Requirements ~eneral. Lubricants shall aonform to one of the following: MIL-L-6086 MIL-L-15719 MIL-L-17331 MIL-H-17672 MIL-L-233Q8 MIL-Q-23a2r MIL-G-24139 DOD-Q-24508 MIL-L-4601O MIL-G-81322 MIL-L-S1329

VV-L-800 VV-P-236 MIL-L-2105 MIL-L-3150 MIL-L-3918 MIL-L-6085

4.2 4.3 5.

Silicones. Silicone compounds shall not be used as lubricants. QraDhite base lubricants. Qrapbite base lubricants shall not be used. Information
fon

guidance onlv.

5.1 Variety. The number of different lubricants should be held to a minimum. 5.2 Volatility. Low volatility lubricants should be used where practical

5.3 Compatibility. Tbe lubricant Ehould be chemically inert with regard to the materials it contacts. 5.4 Carcin0tien8. Certain chemicals have been identified in tbe occupational Safety and Health Aat (OSHA) as cancer-producing substances (carcinogens) Before using any materials which might contain these chemicals, they should be evaluated in accordance with 29 CFR 1910. Consideration of the toxicity of a substance should be given p~io~ to material selection.

43-2

MIL-STD-454N REQUIREMENT 44 FIBROUS MATERIALS, ORGANIC 1. PurDo8e. This requirement establishes criteria for tbe selection and application of organic fibrous materials. 2. Documents aDDliCabie tO ReqUi~@ment 44: Thread, Cotton Thread, Polyester Thread, Linen Thread, Nylon Cloth, Duck, Cotton: Fire, Water, Weather, and Mildew Resistant Webbing, Textile, Cotton, General Purpose, Natural or in CO1OP8 Cords, Yarns, and Monofilament, Organic Synthetic Fiber Thread and Twine, Mildew Resistant or Water Repellant Treated Webbings, Textile, Woven Nylon Cloth, Laminated, Sateen, Rubberized Webbing, Textile, Woven Nylon, Impregnated Code of Federal Regulations, Title 29, Chapter XVII, Part 1910

V-T-276 V-T-285 V-T-291 V-T-295 CCC-C-428 MIL-W-530 MIL-C-572 MIL-T-3530 MIL-W-4088 MIL-C-9074 MIL-W-27265 29 CFR 1910

3. Definitions. Not applicable. 4. Reauirement8 4.1 Webbin~

4.1.1 Cotton. Cotton webbing shall conform to MIL-W-530, class 4 or 7. Class ishall be used when webbing will come in contact with natural or synthetic rubber or class 4 when prolonged contact with the skin may occur. 4.1.2 NNylon webbing shall conform to MIL-W-4088 or class R of MIL-W-2?265. 4.2 Cotton duck. Cotton duck used fon protective enclosures shall confo~m to type I or type II of CCC-C-428. Medium texture number 4 shall be used for heavy duty service and hard textune number 12 shall be used for services requiring light weight. 4.3 Thread. Thread shall conform to V-T-276, V-T-285, V-T-291, or V-T-295

REQUIREMENT 44 8 May 1991 44-1

MIL-STD-454N

4.3.I Treatment. Cotton and linen thread shall be treated in accordance with MIL-T-3530. Type 1, class 2 mildew inhibiting agent shall be used when thread will come in contact with natural or synthetic ~ubben on type 1, class 1 when prolong contact with the skin may oocur. 4.4 Sateen. Laminated, two-ply rubberized cotton sateen shall conform to MIL-C-QOY4. This sateen shall not be used when prolonged contact with the skin may occur. 4.5 Cords. yarn, and monofilaments. Cords, yarns, and monofilaments shall conform to MIL-C-572. Types PVCA, AR, VCR, and CTA shall not be used where they may be exposed to fungus attack. 5. Information fOIIguidance only 5.1 Shrinkage. Fabric and thread should be preshrunk or allowanae should be made for shrinkage in orde~ to provide fon satisfactory fit of finished items both before and aften they are immersed in water and then dried. 5.2 Carcinogens. Certain chemicals have been identified in the Occupational Safety and Health Act (OSHA) as cancer producing substances (carcinogens) Before using any materials which might contain these chemicals, they should be evaluated in accordance with 29 CFR 1L!1O. Consideration of the toxicity of a substance should be given prior to material selection.

44-2

MIL-STD-454N REQUIREMENT 45 CORONA AND ELECTRICAL BREAKDOWN PREVENTION 1. Puruose. This requirement establishes criteria for the prevention of corona and electrical breakdown. 2. Documents auulicable to Requirement 45: ASTM D149-87 Dielectric Breakdown Voltage and Dielectric Strength of Solid Electrical Insulating Materials at Commercial Power Frequencies Detection and Measurement of Partial Discharge (Corona) Pulses in Evaluation of Insulation Systems

ASTM D1868-81

3.

Definitions

3.1 Corona (air). A luminous discharge due to ionization of the air surrounding a conductor caused by a voltage gradient exceeding a certain critical value, called the partial discharge (corona) inception voltage (CIV). 3.2 Partial discharge (corona) inceution voltage (CIV). The lowest rma voltage at which continuous partial discharges above Some stated magnitude (which may define the limit of permissible background noise) occur as the applied voltage is gradual1y increased. 3.3 Partial discharfie(corona) extinction voltaie (CEV). The highest rms voltage at which partial discharges above some stated magnitude no longer occur a~ the applied voltage i8 gradually decreased from above the inception voltage. 3,4 Breakdown. A disruptive discharge through insulatiori, involving a sudden and large increase in current through the insulation because of oomplete failure under electrostatic stress. Also called punctu~e. 4. Requirements

4.1 Corona cmevention. The CEV shall be at least 150 pencent of the peak circuit voltage, co~nesponding to the maximum specified steady-state rnm supply voltage. This requirement applies: a. When the equipment iE terminated with the cabling or other accessory equipment with which it is intended to be used and

REQUIREMENT 45 15 December 1989 45-1

MIL-STD-454M b.When the equipment is operated under the specified environmental service conditions and c. When the equipment is supplied with the specified power source frequencies and voltages including commonly recurring transients. 4.2 Electrical breakdown Prevention. The equipment shal1 be designed and manufactured with electrical clearance spacing, leakage (creepage) distances, and insulation characteristics adequate to prevent electrical breakdown. This requirement applies under all specified environmental service conditions including service life and using the specified operating voltages (including transients). Liquid dielectnicn, gages other than air, or pressurization to prevent electrical breakdown shall not be used unless approved by the procuring activity. 5. Information for guidance only

5.1 Effects of corona. Corona occurring at the interface of an insulator and a metal can damage or reduce the life of an insulating system. In general, inorganic insulating materials ape more nesistant to the damaging effect= of corona than organic insulating materials. Comona also generates electromagnetic interference and liberates ozone, a toxic, oxidant gas. 5.2 Insulation system. Corona can occur within cavities between an insulating material and a metal surface which are in contact. Therefore, care should be exe~cised to avoid cavities at such interfaces whe~e high voltages am encounte~ed. 5.3 Metal parts. Sharp edges and pointg should be avoided on metal parts which are included in high intensity electric fields. 5.4 Corona testin.e. There are many factors which determine whether or not oorona will occur, including temperature, humidity, ambient pressure, test specimen shape, rate of voltage change and the previoue hiBtory of the applied voltage. Test methods such as ASTM D1868 may be used but the test results lack accuracy and repeatahi1ity and require g~eat care due to the personnel hazards involved. 5.5 Electrical breakdown testinfi. The breakdown voltage of a given insulating material is dependent upon electrode size and shape, insulator thickness, temperature, humidity, rate of voltage application, voltage waveform and voltage frequency. When testing, care must be exercised to assure that the insulating material is evaluated under the actual environmental conditions which apply to the equipment and that the occurrence of corona or localized heating does not mask the true breakdown voltage. A test usable at power frequencies (25 to 800 Hz) is ASTM D149.

45-2

MIL-STD-454N REQUIREMENT 46 MOTORS AND ROTARY POWSR CONVERTERS 1. Purpose. This requirement establishes criteria for the selection and application of motors and rotary power converters. *2. Documents applicable to Requirement 46: Dynamotors, General Specification for Generator, Electric, Direct Current (Naval Shipboard Use) Generator, Alternating Current, 60 Cycle (Naval Shipboard Use) Motor-Generator, Skid Mounted, Type MD-4 Motor, Alternating Current, 400 Cycle, 115/200-Volt System, Aircraft, General Specification for Motors, Direct Current, 28 Volt System, Aincnaft, General Specification for Frequency Converter, Mobile, Type MC-1A Motor, 60 Cycle, Alternating Cur~ent, Fractional Horsepower (Shipboard Use) Moto~s, 60 Hertz, Alternating Current, Integral Horsepower (Shipboard Use) Motors, Direct Current, Integral Horsepower, Naval Shipboard Moton, Direct Current, Fractional Ho~sepowem, (Shipboard u8el Motor-Generators, DC to AC, Shipboard Service Motor-Generator, 60 Hertz AC to 400 He~tz AC, Shipboa~d Service Motor-Generator, 60 Cycle AC to 400 Cycle AC (Voltage and Frequency Regulated) Shipboard Service Blowers, Miniature, for Cooling Electronic Equipment, General Specification for

MIL-D-24 MIL-Q-3111 MIL-G-3124 MIL-M-4820 MIL-M-7969 MIL-M-8609 MIL-F-Q397 MIL-M-17059 MIL-M-17060 MIL-M-17413 MIL-M-17556 MIL-M-19097 MIL-M-19160 MIL-M-19633 MIL-B-23071

3. 4.

Definitions. Not applicable. Requirements

*4.1 Motors - alternating cument. Alternating current motors shall confo~m to MIL-M-7969, MIL-M-17059 or MIL-M-17060, except that any motor used with a miniature blower for cooling electronic equipment shall be in accordance with MIL-B-23071

REQUIREMENT 46 30 June 1992 46-1

MIL-STD-454N

*4.2 Motors - direct current. Direct current motors shall conform to MIL-M-8609, MIL-M-17413 or MIL-M-17556.
q 4.3

Motor-Generators. Motor-generators shall conform to one of the following: MIL-M-4S20 MIL-M-EJ397 MIL-M-19097 kfIL-M-19160 MIL-M-19633

4.4 Generators - alternating current. Alternating current generators shall confomm to MIL-Q-3124. 4.5 Generators - direct current. Direct current generators shall conform to MIL-Q-3111. 4.6 5. Dvnamotors. Dynamotors shall conform to MIL-D-24. Information for guidance only. Not applicable

46-2

MIL-STD-454N REQUIREMENT 47 ENCAPSULATION AND EMBEDMENT (POTTING) 1. Purpose. This requirement establishes criteria for encapsulating and embedding (potting) a part or an assembly of discrete Parts. COnfOr~l coating of printed circuit assemblies is excluded from this requirement. 2..Documents aDDlicable to Requirement 47: MIL-S-8516 MIL-I-16923 MIL-S-23586 MIL-M-24041 MIL-I-S1550 29 CFR 1910 Sealing Compound, Polysulfide Rubber, Electric Connectors and Electric Systems, Chemically Cured Insulating Compound, Electrical, Embedding Sealing Compound, Electrical, Silicone Rubber, Accelerator Required Molding and Potting Compound, Chemically Cured, Polyurethane (Polyether Based) Insulating Compound, Electrical, Embedding, Reversion Resistant Silicone Code of Federal Regulations, Title 29, Chapter XVII, Part 1910

3. Definitions 3.1 Encapsulation. A process for encasing a part or an assembly of discrete parts within a protective material which is generally not over 2.5 mm thick and does not require a mold or container. 3.2 Embedment (D otting) A process for encasing a part or an assembly of discrete parts within a protective material whiah is generally over 2.5 mm thick, varies in thickness, fills the connecting areas within an assembly, and nequi~es a mold or container to confine the material while it is hardening. Potting is an embedding process wbene the protective material bonds to the mold or container so that it becomes integral with tbe item. 4. Requirements. Encapsulation and embedment materials shall be of a nonrever8ion type and shall be #elected from the following specifications: MIL-S-8516, MIL-I-16923, MIL-S-23586, MIL-M-24041, and MIL-I-81550. The materials selected shall be capable of filling all voids and air spaces in and around the items being encased. For Air Force applications, approval for uEe of any material other than t~anspanent silicone in accordance with MIL-I-81S50 shall be requested through the procuring activity from the Wright Research and Development Center, ATTN: MLSE, Wright-Patterson AFB OH 45433-6S23. 5. Information for guidance only

REQUIREMENT 47 15 December 1988 47-1

MIL-STD-454N

5.1 Selection. The following points should be considered when selecting an encapsulation or embedment material: a. Need for precautions due to hazardous characteristics of the material

b. Electrical, mechanical and thermal properties, including tear resistance, resistance to flame, chemicals, moisture, water, humidity, fungus, and temperature extremes c. Color or transparency d. Dissipation factor e. Specific gravity f. Shrinkage g. Heat distortion parameters h. Stresses on parts i. Durometer hardnesa j. Adhesion to substrates (and priming] k. Temperatures of application and curing 1. Repairability m. Dielectric constant n. Volume resiativity o. Reversion resistance, including hydrolytic stability p. Vincosity q. Solvent affects r. Compatibility with parts or assemblies to which applied. 5.2 Application. The encapsulation or embedment of microelectronic modules and equipment modules should be avoided, except whe~e specifically indicated by the requirements of a particular application. In such instances, the module degign should be completely verified fon the particular encapsulation

47-2

MIL-STD-454N

or embedment materials and processes to be employed. Any changes in module design, materials, and processes may require re-evaluation of the modules. In particular, extreme temperature aging and temperature cycling tests should be performed to verify adequacy of the design. Wherever economically feasible, the module to be encapsulated or embedded should be designed as a throw-away unit. 5.3 Carcinogens. Certain chemicals have been identified in the Occupational Safety and Health Act (OSHA) as cancer-producing substances (carcinogens) . Before using any materials which might contain these chemicals, they should be evaluated in accordance with 29 CFR 1910. Consideration of the toxicity of a substance should be given prior to material selection.

47-3

MIL-STD-454N REQUIREMENT 48 GEARS 1. PurDose. This requirement establishes criteria for the selection and application of gears. 2..Documents applicable to Requirement 48: Index American Qear Manufacturers Association (AGMA)

3. Definitions. Not applicable. 4. Requirement. Gears not operating in a lubricant bath shall be made of corrosion resistant materials. Gears operating in a lubricant bath containing a corrosion inhibiting additive may be made of noncorrosion resistant materials. 5. Information for guidance only 5.1 Designation. Gears should be designated, dimensioned, tolerance and inspected in accordance with the applicable AQMA specifications. 5.2 Planetary or epicvclic gearing. Planetary or epicyclic gearing is preferred to worm gearing. 5.3 Nonmetallic ~ears. Nonmetallic geans may be used when they meet load, life, and environmental requirements of the applicable specification.

REQUIRRMRNT 48 10 September 1987 48-1

MIL-STD-454N REQUIREMENT 49 HYDRAULICS 1. PurDose. This requirement establishes criteria for the design and installation of a bydnaulic system when it functions as an integral part of an electronic system. 2.Documents aDDlicable to Requirement 49: MIL-H-5440 MIL-H-8B91 MIL-H-25475 Hydraulic Systems, Aircraft, Types I and II, Design, Installation, and Data Requirements for Hydraulic Systems, Manned Flight Vehicles, Type III, Design, Installation, and Data Requirements for Hydraulic Systems, Missile, Design, Installation, Tests, and Data Requirements, General Requirements for Fluid Power Cylinders, Dimension Identification Code for Fluid Power, Glossary cf Terms for Cylinder Bore and Piston Rod Sizes for Fluid Power Cylinders Electric Resistance Welded Mandrel Drawn Hydraulic Line Tubing Use of Fine-Resistant Fluids fcr Fluid Powen Systems, Practices fon tbe Mounting Flanges and Shafts fon Positive Displacement Fluid Power Pumps and Motors, Dimensions and Identification Code for Mounting Surfaces of Sub-Plate Type Hydraulic Fluid Power Valvee, Dimensions fcr Bore and Rod Size Combinations and Rod End Configurations for Cataloged Square Head Industrial Fluid Power Cylinders Symbols for Marking Electrical Leada and Ports cn Fluid Power Valves Static Pressure Rating Methods of Squa~e Head Fluid Pcwer Cyclinder8 Seamless Low Carbon Steel Hydraulic Line Tubing Hydnaulic Tube Fittings Hydraulic Flanged Tube and Hose Connections, 4 Bolt, Split Flanged Type

ANSI B93.1-1964 ANSI B93.2-1971 ANSI B93.3-1968 ANSI B93.4M-1981 ANSI B93.5-1979 ANSI B93.6-1972

ANSI B93.7-1968 ANSI B93.8-1968

ANSI B93.9M-1969 ANSI B93.10-1969 ANSI B93.llM-1981 ANSI SAE JS14f ANSI SAE J518@

3. Definitions. Not applicable. 4. Reaui~ement8

REQUIREMENT 49 10 September 1987 49-1

MIL-STD-454N

4.1 Aircraft or manned flight vehicles. The design and installation of hydraulic systems for aircraft or manned flight vehicles shall conform to the applicable type and class or system described in MIL-H-544o or MIL-H-88Q1. 4.2 Missiles. The design and installation of hydraulic systems for missiles shall conform to the applicable type and class of system shown in MIL-H-25475. 5. Information for Euidance only. The following documents contain additional information on hydraulic design: AW31 ANSI ANSI ANSI ANSI ANSI ANSI B93.1 B93.2 B93.3 B93.4M B93.5 B93.6 B93.Y ANSI ANSI ANSI ANSI ANSI ANSI B93.8 B93 QM B93.10 B93.llM SAE J514 SAE J51S

49-2

MIL-STD-434!J REQUIREMENT 50 INDICATOR LIGHTS 1. Puruose. This requirement establishes criteria for selection and application of indicator lights and associated items. 2. Documents applicable to Requirement 50: MIL-L-3661 MIL-L-6363 MIL-L-7806 MIL-L-7961 MIL-L-15096 MIL-S-19500 MIL-STD-1472 Lampholders, Indicator Lights, Indicator-Light Housings, and Indicator-Light Lenses, General Specification for Lamps, Incandescent, Aircraft Senvice, General Requirements for Light, Panel, Plastic Plate Lighting Lights, Indicators, Press to Test Lamp, Glow, Qeneral Specification for Semiconductor Devices, General Specification for Human Engineering Design Criteria for Military Systems, Equipment and Facilities

3. Definitions. Not applicable. 4. Requirements 4.1 Lights and accessories. Indicator lights, indicator light housings, lampholders, lenses, and lamps shall be selected in accordance with table 50-1. 4.2 Visual displav and legend lights. Visual display and legend lights shall comply with the requi~ements in hfIL-STD-1472. 4.3 Light emittinE diodes (LEDs) LEDE when used as indicator lights shall conform to the applicable detail specifications of MIL-S-19500. 5. Information for guidance only. Not applicable.

