GENERAL GUIDELINES FOR ELECTRONIC EQUIPMENT

1 MIL-HDBK-454A03 NOVEMBER 2000_____SUPERSEDINGMIL-HDBK-45428 APRIL 1992 DEPARTMENT OF DEFENSEHANDBOOKGENERAL GUIDELINES FORELECTRONIC EQUIPMENT This handbook is for guidance only. Do not cite this document as a N/A AREA GDRQDISTRIBUTION STATEMENT A. Approved for public release; distribution is by IHSL icensee=Boeing/5910770001 Not for Resale, 11/03/2006 14:57:12 MSTNo reproduction or networking permitted without license from IHS--``,,,,,``,,`,`````,,,,``,``-`-`,,`, ,`,`,,`---MIL-HDBK-454 AiiFOREWORD1. This handbook is approved for use by all Departments and Agencies of the Department ofDefense 2. This handbook is for guidance only. This handbook cannot be cited as a requirement. If it is,the contractor does not have to comply. 3. This handbook is the technical baseline for the design and construction of electronicequipment for the Department of Defense.

2 It captures in one document, under suitablesubject heading, fundamental design GUIDELINES for multiple GENERAL ELECTRONIC opportunity to focus on a single document, afforded to contractors, results in substantialsavings to the Government. This handbook was prepared by and is regularly updatedthrough the cooperative efforts of Government and industry. The following Governmentdocuments are intimately associated with this handbook. MIL-HDBK-2036 GENERAL Requirements for ELECTRONIC EQUIPMENT Specifications. DOD-E-8983 ELECTRONIC EQUIPMENT , Aerospace, Extended Space Environment, GENERAL Specification for. MIL-HDBK-11991 Electrical, ELECTRONIC and Electro-mechanical EQUIPMENT , Guided Missile and Associated Weapon Systems, Design of. MIL-F-18870 Fire Control EQUIPMENT , Naval Shipboard, GENERAL Specification for.

3 MIL-PRF-28800 Test EQUIPMENT for Use with Electrical and ELECTRONIC EQUIPMENT , GENERAL Specification for. 4. Beneficial comments (recommendations, additions, deletions) and any pertinent data whichmay be of use in improving this document should be addressed to Defense Supply center ,Columbus, ATTN: DSCC-VSC, 3990 E. Broad St. Columbus, OH 43216, by using theStandardization Document Improvement Proposal (DD Form 1426) appearing at the end ofthis document or by letter. Provided by IHSL icensee=Boeing/5910770001 Not for Resale, 11/03/2006 14:57:12 MSTNo reproduction or networking permitted without license from IHS--``,,,,,``,,`,`````,,,,``,``-`-`,,`, ,`,`,,` applicable to ELECTRONIC of of of Individual Airborne, Space, Other terms are defined in the individual of selection and application GUIDELINES for ELECTRONIC EQUIPMENT from previous term (key word) listing4 Individual GuidelinesGuideline 1 - Safety Design Criteria - Personnel HazardsGuideline 2 - CapacitorsGuideline 3 - FlammabilityGuideline 4 - Fungus-Inert MaterialsGuideline 5 - SolderingGuideline 6 - BearingsProvided by IHSL icensee=Boeing/5910770001 Not for Resale, 11/03/2006 14:57.

