mil-std-454l mil-std-454k standard general reque=m3jts...

MIL-STD-454L20 September 1988SUPERSEDINGMIL-STD-454K14 February 1986

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MILITARY STANDARD

STANDARD GENERAL REQuE=M3JTS FORELECTRONIC EQUIPMENT

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D1STRIEWTION STATEMENT A. Approved for public release; dktribution is unlimited.

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MIL-STD-454L20 September 1988

DEPARTMENT OF DEFENSE

A Washington DC 20360

Standard General Requirements for Electronic Equipment

‘MIL-STD-454L

.1. This Military Standard is approved for use by all Departments and Agencies of theDepartment of Defense.

2. Beneficial comments (recommendations, additions, deletions) and any pertinent datawhich may be of use in improving thk document should be addressed to AeronauticalSystems Division, Attn: ENES, Wright-Patterson AFB OH 45433-6503, by using theself–addressed Standardization Document Improvement ,Yroposal (JID Form 1426) ap-pearing at the end of this document or by letter.

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FOREWORD

This standard is the technical baseline for the design and construction of electronicequipment for the Department of Defense. It capnrres in one document, under suitablesubject headings, fundamental design requirements for twelve general electronic specifi-cations. The opportunity to focus on a single document, afforded to contractors, resultsin substantial savings to the Government. This standard was prepared and is semi-annually updated through the cooperative efforts of Government and industry. Thefollowing Government documents are intimately associated with thk standard:

MU--I-983

ML-E-4158

MIL-E-5400

MILE-8189

DOD-E-8983

ML-P-11268

MILE-11991

MIL-E-16400

MLL-F-18870

MIL-T-21200

MIL-T-28800

FAA-G-21OO

Interior Communication Equipment, Naval Shipboard, Basic DesignRequirements for (Not for New Design)

Electronic Equipment, Ground, General Specification for

Electronic Equipment, Aerospace, General Specification for

Electronic Equipment, Missiles, E?oosters and Allied Vehicles,General Specification for (Not for New Design)

Electronic Equipment, Aerospace, Extended Space Environment,General Specification for

Parts, Materials, and Processes Used in Electronic Equipment

Electronic, Electrical and Electromechanical Equipment,Guided Missile and Associated Weapon Systems, GeneralSpecification for

Electronic Interior Communication and Navigation Equipment,Naval Ship and Shore, General Specification for

Fire Control Equipment, Naval Shipboard, General Specification for

Test Equipment for Use with Electronic and Electrical Equipment,General Specification for (Not for New Design)

Test Equipment for Use with Electrical and Electronic Equipment,General Specification for

Electronic Equipment, General Requirements

111

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CONTENTS

Paragraph

~ 1. SCOPE1.1 Requirements applicable to electronic equipment1.2 Revision of requirements1.3 Method of reference1.4 Interrelationship of requirements

.2. APPLICABLE DOCUMENTSDEFINITIONS

:: GENER4L REOUREMENTS4.1 Application -4.2 Use of selection and application standards5. DETAIL REQUIREMENTS6. NOTES

Individual Requirements

Requirement 1- Safety Design Criteria - Personnel HazardsRequirement 2- CapacitorsRequirement 3- FlammabilityRequirement 4- Fungus-Inert MaterialsRequirement 5- SolderingRequirement 6- BearingsRequirement 7- InterchangeabilityRequirement 8- Electrical Overload ProtectionRequirement 9- WorkmanshipRequirement 10- Electrical ConnectorsRequirement 11 - Insulating Materials, ElectricalRequirement 12- Fastener HardwareRequirement 13- Structural WeldingRequirement 14- Transformers, Inductors, and CoilsRequirement 15- Metals, Corrosion ResistanceRequirement 16- Dissimilar MetalsRequirement 17- Printed WiringRequirement 18- Derating of Electronic Parts and MaterialsRequirement 19- TerminationsRequirement 20- Wire: Hookup, InternalRequirement 21 - Castro s

.!?Requirement 22- Parts election and ControlRequirement 23- AdhesivesRequirement 24- Welds: Resistance, Electrical InterconnectionsRequirement 25- Electrical PowerRequirement 26- Arc-Resistant MaterialsRequirement 27- BatteriesRequirement 28- ControlsRequirement 29- Electron TubesRequirement 30- Semiconductor DevicesRequirement 31 - Moisture Pockets

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CONT&E$ - Continued

Requirement 32- Test ProvisionsRequirement 33- ResistorsRequirement 34- NomenclatureRequirement 35- ReliabilityRequirement 36- AccessibilityRequirement 37- Circuit BreakersRequirement 38- Quartz Crystals and Oscillator UnitsRequirement 39- Fuses and Fuse HoldersRequirement 40- ShuntsRequirement 41- SpringsRequirement 42- Tuning Dial MechanismsRequirement 43- LubricantsRequirement 44- Fibrous Materials, OrganicRequirement 45- Corona and Electrical Breakdown PreventionRequirement 46- Motors and Rotary Power ConvertersRequ~rement 47- Encapsulation and Embedment (Potting)Requirement 48- GearsRequirement 49- HydraulicsRequirement 50- Indicator LightsRequirement 51- Meters, Electrical IndicatingRequirement 52- Thermal DesignRequirement 53- Waveguides and Related DevicesRequirement 54- MaintainabilityRequirement 55- EnclosuresRequirement 56- Rotary Servo DevicesRequirement 57- RelaysRequ~rement 58- SwitchesRequirement 59- BrazingRequirement 60 – Sockets and AccessoriesRequirement 61- Electromagnetic Interference ControlRequirement 62- Human EngineeringRequirement 63- Special ToolsRequirement 64- Microelectronic DevicesRequirement 65- Cable, Coaxial (RF)Requirement 66- Cable, MulticonductorRequirement 67- MarkingRequirement 68- Readouts and DkplaysRequirement 69- Internal Wtring PracticesRequirement 70- Electrical FiltersRequ~rement 71 - Cable and Wire, InterconnectionRequirement 72- SubstitutabilityRequmement 73- Standard Electronic ModulesRequirement 74- Grounding? Bonding, and ShieldlngRequirement 75- Electrostatic Discharge Control

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CONTENTS - Continued

Figure

Figure 17-1

“ Tables , Id

Table 1-1Table 1-IITable 4-ITable 10-1Table 20-1Table 21-1Table 26-ITable 41-ITable 41-IITable 41-IIITable 50-1Table 53-ITable 66-ITable 69-ITable 71-1Table 71-II

Indexes

Index I-1Index I-2

Preferred printed wiring board sizes

Probable effects of shockSuitable protective measuresFungi-susceptibility of materialsAbbreviations for thermocouple materialsWire, electricalGeneral comparison of metallic casting processesArc-resistant materialsMaterials for electrical spring applicationCorrosion resisting steel for springsCarbon steel for springsIndicator lights and associated itemsWaveguides and related devicesCable, multiconductorElectrical clearance and leakage (creepage) distancesWire, electrical, interconnectionCable, multiconductor, interconnection

Index of Documents Applicable to MIL-STD-454LSubject Index



STANDARD GENERAL REQUIREMENT S FOR ELECTRONIC EQUIPMENT

1. SCOPE

1.1 Re u“r m nt~ roni eauiDmen~. T& standard covers thecommon requirements to be used in military specifications for electronic equipment.

1.2 )7evision of reau irements. Revisions of individual requirements are indicated by adate below the re~uirement number located at the bottom of the page. A note,“Supersedes Requwement (no.) (date)”, is placed in the lower comer of each revisedpage, opposite the requirement number and date. When the basic document is revised,those requirements not affected by change retain their existing date.

1.2.1 I@&@ Although individual requirements are reviewed and updated orvalidated at least one every eighteen months, requirements are not redated unlesstechnical changes are made.

1.3, M th~. Requirements contained herein shall be referenced in theindividual specification by specifying thk standard and the requirement number.

1.4 Int&relationship of requirements. Each requirement is intended to cover somediscipline in the design of equipment, such as a procedure? a process or the selectionand application of parts and materials. Many of these disciplines, however, cannotretain a clear-cut separation or isolation from others so that when requirements ofJ41L-STD-454 are referenced in a specification some requirements will undoubtedlyhave a direct interrelationship with other requirements. This interrelationship should betaken into consideration when invokkg or using these requirements.

2. APPLICABLE DOCUMENTS

2.1, Individual Requirements. See paragraph 2 of each individual requirement for alisting of apphcable documents contained therein, including those for guidance only.Documents referenced in the individual requirements apply to the extent specifiedtherein.

2.1.1 ~s. Unless otherwise specified, the applicable issues shall bethose listed in that issue of the Department of Defense Index of Specifications andStandards (DODISS) specified in the solicitation. The applicable issue ofnongovemment documents shall” be the issue specified.

2.1.2 -. Copies of specifications, standards, drawings! and publications requiredby contractors in connection with specific procurement functions should be obtainedfrom the procuring activity or as directed by the contracting officer.

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2.1.3 Jndustrv add ressesj. Addresses for obtaining documents referenced herein butnot obtainable from the Government are as follows:

AGMA

ANSI

‘,.,

ASM

ASTM

AWS

EIA

IEEE

IPc

NAS

NFPA

UL

American Gear Manufacturers Association1901 North Fort Meyer DriveSuite 1000Arlington VA 22209

American National Standards institute1430 BroadwayNew York NY 10018

American Society for MetalsMetals Park OH 44073

American Society for Testing and Materials1916 Race StreetPhiladelphia PA 19103

American Welding Society550 NW LeJeune RoadPO Box 351040Miami FL 33135

Electronic Industries Association2001 Eye Street, NWWashington DC 20006

Institute of Electrical and Electronics Engineers820 Second AvenueNew York NY 10017

Institute for Interconnecting and Packaging Electronic Circuits7380 North Lincoln AvenueLkcolnwood IL 60646

National Standards Association5161 River RoadBethesda MD 20816

National Fire Protection AssociationBatterymarch ParkQuincy MA 02269

Underwriters Laboratory, Incorporated333 Pfingsten RoadNorthbrook IL 60062

3. DEFINITIONS

3.1 As used in thk standard, the word “airborne” denotes those applications peculiarto aircraft and missile or other systems designed for operation primarily within

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the earth’s atmosphere; “space” denotes application peculiar to spacecraft and systemsdesigned for operation near or beyond the upper reaches of the earth’s atmospher%and “aerospace” includes both airborne and space applications.

3.2 Other terms are defined in the individual Requirements.

4. GENERM. REQUIWMENTS

4.1 A~ i ion, The Requirements contained herein are intended to provide uniformrequirements applicable to electronic equipment, unless otherwise specified in theRequirement, and shall be incorporated by reference in general equipmentspecifications. Other documents may reference Requirements when applicable.