REQUIREMENT 50 1 May 1991 so-1

MIZ-ST13-454N

TABLE SO-I.Indicator Iighte andaesoclated items.

r
I

MXL-L-MXL-L- MIL-L- MXL-L- MIL-L- ML-S$S61 7806 1961 6363 15098 19500 x x

M-L- W-L00111 00116

Indicator lights x

Indicator 1ight housings x

Lamp holders

hvnses

Incandescent lamps, general purpose

F
Ueon larKIa

Incandescent lamps, severe environment

x x x

Fluorement lamps

50-2

MIL-STD-454N REQUIREMENT 51 METERS, ELECTRICAL INDICATING 1. Purpose. This requirement establishes criteria for the selection and application of electrical meters. 2. Document# aDDliCable to Requirement 51: MIL-M-7793 MIL-M-16034 MIL-M-1612S MIL-I-81219 MIL-STD-127Q Meter, Time Totalizing Meter, Electrical Indication (Switahboa~d and Portable Types) Meters, Electrical, Frequency Indicator, Elapsed Tima, Electrochemical Metensr Electrical Indicating, Selection and Use of

3. Definitions. Not applicable. 4. Requirements. Meters shall be selected and applied in accordance with MIL-STD-1279. Meters required other than those listed in MIL-STD-1279 shall confo~m to one of the following epecification8: MIL-M-7793, MIL-M-16034, MIL-M-16125, MIL-I-81219. 5. Information for guidance only. For analog meters, the normal operating value of the quantity to be indicated should be between 1/3 and 3/4 of full scale deflection, whereve~ practicable.

REQUIREMENT 51 20 September 19S8 51-1

MIL-STD-4S4N REQUIREMENT 52 THERMAL DESIGN 1. PurDose. This requirement establishes criteria for thermal design. 2. Documents applicable to Requirement 52: F-F-300 MIL-F-16S52 MIL-B-23071 MIL-HDBK-251 3. Definitions 3.1 Auxiliary heating or cooling. External heating or cooling devices not normally part of the equipment configuration. 3.2 Cold Dlate. A heat transfer surface cooled by forced air or other heat transfer fluid to which heat dissipating parts are mounted. 3.3 Contaminant. Any foreign substance contained in air or other heat transfer fluid which adversely affects cooling performance, such as dust particles, lint, oil, sludge, etc. 3.4 Direct impingement. Passing cooling air over parts without the use of cold plates or heat exchangers. 3.5 Entrained water. Water condensed from the cooling air and carried along with the cooling air. 3.6 External source 6UDDlied cooling air. Forced air supplied fPOM a conditioning source such as an air conditioner OF aircraft environmental control system which is not normally a part of the electronic equipment. 3.7 Forced air cooling. The dissipation of heat to cooling air, including ram air, supplied by a sourae with sufficient p~essure to flow through the unit. 3.8 Heat exchanger. An air-to-air or liquid-to-air finned duct arrangement which is used to transfer dissipated heat from a hot neciraulating fluid to the cooling fluid by conduction through the finned surfaces. Filter, Air Conditioning, Viscous-impingement and Dry Types Cleanable Filter, Air Environmental Control System, Cleanable, Impingement (High Velocity Type) BlowerB, Miniature, for Cooling Electronic Equipment, General Specification for Reliability/De8ign, Themaal Applications

REQUIREMENT 52 30 June 19S9 52-1

MIL-STD-454N

3.9 Natural coolinf. The dissipation of heat to surroundings by conduction, convection, radiation, or any combination thereof without the benefit of extennal cooling deviceg. 3.10 & An element or component used in tbe production of an electronic equipment or subsystem, such as a microcircuit, diode, transistor, capacito~, resistor, relay switch, or tnansfommen. 3.11 Pressure drOD (differentialmessupe). Resistance to flow usually measured as the static pressure difference across the electronic equipment from inlet to coolant outlet. 4. Reauir.ementa 4.1 Forced air cooling. Forced air cooling shall be used only when natural cooling is not adequate. Exhaust and recirculating fans and blowers shall be driven by ac brushless motors or by pnope~ly shielded dc moto~s. Miniature blowers shall conform to MIL-B-!23071. Air filters shall be provided for air intakes for fan and blower cooled unitg when required to protect internal parts. Filters, when used, shall conform to F-F-300 or MIL-F-16552, and shall be removable for cleaning without disassembly of the equipment. All ventilation openings shall be designed and located to comply with electromagnetic interference, undesired radiation and enolosure requirements. Air exhaust shall be directed away from operating personnel. 4.1.1 External source. For equipment designed for use with external sounce supplied cooling air, which may contain entrained water or other contaminants detrimental to the equipment, precautionary measures shall be taken to avoid direct impingement on internal parts and circuitry by channeling or use of heat exchangers. 4.1.2 Aircraft amlicatlon. Equipment that is intended for use in aircraft and requires forced air cooling shall be designed using cold plates or heat exchangers so that none of the cooling air will come into contact with internal parts, circuitry, or connectors. 4.2 Other cooling methods. Prior approval of the procuring activity shall be obtained when heat densities or other design requirements make the uae of air for cooling impractical and altennate methods, such as liquid, evaporative, change of phase material, or heat pipes, are ~equired. 5. Information for Euidance onl!f.The design factors which should be considered in dete~mining the required fan or blower characteristics include #uch factors as amount of heat to be dissipated, the quantity of air to be delivewd at the pressune drop of the enclosed equipment, tbe allowable noise

52-2

MIL-STD-454N

level, the permissible level of heat that may be exhausted into the surrounding environment, and other pertinent factors affecting the cooling requirement of the equipment. Induced drafts and ventilation by means of baffles and internal vents should be used to the greatest practicable extent. When practicable, ventilation and air exhaust openings should not be located in the top of enclosures or in front panels. When it is impractical to avoid direct impingement on internal parts and circuitry by channeling or use of heat exchangers, the waten and contaminants should be removed from the cooling air by suitable water and contaminant removal devices. 5.1 External source. For equipment designed for use with external source supplied cooling air, minimum differential pressure (pressure drOp) Of the cooling air through the equipment heat exchanger or cold plate should be maintained, consistent with adequate cooling. 5.2 DesiEn fuidance. MIL-SDBK-251 may be ueed as a guide for detail information on thermal degign of electronic equipment.

52-3

MIL-STD-454N REQUIREMENT 53 WAVEGUIDES AND RELATED DEVICES 1. Purpose. This requirement establishes criteria for the selection and aPPliOatiOn of waveguides and related devices. 2. Documents &DDliCable to ReCJUiFeIDent 53: MIL-Q-24211 MIL-S-55041 MIL-STD-1327 MIL-STD-1328 MIL-STD-1329 MIL-STD-1352 MIL-STD-1358 MIL-STD-1636 MIL-STD-1637 MIL-STD-1638 MIL-STD-1639 MIL-STD-1640 MIL-STD-2113 MIL-STD-2162 MIL-HDBK-216 MIL-HDBK-660 Gaskets, Waveguide Flange, General Specification for Switches, Waveguide, General Specification for Flanges, Coaxial and Waveguide; and Coupling Assemblies, Selection of Couplers, Directional (Coaxial Line, Waveguide, and Printed circuit), Selection of Switches, RF Coaxial, Selection of Attenuations, Fixed and Variable, Selection of Waveguides, Rectangular, Ridge and Circular, Selection of Adapters, Coaxial tc Waveguide, Selection of Dummy Loads, Electrical, Waveguide, Coaxial, and Stripline, Selection of Waveguide Assemblies, Rigid and Flexible, Selection of Power Dividers, Power Combiners, and Power Divider/ Combiners, Selection of Mixer Stages, Radio Frequency, Selection of Radio Frequency Circulators and Isolators, Selection of Amplifiers, Radio Frequency and Microwave, Solid State, Selection of RF Transmission Lines and Fittings Fabrication of Rigid Waveguide As8embliea (Sweep Bends and Twists)

3. Definitions. Not applicable. 4. Reauirementa. Waveguides and related devices shall be selected in accordance with the standards appearing in table 53-I and shall conform to a specification listed in the table or to a specification imposed by the listed standard. 5. Information for guidance only 5.1 RF transmission lines and fittings. MIL-HDSK-216 should be used as a technical information guide for RF transmission lines and fittings. 5.2 Rigid waveguide assemblies. MIL-HDBK-660 should be used as a guide to the fabrication of rigid waveguide assemblies wbene bends and twists are required to satisfy a particular application.

53-1

REQUIREMENT 53 20 Septemben 19S8

MIL-STD-454N TABLE 53-I. Waveguides and related devices.

Item Description lAda,teFs

Applicable Documnt \Coa.xial toWaveguideI MIL.-STD-U336

CirculatOr# Couplers

SF-SMA andWaveguide Directional Coaaial Ihveguide and Prtd Ckt

MIL-S7D-2113 MIL-3Y0-1328

Coupling .Wemblies

Quick-Disconnect for ML-ND-1327 Subminiature Waveguide Flanges Waveguide, Coaxial andStripIine MIL-S9D-1637

DwqvLoads

Imnges

lWaregideandCoaxial I MIL-STO-1327

Mixer Stageo

SF-DIP, Flatpack, WIand Connector

MIL-S7D1640

MIL-.WD-1E39

EIL-S-55041

I
Waveguide Acsembliea Waveguides

SFCoaxial Flexible andRigid Rigid Rectangular Eigid Circular, Single andDouble Ridge

MIL-STD-1329 MIL-STO-1638 MIL-2TD-1358

53-2

MIL-STD-454N REQUIREMENT 54 MAINTAINABILITY 1. PurDose. This requirement offers guidance as to maintainability requirements which must be considered when preparing contractual documents. IT DOES NOT ESTABLISH REQUIREMENTS, AND MUST NOT BE REFERENCED IN CONTRACTUAL DOCUMENTS. Maintainability program tasks, quantitative requirement, and verification OP demonstration requirements must be directly specified in the contract or the system/equipment specification, as appropriate. 2. Documents applicable to Requirement 54: MIL-STD-470 MIL-STD-471 MIL-STD-721 MIL-HDBK-472 Maintainability Program for Systems and Equipment Maintainability Verificati on/Demonstration/Evaluation Definitions of Temna fon Reliability and Maintainability Maintainability Prediction

3. Definitions. Not applicable. 4. Requirements. Not applicable. 5. Information for guidance onl~ 5.1 Maintainability Droj?ram. Maintainability engineering and accounting tasks aimed at preventing, detecting, and correcting maintainability design deficiencies and providing maintainability related information essential to acquisition, operation, and support management should be included in contract requirements with the objective of establishing and maintaining an efficient maintainability program according to life cycle phase. MIL-STD-470 is the overall program document for the area. Other maintainability documents which may be invoked through MIL-STD-470 or which may be cited di~ectly as a basis for contract msquirements include MIL-STD-471, MIL-STD-721, and MIL-HDBK-472. 5.2 Quantitative requirements. Quantitative maintainability requirements and verification on demonstration requirements should be established as appropriate to program phase.

REQUIREMENT 54 12 February 1988 54-1

MIL-STD-454N REQUIREMENT 55 ENCLOSURES 1. PurDose. This requirement establishes criteria fon the design and construction of enclosures. 2. Documents aDRlicable to Reauir.ement 5S! MIL-C-1Y2 Cases, Bases, Mounting, and Mount8, Vibration (For Use With Electronic Equipment in Aircraft) Mounting Bases, Flexible Plastic Foam MIL-M-81288 Definitions of and Basic Requirements for Enclosures for MIL-STD-10S Electnic and Electronic Equipment EIA RS-31O-C-77 Racks, Panels, and Associated Equipment 3. Definitions 3.1 Enclosures. Enclosures are hcusings such as consoles, cabinets, and cases, which are designed to provide protection and support to mechanism, parts, and assemblies. 4. Requirements 4.1 Cases and mcuntin.dbases for airborne equivment. Materials, bonding, shielding and performance requirements of MIL-C-172 shall apply to all cases. Mounting bases shall conform to MIL-C-lf2or MIL-M-81288, as applicable. 4.2 De@ee of enclosure. Enclosures shall be designed in accordance with MIL-STD-1OS, table I for the degree of enclosu~e best suited to tbe application. Moisture absorbent materials such as open-celled foam shall net be used to fill moisture pockets. 4.3 Materials. Materials used shall be corrcsion and deterioration nesistant or aoated to resist corrosicn and deterioration. 4.4 Racks and panels. The internal clearance and the equipment mounting hcles of racks and panels shall be in accordance with EIA RS-31O-C. 4.5 Test requirements. Enclosures shall be tested as specified in MIL-STD-1OS. 5. Information for guidance cnly

REQUIREMENT 55 10 Septemben 1987 55-1

MIL-STD-454N

5.1 Cases for aerospace ground support equipment. The detailed equipment specification or contract for the particular equipment will specify the type of case to be supplied by the contractor. T~ansit cases and combination type cases may not be required for ship, depot, or field shops wherever the area of use is protected or controlled for human occupancy. 5.2 Desiccants. Where moisture build up in sealed equipment cannot be tolerated, the use of desiccants or dehydrating agents #hould be considered. 5.3 Materials. Materials for the enclosure should be the lightest pra@tical consistent with the strength required for sturdiness, serviceability and .saf ety.

55-2

MIL-STD-454N REQUIREMENT 56 ROTARY SERVO DEVICES 1. PurDose. This requirement establishes criteria for the selection and application of rotary servo devices such as sexwomotor8, Synchros, electrical Penolvere, tachometer generato~s, encodere, and tranaolvers. *2. Documents applicable to Reffuirement 56: MIL-S-22432 MIL-S-22820 MIL-T-22821 MIL-R-50781 MIL-E-81512 MIL-S-81746 MIL-S-81963 MIL-T-83727 MIL-E-85082 MIL-STD-71O MIL-STD-1451 MIL-HDBK-218 MIL-HDBX-225 MIL-HDBK-231 Servomotors, General Specification Servomoton-Tachome ter Genenator AC, General Specification for Tachometer Generator AC, Qeneral Specification for Resolven, Electrical, Linean, GeneraI Specification for Encoder, Shaft Position to Digital, Contact Type, Altitude Repo~ting, Qenenal Specification fop Servtorqs, General Specification for Servo Components, Pnecision Instrument, Rotating, Common Requirements and Tests, General Specification for Transolvens, General Specification for Encoder8, Shaft Angle to Digital, General Specification for Synchros, 60 and 400 Cycle Resolvers, Electrical, Selection of Application of Electrical Resolvers Synchros, Description and Operation Encoder, Shaft Angle to Digital

3. Definitions. Not applicable. 4. Requirements 4.1 Rotary servo devices. Rotary servo devices shall conform to MIL-S-81963 aa applicable. 4.2 Servomotors. Servomotors shall conform to MIL-S-22432.

4.3 Synchro8. Synchros shall be selected and applied in accordance with MIL-STD-71O. 4.4 Electrical resolvers. Electrical resolve~e shall be eelected and applied in accordance with MIL-STD-1451. 4.5 Electrical linear resolvers. Electrical linear resolvers shall conform to MIL-R-50781.

REQUIREMENT 56 30 June 1992 56-1

MIL-STD-454N

4.6 Tachometer j?enerators. Tachometer generators shall conform to MIL-T-22821. 4.7 Tranaolvers. Transolvers shall conform to MIL-T-83727.

4.8 Encoden8. Encoders shall conform to MIL-E-85082 for general application. For altitude reporting applications, encoderB shall conform to MIL-E-a1512. 4.9 Servomotor-tachometer feneratorg. Servomotortachometer generators shall conform to MIL-S-22B20. 4.10 Servtoras. Servtorqs shall conform to MIL-S-81746.

*5. Information for iuidance only. The following documents contain additional information for application: MIL-HDBK-218 MIL-HDBK-225 MIL-HDBX-231 (Resolvers) (Synchros) (Encoders)

56-2

MIL-STD-454N REQUIREMENT 57 RELAYS 1. PurDose. This requirement establishes criteria for the selection and application of relays. 2. Documents aDDliCable to Reauinement 57: Relays, Reed, Dry, General Specification for Relays, Selection and Application

MIL-R-83S16 MIL-STD-1346 3. 4.