4 12 MSTNo reproduction or networking permitted without license from IHS--``,,,,,``,,`,`````,,,,``,``-`-`,,`, ,`,`,,`---MIL-HDBK-454 AivGuideline 7 - InterchangeabilityGuideline 8 - Electrical Overload ProtectionGuideline 9 - WorkmanshipGuideline 10 - Electrical ConnectorsGuideline 11 - Insulating Materials, ElectricalGuideline 12 - Fastener HardwareGuideline 13 - Structural WeldingGuideline 14 - Transformers, Inductors, and CoilsGuideline 15 - Metals, Corrosion ResistanceGuideline 16 - Dissimilar MetalsGuideline 17 - Printed WiringGuideline 18 - Derating of ELECTRONIC Parts and MaterialsGuideline 19 - TerminationsGuideline 20 - Wire, Hookup, InternalGuideline 21 - CastingsGuideline 22 - Parts Selection and ControlGuideline 23 - AdhesivesGuideline 24 - Welds, Resistance, Electrical InterconnectionsGuideline 25 - Electrical PowerGuideline 26 - Arc-Resistant MaterialsGuideline 27 - BatteriesGuideline 28 - ControlsGuideline 29 - Electron TubesGuideline 30 - Semiconductor DevicesGuideline 31 - Moisture PocketsGuideline 32 - Test ProvisionsGuideline 33 - ResistorsGuideline 34 - NomenclatureGuideline 35 - ReliabilityGuideline 36 - AccessibilityGuideline 37 - Circuit BreakersGuideline 38 - Quartz Crystals and Oscillator UnitsGuideline 39 - Fuses and Fuse HoldersGuideline 40 - ShuntsGuideline 41 - SpringsGuideline 42 - Tuning Dial MechanismsGuideline 43 - LubricantsGuideline 44 - Fibrous Materials, OrganicGuideline 45 - Corona and Electrical Breakdown PreventionGuideline 46 - Motors and Rotary Power ConvertersGuideline 47 - Encapsulation and Embedment (Potting)

5 Guideline 48 - GearsGuideline 49 - HydraulicsGuideline 50 - Indicator LightsGuideline 51 - Meters, Electrical IndicatingProvided by IHSL icensee=Boeing/5910770001 Not for Resale, 11/03/2006 14:57:12 MSTNo reproduction or networking permitted without license from IHS--``,,,,,``,,`,`````,,,,``,``-`-`,,`, ,`,`,,`---MIL-HDBK-454 AvGuideline 52 - Thermal DesignGuideline 53 - Waveguides and Related DevicesGuideline 54 - MaintainabilityGuideline 55 - EnclosuresGuideline 56 - Rotary Servo DevicesGuideline 57 - RelaysGuideline 58 - SwitchesGuideline 59 - BrazingGuideline 60 - Sockets and AccessoriesGuideline 61 - Electromagnetic Interference ControlGuideline 62 - Human EngineeringGuideline 63 - Special ToolsGuideline 64 - Microelectronic DevicesGuideline 65 - Cable, Coaxial (RF)Guideline 66 - Cable, MulticonductorGuideline 67 - MarkingGuideline 68 - Readouts and DisplaysGuideline 69 - Internal Wiring PracticesGuideline 70 - Electrical FiltersGuideline 71 - Cable and Wire, InterconnectionGuideline 72 - SubstitutabilityGuideline 73 - Standard ELECTRONIC ModulesGuideline 74 - Grounding, Bonding, and ShieldingGuideline 75 - Electrostatic Discharge ControlGuideline 76 - Fiber OpticsGuideline 77 - Integrated DiagnosticsGuideline 78 - ProducibilityTablesTable 1-IProbable effects of shockTable 1-IISuitable protective measuresTable 4-IFungi-susceptibility of materialsTable 10-IAbbreviations for thermocouple materialsTable 20-IWire.

6 ElectricalTable 21-IGeneral comparison of metallic casting processesTable 26-IArc-resistant materialsTable 41-IMaterials for electrical spring applicationTable 41-IICorrosion resisting steel for springsTable 41-IIIC arbon steel for springsTable 50-IIndicator lights and associated itemsTable 53-IWaveguides and related devicesTable 66-ICable, multiconductorTable 69-IElectrical clearance and leakage (creepage) distancesTable 71-IWire, electrical, interconnectionProvided by IHSL icensee=Boeing/5910770001 Not for Resale, 11/03/2006 14:57:12 MSTNo reproduction or networking permitted without license from IHS--``,,,,,``,,`,`````,,,,``,``-`-`,,`, ,`,`,,`---MIL-HDBK-454 AviTable 71-IICable, multiconductor, interconnectionIndexesIndex I-1 Index of Applicable DocumentsIndex I-2 Subject IndexProvided by IHSL icensee=Boeing/5910770001 Not for Resale, 11/03/2006 14:57:12 MSTNo reproduction or networking permitted without license from IHS--``,,,,,``,,`,`````,,,,``,``-`-`,,`, ,`,`,,`---MIL-HDBK-454A1 1.