4.2 use of selection and armlication standardS. When a selection and applicationstandard is invoked in a Requirement, the devices or parts selected shall conform tothe applicable military specifications referenced in the standard.

5. DETAIL REQUIREMENTS

5.1 Individual Requirements for electronic equipment follow.

6. NOTES

6.1 The margins of this standard are marked with asterisks to indicate where changes(additions, modifications, corrections, deletions) from the previous issue were made.‘His is done as a convenience only and the Government assumes no liabilitywhatsoever for any inaccuracies in these notations. Bidders and contractors arecautioned to evaluate the requirements of this document based on the entire contentirrespective of the marginal notations and relationship to the last previous issue.

6.2 Subiect term (kev word) Iistirw.

Cable selection NomenclatureCorona protection Parts selectionEncapsulation Printed wiringFasteners SafetyFlammability SolderingFungus protection Substitutability of partsInterchangeability of parts Thermal designMarking WaveguidesMaterials selection W:re selectionMicroelectronics Workmanship

Custodians: Preparing activity:Army - ER Alr Force - 10Navy - ASAir Force -11 Agent

Air Force -11Review activities:

Army - AR, AV, CR, ME, MI, TENavy - EC, SH, OSAir Force -17, 19, 85

Project GDRQ-0068

Other:DLA - ESFAA

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MIL-STD-454L

REQUIREMENT 1

SAFETY DESIGN CRITERIA - PERSONNEL HAZARDS

1. n~e. This requirement establishes safety design criteria and provides guidelinesfor persomel protection.

2. Pocume ts amn licable to Reau irement k

MIL-B-5087

NEL-STD-131O

MIL-STD-1472

MIL-HDBK-600

ANSI C95.1-1982

ANSI C95.2-1982ANSI N2.1-1969ANSI Z35.1-1972ANSI Z35.2-1968ANSI Z35.4-1973

Bonding, Electrical, and Lightning Protection, forAerospace SystemsSKlpboard Bonding, Groundktg, and Other Techtdques forElectromagnetic Compatibility and Safety ShieldingHuman Engineering Design Criteria for Military Systems,Equipment and FacilitiesGuidelines for Identification, Markings, Labeling, Storage,and Transportation of Radioactive CommoditiesSafety Le;els with Respect to Human Exposure to RadioFrequency Electromagnetic Fields, 300 KHz to 100 GHzRadio Frequency Radiation Hazard Warning SymbolRadiation SymbolAccident Prevention Signs, Specification forAccident Prevention Tags, Specification forSpecification for Informational Sims Complemental toA&Sl Z35.1, Accident Preventio~ Signs - -

ANSI Z53. 1-1979 Marking Physical Hazards, Safety Color Code forNFPA 70-1987 National Electrical CodeCode of Federal Regulations, Title 10, Chapter I, Part 20Code of Federal Regulations, Tide 21, Chapter I, Subchapter JCode of Federal Regulations, Title 29, Chapter XVII, Part 1910

3. Definitions

3.1 Chassis. electrical equi~ment. The chassis is a structural item fabricated in suchmanner as to facilitate assemblage and interconnection of electrical or electronic itemsfor the specific purpose of providing a basis for electrical or electronic circuits. Itnormally has drilled or stamped holes to accommodate the items but may include onlythe items necessary for its own mounting and support.

3.2 EI&OE. The frame is any construction system fitted and united together, designedfor mounting or supporting electrical or electronic parts or units.

3.3 E&M&. The design feature of a part, unit or equipment which causes the itemto fail only into a non-hazardous mode.

3.4 Interlock. An interlock is an automatic switch which eliminates all power from theequipment when an access door, cover or plate is removed.

3.4.1 Ehmass interlock. A bypassable interlock is an automatic switch with a manuallyoperated electrical bypass device to allow equipment maintenance operations.

SupersedesREQUIREMENT 114 February 1986

1-1

REQUIREMENT110 September 1987


IMIL-STD-454L

4. Beau emen Sir t

4.1 F~. The design and development of all military electronic equipment shallprovide fail-safe features for safety of personnel during the installation, operation,maintenance, and repair or interchanging of a complete equipment assembly or compo-ment parts thereof.

4.2 Bond irw in hazardous a ea~ Electronic equipment to be installed in areas whereexplosive or fire hazards exi~t shall be bonded in accordance with IvBL-B-5087 for

~. aerospace systems, MIL-STD-l310 for shipboard system:, and NFPA 70, Chapter 5,ffor ground systems, or as otherwise specified in the detad equipment specification.

14.3 ~emDeratu rc. At an ambient temperature of 25”C, the operating temperature ofcontrol panels and operating controls shall not exceed 49”C. Other exposed parts sub-

1 ject to contact by operating personnel shall not exceed 60”C.

4.4 ~. The design shall incorporate methods to protect personnel from inad-vertent contact with voltages capable of producing shock hazards.

4.4.1 z. Means shall be provided so that power may be cut off while installing,replacing, or interchanging a complete equipment, assembly, or part thereof. Interfacewith electrical power sources shall be in accordance with the applicable regulations orrequirements. If a main power switch is provided, it shall be clearly labeled as suchand shall cut off all power to the complete equipment.

4.4.2 Ground. The design and construction of equipment, excluding self-poweredequipment, shall insure that all external parts, surfaces. and shields, exclusive ofantenna and transmission line terminals, are at ground potential at all times duringnormal operation. The design shall include consideration of ground currents andvoltage limits (possible arcing) established on a basis of hazardaus location. Antennaand transmission line terminals shall be at ground potential, except for radio frequency

..(rf) energy on their external surfaces.

4.4.2.1 Self-oowered eauiDment. Self-powered equipment shall have all external sur-faces at the same potential.

4.4.2.2 ~~. Plugs for use with metal cased portable tools and equip-ment shall have provisions far automatically grounding the metal frame or c?se o!tools and equipment when the plug is mated with receptacle, and the grounding pmshall make first, break last. Ground connections to shields, hinges, and other mechani-cal parts shall not be used to complete electrical circuits. Any external or inter-connecting cable, where a ground is part of the circuit, shall carry a ground wire inthe cable terminated at both ends in the same reamer as the other conductors. In nocase, 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 completeelectrical circuits. A point on the electrically conductive chassis or equipment frameshall serve as the comman tie point for static and safety grounding. The path from thetie point to ground shall:

a. Be continuous and permanent.

REQUIREMENT 110 September 1987

SupersedesREQUIREMENT114 February 1986

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MIL-STD-454L

b. Have ample carrying capacity to conduct safely any fault currents that may be im-posed upon it.

c. Have impedance sufficiently low to limit the potential above ground and to facilitatethe operation of the over current devices in the circuits.

d. Have sufficient mechanical strength of the material to minimize possibility ofground disconnection.

4.4.2.3 I-Iinee d or slide mounted oanels and doo rs. Hinges or slides shall not be usedfor grounding paths. Panels and doors containing meters, switches, test points, etc.shall be attached or hinged in such a manner as to insure that they are at the sameground potential as the equipment in which they are mounted, whether in a closed oropen position. A ground shall be considered satisfactory if the electrical connection be-tween the door or panel and the system tie point efi]bits a resistance of 0.1 ohm orless and has sufficient ampacity to insure the reliable and immediate tripping of equip-ment over-current protection devices.

4.4.2.4 ~fjg. Except where a conflict with single-point shieId grounding require-ments would be created, shielding on wire or cable shall be grounded to the chassis orframe. 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 groundtermination. The shielding shall end at a sufficient distance from exposed conductorsto prevent shorting or arcing between the conductor and the shielding.

4.4.3 ~ n act. The design shall incorporate methods to protect personnelfrom accidental contact with voltages in excess of 30 volts rms or dc during normaloperation of a complete equipment.

4.4.3.1 ~. All contacts, terminals and like devices having voltagesbetween 70 and 500 volts rms or dc with respect to ground shall be guarded from acci-dental contact by personnel if such points are exposed to contact during direct supportor operator maintenance. Guards or barriers may be provided with test probe holeswhere maintenance testing is required.

4.4.3.2 Hieh voltaee euarding. Assemblies operating at potentials in excess of 500vo[ts shall be completely enclosed from the remainder of the assembly and equippedwith nonbypassable interlocks.

4.4.3.3 Voltaee measu rement. When the operation or maintenance “of equipment em-ploying potentials in excess of 300 volts peak could require that these voltages bemeasured, the equipment shall be provided with test points so that these voltages canbe measured at a relatively low potential level. In no case shall the potential exceed300 volts peak relative to ground. Test points with voltages above 30 volts shalt havethe conducting material recessed a distance no less than the diameter of the ,the probehole and a minimum of 0.06 inch. If a, voltage divider is used, the vol~ge dnuderresistance between the test point and ground shall consist of at least two resistors ofequal value in parallel.


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MIL-STD-454L

.4.4.3.4 Gua rdine of rf voltaees. Transmitter output terminals, antennas and other de-vices that carry sufficient rf voltage to bum or injure personnel shall be protected fromaccidental contact in the same manner as for ac voltages in the 70 to 500 volt range.

4.4.3.S Main Dower switch. The power input side of the main power switch and the. incoming power line connections shall be given physical protection against accidental

contact.

4.4.4 Protect ive devices

, 4.4.4.1 bterlocks. When a unit is provided with access doors, covers or plates, these~,access points shall be interlocked as follows:

~:a. No interlocks are required when all potentials in excess of 70 voks are completelyprotected with guards or barriers to prevent accidental contact under all conditions ofoperation or any level of maintenance.

b. Bypassable interlocks are required when voltages between 70 and 500 volts are ex-posed as the result of an access door, cover, or plate being opened. Note that theseinternal voltages are allowed to be unguarded only if they are not exposed during di-rect support or operator maintenance. The bypass device shall be of such design thatclosing the associated ‘door, cover or plate will automatically open the bypass deviceand leave the interlock in position to function normally. Vkual means shall be pro-vided to indicate when the interlock is bypassed.

c. Nonbypassable interlocks are required when any voltage in excess of 500 volts isexposed as a result of an access door, cover or plate being opened.

4.4.4.2 ~. When a battle short switch is required by the individualequipment specification, a readily visible indicator light shall be provided to indicatewhen the battle short switch is ON.

4.4.4.3 Safetv switches. Safety switches which will deactivate associated mechanicaldrive units shall be provided for the purpose of disconnecting these units without dis-connecting other pans of the equipment. Such remotely located units and assembliesshall have provision for nonoverrideable safety switches to allow independent discon-nect in the associated equipment.