Definitions. Not applicable Requirements

4.1 Selection. UnlesE otherwise specified, the order of precedence for relay selection shall be as follows: a. Relays ligted in MIL-STD-1346. Reed relays shall conform to MIL-R-83316 b. DESC selected item drawing relays, subject to procuring activity approval. c. Other relays, subject to procuring activity approval. Sufficient detail must be presented (e.g., contact loads, coil voltages of requested relay vs the standard part) to justify the uge of the nonstandard part. 4.2 Application. Relays shall be applied in accordance with MIL-STD-1346. The use of reed relays in airborne applications requires procuring activity approval. 5. Information for fiuidanceonly. Not applicable.

REQUIREMENT 57 20 September 1988 57-1

MIL-STD-454N REQUIREMENT 58 SWITCHES 1. PurDo8e. This requirement establishes criteria for tbe selection and application of switches and associated hardware. This requirement is not applicable to RF coaxial switches. 2. Documents applicable to Requirement 58: MIL-S-12285 MIL-S-15743 MIL-S-1S396 MIL-S-83731 MIL-STD-1132 Switch, Thermostat@ Switches, Rotary, Enclosed Switches, Meter and Control, Naval Shipboard Switch, Toggle, Unsealed and Sealed Toggle, General Specification for Switche# and Associated Hardware, Selection and Use of

3. Definitions. Mot applicable. 4. Reauirementa 4.1 Selection and application. Switches and associated hardware shall be selected and applied in accordance with MIL-STD-1132. Switches required other than those listed in MIL-STD-1132 shall conform to one of the following specifications: MIL-S-122S5, MIL-S-15743, MIL-S-183Q6, and MIL-S-83731. 5. Information for Euidance only. Not applicable.

REQUIREMENT 5S 20 September 19SS 58-1

MIL-STD-454N REQUIREMENT 59 BRAZING 1. PurDose. This requirement establishes cmiteria for brazing. 2. Document aDDliQable to Requirement 59: MIL-B-7883 Brazing of Steels, Copper, Copper Alloys, Nickel Alloys, Aluminum and Aluminum Alloys

3. Definitions. Not applicable. 4. Requirements. Brazing of steel, copper, copper alloys, nickel alloys, aluminum, and aluminum alloys shall be in accordance with MIL-B-7883. 5. Information for i?uidance only. Electrical connections of stranded or insulated wire or those having construction which may entr,apfluxes should not be brazed.

REQUIREMENT 59 12 Febmuar.y1988 59-1

MIL-STD-454N REQUIREMENT 60 SOCKETS AND ACCESSORIES 1. PuPDOse. This requirement established criteria for tbe selection and application of sockets and accessories for plug-in parts. 2. Documents aDDliCable to Requirement 60: MIL-S-12883 MIL-S-24251 MIL-M-3B527 MIL-S-S3502 MIL-S-83734 Socket and Accessories for Plug-In Electronic Components, General Specification for Shield, Retainer (Bases), and Adapters, Electron Tube, Heat Dissipating, General Specification for Mounting Pads, Electrical-ElectronicComponent, General Specification for Sockets, Plug-In Electronic Components, Round Style, QeneFal Specification for Sockets, Plug-in Electronic Components, Dual-in-line (DIPs) and Single-in-line packages (SIPS), General Specification fop

3. Definitions. Not applicable. 4. Reauinements 4.1 Soaketa. Sockets for plug-in electronic parts shall be of tbe single unit type and shall conform to MIL-S-12883, MIL-S-83502 or MIL-S-83734. The use of sockets for microcircuits nequireg approval of the procuring activity. 4.2 Shields. Heat dissipating tube shields shall confarm to MIL-S-24251

4.3 Mountinfipads. Where mounting pads are required for use with small electrical or electronic devices, they shall conform to MIL-M-38527. 5. Information fop guidance only 5.1 Use of sockets. The use of sockets in mission related and ground support equipment should be kept to a minimum, due to the possibility of intermittent connections during shock, vibration, and temperature cycling 5.2 Shield bases. Shield bases, for use with heat dissipating shields, should be mounted on clean, smooth, metallic mating surfaces, to minimize the contact resistance (themal and electrical) between the base and the supporting chassis.

REQUIREMENT 60 20 September 1988 60-1

MIL-STD-454N REQUIREMENT 61 ELECTROMAGNETIC INTERFERENCE CONTROL 1. PuPDOse. This requirement establishes criteria for electromagnetic interference control. 2. Documents aDQliCable to Reauir.ement 61: Electromagnetic Emission and Susceptibility Requirements for the Control of Electromagnetic Interfe~en@e Electromagnetic Interference Chanacteniatics, Measurement of Radar Engineering Design Requirements, Elect~omagnetic Compatibility Guidance fop the Design and Test of Systems Protected Against the Effects of Electromagnetic Energy National Telecommunications and Information Administration Manual of Regulations and Procedure8 for Radio Frequency Management

MIL-STD-461 MIL-STD-462 MIL-STD-469 MIL-HDBK-253 NTIA Manual

3. 4.

Definitions. Not applicable Heauirements

4.1 General. Electromagnetic interference requirements shall be as specified in MIL-STD-461. *4.2 Radar eauipment. Radar systems and equipment shall also conform to the provisions of section 5.3 of the NTIA Manual as specified in the contmact and to MIL-STD-469 except that MIL-STD-469 shall not be used fon Air Force applications. In the event of conflict, the following descending order of precedence shall prevail! NTIA Manual, MIL-STD-469, MIL-STD-461. 4.3 Tests. Tests and test methods shall be as specified in MIL-STD-462. For other than Air Fence applications, MIL-STD-469 shall also apply fan radar equipment and sy#tema. 5. Information for .4uidance only. MIL-HDBK-253 provides guidance for the design and test of electronic systems which are to be immune to the detrimental effects of electromagnetic energy.

REQUIREfdSNT 61 30 Octoben 1991 6)-1

MIL-STD-454N REQUIREMENT 62 HUMAN ENGINEERING 1. PurDOse. This requirement offers guidance as to human engineering requirements which must be considered when preparing contractual documents. IT DOES NOT ESTABLISH REQUIREMENTS, AND MUST NOT BE REFERENCED IN CONTRACTUAL DOCUMRNTS. Human engineering requirements and related test and evaluation requirements must be directly specified in the contract or the system/equipment specification, as appropriate. 2. Documents amlicable to Requirement 62: MIL-H-46855 MIL-STD-14Y2 Humsn Engineering Requirements for Military Systems, Equipment and Facilities Human Engineering Design Criteria fon Military Systems, Equipment and Facilities

3. Definitions. Not applicable. 4. Requirements. Not applicable. 5. Information for guidance only. Human engineering applied during development and acquisition of military eyatems, equipment, and facilities serves to achieve the effective integration of personnel into the design of the system. The objective of a humsn engineering effort is to develop or improve the crew/equipment/software interfaae and to achieve required effectiveness of humsn performance during system operation, maintenance and control and to make economical demands upon personnel re=ouvcen, skills, training, and coBts. MIL-H-46855 is the overall requirements document for the area. It must be tailored when applied: application guidance is offered in the document. MIL-STD-1472 provides design criteria which msy be selectively applied as requirements or guidance.

REQUIREMENT 62 12 February 198S 62-1

MIL-STD-454N

REQUIREMENT 63 SPECIAL TOOLS

1. Purpose. This requirement establishes criteria for the selection and application of special tools. 2. 3. documents aDDlicable to Requirement 63. Definitions. Not applicable

3.1 Special tools. Tools, including jigs, fixtures, stands, and templates, not listed in the Federal Supply Catalog. 4. Requirements.

4.1 APDPOUal. The use of any special tool shall be subject to the approval of the procuring activity. 4.2 Furnishing and stowint. Special tools needed for operation and organization level maintenance shall be furnished by tbe contmacton and 8hall be mounted securely in each equipment in a convenient and accessible place, or in a centnal accessible location for an equipment array requiring such tools. 5. Information for j?uidance only. The design of equipment should be such that the need for special tools for tuning, adjustment, maintenance, replacement, and installation is kept to a minimum. Only when the required function cannot be provided by an existing standand tool should special tools be considered. Necessary tools should be identified as eanly as possible.

REQUIREMENT 63 10 September 1987 63-1

MIL-STD-454N REQUIREMENT 64 MICROELECTRONIC DEVICES 1. PurDose. This requirement establishes criteria for the selection and application Of microelectronic devices. These criteria are based on the objectives of achieving technological superiority, quality, reliability, and maintainability in military systems. 2.Documents aDDiiCable to Requirement 64: MIL-M-3851O MIL-H-38534 MIL-I-38535 Microcircuits, General Specification for Hybrid Microcircuits, General Specification for Integrated Circuits (Microcircuits)Manufacturing, General Specification for MIL-STD-785 Reliability Program for Systems and Equipment Development and Production Test Methods and Procedures for Microelectronics MIL-STD-883 MIL-STD-975 NASA Standard Electrical, Electronic and Electromechanical Parts List MIL-STD-1547 Parts, Materials and Processes for Space and Launch Vehicles, Technical Requirements for MIL-STD-1562 Lists of Standamd Microcircuits MIL-STD-1686 Electrostatic Discharge Control Program for Protection of Electrical and Electronic Parts, Assemblies and Equipment (Excluding Electrically Initiated Explosive Devices) MIL-BUL-103 List of Standardized Military Drawings (SfdDs) Reliability Prediction of Electronic Equipment MIL-HDBK-217 ANSI/IEEE 1076-1987 VfISICHa~dware Description Language (VHDL) VHSIC Interoperability Standards. Includes specifications for the TM-bus, ETM bus, Pi bus, and VHSIC Electrical Specification. (Copies available from Naval Research Laboratory, Code 530S, Washington, DC 20375-5000). Tester Independent Support Software System (TISSS) Specifications (Copies available from TISSS Program Office, RL/ERD, Griffiss Air Fence Base, NY 13441-5700). 3. Definitions 3.1 Microelectronic devices. Monolithic, hybrid, rf and microwave (hybrid/integrated)circuits, multichip microcircuits, and microcircuit modules. 3.2 Verv hiEh 8Deed integ~ated circuits (VHSIC). A technology development program (1980-1989) for the design and manufacture Of high speed digital integrated circuits with 1.25 and 0.5 micrometer feature sizes for military

REQUIREMENT 64 30 October 1991 64-1

MIL-STD-454N

applications. Many VHSICS incorporate Built-In-Test and later VHSICS will incorporate interoperability features. Table 64-II describes VHSIC characteristics. 3.3 Microwave/millimeter wave monolithic intej?rated circuits (MIMIC). Program to establish the capabilities to design, develop, manufacture and test analog microwave/ millimeter wave integrated cimcuits for use in military systems. 3.4 Advanced microcircuit technolog.v. Microcircuit fabrication and design technology which is newly available for prototype designs and will be available for production in the near future (2-5 years). VHSIC and MIMIC are examples. For digital microcircuits, the performance capability can be approximately characterized by the minimum feature size, the clocking frequency, and the functional throughput rate. (See S.1) 3.5 VHSIC hardware description lanfuage (VHDL). A high level computer language developed under the VHSIC program for describing the signal structure of elect~onic hardware (chips, modules, and sub#ystema). The language describes the signal flow and the structure of the device in terww of the basic circuit models, fundamental logic blocks, and higher level functional assemblies of logic blocks. 3.6 Qualified Device (Microcircuit). Any device or microcircuit which bas met the requirements of MIL-M-3551O, MIL-H-38543, or MIL-I-38535 and is listed on the associated QPL/QML listings. 3.7 Waveform and Vector Exchange Specification (WAVES). A high level computer language developed under the VHSIC and Advanced Tactical Fighten (ATF) prog~ama for describing test vector and wavefOm Stimuli fOr elect~Onic hardware (chips, modules, and subsystems) The WAVES is compatible with the VHDL simulation language and simulation environments. 3.8 Application SDecific Intefirated Circuit (ASIC). Any microcircuit that is custom designed or any programmable microcircuit (e.g. EPROM, EEPROM, UVEPROM, PLA, PLD, gate array, sea of gates, standard cell library, etc.) that is programmed or personalized to perfo~m a specific equipment or austom function. 4. Requirements 4.1 Selection

4.1.1 Technoloj?v. At each stage in new and re-engineered system designs, i.e., concept studies, demonstration and validation, and full scale

64-2

MIL-STD-454N

development, the advanced microcircuit technologies which meet reliability, performance, and cost requirements of the application shall be evaluated for use in the production phase. 4.1.2 Reliability. Microelectronic devices in military systemc in full scale development and production shall, as a minimum, conform to the applicable pnoduct assurance level of MIL-M-3851o, MIL-H-38s34, or MIL-I-38535. 4.1.3 Order of precedence. Unless otherwise specified, the order of precedence shall be as follows: a. Microcircuits listed in table I of MIL-STD-1562.

b. Other MIL-M-3851O, MIL-H-38534, OF MIL-I-38535 microcircuits not listed in tables III, IV and V of MIL-STD-1562. c. Other microcircuits listed in table II of MIL-STD-1562 as preferred for new design, Eubject to pnocuring activity approval. d. A@tive Standa~dized Military Drawing (SMD) or DESC drawing microcircuit not listed in tables III, IV and V of MIL-STD-1562, subject to procuring activity approval. e. Other microcircuits (see 4.1.5), subject to procuring activity approval

4.1.4 Qualified devices. When the contract or purchase order for new design, redesign, or part level upgrade of military ha~dware specifie= tbe use of MIL-STD-883 class B or S microcircuits, and there is a qualified device of tbe required generic chip and package type or case outline, the qualified class device shall be the only device authorized in that design. 4.1.4.1 Suace Applications. When qualified devices are not available or cannot be qualified by tbe manufacturer, the requirements of MIL-STD-875 or MIL-STD-1547 shall apply. 4.1.4.2 Other ADPliCati0n8. When a qualified device does not exist and a SMD device of the nequired generic chip and package type or case outline does exist, the SMD device shall be the preferred device authorized for that design. 4.1.5 Other miaroci~cuits. For other than qualified devices, the following information #hall be inaluded in the nonstandard part approval request (except where identification of a military detail specification, or SMD number satisfies this requirement or other dinection iE given):

64-3

MIL-STD-454N

a. Device nomenclature, marking, configuration, functional requirements, parameters and limits sufficient to insure the required form, functions and interchangeability. b. Required environmental, endurance (life) and other design capability tests. c. Quality assurance requirements, including screening and lot quality conformance (acceptance) tests. As a minimum, devices shall be procured to all the requi~ements of MIL-STD-883 paragraph 1.2.1. Rybnid or integrated microcircuits shall be procured to the requirements of MIL-H-38534 or MIL-I-38535. The applicable detail specification, SMD or vendor/contractor document shall be specified for electrical performance, mechanical, and final electrical test requirements. d. An evaluation of the projected availability and product assurance status for the time of production and through the projected life of the system. e. Device design and test documentation in the VSDL and WAVES format (see 4.5.3 and 4.5.4). 4.1.6 Electrostatic sensitive uarts. Microcircuits are susceptible to electrostatic discharge (ESD) damage. Microcircuit susceptibility is claazitied in MIL-STD-1686 and Test Method 30i5 of MIL-STD-883. When device susceptibility is not available, it can be determined using Test Method 3015 or Appendix B of MIL-STD-1686. Microcircuits from the ESDS Class necessary to meet system ESD requirements shall be selected. ESD susceptibility of microcircuits are listed in the associated QPL/QML listings of MIL-M-3851O for JAN devices and MIL-H-38534 or MIL-I-38535 for the individual device. 4.2 Programmable devices. Use of programmable devices, regardless of type, requires approval of the procuring activity. 4.3 Fu8ible link devices. When fusible link devices (PROMS, PALs, PLDs, eta) are programmed by the user, parametric and functional electrical tests in accordance with MIL-STD-883, Method 5005, (+roupA, Subgroups 7 and 9 as a minimum, shall be performed aften programming to verify the specific program configuration and effectiveness of link fusing. This testing shall be done on a 100Z basis when performing board or 8ubsystem/system simulations. 4.4 PackaEes. Microcircuit device= used in equipment shall be hermetically sealed in glass, metal or ceramic (or combinations of thege) packages. No organic or polymeric materials such as lacquers, varnishes, coatings, adheeives, or greages shall be used inside the microcircuit package, unless otherwise specified. No det!iccants shall be contained in the microcircuit package, unless otherwise specified.

64-4

MIL-STD-454N

4.5 Device design and test documentation 4.5.1 ASIC documentation in VHDL. Digital Application-Specific Integrated Circuits (ASICS) designed after 30 Septemben 1988 shall be documented by means of structural and behavioral VHSIC Hardware Description Language (VHDL) descriptions in accordance with IEEE 1076. (See paragraph 5.7)Behavioral VHDL descriptions shall include function and timing at the ports accurate enough to enable the performance of test generation and determination of fault detection/fault isolation levels at the integrated circuits pins when performing board OP subsystem simulations. 4.5.2 Fault coveraee. For all digital microcircuits developed or modified after 31 December 1991, fault coverage shall be documented in accordance with MIL-STD-S83 Test Method 5012 for all manufactu~ing-level logic tests. 4.5.3 Qualified Device Documentation in VHDL. Digital qualified devices for use in board level designs after 31 December 1991 shall be documented by means of behavioral VHDL descriptions in accordance with ANSI/IEEE 1076. (See paragraph 5.7) Behavioral VHDL descriptions shall include function and timing at the port accurate enough to perform test generation and determine fault detection/fault isolation levels at the integrated circuit pins. 4.5.4 ASIC test stimuli documentation in WAVES. Digital ASICS designed after 31 December 1991 shall have all test vectors and test waveforms documented and delivered to the Government in tbe WAVES format. 4.6 Cost considerations. Microelectronic devices =hall be selected on tbe basis of overall life cyale cost. 5. Information for guidance only 5.1 Technology prog~ession. The u6e of advanced micno@ircuit technology should be considered and evaluated in the design of all #ystema/equipment. For critical weapon systems applications, and fo~ system development schedules projected to be longer than four yea~a,tbe performance advantage provided by advanced technologies, such as VHSIC and MIMIC, should be evaluated early in the system development phasea fan use in the procu~ement stage. 5.1.1 P~ojected availability. The pvojected availability of advanced digital (VHSIC) technologies for use in progressive stages of system development isprovided in table 64-I to aid in performing this evaluation.