7 GUIDELINES applicable to ELECTRONIC EQUIPMENT . This handbook provides guidance andlessons learned in the selection of documentation for the design of ELECTRONIC EQUIPMENT . Thishandbook is for guidance only. This handbook cannot be cited as a requirement. If it is, thecontractor does not have to Revision of GUIDELINES . Revisions of individual GUIDELINES are indicated by a date belowthe guideline number located at the bottom of the page. When the basic document is revised,those GUIDELINES not affected by change retain their existing Redating. Although individual GUIDELINES are reviewed and updated or validated atleast once every eighteen months, GUIDELINES are not redated unless technical changes are Method of reference. GUIDELINES contained herein should be referenced by specifyingthis handbook and the guideline number for guidance Interrelationship of GUIDELINES .

8 Each guideline is intended to cover some discipline inthe design of EQUIPMENT , such as a procedure, a process or the selection and application of partsand materials. Many of these disciplines, however, cannot retain a clear-cut separation orisolation from others so that when GUIDELINES of MIL-HDBK-454 are referenced in a specificationsome GUIDELINES will undoubtedly have a direct interrelationship with other GUIDELINES . Thisinterrelationship should be taken into consideration when referencing these GUIDELINES . 2. APPLICABLE DOCUMENTS. Individual GUIDELINES . See section 2 of each individual guideline for a listing ofapplicable documents. Documents referenced in the individual GUIDELINES apply to the extentspecified Applicable issues. Unless otherwise specified, the applicable issues should be thoselisted in that issue of the Department of Defense Index of Specifications and Standards (DODISS)specified in the solicitation.

9 The applicable issue of nongovernment documents should be theissue Copies. Copies of specifications, standards, drawings, and publications required bycontractors in connection with specific procurement functions should be obtained from theprocuring activity or as directed by the contracting Industry addresses. Addresses for obtaining documents referenced herein but notobtainable from the Government are as follows:Provided by IHSL icensee=Boeing/5910770001 Not for Resale, 11/03/2006 14:57:12 MSTNo reproduction or networking permitted without license from IHS--``,,,,,``,,`,`````,,,,``,``-`-`,,`, ,`,`,,`---MIL-HDBK-454A2 AGMAA merican Gear Manufacturers Association1500 King Street, Suite 12 Arlington VA 22314 AMSS ociety of Automotive Engineers, Commonwealth DriveWarrendale PA 15096 ANSIA merican National Standards Institute 11 West 42nd StreetNew York NY 10036 ASMEA merican Society of Mechanical Engineers 22 Law Drive Box 2900 Fairfield NJ 07007-2900 ASMA merican Society for Metals Metals Park OH 44073 ASTMA merican Society for Testing and Materials 100 Barr Harbor DriveWest Conshohockan PA 19428-2959 AWSA merican Welding Society 550 NW LeJeune RoadMiami FL 33126 EIAE lectronic Industries Alliance 2500 Wilson VA 22201-3834 IEEEI nstitute of Electrical and Electronics Engineers IEEE Service Center445 Hoes LanePO Box 1331 Piscataway NJ 08855-1331 IPCI nstitute for Interconnecting and Packaging ELECTRONIC Circuits 2215 Sanders Rd.

10 Suite 200 SouthNorthbrook IL 60062 NASN ational Standards Association 1200 Quince Orchard BoulevardGaithersburg MD 20878 Provided by IHSL icensee=Boeing/5910770001 Not for Resale, 11/03/2006 14:57:12 MSTNo reproduction or networking permitted without license from IHS--``,,,,,``,,`,`````,,,,``,``-`-`,,`, ,`,`,,`---MIL-HDBK-454A3 NFPAN ational Fire Protection Association Batterymarch ParkQuincy MA 02269-9101 ULUnderwriters Laboratories, Incorporated 333 Pfingsten RoadNorthbrook IL 600623. Airborne, Space, Aerospace. "Airborne" denotes those applications peculiar to aircraftand missile or other systems designed for operation primarily within the earth's atmosphere;"space" denotes application peculiar to spacecraft and systems designed for operation near orbeyond the upper reaches of the earth's atmosphere; and "aerospace" includes both airborne andspace Other terms are defined in the individual GENERAL Application.