4.4.5 Dkchareirw devices

4.4.5.1 Automatic discharee devices. High voltage circuits and capacitors shall be pro-vided with discharging devices unless they discharge to 30 volts or less withh two sec-onds after power removal. The particular discharging device that is chosen shall insurethat the capacitor or high voltage circuit is discharged to 30 volts or less within twoseconds. These protective devices shall be positive acting, highly reliable, and shall ac-tuate automatically either by mechanical release or by electrical solenoid when thedoor or cover is opened. When resistive bleeder networks are used to dischargecapacitors, the bleeder network shall consist of at least two equal valued resistors inparallel.




MIL-STD-454L

4.4.5.2 “~hortine rods. Shorting rods shaIl be provided with aIl transmitting equipmentwhere voltages are in excess of 70 volts rms or dc. Where size permits, shorting rodsshall be stored within the transmitting equipment, permanently attached, and readilyaccessible to maintenance personnel. The permanently attached rod shall be connectedthrough a flexible stranded copper wire (covered with a transparent sleeving) to thestud provided at the transmifler main frame. Where size does not permit internal stor-age of the shorting rod, a grounding stud shall be provided to permit attachment of aportable shorting rod. The connection to the stud shall be such that accidentalloosening or high resistance to the ground is prevented.

4.4.6 co nnecto rs. Connectors used to provide separation of or connection to multipleelectric circuits shall be selected so that it will be impossible to insert the wrong plugin a receptacle or other mating unit. Where design considerations require plug and re-ceptacles of similar configuration in close proximity, the mating plugs and receptaclesshall be suitably coded or marked to clearly indicate the mating connections. Plugs andreceptacles shall not be of similar configuration if the major unit contains explosiveitems. The design of the connector shall be such that the operator is not exposed toelectrical shock or bums when normal disconnect methods are used. Exposed pin con-tacts shall not be energized (hot) after being disconnected from the socket contacts.

4.5 Radiation. The design of all equipment for which a federaI standard exists underthe Code of Federal Regulations (CFR), Title 21, Chapter I, Subchapter J, on the Ra-diation Control for Health and Safety Act of 1968, shall conform to the appropriatefederal standard.

4.5.1 Microwave and rf radiation. All electronic equipment or electrical devices capa-bIe of emitting microwave or rf radiation between 300 KHz and 100 GHz shall be sodesigned, fabricated, shielded and operated as to avoid overexposure of personnel. Inareas where unintended radiation levels exist, equipment design and installation in anyunrestricted area accessible to personnel shall meet the requirements of ANSI C95. 1.Shields, covers, doors, etc, which when opened or removed will allow microwave andrf radiation to exceed the above, shall be provided with nonbypassable interlocks.

4.5.2 X radiation. All electronic or electrical devices capable of producing X radia-tion shall be so designed, fabricated, shielded and operated as to keep personnel expo-sure as low as reasonably achievable. For equipment and installation design, shieldingrequirements shall be maintained at all times which limit radiation levels to not greaterthan 2 milliroentgens (mr) in any one hour and 100 mr in any 7 consecutive days atthe operator position or within 5cm from the equipment (whichever is closer) in anyunrestricted area accessible to personnel. In addition, these levels shall be reducedwhenever necessary to ensure that exposed personnel never receive an absorbed doseto the whole body or any critical organ in excess of 125 millirem per calendar quarteror 500 millirem per year. Other exposure shall be based on application criteria andlimits as required by Nuclear Regulatory Commission Rules and Regulations, CFR, Ti-tle 10, Chapter I, Part 20; OSHA Regulations, CFR, Title 29, Chapter XVE:Part1910,96; and FDA Regulation, CFR, Title 21, Chapter I, Subchapter J, RadiologicalHealth. Equipment which, when shields, covers, doors, etc. are removed, will allOw Xradiation to exceed 2.0 mr per hour shall be provided with nonbypassable interlocks.


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MIL-STD-454L

4.5.3 J-aser radiation. Laser equipment and system design, installation, and opera-tional and maintenance procedures shall conform to CFR, Thle 21, Chapter I, Sub-chapter J, Part 1040. If Title 21 cannot be met because of. operational requirements, anexemption shall be requested from the procuring activity and applicable military lasersafety regulations shall be used as a design requirement.

4.6 Mec hanical. The design of the equipment shall be such as to provide personnelmaximum access and safety while installing, operating, and maintaining the equipment.Equipment design shall include provisions to prevent accidental pulling out of drawersor rack mounted equipment components. Suitable protection shall be provided to pre-vent contact with moving mechanical parts such as gears, fans, and belts when the

~equipment is complete and operating. Sharp projections on cabhets, doors, and simi-Jar parts shalI be avoided. Doors or hinged covers shall be rounded at the comers andprovided with stops to hold them open.

4.6.1 Mechanical interconnection. The design shall provide positive means to preventthe inadvertent reversing or mismating of fittings; couplings; fue!, oil, hydraulic, andpneumatic lines; and mechanical linkage. When prevention of mismating by designconsideration is not feasible: coding or marking shall be employed when approved bythe procuring activity. Coding and marking will not be approved as a substitute forproper desigit or items involving explosive, emergency, or safety critical systems.

4.6.2 ~. Equipment power switches shall be so selected andlocated that accidental contact by personnel will not place equipment in operation.

4.6.3 Cathode rav tubes. Provision shall be incorporated to protect personnel frominjury due to implosion of cathode ray tubes.

4.7 EauiDment safetv markines. Danger, caution, etc, signs, labels and markings shallbe used to warn of specific hazards such as voltage, current, thermal, or physical. Thesigns, labels, and markings shall be as permanent as the normal life expectancy of theequipment on which they are affixed. Guards, barriers, and access doors, covers orplates shall be marked to indicate the hazard which may be reached upon removal ofsuch devices. When possible, marking shall be located such that it is not removedwhen the barrier or access door is removed. Additional] y, hazards internal to a unitshall be marked adjacent to hazards if they are significantly different from those ofsurrounding items. Such a case would be a high voltage terminal in a group of lowvoltage devices.

a. Physical hazards shall be marked with color codes in accordance with ANSI Z53.1where applicable to electronic equipment.

b. For potentials between 70 and 500 volts, warning signs or labek shall be in accor-dance with ANSI Z35.1: Class II, and ANSI Z35.4, and shall read, as a minimum,“Caution - (btsert maximum voltage applicable) Volts.”

c. For potentials in excess of 500 volts, warning signs or labels shall be in accordancewith ANSI Z35.1, Class I and ANSI Z35.4, and shall read, as a minimum, “Danger -High Voltage - (lmertmaximumvoltage applicable) Volts.”


L. Supersedes

REQUIREMENT114 Februay 1988

1-8


,

MIL-STD-454L

d. Microwave or rf radiation signs shall be in accordance with ANSI Z35.1 and ANSIC95 .2. Labels shall be provided on all radiation shields to warn personnel of theradiation hazards involved upon removal thereof. Any item which can emit radiationlevels in excess of those specified in paragraph 4.5.1 shall be labeled. Minimum safeclearance distances shall be clearly marked. Warning signs shall be posted in all areashaving electronic equipment designed to operate between 300 KHz and 100 GHz withintended electromagnetic radiation levels exceeding those in paragraph 4.5.1.

e. (1) Laser labels shall be in accordance with ~ Title 21, Chapter I, SubchapterJ, Part 1040.

(2) Military exempt laser labels: A permanent label shall be affixed on all mili-tary laser systems that have been certified exempt from CFR, Title 21, Part 1040 (Per-formance Standards for Light-Emitting Products), which reads:

CAUTION

This electronic product has been exempted from FDA radiation safety performancestandards, prescribed in the Code of Federal Regulations, Title 21, Chapter I,Subchapter J, pursuant to Exemption No. 76 EL-01 DOD issued on 26 July 1976.This product should not be used without adequate protective devices or procedures.

f. Shields which protect personnel from X radiation shall be labeled in accordancewith CFR, Title 10, Chapter 1, Part 20.

g. Coding for accident prevention tags shall be in accordance with ANSI Z35.2.

h. The marking or labeling of commodities containing radioactive materials shall be inaccordance with CFR, Title 10, Chapter I, Part 20.

i. Ionizing radiation hazard symbols shall be in accordance with ANSI N2. 1.

4.8 H~

4.8.1 G~. The materials, as installed in the equipment and under serviceconditions specified in the specific equipment specification, shall not liberate gaseswhich combhe with the atmosphere to form an acid or corrosive alkali, nor shall theyliberate toxic or corrosive fumes which would be detrimental to the performance of theequipment or health of personnel. The materials also shall not liberate gases which willproduce an explosive atmosphere.

4.8.2 Mercury. Materials and parts containing mercury shall not be used unless use ofmercury is specifically required or approved by the procuring activity.

4.8.3 Radioac e mativ terials. Use of radioactive materials shall conform to NuclearRegulatory Commission regulations and shall require approval of the procuring activity.Radium shall not be used to achieve self-luminosity.

StmersedesREQUIREMENT110 September 1987

REQUIREMENT 114 February 1986

1-7


MIL-STD-454L

4.8.4 !las s fibers. Glass fiber materials shall not be used as the outer surface orcovering on cable?, wire or other items where they may cause skin irritation to operat-ing personnel. Tlus does not preclude the use of military specification wire and cable.When maintenance procedures require access to glass fibers, such as insulation, aproper caution note shaII be provided.

5. Jnforma tion for eu idance only

,5.1 Hums n engineering. Human engineering factors affecting safety should be consid.ered when establishing general or detailed design criteria. Wgorous detailedoperational or maintenance procedures are not acceptable substitutes for an inherently

.:safe design. Hazard and safety requirements of MJL-STD-1472 should be used as a

..guide.

5.2 E~. Proper instructions in acciden~ prevention and first-aid proceduresshould be given all persons engaged in electrical work to fully inform them of thehazards involved.

5.2.1 Shock hazards. Current rather than voltage is the most important variable inestablishing the criterion for shock uttensity. Three factors that determine the severityof electrical shock are: (1) quantity of current flowing through the body; (2) path ofcurrent through the 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 resis-tance of the bodv, contact conditions, and the path through the body. See table l-I.Sufficient curren~ “passing through any part of ~he body ~N cause severe bums andhemorrhages. However, relatively small currents can be lethal if the path includes avital part of the body, such as the heart or lungs. Electrical bums are usually of twotypes, 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 th~ough the skin andtissue. While current is the primary factor which determines shock severity, protectionrequirements are based upon the voltage involved to simplify their application. Incases where the maximum current which can flow from a point is less than the valuesshown for reflex action, protection requirements may be relaxed.

TABLE l-I. Probab Ie effects of shock.