64-5

MIL-STD-454N TABLE 64-I. Digital technology pv0gPe88i0n prediction. Year Concept I D&V II FSD III P&D

1987 1988 1989 1990 1991 1992 1993 1994

.5 - 1.0 .5 .5 .4 .4 .3 .25 .25 .8 .7 .6 .5 .4 .3 .3

1.0 - 1,25 .8 - 1.0 .7 - 1.0 .5 .5 .4 .3 .8 .6 .6 .5 .4

1.0 - 1.25 1.0 - 1.25 .8 - 1.0 .6 - 1.0 .6 .5 .4 .8 .7 .6 .5

1.25 - 1.5 1.0 - 1.25 1.0 - 1.25 .8 - 1.0 .7 .6 .5 .8 .7 .6

D&V:

Demonstration and Validation

FSD: Full Scale Development P&D: Production and Deployment

I, II, III! System Development Milestones 5.1.2 Performance characteristics. The numbers in table 64-I represent the minimum feature size which generally characterizes the performance and characteristics of digital technology. (See table 64-II.) 5.2 Reliability DPediCtiOn. When requined, microcircuit reliability predictions should be prepared in accordance with MIL-HDBK-217. 5.2.1 Reliability prediction. When required. microcircuit reliability predictions should be prepared in accordance with MIL-HDBK 217. 5 .2.2 Reliability assurance. A plan should be in place to assure that microelectronic devices meet the reliability requirement of paragraph 4.1.2 at the time of full scale development. This plan should p~ovide fo~ resubmission of parts list, if so invoked by aontract, thnough DESC/MPCAG priorito procurement of parts to be used in actual prcductio~ to assure that all evaluations are based on the most recent standardization status.

64-6

MIL-STD-454N

5.3 Microcircuit obsolescence. Due to rapid technology advances, many military and commercial microcircuits listed in specifications and catalogs are either obsolete or are nearing obsolescence. The use of these devices will affect the mission objectives of the using equipment. For Navy equipment current information on microcircuits that may be nearing obsolescence may be obtained from the Naval Avionics Center, Code 435, Indianapolis, Indiana 46219-2189, telephone (317) 3S3-3767. 5.4 Use of non-hermetic microcircuits. Upon specific request and approval by the procuring activity to waive the requirements of 4.1, non-hermetic microcircuits may be considered for use in ground fixed (GF) or ground benign (GB) environments as defined in MIL-HDBK-217. They should meet all the requirements of the equipment specification, temperature and humidity should be completely controlled in t~ansit, storage, and application. Provisions should be made for logistic availability. TABLE 64-II. Performance characteristics - digital microelectronics.

Characteristic Min feature size

Units micrometers 1.25 0.5

Temperature range

degrees Celsius

-55 to 125

-55 to 125

Min clock frequency

MHz

25

100 on chip

FTR

gate Hz/sq cm

5 exp 11

1 exp 13

Testability BIT fault coverage stuck at stuck open (CMOS) Test bus Interoperabi 1ity *IAW VHSIC Interoperability Standard 64-1

98% of detectable faults

98% of detectable faults

95

95 75

ETM or TM* yes

ETM or TM* yea

MIL-STD-454N

5.5 Testability. New and upgraded systems should exploit chip level built-in-test features to enhance the testability and operational availability of the module or system. When advanced digital modules or boards are developed, microcircuits incorporating the VHSIC ETM-BUS on VHSIC TM-BUS should be used. (See VHSIC Intenoperability Standards.) 5.6 Life cycle cost evaluation. The following factons should be considered in esti~ting life cycle costs associated with selection ot microcircuit devices or technologies! a) effect of built-in-test on repain, maintainability, operational availability, and reconfigurability; and b) value of VHDL descriptions of chips, modules, and boards in resupply, multiple source development, and design upgrade. 5.7 ASIC Documentation Reference. Data Item Description, DI-EGDS-80811, provides the documentation preparation and delivery instructions for ASIC

64-S

MIL-STD-454N REQUIREMENT 65 CABLE, COAXIAL (RF) 1. PurDose. This requirement establishes criteria for the #election and application of coaxial radio frequency (rf) cable. 2. Documents applicable to Requirement 65! MIL-C-17 MIL-L-38Q0 MIL-C-22931 MIL-C-23S06 MIL-HDBX-216 Cable, Radio Frequency, Flexible and Semirigid, General Specification for Lines, Radio Frequency Transmission (Coaxial, Air Dielectric) Cable, Radio Frequency, Semirigid, Coaxial, Semi-Air Dielectric, General Specification for Cable, Radio Frequency, Coaxial, Semirigid, Foam Dielectric, General Specification fon RF Transmission Lines and Fittings

3. Definitions. Mot applicable. 4. Requirements 4.1 Cable selection. Selection of coaxial cable shall be in accordance with MIL-C-1?, MIL-L-3S90, MIL-C-22931 or MIL-C-23S06. Other types of cable may be used provided they are selected from specifications acceptable for the specific application and approved by the procuring activity. *4.2 ADDlication restriction. Cablea with polyvinyl chloride insulation shall not be used in aerospace applications. Use of these cables in any other application requires prior approval by the proauring activity. 5. Information for guidance only 5.1 ADDli Cati OII Euidance. MIL-HDBK-216 may be used as a technioal information guide to applications of transmission lines and fittings. 5.2 Critical circuits. FOIIuse above 400 MHz and in cnitical nf circuits, elements such as environmental requirements, short leads, and grounding should be considered in design application, along with critical electrical characteristics such ag attenuation, capacitance, and structural return 10ss

REQUIREMENT 65 15 December 19S9 65-1

MIL-STD-454N REQUIREMENT 1313 CABLE, MULTICONDUCTOR 1. Puruose. This requirement establishes criteria for selection and application Of eledtpicd multiconductor cable for use within electronic equipment. *2. Documents aDDliCable to Requirement 66: QQ-W-343 MIL-C-1Y MIL-C-442 MIL-C-3432 MIL-W-50B6 MIL-W-5845 MIL-W-5846 MIL-W-590B MIL-C-7078 MIL-w-e777 MIL-C-13777 MIL-W-16878 MIL-C-19547 MIL-W-22759 MIL-C-23437 MIL-C-24640 MIL-C-24643 MIL-W-25038 MIL-C-27072 MIL-C-2Y500 MIL-C-49035 MIL-C-55021 Wire, Electrical, Copper (Uninsulated) Cables, Radio Frequency, Flexible and Semirigid, General Specification for Cable (Wire), Two Conductor, Parallel Cable (Powen and Special Punpose) and Wire, Electrical (300 and 600 Volts) Wire, Electric, Polyvinyl Chloride Insulated, Copper or Copper Alloy Wire, Electrical, Iron and Constantan, Thermocouple Wire, Electrical, Chromel and/or Alumel, Thermocouple Wire, Electrical, Copper and Constantan, Thermocouple Cable, Electric, Aerospace Vehicle, General Specification for Wire, Electrical, Silicone-Insulated,Copper, 600 Volt,
200C

Cable, Special Purpose, Electrical: General Specification for Wire, Electrical, Insulated, General Spe@ifiaation for Cable, Electrical, Special Purpose, Shore Use Wire, Electric, FluoPopolymer-In8 ulated, Copper or copper Alloy Cable, Electrical, Shielded Pairs Cable, Electrical, Lightweight, for Shipboard Use, Qeneral Specification for Cable and Cond, Electrical, Low Smoke, for Shipboard Use, ffeneralSpecification for Wire, Electrical, High Temperature and Fire Resistant, Aircraft Cable, Special Pu~pose, Electrical, Multiconductor Cable, Electrical, Shielded and Unshielded, Aerospace Cable, Power, Electrical (Flexible, Flat, Unshielded] (Round Conductor), General Specification for Cable, Twisted Pairs and Triples, Internal Hookup, General Specification for

REQUIREMENT 66 30 June 1992 66-1

MIL-STD-454N

MIL-W-81044

MIL-W-81381 ASTM A580-90 ASTM B33-74

Wire, Electric, Crosslinked Polyalkene, Crosalinked Alkane-imide Polymer, or Polyarylene Insulated, Copper or CoPPen Alloy Wire, Electric, Polyamide-Insulated, Copper OF Copper A11oY Wire, Steel, Stainless and Heat Resisting Tinned Soft or Annealed Copper Wire for Electrical Punposes

3. Definitions. Not applicable. 4. Reauirement8 4.1 Selection and application. Selection and application of multiconductor cable shall be in accordance with table 66-I. 4.2 Solid or stranded. Either solid on stranded conductors may be used (within the restrictions of the particular wire or cable specification) except that (a) with the exception of thermocouple and flat cable wire, only stranded wire shall be used in aerospace applications, and (b) for other applications stranded wire shall be used when so indiaated by the equipment application. Specifically, with the exception of flat multiconductor flexible cable, stranded wire shall be used for wires and cables which are normally flexed in use and serviaing of the equipment, such as cables attached to the movable half of detachable connectors. 4.3 Application reStriCti0n6

4.3.1 Cable containing MIL-W-1687S wire shall not be used for Air Force or Navy aerospace applications. 4.3.2 Cables with polyvinyl chloride insulation shall not be used in aerogpace applications. Use of these cables in any other application requires prior approval of the proauring activity. 4.3.3 MIL-W-22759 wire with only single polytetrafluoroethylene insulation used in Air Force space and missile applications shall require the approval of the procuring activity. 4.3.4 Silver plated copper wire shall not be used in applications invalving Army missile systems. 5. Information for Euidance only. Not applicable.

66-2

141L-slD-454N

. ----

.. .

66-4

MIL-STD-454N

1 :

II

. . .. - j...

66-5

MIL-STD-454N

c,

-.1

ml

66-6

MIL-STD-454N REQUIREMENT 67 MARKINQ 1. Purpose. This requirement established criteria for external and intermal markings on equipment, assemblies and component parts. Marking for safety, shipping and handling is not within the scope of this requirement. 2. Documents applicable to Requirement 67: L-S-300 MIL-M-13231 MIL-P-15024 MIL-N-18307 Sheeting and Tape, Refletting, Nonexposed Lens, Adhesive Sacking Marking of Electronic Items Plate, Tags and Sands for Identification of Equipment Nomenclature and Identification for Electronic, Aeronautical and Aeronautical Support Equipment, Including Ground Support Equipment Servo-Components Precision Instrument, Rotating, Common Requirements and Tests, General Specification for Abbreviations for Use on Drawings, Specifications, Standards and in Technical Documents. Identification Marking of U.S. Military Property Joint Photographic Type Designation System Marking of Connections for Electrical Assemblies Joint Electronics Type Designation System Definitions of Item Levels, Item Exchangeability, Models, and Related Terms Aircrew Station Signals Legends for Use in Airc~ew StationE and on Airborne Equipment Bar Code Symbology Standard Marking of Electrical and Electronic Parts Electrical and Electronic Parts and Equipments, Reference Designations for

MIL-S-81963 MIL-STD-12 MIL-STD-130 MIL-STD-155 MIL-STD-195 MIL-STD-196 MIL-STD-280 MIL-STD-411 MIL-STD-7B3 MIL-STD-1189 MIL-STD-1285 IEEE 200-1975

3. Definitions. Not applicable. 4. Reauiremente 4.1 Patent information. At the manufacturers option, patent information may be included on equipmant, subject to the following restrictions: a. The identification plate may contain patent information when approved by the procuring activity. b. The location of and method used to mark patent information shall not conflict with any specified equipment requirements, such as ma~king, enclosure integrity, control and indicator locations, etc.

67-1

REQUIREMENT 67 20 September 19SS

MIL-STD-454N

c. Patent information shall not be located on or in equipment having a security classification of confidential or higher, with the exception that patented items used in security classified equipment, when marked, shall be marked in such a manner that patent information will be visible only when the item is removed or di8a8sembled fo~ repair or replacement. 4.2 SymboioQ 4.2.1 Reference desi~nations. Except for external connectors and cables, reference designations shall be employed to identify the location of each item for its particular circuit application. The identification and marking of reference designators for parts and equipment shall be in accordance with IEEE 200.On subminiatunized assemblies, such as printed or etched boards or other forms of assembly where space is at a premium, the reference designations need not be mmked. In lieu thereof, reference designation marking shall be shown by means of pictorial diagrama, line drawings, photograph , or other media to provide for circuit identification (by means of reference designations) in the appropriate handbooks fon the equipment. It shall not be mandatory to mark the reference designations of parts in nonrepairable subassemblies. Connectors may be further identified on that side of the panel to which the mating connector attaches, by a name denoting the function of tbe cable attached thereto. External cables shall be assigned reference designations W1 , W2, etc, in accordance with IEEE 200. The numerical portions of the reference designations shall be consecutive, where practicable. 4.2.2 Abbreviations and legends. Abbreviations and legends shall confonm to MIL-STD-12, MIL-STD-411, or MIL-STD-783, as applicable. 4.3 Marking methods. Equipment, parta and assemblies shall be permanently marked or identified. Permanency and legibility shall be as required in MIL-STD-130. 4.3.1 Direct marking. Markings may be applied dinectly to a part or an assembly by die or rubber stamping, etching, eng~aving, molding, casting, forging, decalcomania transfer, stenciling, on silk sareening. 4.3.2 Plates. Information and identification plates shall conform to and shall be marked in accordance with MIL-P-15024. 4.3.2.1 Identification (ID) Dlates. The ID plate shall be fastened in such a manner as to remain firmly affixed throughout the normal life expectancy of the item to which it is attached. Type G, adhesive-backed metal, ID plates shall be used on hermetically sealed items, magnesium cases, or othar items where mounting of a plate by mechanical fasteners is impractical.

67-2

MIL-STD-454N

4.3.2.2 ID plate location. Plates shall be located so that they are not obscured by other parts. 4.3.3 Markinficables, cords and wires. The following methods shall be used to mark cables, co~ds and wires: a. Molded on the cable or cord. b. Stamped on the cable, cord or wire. c. Bands in accordance with MIL-P-15024, securely attached or captivated. d. Adhesive tag or tape that wi11 withstand the applicable environmental requirements. 4.4 Bar codes. Bar codes shall conform to MIL-STD-1189.

4.5 Type designated items. Each item which is type designated in accordance with MIL-STD-196 or MIL-STD-135 shall contain an identification marking in accordance with MIL-N-1B307 for Navy and AiP Force on MIL-M-13231 for Army. These items are systems (electrical-electronic) , sets, groups, and some units and assemblies, as defined in MIL-STD-280. 4.6 Fuse holders. The current rating of fuses shall be marked adjacent to the fuse holder. In addition, SPARE- shall be marked adjacent to each spare fuse holder. 4.7 Connections. Marking adjacent to plugs, jacks and other electrical connectors shall identify the connected circuits to preclude cross connections. The connections to electrical pants such aa motors, generators and transformer shall be marked in accordance with MIL-STD-195. 4.8 Servo-component connection and mankings. Servo-component marking and connection identification shall conform to MIL-S-81963. 4.9 Controls and indicating devices. Ma~kings shall be provided on the front of each exterior and interior panel and panel doo~, also on control mounting surfaces of each chassis, subpanel, etc, to clearly (though necessarily briefly) designate the functions and operations of all controls, fuses, and indicating devices mounted thereon, protruding through, or available through access holes therein. All markings shall be located on the panel on chaasis in correot relationship to the ~egpective designated items. 4.10 Sockets. The chassis shall be marked to identify both sockets and parts, modules or assemblies to be plugged into the sockets. The side of the chassis upon which items are plugged into sockets shall be marked, adjacent

67-3

MIL-STD-454N

to each socket, with the reference designation for the item. The reverse side of the chassis shall be marked, adjacent to each socket, with the reference designation used in the circuit diagram and table of parts to identify the socket itself If space does not permit marking of reference designations for sockets and parts, modules, or assemblies mounted in sockets, a location diagram shall be placed where it is visible when viewing the chassis, and shall display the mmkings described herein. 4.11 Cables, cords and wires. All cables, cords and wires which require disconnection to remove units for senvicing and maintenance shall be uniquely identified. 4.12 Printed wiring boards. Markings on printed wiring boa~da shall not interfere with electrical opemation. When ink is used, it shall be non-conductive. Markings shall be considered when leakage (creepage] distances are determined. 4.13 Replaceable parts and assemblies. Replaceable parts and assemblies shall be marked for identification in accordance with MIL-STD-1285 or MIL-STD-130, as applicable. 4.14 Programmable itenw Equipments which are software programmable shall indicate the identifying number and revision of the software program which has been loaded into memory. The preferred method is to pmovide either a local or a ~emote display which ig under the control of the software program. HoWaver, when the uae of a display is not practical, the equipment enclosune shall be marked with the information as follows: 4.14.1 Preproduction and production equipment shal1 be marked with the identifying number and revision of the software program. The identifying number shal1 be preceded by the words software program 4.14.2 Development equipment shall be marked in a manner similar to preproduction and production equipment, except that means shall be provided to easily change the revision letter by the use of a matte surface for hand marking or by using selfadhesive labels. The u8e of the revision letter or number and a patch letter or number is permissible. 4.14.3 The marking requirement doea not apply when changes to the software program are accomplished by making a hardware change (for example, when the software program resides in fusible link devices such as PRObfa) In such caEea, the marking requirements applicable to a handwane change shall apply. 5. Information for j?uidan@e only 5.1 RefIective msnke~s. Where reflective msrkers are required reflective polyester tape in accordance with L-S-300 may be used.

67-4

MIL-STD-454!4 REQUIREMENT 68 READOUTS AND DISPLAYS 1. Purpose. This requirement establishes criteria for the selection of neadouts and displays. *2.Documents applicable to Requirement 68: MIL-D-28803 Display, Optoelectronic, Readouts, Segmented, General Specification for Displays, Diode, Light Emitting, Solid State, General Specification for

MIL-D-87157

3. Definitions. Readouts and displays are devices which are designed pnimar. ily to convert electrical information into alphanumeric on symbolic presentations. These devices may contain integrated circuitry to function as decode~s or drivers. 4. Requirements *4.1 Optoelectronic t!me readouts. Incandescent type readouts shall conform to MIL-D-28803. 4.2 Lifihtemittinfi diode displays. Visible light emitting diode displays shall conform to MIL-D-87157, quality level A or B. 5. Information for .@idance only. Not applicable.

REQUIREMENT 68 30 June 1992 68-1

MIL-STD-454N REQUIREMENT 69 INTERNAL WIRING PRACTICES 1. Purpose. This requirement establishes criteria for internal wiring practices. 2. Documents armlicable to Requirement 69: MIL-T-152 MIL-V-173 MIL-I-631 MIL-T-713 MIL-I-3158 MIL-I-3190 MIL-T-7926 MIL-I-22076 MIL-I-23053 MIL-S-23190 MIL-T-43435 MIL-STD-108 MIL-STD-1130 Treatment, Moisture and Fungus Resistant, of Communications, Electronic and Associated Electrical Equipment Varnish, Moisture-And-Fungus Resistant (For Treatment of Communications, Electronic, and Associated Equipment) Insulation, Electrical, Synthetic-Resin Composition, Non-Rigid Twine, Fibrous: Impregnated, Lacing and Tying Insulation Tape, Electrical Qlass-Fiber (Resin Filled); and Cord, Fibrous-Glass Insulation Sleeving, Electrical, Flexible, Coated, General Specification for Terminals, Lug: Splices, Conductors: Crimp Style, Copper, General Specification for Insulation Tubing, Electrical, Non-Rigid, Vinyl, Very Low Temperature Grade Insulation Sleeving, Electrical, Heat Shrinkable, General Specification for Straps, Clamps, and Mounting Hardware, Plastic and Metal for Cable Harness Tying and Support Tape, Lacing and Tying Definition of and Basic Requirements for Enclosure for Electric and Electronic Equipment Connations, Electrical, Solderless, Wrapped

3. Definitions. Not applicable. 4. Requirements 4.1 Clearance and leakage (c~eemge) di=tancen. Clearance between solder connections or bare conductorB, such as on terminal stnipg, stand offs on Bimilan connections, shall be such that no accidental contact can occur between adjacent connections when subjected to service conditions specified in the equipment specification. For electrical clearance and leakage dintancea, see table 69-1. 4.2 ThrouEh hole protection. Whenever wires are run through holes in metal partitions, shields, and the like, less than 3 mm in thickness, the holes REQUIREMENT 69 16 February 1989 69-1

MIL-STD-454N

shall be equipped with suitable mechanical protection (grommet) of insulation. Panels 3 mm or more in thickness either shall have grommets or shall have the hole edges rounded to a minimum radius of 1.5 mm:

TABLE 69-I. Electrical clearance and leakaEe (creepafie) distances. Voltage ao (rnw) or dc To 150 Clearance (mm) 1.5 3 6 Leakage Distances (mm) Enclosure I Enclosure II 1.5 3 9.5 1.5 6 19

Condition A B c

150-300

A B c

1.5 3 6

1.5 3 12.5

1.5 6 19

300-600

A B c

1.5 3 6

3 6 12.5

3 6 19

600-1000

A B c

3 6 12.5

9.5 19 38

12.5 25 50

Condition A. For use where the effect of a short circuit is limited to the unit, and where normal operating power does not exceed 50 watts. Condition B. For use where short circuit protection in the form of fuses, circuit breakers, etc, is provided, and where normal operating power does not exceed 2000 watts. Condition C. For use where short circuit protection in the form of fuses, circuit breakers, etc, is provided, and where normal operating power exceeds 2.000wattE.

69-2

MIL-STD-454N Enclosure 1. Enclosure I is an equipment enclosure which has no openings, or in which the openings are so constructed that drops of liquid or solid particles striking the enclosure at any angle frOm O_ tO 15_ frOm the downward ventical cannot enter the enclosure either directly on by striking and running along a horizontal or inwardly inclined surface. (*Drip-proof enclosure for other than motors, generators, and similar machines of MIL-STD-108 meets the description). Enclosure II Enclosure II is any equipment enclosure which affords less protection than enclosure 1. 4.3 Wiring arrangement. Wiring shall be arranged to permit bundling by one or more of the following methods or permanently mounted in cable ducts. 4.3.1 Lacing. Twine shall be in accordance with Type P of MIL-T-713. Tape shall conform to MIL-T-43435. Cordage shall be in accordance with Type SR-4.5 of MIL-I-3158. 4.3.2 Binding. Tape for binding shall be as specified in MIL-T-43435. 4 .3.3 Sleevintiinsulation. Sleeving insulation shall conform to MIL-I-631, MIL-I-3190, MIL-I-22076, or MIL-I-23053. 4.3.4 WrauDinE and tvinf. Plastic devices for wrapping and tying of wipes shall conform to MIL-S-23190. 4.4 Solderless wraurmd wipe connections. Soldenless wrapped wire connections shall be in accordance with MIL-STD-1130. Procuring activity approval is required for Navy ai~borne and Army missile applications. 4.5 claIIIDed connections. In no case shall electrical oonnectiona depend upon wi~en, lug=, terminals, and the like, clamped between a metallic member and an insulating metenial of other than a ceramic on vitric nature. Such connections shall be clamped between metal members, preferably, such as an assembly of two nuts , two washer= and a machine screw. 4.6 Connectors, insulation sleeving. Unpotted connectors furnished as integrml wired in parts of artioles of equipment shall have a piece of insulating tubing placed over each wire in the connector. The tubing shall be long enough to cover the contact and at least 12.5 mm of insulation of the wire attached to it; but in no case shall the length of the tubing exceed 50 mm. The minimum length of 12.5 mm may be reduced to 4.5 mm where restricted volume does not permit longer tubing (such as in miniaturized electronic subassemblies) . The tubing shall fit tightly over the contact or be tied 8ecunely enough so that it will not slide off. If bare wine is used, the tubing shall be long enough to extend at least 6 mm beyond the contact, metal

69-3

MIL-STD-434N

shell or clamp, whichever projects the farthest. This paragraph does not apply to connectors with body insulated crimp-on contacts, to insulation displacement connectors or mae8 soldered flat cable connectors, nor does it aPPIY to wire wrapped connectors in accordance with MIL-sTD-1130. 5. Information for Euidance only 5.1 Wiring arrangement. All wiring should be arranged in a neat and workmanlike manner. The use of preformed cableg and wiring harness is preferred to the point-to-point method of wiring. Wires should be bundled and routed to minimize electrical coupling. Unless suitably protected, wire or cable attached to sensitive circuit= should not be placed adjacent to a disturbing circuit. 5.2 Internal wirinfi.Stranded wire is preferred: however, solid wire may be used in the equipment, provided such wire is so insulated or held in place that it does not fail or show excessive motion likely to result in failure when the equipment is subjected to vibration and #hock encountered under the specified Eervice conditions. An uninterrupted wire is preferable to a junction. The following descending order of preference exists when junctions are used, and the choice of the listed junctions should be determined by consideration of reliability factors, maintenance factors, and manufacturing procedural: a. Permanent splices. b. Bolted connections c. Connectors. 5.3 WirinE Protection. The wiring should be secured and protected against chafing due to vibration or movement (such as slide out racks or drawers) For securing of wiring, polyamide clamps or wrapping and tying devices with integral mounting facilities or adhesive bonding are preferred. Metal clamps, if used, 8hould be cushioned. Individual conductors thus secured should lie essentially parallel. 5.4 Cable ducts. Where cable ducts are employed, provisions Ehould he made for the removal of any wire that !OEYbecome faulty. For example, covers may be employed at intervals to aid in the removal of a faulty wire. 5.5 Bend radius. The bend radius of polyethylene cable should not be less than five times the @able diameter.to avoid establishing a pemanent set in the cable

69-4

MIL-STD-454N

5.6 Sleevinfi. Flexible plastic sleeving, either nonflammable, self extinguishing, or flame retardant, should be used on cables subject to flexing, such as panel door cables. The sleeving should be secured under cable clamps at each end, and the cable should be formed and secured so that the cable will not be subject to abrasion in its normal flexing motion. In cases where abrasion cannot be avoided, additional protection should be provided 5.7 Panel door cables. Wiring to parts on a hinged door should be in a single cable if possible, arranged to flex without being damaged when the door is opened and closed. 5.8 Slack. Wires and cable should be as short as practicable, except that sufficient slack should be provided to: a. Prevent undue stress on cable fores, wires and connections, including connections to resiliently supported parts, b. Enable parts to be removed and replaced during servicing without disconnecting other parts, c. Facilitate field repair of broken or cut wires, d. Permit units in drawers and slide out racks to be pulled out to the limit of the slide or support travel without breaking connections Units which are difficult to connect when mounted, should be capable of movement to a more convenient position for connecting and disconnecting cables. When drawers on racks are fully extended and rotated, if rotatable, the @able bend radius should not be less than three times the cable assembly diameter. when flat molded cable assemblies am used, the bend radius should not be less than ten times the cable assembly thickness, e. Permit replacement of the connected part at least twice. Exceptions to this provision are cases where rf leads must be as short as possible for electrical reaaons, when fixed path rotating iH apecified, on the amount of slack is limited by space available, f. Ensure freedom of motion of lugs or terminals normally intended to have come degree of movement. 5.9 SuDDor. t. Wire and cable should be properly supported and secured to p~event undue st~eng on the conductors and terminals and undue change in position of the wire or cable duning and after subjection of the equipment to specified 8ervice conditions, or after service or nepai~ of the equipment in

69-5

MIL-STD-454N

a normal manner. When shielding on wire or cable is unprotected by an outer insulation, adequate support is necessary to prevent the shielding from coming in contact with exposed terminals or conductors. Twine or tape should not be used fom securing wire and cable. 5.10 Cable and harness design. Cables and separable harnesses should be of the two-connector type. The two connectors should be of the same number of contacts and all contacts should be wired point-to-point (i.e., pin 1 to pin 1, pin A to pin A, or pin 1 to pin A and up in sequence) A minimum number of conneator types and contact configurations within a type should be used consistent with non-crosmating requirements and circuit and spare considerations. 5.11 Solderiess crimp connections. Solderless crimp connections should meet the following requirements: a. Insulated, solderless lugs are pneferred and should conform to MIL-T-7928. b. Where thermal or other considerations prevent the use of insulated lugs, non-insulated solderless lugs conforming to MIL-T-7Q28 should be used, provided they are covered with an insulating sleeve. 5.12 Fungus Protection. Prior to attachment of terminals to prepared lengths of cables which contain matenials that will support fungus, the ends should be pnotected against entrance of moisture and fungus by treatment with a fungicidal varnish conforming to MIL-V-173 in accordance with MIL-T-152.

69-6

MIL-STD-454N REOUIREMENT 70 ELECTRICAL FILTERS 1. Purpose. This requirement establishes criteria for the selection and application 0+ electrical filters. 2. Document applicable to Requirement 70: MIL-STD-1395 Filters and Networks, Selection and Use o+

3. Definitions. Not applicable. 4. Requirements. Electrical filters shall be selected and applied in accordance with MIL-STD-1395. 5. Information for quidance only. Not applicable.

REQUIREMENT 70 20 September 1988 70-1

MIL-STD-454N REQUIREMENT 71 CABLE AND WIRE, INTERCONNECTION 1. PurDose. This requirement establishes criteria for the selection and application of electric cable and wire used for interconnection between units. *2. Documents applicable to Requirement 71: QQ-W-343 MIL-C-17 MIL-W-76 MIL-C-442 MIL-C-3432 MIL-W-5086 MIL-W-5845 MIL-W-5846 MIL-W-5908 MIL-C-7O78 kfIL-W-8i7/ MIL-C-13777 MIL-W-16878 MIL-W-19150 MIL-C-1Q547 MIL-W-22759 MIL-C-23437 MIL-C-24640 MIL-C-24643 MIL-W-25038 MIL-C-27072 MIL-C-27500 MIL-C-55021 MIL-W-81044 Wire, Electrical, Copper (Uninsulated) Cables, Radio Frequency, Flexible and Semi-rigid, General Specification for Wire and Cable, Hookup, Electrical, Insulated Cable, Two Conductor, Parallel Cable (Power and Special Purpose) and Wire, Electrical (300 and 600 Volts) Wire, Electric, Polyvinyl Chloride Insulated, Copper or Copper Al10Y Wire, Electrical, Iron and Constantan, Thermocouple Wire, Electrical, Ch~omel and Alumel, Thermocouple Wine, Electniaal, Copper and Constantan, Thermocouple Cable, Electric, Ae~ospa@e Vehicle, General Specification
for

Wire, Electrical, Silicone-Insulated, Copper, 600 Volt, 200C Cable, Special Purpose,-Ele@tnical: QenePal Specification fOP Wire, Electrical, Insulated, General Specification for Wine, Insulated, Hard Drawn Coppem Cable, Electrical, Special Purpose, Shore Use Wire, Electnic, Fluoropolymer-In8 ulated, Copper or Copper Alloy Cable, Electrical, Shielded Pairs Cable, Electrical, Lightweight, for Shipboard Use, General Specification for Cable and Cord, Electrical, Low Smoke, for Shipboard Use, General Specification for Wire, Electrical, High Temperature and Fire Resistant, QenePal SpecifIcation for Cable, Special Purpose, Electrical, Multiconductor Cable, Electrical, Shielded and Unshielded, Aerospace Cables, Twisted Pairs and Triples, Internal Hookup, GenePal Specification fop Wire, Electric, Cmosslinked Polyalkene, Crosslinked Alkane-imide Polyme~, or Polyarylene Insulated, Coppen OP Copper Alloy REQUIREMENT 71 30 June 1992 71-1

MIL-STD-454N

MIL-W-81381 MS25471 MS2711O ASTM A580-90 ASTM B33-74 3. Definition

Wire, Electric, Polyamide-Insulated, Copper or Copper A11oY Wire, Electrical, Silicone Insulated, Copper, 600 Volt, 200C, Polyester Jacket Wire, Electrical, Silicone Insulated, Copper, 600 Volt, 200C, FEP Jacket Wire, Steel, Stainless and Heat Resistant Tinned Soft or Annealed Copper Wine for Electrical Purposes

3.1 Interconnecting wire. Insulated, single-conductor wire used to carry electric current between units. 3.2 Interconnecting cable. Two or more insulated conductors contained in a common covering on one or more insulated conductors with a gnoss metallic shield outer conducto~ used to carry electrical current between units. 4. Reauiremente 4.1 Wire selection. Selection of wire for interconnection between units shall be in accordance with table 71-1. 4.2 Multiconductor cable selection. Selection of multiconductor cable for interconnection between units shall be in accordance with table 71-11. 4.3
ADpli Cati OII r.2StPi Cti011S

4.3.1 MIL-W-76 shall be used for Army application only (see 4.3.3) 4.3.2 MIL-W-16878 Eball not be used for Air Force or Navy aerospace applications. 4.3.3 Cable or wire with polyvinyl chloride insulation shall not be used in aerospace applications. Use of these wires on cables in any othen application requires prior approval of the procu~ing activity. 4.3.4 MIL-W-22759 wire with only single polytetrafluoroethylene insulation used in Air Force space and missile applications #hall require the approval of the procuring activity. 4.3.5 Use of aluminum wire requireg specific approval by the procuring activity. 4.3.6 Silver plated copper wine shall not be used in applications involving Army missile systems.

71-2

MIL-STD-454N

5. Information for fiuidance only 3.1 Pulsed or rf signals. All interconnecting cables carrying pulsed or rf #ignals should be coaxial cables or waveguides and should be terminated, when possible, in the charactenistia impedance of the t~anamitting media.

71-3

MIL-STB454N

71-4

MIL-STD-454N

71-5

MIlA71D-454N

71-6

71-7

MIL-STtF454N ~.