Current Values (Mlliarnperes)

AC Effects

25 Hz TO 400 HzDC

o-1 0-4 Perception1-4 4-15 Surprise4-21 15-180 Reflex action

21-40 80-160 Muscular inhibhion40-100 160-300 Respiratory blockOver 100 Over 300 Usually fatal

Supersedes

REQUIREMENT 1 REQUIREMENT110 September 1987 14 February 1986

1-6


MIL-STD-454L

5.2.2 msu lation of controls. All control shafts and bushings thereof should begrounded whenever practicable. Alternatively, the control knobs or levers and allattachment screws that can be contacted during use should be electrically insulatedfrom the shaft.

5.2.3 c~l s Ground connection to an electrically conductive chassisor frame should be mechan~cally secured by soldering to a spotwelded terminal lug orto a portion of the chassis or frame that has been formed into a soldering lug, or byuse of a terminal on the ground wire and then securing the terminal by a screw, nut,and Iockwasher. The screw should fit in a tapped hole in the chassis or frame or itshould be held in a through-hole by a nut. When the chassis or frame is made ofsteel, the metal around the screw hole should be plated or tinned to provide a corro-sion resistant connection. When aluminum alloys are used,. the metal around thegrounding screw or bolt hole may be covered with a corrosion resistant surface filmonly if the resistance through the film is not more than 0.002 ohm. Hardware usedfor mounting of meters, switches, test points, etc, should be grounded, whenever possi-ble.

5.2.4 Acc idental contact. Suitable protective measures are defined in table 1-II.

5.2,4.1 ~kh CUrrent trrotection. Power sources capable of supplying high current canbe hazardous regardless of the voltage at which they operate because of the arcing andheat generated if an accidental short circuit occurs. All power buses supplying 25 am-peres or over should be protected against accidental short circuiting by tools, jewelry orremovable conductive assemblies. This may be accomplished by one or more of thefollowing:

a. Use of guards and barriers.

b. Sufficient space separation to prevent short circuits.

c. Caution - warning signs.

5.2.4.2 ]nterlocks. Various equipment designs require different approaches to the useof interlocks. Interlock use does not modify any other requirements of this standardand must be consistent with equipment or system specifications. Equipment sub-assemblies operating in excess of 500 volts should be considered guarded from acci-dental contact only if they are completely enclosed from the remainder of theequipment and are separately protected by nonbypassable interlocks. (An example ofan equipment where such compartmentalization is desirable is a display unit which util-izes a high voltage power supply for a cathode ray tube.) Modularized or sealed highvoltage assemblies which are opened only at depot level are exempt from interlockingrequirements when approved by the procuring activity.

5.2.4.3 p~s. Terminations such as soldered connections to trans-formers, connectors, splices, etc, which are normally permanent and not used duringroutine maintenance testing, may be protected by permanent insulation such as shrhksleeving, tubing, insulating shields, etc, provided the material is rated for the potentialexposed voltage.



1-9

~ ---.


MIL-STD-454L

5.3 hlec hanical. Design of rack mounted equipment should maintain the center ofgravity as low as possible to minimize’ tipping over.

5.4 Marking. ML-HDBK-600 references known electronic items which requiremarking and may be used as a guide.

5.5 Materials. Certain chemicals have been identified in.the Occupational safety andHeaIth Act (OSHA) as cancer-producing substances (carcinogens). Before using anymaterials wh]ch might contain these chem]cals, they should be evaluated in accordancewith the CFR, Tkle 29, Chapter XVII, Part 1910.


140



MIL

-STD

-454L

SupersedesR

EQ

UIR

EM

EN

114

February1986

141

=1

ala

al

RE

QU

IRE

ME

NT

1Io

September.

1987


MIL-STD-454L

RJ3QUREMENT 2

CAPACITORS

1. fi~e. Thk requirement establishes criteria for the selection and application ofcapacitors.

2. Docume ts amiicable ton Requirement 2:

MIL-C-39006/22 Capacitor, Fixed, Electrolytic (Nonsolid Electrolyte),Tantalum, (Polarized, Sintered Slug), 85 C (Voltage Derated to125 C), Established Reliability, St#e CLR79

MIL-C-39006/25 Capacitor, Fixed, Electrolytic (Nonsolid Ele&rolyte),Tantalum, (Polarized, Sintered Slug) (Extended Range), 85 C(VaItage Derated to 125 C), Established Reliability, Style CLR81

MIL-STD-198 Capacitors, Selection and Use of

3. De finitions. Not applicable.

4. Reou em sir ent

~4~:}8ction. Capacitors shall be selected and applied in accordance with MJL-

4.2 F}xed. ta ntalum electrolytic. For Naval Air Systems Command, the use of wetslug tantalum capacitors (except tantalum cased units in accordance withMIL-C-39006/22 and MIL-C-39006/25) requires the approval of the procuring activity,and silver cased tantalum capacitors shall not be used.

5. Information for QU cidan e onlv. Not applicable:


2-1



MIL-STD-454L

REQUIREMENT 3

FLAMMABILITY

1. I!u!u. This requirement establ$hes criteria for the selection and application ofmaterials with respect to flammabdlty.

2. p en~ irement 3

MIL-STD-202 Test Methods for Electronic and Electrical Component PartsASTM D568-77 Rate of Burning and/or Extent and Time of Burning of

Flexible Plastics in a Vertical Position, Test Method forASTM D635-81 Rate of Burning and/or Extent and Time of Burning of

Self-Supporting P1astlcs in a Horizontal Position, TestMethod for

ASTM D1OOO-82 Pressure-Sensitive Adhesive Coated Tapes Used forElectrical Insulation, Methods of Testing

UL 94 Standard for Tests for Flammability of Plastic Materialsfor Parts in Devices and Appliances

3. Definition. Flammability is a complex characteristic which combines ease ofignition, surface flammability, heat contribution, smoke production, fire gasses, andfire endurance. Flammability is a function of chemical composition, physicalconfiguration, temperature, availability of oxygen, and retardants or additives.

4. Requirements. Materials used in military equipment shall, in the end itemconfiguration, be noncombustible or fire retardant in the most hazardous conditions ofatmosphere, pressure, and temperature to be expected in the application. Fire retardantadditives may be used provided they do not adversely affect the specified performancerequirements of the basic materials. Fire retardance shall not be achieved by use ofnonpermanent additives to the basic material.

5. ~ ida ce onlv. The test used to determine the flammability ofmaterial should be the test specified in the material specification. Since some materialsmay change state or characteristics relative to flammability during application, testsmay be performed on the end item materials mixed/blended/saturatedfimpregnated/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 accordance withASTM D568, ASTM D635, ASTM DIOOO,or MIL-STD-202, Method 111, as applicable.

5.2 Materials not covered by the above tests should be tested in accordancewith a procedure approved by the procuring activity. UL 94 is a useful guide todevelop test methods and offers a comparative scale to define degree of flammability.



3-1


MIL-STD-454L

REQUIREMENT 4

FUNGUS-INERT MATERIALS

1. @QXl%. Thk requirement ~dentifies ~ose materials which me acceptable non.nutnents of fungus and estabhshes condmons under which fungus nutrient materialsare acceptable.

2. Docume nts arm Iicable to Reau irement 4:

ML-T-152 Treatment, Moisture and Fungus Resistant, of Communications,Electronic, and Associated Electrical Equipment

m-v-l 73 Varnish, Moisture and Fungus Resistant (For Treatment ofCommunications, Electronic, and Associated Equipment)

MIL-STD-81O Environmental Test Methods and Engineering GuidelinesCode of Federal Regulations, Thle 29, Chapter XVII, Part 1910.

3. De firtition~

3.1 Fu neus-inert material. A material which, in all modified states and grades, is nota nutrient to fungi.

3.2 Jlmicide. A substance that destroys or inhibits the growth of fungi.

4. Requirements

4.1 Preferred materials. Fungus-inert materials listed in Group I of table” 4-I are pre-ferred 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 itsuse except from the viewpoint of the resistance of the material to fungi.

4.2 Accemable materials. Those materials listed in Group II of table4-I may be used,provided it has been demonstrated that they meet the requirements of paragraph 4.4.When materials are compounded with a permanently effective fungicide in order tomeet the fungus test requirement, there shall be no loss of the original electronic orphysica~ properties required by the basic material specification. Fungicides containingmercury shaI1 not be used.

4.3 Hermet icalty Sealed arm lications. Fungus nutrierit materials may be used untreatedwithht hermetically sealed enclosures.

4.4 ~ ti g. Group II materials shall be subjected to the fungus test specifiedin MIL-STD-81 O, Method 508, for a period of 28 days. Certification by a qualifiedlaboratory or by the material producer, based on test data on record that the materialmeets Grade O or Grade 1 requirements of table 508-1, Method 508, MTL-STD-81O, issufficient evidence of acceptability.

SupersedesREQUIREMENT 412 Februa~ 1988


4-1


MIL-STD-454L

TABLE 4-I. Fungi susceptibility of materials.

Grouo 1- Funeus -inert ma ti

(Fungus-inert in all modified states and grades)

Acrylics 1/ PolyamideAcrylonitrile-styrene PolycarbonateAcrylonitrile-vinyl-chloride Polyester-glass fiber laminates

copolymer Polyethylene, high densityAsbestos (above 0.940)Ceramics Polyethylene terephthalateChlorinated polyester PolyimideFluorinated ethylenepropylene copolymer PolymonochlorotrifluoroethyleneG,%) Polypropylene

PolystyreneMetals PolysulfoneMica PolytetrafluoroethylenePlastic laminates: Polyvinylidene chloride

Silicone-glass fiber Silicone resinPhenolic-nylon fiber Siloxane-polyolefin polymer

Diallyl phthalate Siloxane polystyrenePolyacryionitrile

~s

(May require treatment to attain fungus resistance)

ABS (acrylonitrile-butadiene-styrene) Polyethylene, low and mediumAcetal resinsCellulose acetate

density (0.940 and below)Polymethyl methacrylate

Cellulose acetate butyrate Polyurethane (the ester types areEpoxy-glass fiber laminatesEpoxy-resin

particularly susceptible)Polyricinoleates

Lubricants Polyvinyl chlorideMelamine-formaldehyde Polyvinyl chloride-acetateOrganic polysulphides Polyvinyl fluoridePhenol-formaldehyde Rubbers, natural and syntheticPolydichlorostyrene Urea-formaldehyde

~/ Literature shows that under certain conditions polyamides may be attacked byselective micro-organisms. However, for military applications, they are consideredGroup I.


4-2



MIL-STD-454L

5. In~y idance onl

5.1 fiocess-related materials. Processing materials to be tested for fungus resistancein accordance with paragraph 4.4, such as paint, ink, coatings, adhesives, lubricants,viscous damping fluids, silicone grease, etc, should be prepared in the form of 2-inchsquares or cwcles no more than 1/16 inch tilck. for testing. Liquid or paste materialsshould be prepared by impregnating to saturation a sterile sample of glass fabric.