.1

>1

71-8

MIL-STD-454N

A_LL

NIL-STD-454N

71-10

71-11

iVIL-SJD--454N

J-lL__li
71-12

MIL-STD-454N REQUIREMENT 72 SUBSTITUTABILITY 1. Purpose. This requirement establishes criteria for the selection and application of substitute parts. 2. Documents armiicable to Requirement 72! MIL-STD-4S0 MIL-sTD-9a3 COnfiguPati On COntFOl - Engineering Changee, Deviation6 and Waivers Substitution List for Micnocincuits

3. Definitions. Not applicable. 4. Requirements

4.2 Commercial Darts. When the equipment design specifies a commercial part, a military specification part may be substituted when the form, fit and functional characteristics of the military part ame equal to on better than thoge of the specified commercial part under equivalent environmental conditions. Applicable microcircuits are listed in MIL-STD-9B3. Other substitutions are subject to applicable configu~ation cont~ol procedures of MIL-STD-480. 4.3 Unavailable Darts. When the equipment design specifies a part that is unavailable, a substitute part which meets the form, fit and functional characteristics of the specified pa~t may be substituted after approval is obtained from the applicable procuring activity. Applicable microcircuits are listed in MIL-STD-983 Other substitutions are subject to the applicable configuration control pnocedunes of MIL-STD-480. 4.4 Initial aualifi@ation/reliability demonstration. Substitute parts with quality/reliability characteristics superior to those specified in the parts list shall not be used in equipment to be subjected to initial qualification or demonstration tests. 5. Information for guidance onlv. Not applicable.

REQUIREMENT 72 16 December 1989 72-1

MIL-STD-454N REQUIREMENT 73 STANDARD ELECTRONIC MODULES 1. Purnose. This requirement establishes criteria for the selection and application of standard electronic modules (sEM). *2. Documents apDli@able MIL-M-2a787 MIL-STD-1378 MIL-STD-1389 MIL-KDBK-246 to Requirement 73!

Modules, Standand Elect~oni@, General Specification for Requirements for Employing Standard Electronic Modules Design Requirements for Standard Electronic Modules Program Managers Guide for the Standard Electronic Modules Program

3. Definitions. Not applicable. 4. Requirements. Requirements for the design and application of standard electronic modules shall be in accordance with MIL-STD-1389 and MIL-STD-1378. Standard electronic modules shal1 be in accordance with MIL-M-28787 *5. Information for guidance onlv. Guidance for program and acquisition managers as to the applicability of SEME for specific system/equipment acquisitions is provided in MIL-SDBK-246.

REQUIREMENT 73 30 June 1992 73-1

MIL-STD-454N REQUIREMENT 74 GROUNDING, BONDING, AND SHIELDING 1. Purpose. This requirement establishes grounding, bonding, and ehielding interface criteria for installation of electronic equipment. 2. Documents applicable to Requirement 74! Bonding, Electrical, and Lightning Protection, for Aerospace Systems MIL-STD-18S-124 Grounding, Bonding, and Shielding for Common Long Haul/Tactical Communication Systems Including (hound Based Communications-ElectronicsFacilities and Equipments MIL-STD-131O Shipboard Bonding, Grounding, and Other Techniques for Electromagnetic Compatibility and Safety Shielding MIL-STD-1542 Electromagnetic Compatibility (EMC) and flrounding Requirements for Space System Facilities MIL-STD-1S57 Grounding, Bonding, and Shielding Design Pmactiaes MIL-HDBK-419 Ground, Bonding, and Shielding for Electronic Equipments and Facilities MIL-B-5087 3. Definitions. Not applicable. 4. Requirements. Grounding, bonding, and shielding provisions shall be inco~porated into equipment design, as necessary, to enable installation of equipment into the applicable platform or faaility. The g~ounding, bonding, and shielding installation and interface requirements are specified in the following documents: Aerospace ground support facilities Aircraft and space vehicles Ground telecommunicationsC-E equipment Shipboard equipment Ground space systems facilities Other Army ground equipment MIL-B-5087 MIL-B-5087 MIL-STD-18S-124 MIL-STD-131O MIL-STD-1542 MIL-STD-1S57

5. Infonmation for fuidance only. Extensive guidance for grounding, bonding and shielding may be found in MIL-HDBK-419.

REQUIREMENT 74 15 December 19S9 74-1

MIL-STD-454N REQUIREMENT 75 ELECTROSTATIC DISCHARGE CONTROL 1. Purpose. This requirement offers guidance regarding the handling and control of electronic parts and assemblies that are susceptible to damage or degradation from electrostatic discharge. IT DOES NOT ESTABLISH REQUIREMENTS AND MUST NOT BE REFERENCED IN CONTRACTUAL DOCUMSNTS. Requirements for the este.blishment and implementation of an electrostatic discharge (ESD) control program in accordance with MIL-STD-16S6 must be dinectly specified in the contract or equipment specification. 2.Documents aDDlicable to Requirement 75: MIL-M-3S51O MIL-STD-SS3 MIL-STD-16S6 Microcircuits, General Specification fon Test Methods and Procedures for Microelectronics Electrostatic Discharge Control Prog~am fop P~otection of Electrical and Electronic Parts, Assemblies, and Equipment (excluding electrically initiated explosive devices) Electrostatic Di#charge Control Handbook for Protection of Electrical and Electronic Parts, Assemblies, and Equipment (excluding electrically initiated explosive devices)

DOD-HDBX-263

3. Definitions. Definitions of applicable terminology may be found in MIL-M-3S51O, MIL-STD-8S3, MIL-STD-16S6, and DOD-HDBK-263. 4. Requirements. Not applicable. 5. Information for Euidance onlv 5.1 ESD control program. MIL-STD-16S6 establishes the ~equirements for the establishment, implementation, and monitoring of an ESD control program, including identification of electrostatic discharge sensitive (ESDS) items, classification of ESD sensitivity levels, control program elements, extent of program element applicability to each acquisition, protective meaau~en to be employed in equipment design, handling, storage, and packaging of ESDS items, protected wonk a~eas, personnel t~aining, ESD audits and program reviews, and tailoring Appendix A of MIL-STD-16S6 establishes the cnite~ia and procedure ton classifying ESDS parts by tegt. Appendix B of MIL-STD-1686 identifies and claseif ies ESDS items DOD-HDBK-263 provides guidelines for the establishment and implementation of an ESD control program in accordance with MIL-STD-16S6. 5..2General guidelines for an ESD control p~ofram. Any program designed for the prevention of ESD damage to ESDS parts and assemblies should be based on the following considerations!

REQUIREMENT 75 12 February 19SS 75-1

MIL-STD-454N

a. Identification of ESDS parts and assemblies and determination of sensitivity b. Minimization of static charge generation c. Reduction of stored charges (grounding) d. Isolation of ESDS parts (Faraday shielding and line transient protection) e. Proper handling, storage, and transportation of ESDS paintsand assemblies f. Personnel training and certification g. Protected work areas.

75-2

MIL-STD-454N REQUIREMENT 76 FIBER OPTICS 1. PuPPose. This requirement establishes the criteria for the selection, application and testin8 Of fiber Optic ~terial. devices and acces#Orie#. 2. Documents aDDlicable to Requirement 76: MIL-STD-18B-111 Subsystem Design and Engineering Standards for Common Long Haul and Tactical Fiber Optics Communications Product Assurance Program Requirements for Electronic and Fiber Optic Parts Specifications Fiber Optic Test Methods and Instrumentation Interface Designs and Dimensions for Fiber Optic Interconnection Devices Fiber Optic Symbols Insert Arrangements for MIL-C-28876(Navy) Environment Resisting Fiber Optic Connectors Crimping Tool, Terminal, Hand Detector, PIN, Fiber Optic (Metric) Coupler, Passive, Fiber Optic, Qeneral Specification fop (Met~i@) Sourses, LED, Fiber Optic (Metric) Splice, Fiber Optic Cable, General Specification for (Metric) Harness Assemblies, Cable, Pressure Proof, Fiber

MIL-STD-7Q0

DOD-STD-1678 DOD-STD-1863

DOD-STD-1864 MIL-STD-2163

MIL-c-22520/lo DOD-D-24620 MIL-C-24621

DOD-S-24622 MIL-S-241323

MIL-H-24626 optic MIL-P-24627

Penetrators, Bulkhead, Connectonized, Fiber Optic (for Inboard Use on Navy Ships and Subma~ines) Penetratora, Hull, Connectorized, Connecto~a, Pressure Proof, Fiber Optic, Submarine

MIL-P-24628

REQUIREMENT 76 30 October 1991 76-1

MIL-STD-454N

MIL-S-24725

Switches, Fiber Optic, Shipboard, Electrical Nonlatching, Bypass, Multimode Cable, Standalone (Metric) Attenuators, Fiber Optic, Shipboard, General Specification for Rotary Joints, Fiber Optic, Shipboard (Metric), Qeneral Specification for Interconnection Box, Fiber Optic, Metric, General Specification fon Multiplexer, Demultiplexers, Multiplexer , Demultiplexers (Muldems) , Frequency Division, Fiber Optic, Interfaceable, Shipboard (Metric), General Specification for Light Sources, Rigid and Flexible, Fiberscope, Fiber Optic (Metric) , General Specification for Controllers, Interface Unit, Fiber Optic (Metric), GenePal Specification for Fiberscope, Fiber Optic (Metric), General Specification for Transmitters, Light Signal, Analog, Fiben Optic (Metric), General Specification for Multiplexer , Demultiplexers, Multiplexer, Demultiplexers (Muldeme) , Time Division, Fibe~ Optic, Interfaceable, Shipboard (Metric), General Specification fop Receivers, Light Signal, Analog, Fiber Optic, Shipboard (Metric), Qeneral Specification for Connectors, Fiber Optic, Environment Resisting (for Navy Shipboard Applications) Termini, Fiber Optic Connector, Removable Fiber, Optical, General Specification for

MIL-A-24726

MIL-R-24i2i

MIL-I-24728

MIL-M-24731

MIL-L-24732

MIL-C-24733

MIL-F-24Y34

MIL-T-24735

MIL-M-24736

MIL-R-24737

MIL-C-28876

MIL-T-29504 MIL-F-49291

76-2

MIL-STD-454N MIL-C-49292 Cable Assembly, Nonpressurized, General Specification for Installing and Bemoval Tools , Electrical Contact, General Specification for Connectors, Fiber Optic, Single Terminus, Qeneral Specification for To018, Fiber Optic, General Specification for Microscope, Optical, fcr Field Inspection of Optical Fibers Kit, Portable Optical Microscope, Militarized, 200X Magnification for Field Inspection of Optical Fibers Connector, Fiber Optic, Circular, Environment Resisting, Hermaphroditic, Qenenal Specification fop Connectors, Fiber Optic Maintenance Kit, Fiber Optic Components, General Specification for Cable, Fiber Optic, Environment Resisting (fon Navy Shipboard Application), General Specification for Fiber Optic Checkout Procedure fon Military Applications System Design Guide for Applying Fiber Optic Technology to Shipboard Systems Fiber Optic Cable Installation Procedures Design Handbook fon Fiber Optic Communications

MIL-I-81969

MIL-C-83522

MIL-T-83523 MIL-M-83524

MIL-K-83525

MIL-C-83526

MIL-C-83532 MIL-M-83S33

DoD-c-a504!l

MIL-HDBK-277

MIL-HDBK-278

MIL-HDBK-282 MIL-HDBK-415 systems IEC-693-80 IEEE-STD-812-S4

Optical Fibers, Dimensions of IEEE Standard Definitions of Terms Relating to Fiber optics

3.

Definitions.

3.1 Definitions of terminology used in fiber optics technology shall be as contained in IEEE-STD-812.

76-3.

MIL-STD-454N

4.

Requirements

4.1 SymboloEv. Graphic symbols for fiber optic parts for uae on engineering drawings, specifications, etc. shall be as contained in DOD-STD-1864. 4.2 Dimensions. Dimensions for optical fibers shall be as specified in IEC-693-80 and MIL-F-49291. 4.3 Interface deeitinsand dimensions. Standard interface designs, dimenniorm and termination types for use in fiber optic connecto~e and coupler8 shall be a8 specified in DOD-STD-1863. 4.4 Sy8ten and subsystem desicn. Fiber optic system and subsystem designs shall be in accordance with the criteria specified in MIL-STD-188-111 (see 5.1 also) 4.5 Test procedures. Standardized test procedures for fiber optic components shall be as 8pecified in DOD-STD-16Y8. 4.6 Light sources.

4.6.1 Light emittin.e diodes (LEDs). Fiber optic LED sources shall conform to the requirements of DOD-S-24622. 4.6.2 FiberscoDe liiht sources. Fiber optic light sources for nigid and flexibie fiberscopes shall conform to the requirements of MIL-L-24Y32. 4.7 splices. MIL-S-24623. Fiber optic splices shall confo~m to the nequinements of

4.8 Cables. Fiber optic cable8 shall conform to the requirements of DOD-C-85045. 4.9 Cable assemblies. Cable assemblies shall conform to the requirements of MIL-C-49292 4.10 Harness assemblies. Fiber optic harness assemblies shall conform to the requirements of MIL-H-24626. 4.11 Connectors. Fiber optic connectors shall conform to the requirements of MIL-C-288Y6 , MIL-C-83522, MIL-C-83526 OXIMIL-C-83532. Insert arrangements for MIL-C-28876 connectors shall conform to MIL-STD-2163. Removable terminale for fiber optic connectors 8hall conform to MIL-T-2Q504. 4.12 Penetr.atOPs. Fiber optic penetrators (hull on bulkhead) shall conform to the requirements of MIL-P-24627 or MIL-P-24628.

76-4

MIL-STD-454N 4.13 Detectors. Fiber optic detectors shall conform to the requirements of DOD-D-24620. 4.14 cOuDlers. MIL-C-24621. Fiber optic couplers shall conform to the requirements of

4.15 Rotary joints. Fiber optic rotary joints shall conform to the ~equivemente of MIL-R-24727. 4.16 Interconnection boxee. Fiber optic inte~connection boxes shall conform to the requi~ement6 of MIL-I-24728. 4.17 MultiDlexens and demultiDlexers. 4.17.1 Freauenov division. Fiber optic frequency division multiplexer and demultiplexers shall conform to the ~equirements of MIL-M-24731 4 .17.2 Time division. Fiber optic time division multiplexer and demultiplexers shall conform to the requirements of MIL-M-24736. 4.18 Controllers, interface unit. the nequinementg of MIL-C-24733. 4.19 Fiberscoues. Fiber optic of MIL-F-24734. Fiber optic controller shall conform to

f iberscopes

shall conform to the requirements

4.20 Transmitters. analod. Fiber optic analog transmitters shall conform to the requirements of MIL-T-24735. 4.21 Receivers, analog. Fiber optic analog receivers shall conform to the requirements of MIL-R-2473Y. 4.22 Attenuators. Fiber optic attenuators shall conform to the requirements of MIL-A-24726. 4.23 Switches. Fiber optic switches shall conform to the requirements of MIL-S-2472S 4.24 TOOIE and Inmection eauirJment. Fiber optic tools, inspection equipment, and related kits shall conform to the requirements of MIL-I-81969, MIL-T-83523, MIL-M-83524, MIL-K-83525, MIL-M-83533 and MIL-C-22520/10. 5. Information for j?uidance onlv.