5.2 P2 nt. When treatment of parts is required to form fungus-resistantmateriaIs, a ‘moisture and fungus proofing (IvfFP) varnish conforming to ML-V-173may be applied in accordance with ML-T-152 after the part is cleaned. The MFPvarnish should not be applied to any part where the treatment will interfere withperformance.

5.3 c arcinoeens. Certain chemicals have been identified in the Occu ational Safety~. Before usingand Health Act (OSHA) as cancer-producing substances (carcinogens

any materials which might contain these chemicals, they should be evaluated inaccordance with the Code of Federal Regulations, Title 29, Chapter XVII, Part 1910.Consideration of the toxicity of a substance should be given prior to material selection.



4-3

.-


MIL-STD-454L

REQUIREMENT 5

SOLDERING

1. XG This requirement establishes procedures for making soldered electrical andelectromc comections.

2. Docume ts arm cable to Reaun Ii irement &

DOD-STD-2000-IDOD-STD-2000-2

DOD-STD-2000-3

DOD-STD-2000-4

Soldering Technology, High Quality/High ReliabilityPart and Component Mounting for High QuaIhy/HghReliability Soldered Electrical and Electronic AssembliesCriteria for High Quality/High Reliability SolderingTechnologyGeneral Purpose Soldering Requirements for Electrical andElectronic Assemblies

3. De finition$. Not applicable.

4. Reau irements. Except for Navy applications, general purpose soldering shall beperformed in accordance with DOD-STD-2000-4. For Navy applications, solderingshall be performed in accordance with the combined requirements ofDOD-STD-2000-1, DOD-STD-2000-2, and DOD-STD-2000-3.

5. ~v

5.1 Navv arm Iications. In the event of conflict between these requirements and othercontractual requirements, differences should be referred to the government contractingofficer prior to proceeding.

5.2 ~ Iications. Certain other applications may require the use ofDOD-STD-2000-I, DOD-STD-2000-2 and DOD-STD-2000-3.


5-1

REQUIREMENT5.10 September 1987


MIL-STD-454L

REQWNNENT 6

BEARINGS

1. ~~e. Thk requirement establishes criteria for the selection and application ofbearings.

2. Pocu ments am licable to Recruirement 6:

FF-B-171FF-B-185

FF-B-187FF-B-195MIL-B-3990MIL-B-5687

MJL-B-8942MIL-B-8943MIL-B-8948MIL-B-13506MIL-B-17380MIL-B-81744MIL-B-81 793

MIL-B-81934MIL-B-81936MIL-STD-1334

Bearings, Ball, Annular (General Purpose)Bearings, Roller, Cylindrical; and Bearings, Roller, Self-AlignirigBearing, Roller, TaperedBearings, Sleeve, (Bronze, Plain or Flanged)Bearing, Roller, Needle, Airframe, Anti-Friction, InchBearing, Sleeve, Washers, Thrust, Sintered, Metal PowderOil Impregnated, General Specification forBearings, Plain, TFE Lined, Self-AfigningBearings, Journal-Plain and Flanged, TFE LinedBearing, Plain Rod End, TFE Lined, Self-AligningBearing, Sleeve (Steel Backed)Bearing, Roller, ThrustBarrier Coating So!ufion, Lubricant Migration Dete,mingBearing, Ball, Preclslon, for Instruments and RotatingComponentsBearing, Sleeve, Plain and Flanged, Self-LubricatingBearing, Plain, Self-Aligning (BeCu Ball, CRES Race)Process for Barrier Coating of Anti-Friction Bearings


4. Requirements

4.1 selection and aDDIication. Bearings best suited to meet the physical, functional,environmental and service life requirements of the application shall be selected fromthose conforming to one or more of the specifications listed below. Replacement ofthe bearing shall be possible without the use of special tools unless such provisionswould adversely affect the proper functioning or semice life of the bearing.

FF-B-171 MIL-B-5687 M5B-17380FF-B-185 MIL-B8942FF-B-187

ML-B-81 793MIJ-A-8943

FF-B-195MIL-B-81934

MIL-B-8948MIL-B-3990

MILA3-81936MIL-B-13506

4.2 Lubricant. Adequate lubricant shall be provided either within the bearing orexternally in the form of oil reservoirs or grease relubrication facilities except as

SupersedesREQUIREMENT 615 August 1961

6-1



MIL-STD-454L

noted in 4.3. Where lubricant replenishment is required, precautions shall be taken toprevent pur$ed or lost lubricant from entering and adversely affecting the operation ofthe electroruc equipment. Where bearings coated with preservative are installed inclosed housings, the preservatives shall be compatible with the lubricant used in theassembly.

4.3 Unlubricated bea rine~. Unlubricated bearings or bush]ngs may be used only inapplications where the presence of a lubricant would be undesirable or detrimentand the functional, environmental and service life requirements can be met in thk

,condhion.

.“4.4 J3arrier coa ting. Bearings requiring a barrier coating shall be coated inaccordance with MIL-STD-1 334. Barrier coating material shall conform toMIL-B81744.

I4.5 ~~. All rolling element bearings shall be adequately protected byseals or shields on the bearing or installed in housings wh]ch provide adequate

I shleldlng to prevent foreign matter from entering the bearing.

4.6 ~F din Ball and roller bearings used for rotating an electricallyenergized equipment shall’ be electrically shunted to avoid current flow through thebearings.

1 4.7 Alienment. Bearings shall be located to ensure proper shaft alignment andsupport.

~5. Information for euidance only

5.1 ~elf-lubricating bearines. Permanently lubricated bearings or bushings of plastic,metallic-plastic combinations, or all metallic materials with or without dry film lubri-

1 cants may be used provided wear products produced during operation will not cause or‘,: contribute to failure of the electronic equipment or bearings.

5.2 Unlubricated bearines. For selection of low friction, long life, unlubricatedbearings refer to ML-B-8942, ML-B-8943, and ML-B-8948.


SupersedesREQUIREMENT615 August 1981

6-2


,

MIL-STD-454L

REQUDWMENT 7

1NTERCHANGEABILIT%

~. EIKQQSQ.This. requirement establishes criteria for the selection and application ofutterchangeable Items.

2. pocu ments armIicable to Reau irement 7:

MJL-STD-280 Definitions of Items Levels, Item Exchangeabliity, Models,and Related Terms

3. Qe finition~. Not applicable.

4. Beau irement$

4.1 hjns. Interchangeable items shall be as defined in MIL-STD-280to permit their installation as interchangeable assemblies, sub-assemblies and partswithout regard to the source of manufacture or supply.

4.2 Stand ard items. Standard items are defined in the applicable general specification.

4.2.1 D~s ~ Provisions shall be made for design tolerances such thatitems having the dimensions and characteristics permitted by the item specificationmay be used as replacements without selection or departure from the specified equip-ment performance.

4.2.2 ~. Standard items shall be used when such items are avail-able. When existing standard items are not available and permission is granted by theprocuring activity for use of a nonstandard item only because the existing standarditems is not available, the equipment shall be so designed that the nonstandard itemcan be replaced by the standard item. Appropriate space, mounting holes, and othernecessary provisions shall be provided for thk purpose unless they conflict with thespecified equipment size requirement. When provision is made for substitute or re-placement items, the standard item to be used for replacement shall be identified inthe applicable documentation.

5. I!lf~ nl

5.1 Choice of Darts and materials. When the item specification provides more thanone characteristic or tolerance, the item having the broadest characteristics andtolerances that will fulfill the equipment performance requirements should be used.

Supersedes : ●.REQUIREMENT7 ““.+‘,29 August 1986 .>.

.+ ,“.. . . 7-i

REQUIREMENT712 February 1988


>

MIL-STD-454L

REQUDWMENT 8

ELECTRICAL OVERLOAD PROTEC’ITOI’J

1. ~w. ~k requirement establishes the criteria and philosophy for electricaloverload protection.

2. ~P n Reouire ent &

MIL-STD-280 Definitions of Item Levels, Item Exchangeability, Models,and Related Terms

MU-STD-1539 Electrical Power, Direct Current, Space Vehicle DesignRequirements

NFPA 70-1987 Nat]onal Electrical Code

3. p~s

3.1 Class 1 eau iDment: Ground and shipboard, including test and checkout groundequipment

3.2 Class 2 eau ioment: Manned aerospace equipment

3.3 Class 3 eau iDment: Unmanned aerospace equipment

4. Reau irements-. The requirements specified herein shall apply only to equipmentand systems as defined in IvIIL-STD-280 for class 1 and class 2 equipment and NILSTD-1539 for class 3 equipment.

4.1 Precinfrl~

4.1.1 Cu rrent overload motection. Current overload protection shall be provided forprimary circuits. Devices such as fuses, circuit breakers, time delays, cutouts, orsolid-state current-interruption devices shall be used to open a circuit whenever anoverload condition occurs. No overcurrent protective device shall be connected inseries with any conductor which is grounded at the power source unless the devicesimultaneously opens all load conductors in the circuit and no pole operatesindependently, or as otherwise allowed by the National Electrical Code, NFPA 70.Protective devices for wired-in equipment shaIl be comected to the load side of theequipment power switch (main circuit power discomect). For portable equipment aseparable comector or the attachment p[ug and receptacle shall serve as the maincircuit power disconnect and the protective device may be on either the line side orthe load side of the equipment on-off switch.

4.1.2 m. Where fuses are used, at least one extra fuse of each type and ratingused 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 tooIs.

SupersedesREQUIREMENT 8 REQUIREMENT829 August 1986 , ,“ 12 February .1988

.,..,. . 8-1


MIL-STD-454L

4.1.3 Circuit brea kers. Circuit breakers shall give a visual indication when tripped.Holding the switching device closed on an overload shall not prevent tripping of thebreaker. Multi-pole circuit breakers shall be used for three-phase equipment and shall

; dkconnect all phases if an overload occurs in any one phase. Circuit breakers shallnot be used as switches unless such breakers have been specifically designed and. . .tested ror mat type serwce.

T4.2 Rotect ion for class 2 eouiument

4.2.1 Current overload D otectr ion. Current overload protection for the equipmentshall be provided by fuses or circuit breakers. Circr.ut breakers shall not be used asswitches unless such breakers have been specifically designed and tested for that typeservice.

4.2.2 @are fuses. When fuses are used, a minimum of one spare fuse for each sizeand rating but a quantity of not less than 10 percent of the total shall be incorporatedin the equipment and shall be contained in the same compartment.

4.3 Botection for class 3 eau iDment. Electrical overload protection shall not be pro-vialed in individual boxes or systems receiving power.

“5. Information for euidance only

5.1 Location. Overload protection for the equipment should be provided therein.For class 1 and class 2 equipment, all protective devices employed in the equipmentshould be in a readily accessible, safe location.

5.2 Resettable circuit protectors. Circuit breakers or other resettable devices shouldbe used to protect critical circuits, or where predictable overloads or surges occurbecause of peculiar equipment functions or operator effects which are unavoidable.

f

,,I REQUIREMENT8

12 February 1988

I .“”


8-2


MIL-STD-454L

REQWfUMENT 9

WORKMANSHIP

1. m. ~is requirement establishes the acceptable workmanship criteria forelectromc equipment. Tfus requmement wdl define those workmanship requirements notnormally covered in subsidiary specifications or drawings.

2. Pocu ments am Iicable to Reauireme nt 9: Not applicable.

3. PAS. Not applicable.

4. Reau rementsi

4.1 Cleaning. After fabrication, parts andassembled equipment shall be cleaned ofsmudges; loose, spattered, or excess soldeu weld metal; metal chips and mold releaseagents; or any other foreign material which might detract from the intended operation,function, or appearance of the equipment.

4.2 fireadedvartso device$. Screws, nuts and bolts shall show no evidence of crossthreading, mutilation, ~r detrimental or hazardous burrs, and shall be firmly secured.

4.3 Bearirw assemblies. Bearing assemblies shall be free of rust, discoloration, andimperfections of ground, honed, or lapped surfaces: Contacting surfaces shall be freeof tool marks, gouge marks, nicks, or other surface-type defects. There shall be nodetrimental interference, binding, or galling.

4.4 -. Wires and cables shall be positioned orprotected to avoid contact withrough or irregular surfaces and sharp edges and to avaid damage to conductors oradjacent parts.

4.S s-g. Shielding on wires and cables shall be secured ina manner that willprevent it from contacting or shorting exposed cu~ent-carrying parts. The ends of theshielding or braid shall be secured to prevent fraying.

5. Inf ro mation for eu yidance on]

5.1 c ontainmen t. The harness and cable form containment means shauld be neat inappearance, uniformly applied, and positioned to retain critical form factors and break-out locations. The containment means (lacing, ties, tiedown straps, etc) should notcause the wire or cable insulation to deform so that performance characteristics areadversely affected.

5.2 brsulation. There should be no evidence of burns, abrading, or pinch marks in theinsulation that could cause short circuits or leakage.

5.3 Clearance. The clearance between wires or cables and heat generating partsshould be sufficient to minimize deterioration of the wires or cables.

SupersedesREQUIREMENT 9 ‘29 August 1986

9-1

REQUIREMENT912 Februay 1988


MIL-STD-454L

REQUREhENT 10

Electrical CONNECTORS

1. WPW ~IS requirement es~bfishes criteria for tie selection ~d appli~tion Ofelectrical comectors.

2. PocrJ ments aDDlicable to Requirement IQ :

MU-J-641ML-P-642

MIL-C-10544

MIL-C-12520

ML-C-55 116MIL.-C-55181

MIL-A-55339

MIL-C-83503

MU-STD-2120

MlL-STD-l 353

MIL-STD-1646

EIA RS 297A-70

Jack, Telephone, General Specification forPlug, Telephone, and Accessory Screws, General SpecificationforConnector, Plug and Receptacle (Electrical, Audio,Waterproof, Ten Contact, Polarized)Connector, Plug and Receptacle (Electrical, Waterproof), andAccessories, General Specification forConnectors, Miniature, Audio, Five-PinConnectors, Plug and Receptacle, Intermediate Power(Electrical) (Waterproof) Type MW, General Specification forAdapters, Connector, Coaxial, Radio Frequency (BcnveenSeries and Within Series)Connectors, Electrical, Flat Cable, and/or Printed WiringBoard, Nonenvironmental, General Specification forConnectors, Electromagnetic Interference (EM) FilterContactElectrical Connectors, Plug-In Sockets and AssociatedHardware, Selection and Use ofServicing Tools for Electric Contacts and Connections,Selection and Use ofCable Connectors for Audio Facilities for Radio Broadcasting

3. Definitions. Not applicable.

4. Reauirement$

4.1 Selection. Selection and use of electrical connectors shall be in accordance withMIL-STD-1353 and as specified herein. Intended use information contained in theindividual comector specifications shall be considered prior to making connectorselections. Contact crimp, installing and removal tools shall be in accordance withMTL-STD-1646 or as specified in the individual comector specifications. However,contractors may use tooling as recommended by the contact or tooling manufacturerprovided that the finished crimp meets all of the performance requirements of thecontact and connector specification. The variety of these tools required within a systemshall be kept to a minimum. Maintenance instructions and other data supplied by thecontractor shall list the military standard tools and contacts.

SupersedesREQUIREMENT 101 September 1982

1o-1



MIL-STD-454L

4.2 Aud o freauei ncv and COIIMDUnicat ion connec~ sDec al Duroosei . Comectorsconforming to MIL-C-10544 or MJbC-55 116 shall be used in audio frequencyapplications, such as head sets and chest set:, exchsdmg pdots’ helmets. For lowlevel, three wire and audio input circuits in fixed plant nontactical sound equipment,

-connectors conforming to EIA RS 297A shall be used.

4.3 co nnectors with thermocomr Ie contacts ~All connectors used in conjunction with$e~o~souples shall have their contact materials identified by one of the following

a. Nameplate securely attached to each connector half or mounted on the panel-moursted receptacles.

b. Insulation sleeving or other markers designed for attachment around wire bundles.Markers shall be attached adjacent to the plug. Contact materials shall be identifiedwith abbreviations in accordance with table 10-1.

TABLE 10-1. Abbreviations for thermoco ude materials.

!,,-

Chromel CR Cobalt coAlumel AL TungstenIron FE Rhenium WREConstantan CN Tungsten wCopper Cu E]dium. IFPlatinum p-r RAodium RHPlatinum Iridium

Rhodium tiRH Rhodium IRRHRhenium RE Molydbenum MO

Gold AU

4.4 fIeavv dutv connectors

4.4.1 power connectors (40-200 amperes) MI power comectors for any groundapplication shall conform to Section 102 of “MIL-STD-1 353 and shall be used withheavy duty jacketed cable as specified on the insert standards.

4.4.2 General mwoose and shiDboard. Connectors for general purpose heavy dutyapplications and shipboard power applications shall conform to Section 102 of MIL-STD-1 353. Connectors used for external applications shall be pressurized and water-proof in the mated and unmated condition in accordance with the requirements ofClasses C or L. Connectors used internally (within a protective enclosure such as ashelter) may be in accordance with Class provided waterproofing or pressurization isnot a requirement for the application.

SupersedesREQUIREMENT101 September 1982


10-2


MIL-STD-454L

4.4.3 “htnle~ nlv). In application where right anglebend is required,’ center lock screw multicontact comectors shall conform toMIL-C-12520 or MIL-C-55181, as applicable.

4.5 ~ nnecto S. Polarized connectors are the preferred styles andshall be used where automatic grounding must be provided to insure safety to equip-ment and personnel. Connectors for general utshty power applications shall conformto Section 106 of MIL-STD-1353.

4.6 plues a d iacks [teleDhone tvDe~. Telephone type jacks and plugs shall conformto MIL-J-64~and MIL-P-642.

4.7 Test iack~. Test jacks shalt conform to Section 105 of MJL-STD-1353. Jacks orreceptacles for use as rf test points shall be selected in accordance with paragraph 4.8.

4.8 ~f connectors. IV connectors shall conform to Section 200 of MIL-STD-1353.Adapters used with rf connectors shall conform to M&A-55339.

4.9 onnC ectors for minted wiring. %Inted circuit connectors shall conform to Sec-tion 104 MIL-STD-1353.

4.10 co nnector wiring. Multiple conductors may terminate in a contact provided thesum of the circular mil areas of the conductors does not exceed the maximum circularmil area for which the contact is rated. Not more than one wire shall be routedthrough any hole in the grommet of an environmentally sealed connector.

4.11 J3xtra contacts. The following requirements are applicable to all articles ofequipment, except those in which it is unlikely that additional circuits will be required.

4.11.1 Oua ntitv and location. Unused connector contacts or contact positions forexternal circuits shall be movided for future use, and shall be located on theperiphery (outer contactsy of the connector. The minimum quantityspecified below:

Total number of used Unused contacts or contactcontacts in connector Po sitions reauired (rein)

shall be as

1 thru 3 1 (optional)4 thru 25 226 thru 100 4101 or over 6

4.11.2 An extra connector shall not be used to meet tlis requirement without theapproval of the procuring activity.

4.11.3 s~ f extr ontacts. The size and rating of extra contacts shallbe compatible with other contacts within the connector.

SupersedesRE’QUIREME~ 101 September 1982

10-3



I MIL-STD-454L

4.11.4 Crimo contact connectors. When crimp contact environmentally sealedcomectors are used, all contact positions shall be filled with contacts.

4.11.5 Sea line du~. Sealing plugs shall be inserted in the grommet holes of unusedcontacts in environmentally sealed comectors.

4.11.6 Potted connecto rs. For potted comectors, each unused contact shall have amaximum gauge wire of 6 inches minimum length attached and identified with thecontact designation for future use. For connectors external to the unit, the wire endshall be suitably capped to prevent moisture from entering the connector.

4.12 Protective measu es ., All unmated connectors shall be protected with metal or‘“plastic caps or otherwis~ stutably protected during maintenance, storage and shipment.

Protective caps specified by military specifications or military standards and designedfor mating with specific connectors shall be used. Unmated connectors which maycontain electrically “hot” circuits while in environmentally hazardous areas shall becovered with moistureproof and vaporproof caps. Connectors on enclosed cabinetmounted equipment need not be provided with protective caps unless an environmentalhazard exists.

4.13 co nnectors for flat conductor cable. Connectors for use with flexible flatconductor cable shall conform to MIL-C-83503.

4.14 Firemoof connectors. Fireproof and firewall connectors shall be class K andshall conform to Section 101 of MIL-STD-l353. Where it is necessary to maintainelectrical continuity for a limited time under continuous flame, both the receptacle andmating plug shall be class K. If flame integrity only is necessary without the need forelectrical continuity, a class K receptacle shall be used, but the mating plug may be ofany type and class. In all cases, the plug and receptacle shall be environmentresisting.

“4.15 Filter Din connectors. Electrical connectors incorporating filter pins shall beconsidered for use only when conventional electrical filters are not acceptable. Whenused, filter pin connectors shall conform to MIL-STD-2120.