5.1 Design guides. Fiber optic system design guide information is available in MIL-HDBK-415 and MIL-HDBK-278.

76-3

MIL-STD-454

5.2 Installation and checkout DroceduPes. Guidance for installation and checkout procedures is contained in MIL-HDBK-277 and MIL-HDBK-282. 5.3 Product assurance rmogram. When a requirement exists for the implementation of a fiber optic product assurance program, refer to MIL-STD-790

76-6

MIL-STD-4S4N

*INDEX OF APPLICABLE DOCUMZNTS Document Requirement Document Requirement

SPECIFICATIONS Federal FF-F-300.. .................... ..52 L-P-516.....................11,26 L-S-300........................67 V-T-276 . ...................... .44 V-T-285 . ...................... .44 V-T-291........................44 V-T-295........................44 W-L-00111......................50 W-L-00116......................50 FF-B-171........................6 FF-B-185........................6 FF-B-187........................6 FF-B-195........................6 FF-B-575.......................12 FF-N-836.......................12 FF-R-556.......................12 FF-S-85........................12 FF-S-86........................12 FF-S-92........................12 FF-S-200.......................12 FF-S-210.......................12 FF-W-84........................12 FF-W-Q2........................12 FF-W-lOO.......................12 KH-I-553.......................11

QQ-S-766........................41 QQ-W-321........................41 QQ-W-343..................20.66.71 TT-S-1732.......................12 VV-L-800........................43 VV-P-236........................43 22-R-765........................26 CCC-C-428.......................44 W-A-121 ...... . .................23 W-A-130 .......................23 MMM-A-132.......................23 MMM-A-134 . .................... ..23 W-A-138 .......................23 MMM-A-181.......................23 W-A-189 .......................23 MMM-A-1617......................23 W-A-1931 ......................23 Mi1itary MIL-I-10.....................11.26 MIL-M-14.....................11,26 MIL-C-17..................65.66.Y1 MIL-B-18........................27 MIL-D-24........................46 MIL-S-61... ....................40 MIL-W-Y6 . ....................2 O.71 MIL-P-79.... . ................11 ,26 MIL-T-152.....................4.69 MIL-C-172.......................55 MIL-V-173.....................4.6!2 MIL-C-442... ................66.71

INDEX 1 30 June 1992 11-1

MIL-STD-454M

Document

Requirement

Document

Requirement

MIL-W-530......................44 MIL-C-572......................44 MIL-I-631...................11,69 MIL-J-641......................10 MIL-P-642......................10 MIL-T-713......................69 MIL-P-997...................11,26 MIL-S-1222.....................12 MIL-I-1361.....................40 MIL-L-2105.....................43 MIL-Q-3111.....................46 MIL-Q-3124.. ..................46 MIL-L-3150.....................43 MIL-I-3158..................11,69 MIL-I-3190..................11,69 MIL-C-3432..................66.71 MIL-T-3530.....................44 MIL-S-3644.....................42 MIL-L-3661.....................50 MIL-I-3825.....................11 MIL-L-3890.....................65 MIL-L-3918.....................43 MIL-A-3920.....................23 MIL-K-3926.....................28 MIL-B-3990......................6 MIL-W-4088.....................44 MIL-M-4820.....................46 MIL-W-5086. .............20.66.71 MIL-B-5087...................1,74 MIL-H-5440.....................49 MIL-A-5540.....................23 MIL-F-5591.....................12 MIL-R-5674.....................12 MIL-B-5687......................6 MIL-W-51345 ...............2 O.66.71

MIL-W-5846................2 O.66.71 MIL-W-5908................2 O.66.71 MIL-L-6085......................43 MIL-L-6086......................43 MIL-L-6363......................50 MIL-B-6812......................12 MIL-W-6858......................13 MIL-C-7078...................66.71 MIL-I-7444......................11 MIL-S-7742......................12 MIL-M-7793......................51 MIL-L-7806......................50 MIL-B-7838.... .................12 MIL-B-7883... ..................59 MIL-R-7885......................12 MIL-T-7928..... .............19.69 MIL-S-7947......................41 MIL-L-7961......................50 MIL-M-7969......................46 MIL-S-8516......................47 MIL-A-8576......................23 MIL-M-.9609 ......................46 MIL-W-8777...................66.71 MIL-R-8814......................12 MIL-B-8831......................12 MIL-S-8S79......................12 MIL-FI-8891 ......................49 MIL-W-8939......................24 MIL-W-8942.......................6 MIL-B-8943.......................6 MIL-W-8948.......................6 MIL-C-Q074......................44 MIL-F-93Q7......................46 MIL-B-10154.....................27

11-2

MIL-STD-454N

Document

Requirement

Document

Requirement

MIL-C-10S44....................10 MIL-B-11188....................27 MIL-S-12285....................58 MIL-C-12520....................10 MIL-S-12883....................60 MIL-T-13020....................11 MIL-M-13231....................67 MIL-S-13282....................41 MIL-B-13506.....................6 MIL-S-13572....................41 MIL-C-13777.................66.71 MIL-P-13949....................17 MIL-P-15024....................67 MIL-P-15037.................11,26 MIL-P-15047....................11 DOD-B-15072....................27 MIL-L-15098....................50 MIL-I-15126....................11 MIL-T-15659....................19 MIL-L-15719....................43 MIL-S-15743....................58 MIL-M-16034....................51 MIL-M-16125....................51 MIL-F-16552....................52 MIL-W-16878..............2 O.66.71 MIL-I-16923....................47 MIL-M-17059....................46 MIL-M-17060....................46 MIL-I-17205....................11 MIL-L-17331 ....................43 MIL-B-173S0.....................6 MIL-M-17413....................46 MIL-M-17556....................46 MIL-H-17672....................43 MIL-P-18177....................11

MIL-F-18240.....................12 MIL-N-18307.....................67 MIL-S-18396.....................58 MIL-I-1.S746 .....................11 MIL-M-19097.....................46 MIL-W-19150..................2O.71 MIL-M-19160.....................46 MIL-P-19161..................I1.26 MIL-8-19166.....................11 MIL-C-19311.....................41 MIL-S-19500..................30.50 MIL-C-19547..................66.71 MIL-M-19633.....................46 MIL-I-22076..................11,69 MIL-I-22129.....................11 MIL-T-22361.....................12 MIL-A-22397 .....................23 MIL-S-22432.....................56 MIL-S-22473.....................12 MIL-C-22520/10..................76 MIL-W-22759...............2 O.66.71 MIL-S-22820.....................56 MIL-T-22821.....................56 MIL-C-22931.....................65 MIL-F-22978.....................12 MIL-I-23053..................11,69 MIL-B-23071..................46.52 MIL-S-23190.....................69 MIL-I-23264.....................11 MIL-L-2339S.....................43 MIL-C-23437..................66,71 MIL-S-23586.....................47

11-3

MIL-STD-454N

Document

Requirement

Document

Requirement

MIL-I-23S94....................11 MIL-T-23648....................33 MIL-C-23S06....................65 MIL-G-23827....................43 MIL-M-24041....................47 MIL-I-24092....................11 MIL-G-24139....................43 MIL-A-24179....................23 MIL-I-24204....................11 MIL-G-24211....................53 MIL-R-24243....................12 MIL-S-24251. ..................60 MIL-M-24325....................26 MIL-I-24391....................11 MIL-Q-24508....................43 DOD-D-24620....................76 MIL-C-24621....................76 DOD-S-24622....................76 MIL-S-24623....................76 MIL-H-24626....................76 MIL-P-24627....................76 MIL-P-24628....................76 MIL-C-24640.................66.71 MIL-C-24643.................66.71 MIL-S-24725....................76 MIL-A-24126 ....................76 MIL-B-24727 . ...................76 MIL-I-24728....................76 MIL-M-24731....................76 MIL-L-24732....................76 MIL-C-24733....................76 MIL-F-24734....................76 MIL-T-24735....................76 MIL-M-24736....................76 MIL-R-24737....................76 MIL-N-2S027....................12 MIL-W-25038.................66.71 MIL-K-25049....................28

MIL-A-25463.....................23 MIL-H-26475.....................49 MIL-P-2551S.....................26 MIL-C-27072..................66.71 MIL-W-27265.....................44 MIL-R-27384.....................12 MIL-C-27500..................66.71 MIL-D-2872S.....................28 MIL-M-2S787.....................73 MIL-D-28803.....................68 MIL-C-28809.....................17 MIL-A-28870.....................17 MIL-C-2SS76.....................76 MIL-T-29504.....................76 MIL-M-38510..................64.75 MIL-M-38527.....................60 MIL-C-39006/22...................2 MIL-C-39006/25...................2 MIL-T-43436.....................69 MIL-L-46010.....................43 MIL-S-4604EI .....................41 MIL-A-46060.....................23 MIL-I-46058.....................17 MIL-P-46112.....................26 MIL-W-46132.....................13 MIL-A-46146.....................23 MIL-S-46163.....................12 MIL-P-46843.....................17 MIL-I-46852.....................11 MIL-R-46855.....................62 MIL-A-4708Q.....................23 MIL-A-47315.....................23 MIL-A-47317.....................23 MIL-A-47318.....................23 MIL-A-48611.....................23 MIL-B-4E1030 .....................27 MIL-C-49055.....................66 MIL-F-49291.....................76

11-4

MIL-STD-454N

Document

Requirement

Document

Requirement

MIL-C-492E12 ....................76 MIL-B-49430....................27 MIL-B-49436....................27 MIL-C-49055....................66 MIL-I-49456....................11 MIL-R-49458....................27 MIL-B-49461....................27 MIL-R-50781....................56 MIL-P-SOB84....................17 MIL-A-52194....................23 MIL-C-S5021.................66.71 MIL-S-55041....................53 MIL-P-55110....................17 MIL-C-9S116....................10 MIL-B-55118....................27 MIL-B-55130....................27 MIL-T-55156....................19 MIL-T-55164....................19 MIL-C-551B1....................10 MIL-B-55252....................27 MIL-O-55310....................38 MIL-A-5533Q....................10 MIL-T-55631....................14 MIL-C-B1021....................41 MIL-W-81044..............2 O.66.71 MIL-I-81219....................!31 MIL-A-81236....................23 MIL-A-81253....................23 MIL-M-8128B....................55 MIL-Q-81322....................43 MIL-L-81329....................43 MIL-W-81381..............2O.66.71 MIL-E-81512....................66 MIL-I-81S50....................47 MIL-B-81744.....................6 MIL-S-81746....................56 MIL-B-81757....................27

MIL-I-81765.....................11 MIL-B-91793......................6 MIL-W-81822.....................20 MIL-B-81E134 ......................6 MIL-B-81936......................6 MIL-S-81963..................56.67 MIL-I-81969.....................76 MIL-A-83377.....................23 MIL-S-83502.....................60 MIL-C-83503.....................10 MIL-R-83616.....................57 MIL-C-83622.....................76 MIL-T-B3523.....................76 MIL-M-83524.....................76 MIL-K-83525.....................76 MIL-C-83526.....................76 MIL-C-83532.....................76 MIL-M-83533.....................76 MIL-T-83721.....................14 MIL-T-83727.....................56 MIL-S-83731.....................58 MIL-S-83734.....................60 MIL-B-83769.....................27 MIL-C-85045.....................76 MIL-I-85080.....................11 MIL-E-85082.....................56 MIL-A-87135.....................23 MIL-D-87157.....................68 STANDARDS Federal FED-STD-H28.....................12 FED-STD-406.....................26

11-5

MIL-STD-454N

Document

Requirement

Document

Requirement

Mi1itary MIL-STD-12.. . . . . . . . . . . . . . . 67 MIL-STD-22.. . .. . .. . 13 MIL-STD-1OS. ...............55.69 MIL-STD-130. . ............. 6? MIL-STD-155. .. ...... .. .. .67 MIL-STD-lSS-111................76 MIL-STD-188-124................74 MIL-STD-195....................67 MIL-STD-196.................34.67 MIL-STD-198...C.C.C..C..........2 MIL-STD-199....................33 MIL-STD-200....................29 MIL-STD-202.....................3 MIL-STD-203....................25 MIL-STD-24S....................13 MIL-STD-255....................25 MIL-STD-275....................17 MIL-STD-276....................21 MIL-STD-2S0.............7. S.36.67 MIL-STD-411....................67 MIL-STD-415....................32 MIL-STD-461....................61 MIL-STD-462....................61 MIL-STD-469....................61 MIL-STD-470....................54 MIL-STD-471....................54 MIL-STD-480....................72 MIL-STD-6S1....................20 MIL-STD-683....................38 MIL-STD-701....................30 MIL-STD-704....................25 MIL-STD-710....................56 MIL-STD-721..............36.36.54 MIL-STD-756....................35 MIL-STD-781....................35 MIL-STD-7S3....................67 MIL-STD-786.................35.64

MIL-STD-790.....................76 MIL-STD-810......................4 MIL-STD-883..................64.75 MIL-STD-889..................15.16 MIL-STD-965.....................22 MIL-STD-975.....................64 MIL-STD-9S1.....................14 MIL-STD-983.....................72 MIL-STD-1130....................69 MIL-STD-1132....................58 MIL-STD-1189....................67 MIL-STD-1261....................13 MIL-STD-1275....................25 MIL-STD-1277....................19 MIL-STD-1279....................51 MIL-STD-128S....................67 MIL-STD-1286....................14 MIL-STD-1310..................1,74 MIL-STD-1327....................53 MIL-STD-1328....................53 MIL-STD-1329 ...................53 MIL-STD-1334.....................6 MIL-STD-1346....................57 MIL-STD-1352....................53 MIL-STD-1353....................10 MIL-STD-135S....................53 MIL-STD-1360....................39 MIL-STD-137S....................73 MIL-STD-1389....................73 MIL-STD-1395. .................70 MIL-STD-1399....................25 MIL-STD-1451....................56 MIL-STD-1472............1.36.5O.62 MIL-STD-1498....................37 MIL-STD-1516....................15 MIL-STD-1539..................8.25 MIL-STD-1542....................74 MIL-STD-1546....................22 MIL-STD-1547............7.18.3O.64

11-6

MIL-STD-454N

Document

Requirement

Document

Requirement

MIL-STD-1562........ . . . . . . . 64 DOD-STD-1578. .. . ........27 MIL-STD-1595........ . . ..13 MIL-STD-1629. ... . ........35 MIL-STD-1636... .. ........53 MIL-STD-1637...................53 MIL-STD-1638...................53 MIL-STD-1639...................53 MIL-STD-1640...................53 MIL-STD-1646...................1O DOD-STD-1678...................76 MIL-STD-1686................64.75 MIL-STD-1857...................74 DOD-STD-1S63...................76 DOD-STD-1864...................76 MIL-STD-2000....................5 MIL-STD-2113...................53 MIL-STD-2118...................17 MIL-STD-2119...................17 MIL-STD-2120...................10 MIL-STD-2162...................53 MIL-STD-2163...................76 MIL-STD-216S...................32 MIL-STD-2175...................21 MIL-STD-2219...................13 MS25471........................71 MS27110........................71 MS27212........................19 MS33522........................12 MS33540........................12 MS33557 ........................12 MS3355S........................42 HANDBOOKS Mi1itary MIL-HDBK-5.....................13 MIL-HDBK-216................53.65 MIL-HDBK-217................35.64 MIL-HDBK-218...................56 MIL-HDBK-246...................73

MIL-HDBK-225....................56 MIL-HDBK-231....................56 MIL-HDBK-251....................52 MIL-HDBK-253....................61 DOD-HDBK-263....................75 MIL-HDBK-277....................76 MIL-SDBK-278....................76 MIL-HDBK-282....................76 MIL-HDBK-415....................76 MIL-HDBX-419....................74 MIL-HDBK-472....................54 MIL-HDBK-600.....................1 MIL-HDBK-660....................53 MIL-HDBK-691....................23 MIL-HDBK-730....................13

OTHER QOVT DOCUMENTS MIL-BUL-103.....................64 10 CFR20 ........................1 21 CFRIOOO - 1050...............1 29 CFR1910 ................... .. .............1.4.11.23.26.43.44.47 MTIA Manual.....................61 Tester Independent Support Software System (TISSS) Spec8.64 VHSIC Interoperabi 1ity Standards64 Army Regulation 700-B3..........27

NON-QOVT DOCUMENTS A(JMASpecificationa.............48 AMS3638E .......................11 AMS3653D .......................11 AMS3654B .......................11 AMS365SA .......................11

11-7

MIL-STD-454U

Document

Requirement

Document

Requirement

AMSIB93. 1-64..................49 ANSI B93.2-71..................49 ANSI B93.3-68..................49 ANSI B93.4M-81.................49 ANSI B93.5-79..................49 ANSI B93,6-72,..,...,.,,,,,,., .49 ANSI B93.7-68..................49 ANSI B93.8-68..................49 ANSI B93.9M-69.................49 ANSI B93.10-69.................49 ANSI B93.llM-81................49 ANSI C95.1-82...................1 ANSI C95.2-82...................1 ANSI N2.1-69....................1 ANSI Z35.1-72 ...................1 ANSI Z35.2-6S...................1 ANSI Z35.4-73...................1 ANSI Z53.I-79...................1 ANSI/AWS A2.4-86...............13 ANsI/Aws A3.o-85...............13 ANSI/IPC-D-322.................17 ANSI/IPC-DW-425/11.............17 ANsI/sAE J514f.................49 ANSI/SAE J518c.................49 ASM Metals Hdbk, Vol 1-1978....41 ASTM A29/A29M-8S...............4l ASTM A122-86...................41 ASTM A139/A139m-LI0 .............4l ASTM A151/A151m-89.............41 ASTM A206-86a/A206m-87. ........41 ASTM A2281A228M-83.............41 ASTM A313-8Y ...................41 ASTM A580-90................67.71

ASTM A682-79....................41 ASTM A6S4/A684M-86 .............41 ASTM B33-74..................66.71 ASTM B194-SB....................41 ASTM B196/B196M-88..............4l ASTM B197/B197M-S9,.............4l ASTM B522-80....................41 ASTM D149-87....................45 ASTM D485-Y3 ..................,.26 ASTM D56S-77.....................3 ASTM D636-S1.....................3 ASTM D1000-S2....................3 ASTM D1868-81...................45 ASTM D3295-81...................11 EIA-297-A.......................10 EIA-310-C.......................55 IEC-693-80......................76 IEEE 812-84.....................76 IEEE 200-1975...................67 IEEE 1076-1987..................64 NAS 498........ . .............. ..12 NAS 547.........................12 NAS 1686........................12 NAS 1687. ..................... ..12 NFPA 70-1990...................1,8 UL 94-80.........................3