5. Information for euidance only. Not applicable.


10-4

/



MIL-STD-454L

REQUDWMENT 11

INsuLATING MATERIALS, ELECTRICAL

1. Puroose. TM: requirement establishes criteria for the selection and application ofelectrical insulating materials.

2. P me Ii~ 11:

L-P-516MIL-I-1OML-M-14MIL-P-79MIL-I-631

ML-P-997

MIL-I-3158

MJL-I-3190ML-1-3825

MIL-I-7444MIL-T-13020

MIL-P-15037

MIL-P-15047

MIL-I-15126

ML-I-1 7205

M.L-I-18057

MIL-P-18177

MIL-I-18746

ML-P-19161

MIL-I-19166

MJL-I-22076

MIL-I-23053

ML-I-23264

Plastic Sheet and Plastic Rod, Thermosetting, CastInsulating Materials, Electrical, Ceramic, Class LMolding Plastics and Molded Plas~c Parts, .ThermosettingPlastic Rod and Tube, Therrnosettmg, LammatedInsulation, Electrical, Synthetic - Resin Composition,NonrigidPlastic Material, Laminated, Thermosetting, ElectricalInsulation, Sheets, Glass Cloth, Silicone ResinInsulation Taoe, Electrical, Glass-Fiber (Resin-Filled), andCord, Fibrou;-GlassInsulation Sleeving, Electrical, Flexible, TreatedInsulating Tape, Electrical, Self-Fusing: For Use inElectronics, Communications, and Allied EquipmentInsulation Sleeving, Electrical, FlexibleTape, Rubber, Unvulcanized, Splicing and Molding(Tapes TL-31 7/U and TL-318/U)Plastic Sheet, Laminated, Thermosetting, Glass-Cloth,Melamine-ResinPlastic-Material, Laminated, Thermosetting Sheets, NylonFabric Base, Phenolic-resinInsulation Tape, Electrical, Pressure Sensitive Adhesive andPressure Sensitive Thermosetting AdhesiveInsulation Cloth and Tape, Electrical, Glass Fiber,VarnishedInsulation Sleeving. Electrical. Flexible, Glass Fiber,Silicone Rubber TreatedPlastic Sheet, Laminated, Thermosetting, Glass Fiber Base,Epoxy-ResinInsulation Tape, Glass Fabric, PolytetrafluoroethyleneCoated -Plastic Sheet, Laminated, Glass .Cloth Polytetrafluoro-ethylene ResinInsulation Tape, Electrical, High-Temperature, GlassFiber, Pressure SensitiveInsulation Tubing, Electrical, Nonrigid, Vinyl, Very LowTemperature GradeInsulation Sleevine. Electrical. Heat-Shrinkable. GeneralSpecification for ‘“Insulators, Ceramic, Electrical and Electronic, GeneralSpecification for

REQUIREME~ 1110 January 1983

11-1



MIL-STD-454L

MIL-I-23594

MfL-I-24024

MIL-I-24092ML-I-24391MfL-I-46852

Insulation Tape, Electrical; High Temperature Polytetra-fluoroethylene, Pressure-SensitiveInsulation, Electrical, High Temperature, Bonded, SyntheticFiber PaperInsulating Varnish, Electrical, ImpregnatingInsulation Tape, Electrical, Plastic, Pressure SensitiveInsulation Tape, Electrical, Self-Adhering, Unsupported

ASTM D3295-81Silicone RubberPTFE Tubing, Specification for

Code of Federal Regulations, Title 29, Chapter XVIf, Part 1910

3. Pe finition$. Not applicable.

I 4. ~eau irements

4.1 Ceramics. Ceramic materials shall conform to MIL-I-1O. Ceramic insulators shallconform 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.

4.3 Sleeving. Sleeving shall conform to MIL=I-631, MIL-I-3190, MU--I-7444,MIL-I-18057, MIL-I-22076, MIL-I-23053, or ASTM D3295-81.

4.4 plastic. thermose ttine. cast. When used for electrical insulation, parts fabricatedfrom cast thermosetting plastic materials shall be in accordance with L-P-516.

4.5 Plastic. thermosettine. laminated. Materials selected shall conform to MIL-P-79,MIL-P-997, MIL-P-15037, MIL-P-15047, ML-P-18177, ML-P-19161, orMIL-I-24024. The preferred base is glass cloth. Electrical insulators fabricated fromlaminated thermosettiqg-plastic sheets, plates, rods and tubes (except transparentplastics) shall be treated after all machhing and punching operations with a suitablemoisture barrier unless the plastic has a moisture absorption of 1.0 percent or less oris used in a hermetically sealed container.

4.6 Plastic. thermosettine . molded. Materials used to mold electrical insulators shall“conform to MIL-M-l 4. Molded parts which undergo subsequent machining shall bevacuum impregnated with a suitable moisture barrier material and dried after allsurface-breaking operations have been completed. Cotton and linen shall not be usedas filler material in any electrical insulator. Materials having moisture absorption of1.0 percent or less, and those used in hermetically sealed containers, need not beimpregnated.

4.7 ~. Insulating varnish shall conform to MIL-I-24092.

4.8 Polwinvl chloride. Polyvinyl chloride insulating materials shall not be used inaerospace applications.

I REQUIREMENT 1110 September 1987

11-2

SupersedesREQUIREMENT1110 Januaty 1983

l.’ /.


MIL-STD-454L

5. lnf~y

5.1 Mu Iatine ma terials. eIectrical. Insulating materials should be selected based onmeeting or exceeding the use requirements, such as:

a. Temperature endurance e. Dielectric constant

b. Moisture absorption and penetration f. Mechanical strength

c. Fungus resistance g. Dissipation factor

d. Dielectric strength h. Ozone resistance

5.2 Carcinogens. Certain chemicals have been identified in the Occupational Safetyand Health Act (OSHA) as cancer-producing substances (carcinogens). Before usingany materials which might contain these chemicals, they should be evaluated inaccordance with the Code of Federal Regulations, Titie 29, Chapter XVII, Part 1910.Consideration of the toxicity of a substance should be given prior to material selection.

SupersedesREQUIREMENT 1110 January 1983


11-3


MIL-STD-454L

FASTENER IWRDWARE

1. ~. This requirement establishes criteria for the selection and application offastener hardware.

2. p c ment io u s arm] cable to Reeru emenir t 12:

FF-B-575FF-N-836

FF-R-556

FF-S-85FF-S-86FF-S-92FF-S-107FF-S-200FF-S-21 oFF-W-84FF-W-92FF-w-looQQ-P-416TT-S-1732

FED-STD-H28MJL-S-1222

MIL-F-5591ML-R-5674MIL-B-6812MIL-S-7742

MIL-B-7838MIL-R-7885MIL-R-8814MIL-B-8831

MIL-S-8879

MIL-T-10727

MIL-F-18240MJL-T-22361MIL-S-22473MIL-R-22978ML-R-24243

Bolts, Hexagon and SquareNut, Square, Hexagon, Cap, Slotted, Castellated, Clinch, Knurledand WeldingRivet, Solid, Small; Rivet, Split, Small; Rivet Tubular, Small; andCaps, Rivet, General PurposeScrew, Cap, Slotted and Hexagon-HeadScrew, Cap, Socket-HeadScrew, Machine; Slotted, Cross Recessed or Hexagon HeadScrews, Tapping and DriveSetscrews; Hexagon Socket and Spline Socket, HeadlessSetscrews, Square Head and Slotted HeadlessWashers, Lock (Spring)Washer, Metal, Flat (F’lain)Washer, Lock (Tooth)Plating, Cadmium (EIectro-deposited)Sealing Compound, PIP? Joint ,and Thread, Lead Free GeneralPurposeScrew-Thread Standards for Federal ServicesStuds, Continuous Thread (Bolt Studs); Nut:, Plain, Hexagon; andSteel Bars, Round - High Temperature SerwceFasteners, Panel -Rivets, Aluminum and Aluminum A11oYBolt, AircraftScrew Threads. Standard. ODtimum Selected Series; GeneralSpecification for ‘Bolt, Internal Wrenching, 160 KSI FITJRivets; Blind, Structural, Pull-Stem and Chemically ExpandedRivets, Blind, Nonstructural TypeBolt, Tensile, Steel, 180 KSI FTU, 450”F, External Wrenching,Flanged HeadScrew Threads, Controlled Radius Root with Increased MinorDiameter, General Specification forTln Plating, Electro-deposited or. Hot-Dipped for Ferrousor Nonferrous MetalsFastener, Externally Threaded 250”F, Self-Locking Element forThread Compound, Antiseize, Zinc Dust-PetrolatumSealing, Locking and Retaining Compounds, Single-ComponentFastener, Rotary, Quick-Operating, High StrengthRivet, Blind, Nonstructural, Retained Mandrel, GeneralSpecification for


REQUIREMENT 1230 August 1984

12-1


MIL-STD-454L

MIL-N-25027 Nut, Self-Locking 250”F, 450”F, and 800”F, 125 KSI FIW,60 KSI lTU, and 30 KSI FIW

MIL-R-27384 Rivet, Blind, Drive TypeMIL-S-46163 Sealing, Lubricating, and Wlcking Compounds, Thread Locking,

Anaerobic, Single ComponentMS33522 Rivets for Blind Attachment, Self-Plugging and Chemically

Expanded Types, Limitations for Design and Usages MS33540 Safety W]ring, and Cotter P@ting, GeneraI Practices for\iMS33557 Nonstructural Rivets for Blind Attachment, Ulmitations for Design

and UsageNAS498 Bolts, Shear

:;NAS547 Fastener, Rotary, Quick-Operating, High Strength

3. Definitions. The following definitions apply to Requirement 12.

3.1 Fastener. A fastener is a mechanical device for holding two or more items orpieces of material together.

3.1.1 Fastener. self-lockhw. A self-locking fastener is a fastener with a prevailing-.,.torque feature that resists rotation by gripping the mating thread.

3.2 Bolts and screws. Bolts and screws, as used herein, refer to the general classifi-cation of externally threaded headed fasteners.

3.3 w. A stud is a headless fastener which is completely or partially threaded withan external thread, and has no specific lockkrg or wrenching provisions.

3.4 ~. A nut is a fastening device having an internal thread or an aperture of lugsor prongs designed to mate with an external thread for the purpose of holdingthreaded members with which it is engaged.

3.5 w. A rivet is a headed fastening device of malleable material with the shankend designed to be expanded, upset, or spread.

3.6 Positive holdinp device. A positive holding device is one that requires unlockktg ordestruction in order to remove the part it holds.

3.7 Soft “material. Any plastic material, or any metal not in a work-hardened of casehardened condition and having a Brinell hardness rating of less than 86, is a softmaterial.