11-S

MIL-SIP3454N

2ubJecJ

3ubJecJ Ilaauirement

Beauirement

fomal cOating . ... ... .. ... ... .....i7 Abbreviations ... .. .... .. ..... . ..... . 67 Con i one Accea.v devi@e# ... .... .. ... .... ... ....ll Connect of .. ... ... .. .... .....36 Acce.e#ibility .. ... ... ... ... ... .... ...36 Accemeibility Cle!lpad ... ... .... .. ... .... .. ... ....(le Mapte?a .. ... ... .... .. .... .. .... ... ...oQ BfConn*@toP . ... ... ... ... ... .... ....lo cPimp Weveguide .... .. .... .. .... ... .... ....53 UarkingOf. . . . . . . . . . . . . . . . . . . . . . ...67 . . . . . . . . . . . . . . . . . . . . . . . . . ...5 Adbeaiven ..... .. ... ... ... ... .. .. .....23 Soldered S!lded. . . . . . . . . . . . . . . . . . . . . . . . . . ...24 Antiseize mspound . . . . . . . . . . . . . . . . . ..ll WireAkap . . . . . . . . . . . . . . . . . . . . . . . ...69 Arc-resiatent materials. . . . . . . . . . . . . .26 C0nnect0F8 Attenueto?a,?! . . . . . . . . . . . . . . . . . . . ...53 Electrical . . . . . . . . . . . . . . . . . . . . ..l. 10 kvriem, electrical . . . . . . . . . . . . . . . . ..l Filter pin. . . . . . . . . . . . . . . . . . . . . . . ..lO Wte?ien . . . . . . . . . . . . . . . . . . . . . . . . . . ..rl Rf cOaxial . . . . . . . . . . . . . . . . . . . . . . . ..lO Bearingassemblies . . . . . . . . . . . . . . . . . . ..O Containment . . . . . . . . . . . . . . . . . . . . . . . . ...9 Bearingn . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..fl contFOLv . . . . . . . . . . . . . . . . . . . . . . . . . . ...28 Boards Insulatim of. . . . . . . . . . . . . . . . . . . . . ..i Diemete vi?ing. . . . . . . . . . . . . . . . . . ..l7 Flexible absfta fo~. . . . . . . . . ...28. 42 hintadwiring . . . . . . . . . . . . . . . . . . . ..l7 COnverte?a, FOteq.pOm . . . . . . . . . . ...46 Boltn. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..ll Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . ...52 hnding COnOnapr.mntiOn . . . . . . . . . . . . . . . . . ...45 Mbeaive . . . . . . . . . . . . . . . . . . . . . . . . . ..!3 Electrical . . . . . . . . . . . . . . . . . . . . ..l. 74 Corweionprotection. . . . . . . . . . . . . 19, 16 Couplers, directional . . . . . . . . . . . . . ...53 Emaing . . . . . . . . . . . . . . . . . . . . . . . . . . . ...59 Cr.eepa.@. distence. . . . . . . . . . . . . . . . . . ..O9 Cabinets . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5S Crystal mitg . . . . . . . . . . . . . . . . . . . . . ...38 Cable, coexjal. . . . . . . . . . . . . . . . . . . . ...65 Cable, noi~iconductor Darating. . . . . . . . . . . . . . . . . . . . . . . . . . . ..l8 . . . . . . . . . . . . . . . . . . . . . ..3i. 55 Interconnection ... .. .. .. ... .... ....ll Desiccenta Internal ... ... .... .... .. .... ... ....66 Devices,aic?oelectronic. . . . . . . . . . . . .64 Capa.3it0~a .. ... .... .... ... ... ... ......2 Devices,nemiconda&m...............3O Carcinogcnsl, 4,11, 23,26, 43,44, 47 Dial mecbanime,tuning. . . . . . . . . . . ...42 Ceees .... ... ... .... ... ... .. .... ... ...55 Dials, cont~ol. . . . . . . . . . . . . . . . . . . . ...28 Castings .... ... ... ... ... ... .... ... ...!ll Dincbarging devic.w . . . . . . . . . . . . . . . . . ..l . . . . . . . . . . . . . . . . . . . . . . . . . . . ..O8 Ci~cuit bmAern . ..... .... .. ... ...8. 37 Di#playa Cieening . ..... ... .. .... .. ... .. .. ... ...9 Dimimilar mtaLa. . . . . . . . . . . . . . . . . . ..l6 Cleamnce .... .... .. .... ... ... .....9. 69 Oynamtoms...........................46 Coaxial cable ... ... ... .. .... .... .....65 coILs .. .... ... .... ... ... ... ... ... ....l4 Commwial parts .. ... ... ... .... ... ...7l INDEX 2 12-1

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3aauirement

3uiJ@

Reauireaant

Wot?ical Bwckllown . . . . . . . . . . . . . . . . . . . . . . . . ...45 tOBnWtiOI!B . . . . . . . . . . . . ..g. lCI,14, 89 Filte?fl . .. .... .... ... .. .... .....lo. 70 Inmlating materials. . . . . . . . . . . . . . ..ll Metem . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..Sl Ove?load protection. . . . . . . . . . . . . . . ...8 Poma? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..l9 fflechoinegnetia inte~ter-me control. . . . . . . . . . . . . . . .01 Electronic part derating. . . . . . . . . . . . . . 18 ElectrOntubas. . . . . . . . . . . . . . . . . . . . . . ..2O Electrostatic Di#&evgeco ntml . . . . . . . . . . . . . . . . ...75 Sensitive partn.............3O.04, 7S 3mbadment . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4l 3ncapsulati0n . . . . . . . . . . . . . . . . . . . . . . ...47 Enclomeen . . . . . . . . . . . . . . . . . . . ..l. S6, $5 3ncoders . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..M Fab?ic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...44 iastene~hardeme . . . . . . . . . . . . . . . . . . . ..ll Faatenm, th?eaded . . . . . . . . . . . . . . . . . ..l!l Fiber Optics. . . . . . . . . . . . . . . . . . . . . . . . ..7O Fib?ouamate~ial, organic. . . . . . . . . . . . .44 Filters, cle&?icai . . . . . . . . . . . . . ..lO. 70 Fini#bcu . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..1S Flmebility . . . . . . . . . . . . . . . . . . . . . . . . . ...9 Flanges, vaveguide . . . . . . . . . . . . . . . . . ...53 FunguaineFt mate? ia16. . . . . . . . . . . . . . ...4 Fungueprotection. . . . . . . . .. . ...4. 44, 69 Fueeboldcrs. . . . . . . . . . . . . . . . . . . . . . . ...39 Fuae8 . . . . . . . . . . . . . . . . . . . . . . . . . . . ...8. 39 Fueible link devices. . . . . . . . . . . . . . . ...64 Deart?ains . . . . . . . . . . . . . . . . . . . . . . . . ...48 6MF8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...48 OaneratOm............................4O Omnding .. . . . . . . . . . . . . . . . . . . . ..l. 6, 74 lluepda, eiectr.ical . . . . . . . . . . . . . . . . . . . ..i Eandles, control. . . . . . . . . . . . . . . . . . . . ..N Ibdtame, faatener. . . . . . . . . . . . . . . . . . ..l2 Eeating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..5l
iiookup wire.................. . .........2O

Emenengineering.., . . . . . . . . . . . . . . . ...82 llqdxaulic8 . . . . . . . . . . . . . . . . . . . . . . . . . ...49 Idanti! ication marking. . . . . . . . . . .20, 07 Indicaton lights . . . . . . . . . . . . . . . . . . . . ..SO Inductors. . . . . . . . . . . . . . . . . . . . . . . . . . . ..l4 Insulating mate?iala, electrical . . . . . . . . . . . . . . . . . . . . . . . . ..ll Interchangeability. . . . . . . . . . . . . . . . . . ...7 Interference, eiectrOmgnetic. . . . . . . . . . . . . . . . . . . ..6i Interlocks. . . . . . . . . . . . . . . . . . . . . . . . . . . ..l Internal wt~ingpractices. . . . . . . . . . . . .69 Item naww, nomenclature . . . . . . . . . . . ...34 Jack@,teiephone/te8t. . . . . . . . . . . . . . . ..lO Knobe,control. . . . . . . . . . . . . . . . . . . ..l. !48 Lacing . . . . . . . . . . . . . . . . . . . . . . . . . . ...9. 69. LampE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..BO Leakage diatance. . . . . . . . . . . . . . . . . . . . ..OB Legends . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...67 Light emitting dioden . . . . . . . . . . . .. SO.68 Lights, indicator. . . . . . . . . . . . . . . . . . . ..5O Lime, rf t?anmis.cicn . . . . . . . . . . ..S3. 65 Lcada,dmag, r4. . . . . . . . . . . . . . . . . . . ...33 Lockingdevices. . . . . . . . . . . . . . . . . ..Kk. 28 LubFicant.c . . . . . . . . . . . . . . . . . . . . . . . ..O. 43 Lugte?ainals: . . . . . . . . . . . . . . . . . . . . . . ..l9 Maintainability. . . . . . . . . . . . . . . . . . . . ...54 tiking . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...67 B-stteeyinstallation . . . . . . . . . . . . . . . ..!l7 Diala. . ... . . . . . . . . . . . . . . . . . . . . . . . . ...42 Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . ..3O. 67 3adioa@tive mateniel. . . . . . . . . . . . . . . . ..l Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..l Materialn Arc-reai#tant. . . . . . . . . . . . . . . . . . . . . ...26 Ca~cinogena . . . . . . . . . . . . . . . ... . . . . . . . . . . . . . . . . . ...1. 4, 11, 13, 26,43, 44, 47 8iectPical insulating. . . . . . . . . . . . . . . ..il Fabric. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...44

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MIL+TE-454N

SubJ@

Beouirement

SdJe&t

Eeauireuent

,.

Materials (cent) Fib?ouaoF@ic . . . . . . . . . . . . . . . . . . ...44 Fiambie . . . . . . . . . . . . . . . . . . . . . . . . . ...3 Fm.guaiaert . . . . . . . . . . . . . . . . . . . . . . ...4 Glans fibers . . . . . . . . . . . . . . . . . . . . . . . ..l Potting. . . . . . . . . . . . . . . . . . . . . . . . ..~..4T ?Oxic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..l kke?cu?g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..l Matai fini8bea. . . . . . . . . . . . . . . . . . . . . . ..lS BetaIs, diaaimflar. . . . . . . . . . . . . . . . . . ..l6 Ueters, electrical . . . . . . . . . . . . . . . . . . ..Sl Mfmoelectmic devicen. . . . . . . . . . . . . . .64 Mfidewt?eatwnt. . . . . . . . . . . . . . . . . . . ...44 kdules Hic?Oci?cuit . . . . . . . . . . . . . . . . . . . . . ...64 Standmdelectronic . . . . . . . . . . . . . . ...73 kistwepacket8 . . . . . . . . . . . . . . . . . . . . ..3l htor-generatOrn. . . . . . . . . . . . . . . . . . . ...46 WOP8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...46 Uticonductor cable Interconnection . . . . . . . . . . . . . . . . . . . ..7l Internal . . . . . . . . . . . . . . . . . . . . . . . . . ...66 flOmenclatwe . . . . . . . . . . . . . . . . . . . . . . . ...34 flon@tandmfp art8. . . . . . . . . . . . . . . . . . . ..l2. tiuta. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..i2 Obmlencence,mfmociwuit . . . . . . . . . . . .64 OrganicfibpouamateFial . . . . . . . . . . . ...44 Oacillatm, cry8tal . . . . . . . . . . . . . . . ...38 Oeerioedprotection, electrica . . . . . . . .18 Pads, wmntint . . . . . . . . . . . . . . . . . . . . . . ..6O Paneis, enclOmm . . . . . . . . . . . . . . . . . . ...59 Parts selection and contm. . . .17, 11, 71 Plastic mteriai, insulating. . . . . . . . . . 11 PIugs, telephone . . . . . . . . . . . . . . . . . . . . ..lO POtting. . . . . . . . . . . . . . . . . . . . . . . . . ..lO. 41 Poser, electrical . . . . . . . . . . . . . . . . ..l. 1S ??inted wiping . . . . . . . . . . . . . . ... . . . . . ..ll Merking of. . . . . . . . . . . . . . . . . . . . . . . ...67 P70tection Electrical overload. . . . . . . . . . . . . . . . ..a Etgbvoltage/cwmt. . . . . . . . . . . . . . . ..l

. . . . . . . . . . ...4. 11, 20, 65, 66, 71 Pvt. @e.rtzc ryntaimitn . . . . . . . . . . . . . . . ..S8 sackE . . . . . . . . . . . . . . . . . . . . . . . . . ...36. 55 Sadiation (lacer, ticromve, X-ray). . . . . . . . . . . . . . . . . . ..l Sadioe.ctivemterial . . . . . . . . . . . . . . . . ..l Reedouta . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6B Seferencedeaigrmtions . . . . . . . . . . . . . . .67 Relayn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..Y7 Reliability . . . . . . . . . . . . . . . . . . . . . . . . ..3S nfcFO@iFcuit . . . . . . . . . . . . . . . . . . . . . ...64 hediction . . . . . . . . . . . . . . . . . . . . . . . ...64 Resiatencemldn. . . . . . . . . . . . . . . . . . . ..l4 Be8i#tora . . . . . . . . . . . . . . . . . . . . . . . . . ...33 Be#olve?n . . . . . . . . . . . . . . . . . . . . . . . . . ...56 M c0nnect0r8 . . . . . . . . . . . . . . . . . . . . . . ..lO Rotarypamerconverters . . . . . . . . . . . . .46 Sotaryaervo devicea. . . . . . . . . . . . . . . ..M Safety [permnnei bm?dl. . . . . . . . . . . ..l Scree8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..l2 Semiconductor devices. . . . . . . . . . . . . . . .30 Se?vodevices . . . . . . . . . . . . . . . . . . . . . ...56 Setsc?em. . . . . . . . . . . . . . . . . . . . . . . . . . ..l2 Sbafta, controi. . . . . . . . . . . . ..l2. !8, 41 Shielding Slectr.icai. . . . . . . . . . . . . . . . . . . ..l. 0, 74 Klect?06agnetic . . . . . . . . . . . . . . . . ..6l. 74 Sbield8. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..6O Sbo@k, electrical, effects of. . . . . . . . . 1
shunts (mteF) . . . . . . . . . . . . . . . . . . . . . ..4o

Signs, accident prevention. . . . . . . . . . . . 1 Sieeving . . . . . . . . . . . . . . . . . . . . . . . ..ll. 69

Soldering. . . . . . . . . . . . . . . . . . . . . . . . . . ...5 Special too18 . . . . . . . . . . . . . . . . . . . . . ...63 Splices. . . . . . . . . . . . . . . . . . . . . . . . . . . ...69 spFings . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..4l Stendapdelectronic modules . . . . . . . . . .73 Stend~d items. . . . . . . . . . . . . . . . . . . . . ...7 9t0pa. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..l8 Stre8srelief . . . . . . . . . . . . . . . . . . . . . ...24

12-3

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Subject

llequirement W!@!

@!!!E!a

9tmctwa1 welding . . . . . . . . . . . . . . . . . . ..l3 SUbmitut.lbillty . . . . . . . . . . . . . . . . . . . . ..m Svitches. . . . . . . . . . . . . . . . . . . . . . . . . . . . ..M Battlesho?t. . . . . . . . . . . . . . . . . . . . . . . . ..l Circuit breakers umd aa. . . . . . . . . ...37 Interlock. . . . . . . . . . . . . . . . . . . . . . . . . . ..l rlf. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..l. 53 $afety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..l Waveguide . . . . . . . . . . . . . . . . . . . . . . . . ...53 !lymbOIOgy . . . . . . . . . . . . . . . . . . . . . . . . . . ...67 Syncbros . . . . . . . . . . . . . . . . . . . . . . . . . . . ...56 Tachomters. . . . . . . . . . . . . . . . . . . . . . . . ...56 Tape BlectPical. . . . . . . . . . . . . . . . . . . . . . . . ..ll M.cing . . . . . . . . . . . . . . . . . . . . . . . . . . . ...69 Reflective. . . . . . . . . . . . . . . . . . . . . . . ...67 ?emtnal Anards,ntr.ips. . . . . . . . . . . . . ..l9 !eminal lugs. . . . . . . . . . . . . . . . . . . . . . . ..l9 feminatim . . . . . . . . . . . . . . . . . ..l. 19, 69 7eatpr0visi0ns . . . . . . . . . . . . . . . . . ..lO. 31 7herml deuifn. . . . . . . . . . . . . . . . . . . . . ...52 9bemist0ra . . . . . . . . . . . . . . . . . . . . . . . . ...33 Tber60c0uple6 . . . . . . . . . . . . . . . . . . . ..iO. 10 7brefid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...44 Vb?eaded device# . . . . . . . . . . . . . . . . . . . . ..lJ Th?eads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..l2 7001s, special . . . . . . . . . . . . . . . . . . . . . . ..6S Toxicmaterials. . . . . . . . . . . . . . . . . . . . . . ..l ?rannformra. . . . . . . . . . . . . . . . . . . . . . . . ..l4 7cansist0?s. . . . . . . . . . . . . . . . . . . . . . . . . ..3o

7mnmimi0n lines, rf . . . . . . . . . . . . . ...53 Tmngolvers . . . . . . . . . . . . . . . . . . . . . . . . . ..$6 Tubashielda. . . . . . . . . . . . . . . . . . . . . . . . ..6O Tubes,electm . . . . . . . . . . . . . . . . . . . . . ..l~ ?uningdial mechanima................42 Typadasignations. . . . . . . . . . . . . . ...34. 67 Va?nisb,Insulating. . . . . . . . . . . . . . . . . ..ll Vebicle#, @rend . . . . . . . . . . . . . . . . . . . . ..l5 VUSIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...64 Wining le.bels.., . . . . . . . . . . . . . . . . ..l. 27 k%abe?a . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..l2 14eveguide8 . . . . . . . . . . . . . . . . . . . . . . . . . ...53 Webbing . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...44 Ualding, stmctural . . . . . . . . . . . . . . . . . ..l3 kkldn, Resistance. . . . . . . . . . . . . . . ..l3. 14 Wire
kIookup ..............................2O

Inte~connection . . . . . . . . . . . . . . . . . . . ..7l 9olido? atranded. . . . . . . . . . . . . ..2O.66 Tbemcouple . . . . . . . . . . . . . . . . . . . . . . ..2O tiirewrap . . . . . . . . . . . . . . . . . . . . . . . . . . ..2O 4ViIIe Identification . . . . . . . . . . . . . . . . . ..2O Wiring hmngement......................~, 69 Connector . . . . . . . . . . . . . . . . . . . . . . . . . ..lO Internal . . . . . . . . . . . . . . . . . . . . . . . . . ...69 hinted . . . . . . . . . . . . . . . . . . . . . . . . . . . ..ll Bigid-flex. . . . . . . . . . . . . . . . . . . . . . . . ..l? 44a~kcmahip . . . . . . . . . . . . . . . . . . . . . . . . . . ..O

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