3.8 screw. self-taD pine. Self–tapping screws are defined as follows:

a. Thread-cutting screw. An externally threaded fastener whose thread is interruptedby flutes or slots for the purpose of cutting its own mating thread.

b. Thread-forming screw. An externally threaded fastener ‘whose thread is designed toform its own mating thread.

REQUIREMENT 1230; August 1984

12-2

SupersedesREQUIREMENT1210 January 1983


MIL-STD-454L

3.9 See. drive. A drive screw is a hardened cylindrical fastener with multiple spiralflutes o:% shank. It also has an end smaller in diameter than the outside diameterof the spiral flutes which acts as. a pilot when driven into a hole.

3.10 Brittle ma terial. A nonmalleable, nonelastic substance which may crack when de-formed.

4.-. Fasteners shall be selected so as \O rem?in secu~e when exposed to equip-ment operational and environmental stresses, mcludmg specified testing. Except forthose items designed to be affixed with one fastener, parts shall be secured in suchmanner that failure of a single fastener will not free the part completely. When prac-ticable, friction between mating surfaces shall not be employed as the sole means ofpreventing f~ed parts from rotating or shifting. For critically stressed applicationssuitable torque values for screw thread assemblies shall be established and torquemeasuring or controlling devices shall be used for tightening the threaded parts.

5. Securing of Darts. Securing of parts by threaded fasteners to materials other thanwood shall be in accordance with the methods outlined in the following subparagraphs.

5.1 ~~. The mounting or assembly of partsmade of soft material to soft material shall be accomplished by one of the followingmeans:

a. A through-screw or secured by a self-locking nut or plain nut and Iock washer.

b. A through-screw secured by a plain nut, with a thread locking compound sealantapplied to the threads of the screw and nut.

c. A screw in a threaded bushing; in a staked, clinched or pressed-in nuu or in an in-sert. The bushing, nut, or insert shall be secured to the structure. Wherever practica-ble, the engaged length of threaded inserts should be at least 1-1/2 times the nominaldiameter of the thread. (Where insert design makes this impossible, the requirementsof. paragraph 11 apply.) Where the material tlickness is not great enough to accommo-date a 1-1/2 times diameter insert, a shorter insert may be used if thread wear ratherthan strength is of primary importance, or a solid bushhg type shall be used, whichprovides equal strength with less length because of the greater aluminum alloy partand the parts must be frequently disassembled in service, the aluminum alloy partsshall be provided with inserts of corrosion-resistant steel or other suitable material.Threaded holes in plastic material, when used with externally threaded fasteners: shaI1be provided with suitable metallic inserts. When a Iockwasher or a self-locking insert,nut, or bushing is not used, a thread locking compounds shall be applied to thethreads of the bolt or screw and insert, nut, or bushing.

d. A screw in a tapped hole, ”with a thread locking compound sealant applied to thethreads of the screw.

e. A stud in a tapped hole


REQUIREMENT1230 August 1984

12-3


MIL-STD-454L

NOTE: The use of threaded fasteners made of aluminum alloy or magnesium to matewith threaded parts ,of aluminum alloy or magnesium shalI be avoided whereverpossible. Where such is required, an antiseize compound shall be used to prevent

. seizing of the threads.

5.1.1 Hat washers. Flat washers shall be used for the following applications:

a. Between screw heads and soft materials, unless a washer head screw, 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 shall beprovided to prevent marring or chipping of the material or the applied protective -coating, except in areas where an electrical ground is required.

d. Except where it conflicts with electromagnetic interference considerations, a flatwasher shall be used between an organically finished material and lock-washers, boltand screw heads, or nuts.

5.2 Mountine of hard material to soft material. In addition to the methods outlined in5.1, a screw with a Iockwasher in a threaded bushing, insert, or tapped hole may beused.

5.3 ~ountine of soft material to hard ma terial. IrI addition to the methods outlined in5.1, other means which may be used are:

a. A seIf-locking screw in a hole tapped into the hard material.

b. A Self-tapping screw into the hard material when used within the limitations of,.paragraph 10.

5.4 Mountine of hard material to hard material. Any of the methods outlined in 5.1through 5.3 may be used.

5.5 Fastening of brittle materials. Brittle castings or parts made of ceramic or otherbrittle material shall be properly cushioned when necessary to prevent breakage.Washers or gaskets of suitable material and compressibility shaI1 be used between theotherwise facing surfaces of the brittle part and other brittle or metal parts, whenpracticable, to prevent breakage or damage to the protected parts during assembly orfrom severe shock, vibration or temperature changes encountered under the specifiedservice conditions. Lead washers shall not be used.

5.5.1 Mo untine of Darts. Threaded devices securing parts mounted with pliablewashers shall not depend upon Iockwashers as a lock]ng device. Threaded holes inceramic material shall be avoided for assembly or mounting of parts, if possible.


12-4

—



MIL-STD-454L

6. W

6.1 ~Do Iication. Rivets shall be used, where practicable, in preference to otherhardware for securing parts not requiring removal when the equipment is serviced.Rivets shall not be used for mounting items normally subject to replacement, such ascapacitors, resistors, transformers, inductor!, or tube sockets. Wherever the tMcknessof metal which accepts the heads of flush rivets is less than the height of the rivetheads, the material shall be dimpled rather than countersunk. Where practicable, thedistance from the center of rivet holes to the edge? of the material in which the rivetsare placed shall not be less than 1-1/2 times the rivet diameter. Rivets for joiningmagnesium parts shall be composition 5056 anodized aluminum alloy or an aluminumalloy having equal galvanic compatibility with the magnesium. Where applicable,design and limitations of rivets shall be in accordance with MS33522 and MS33557.

6.1 Selection. Rivets shall conform to one of the following specifications:

a. Small solid, split, tubular and general purpose rivets shall conform to FF-R-556.

b. Aluminum and aluminum alloy rivets shall conform to ML-R-5674.

c. Nonstructural blind rivets shall conform to ML-R-8814.

d. Structural blind, pull-stem rivets shall conform to ML-R-7885.

e. Blind, drive type rivets shall conform to MIL-R-27384.

f. Blind, nonstructural, retained mandrel type rivets shafl conform to ML-R-24243.

7. ~ Iing. Wherever the proper functioning of devices isdependent upon maintaining a prescribed relationship between control shafts andassociated couplings, collars, gears, and similar parts not permanently fastened to theshaft, such parts shall be secured by positive Iockhg devices. Keyed or splined partsshall be axially restrained if such movement would be detrimental to the operatingcharacteristics. Appropriate set screws may be used for axial restraint. Light-dutyitems, such as indicator mechanisms and other devices normally designed to usefriction locking means for adjustment, are exempted from this requirement. Socketstyle set screws are preferred.

7.1 Set screws. One set screw may be used on a flaned shaft. Two set screws at 90”to 120° displacement shall be used when the shaft is not flatted. Cone-point setscrews shall not be used, except when the opposing metal has been properly counter-sunk to receive the cone-point.

8. A3 n Is IateQ. The type, design, and spacing ofthe fastening ~evices used to re~in avm~ss ~evices shall be consistent with the desireddegree of closure and frequency of required access.

8.1 Screws and bolts for access device$. If used, screws and bolts shall beself-aligning, of the captive type when practicable. It shall be possible to remove thefasteners for replacement without damaging the attached panel or access door.


REQUIREMENT 123L3Augus! 1984

12-5


MIL-STD-454L

8.2 9u rte turn faste ners. Quarter-turn fasteners shall be used only to retain non-structur~l a~~ess to devices where quick access is necessary. Those fasteners shallconform to MCL-F-5591.

8.3 Qu ick acceu. Rotary, quick-operating, high strength panel fasteners such as thoseconforming to MIL-F-22978 or NAS 547 shall be used to retain structural access de-vices where quick access is necessary.

9. Cou ntersinking. Fasteners should not normally be countersunk in sheet materialhaving a ti]ckness less than 1-1/2 times the height of me fastener head (in no case‘shall a feather edge be created). Thimer material should be dimpled to assure properseating, with the fastener head edge flush with or below the surface of the material.

10. Thre ad-formitw thread-cun irw. and drive screws. Thread forming, thread-cutting,and drive screws shall not be used except as follows:

a. For the Dermanent attachment of name dates to sheet metal where it is macticableto extrude ‘tie hole permitting a minimum ‘l/8-i,nch full-thread engagement:

b. Whh the specific approval of the procuring activity, thread-forming screws may beused on equipment to be installed in a static (fixed station) environment for low-stressapplications where’ disassembly is not normally anticipated.

c. For the permanent attachment of nameplates to material having nominal tilcknessof l/8–inch or greater.

11. Thread eneaeement. For highly stressed applications, screws or bolts shall have aminimum thread engagement of 1-1/2 times their nominal diameter in tapped partsother than nuts. In normal applications, screws or bolts shall have a minimum engage-ment length equal to their nominal diameter in tapped parts other than nuts. When theassembly is not frequently disassembled and where maximum strength is not required,

:<Iess thread engagement may be used, provided special provisions are made to insurecompliance with required conditions.

12. LenethS. The length of the screws and bolts installed with nuts shall be such thatthe exposed portion is a minimum of 1-1/2 threads. Maximum length shall be limitedby the nearest larger standard screw length. These rules apply except when such pro-jection will result in corona discharge or when design requirements cannot be met.

13. Jmckine devices. All threaded asseinblies shall be vibration and shock proof.

13.1 Freaue nt disassembly. Whenever practicable, where frequent disassembly (morethan 15 times) is not expected, self-locking nuts shall be used in lieu of lockwashers.

13.1.1 Stud mounted comnonentS. Self-locking nuts shall be avoided on stud-mounted components unless the stud material is compatible with the strength ormaterial of the nut used.



12-6


MIL-STD-454L

13.2 J301ts or screws without nuts In applications requiring the use of bolts or screwswithout nuts, one of the following “locking devices or methods shall be used:

a. Lockwashers under the heads of the bolts or screws

b. Self-locking screws

c. Self-lotting thread inserts

d. A locking or retaining compound applied to the threads

e. Safety wire through driIled heads.

13.3 Castellatecf nuts. Castellated nuts with cotter pins are acceptable.\

13.4 ~ crews.. Flat head screws, when not secured by other locklng means,shall be secured by the application of a retaining compound. Stakhg by means of up-setting metal is acceptable for permanent assemblies when other means are impractica-ble or unsatisfactory for design reasons.

13,5 Retainine comDounds. Retaining compound or nonmetallic retaining devices inscrews or nuts shall not be used where the specified serwce conditions or processing,such as baking of paints or soldering, might deteriorate the material. Retammg com-pounds which exceed the strength of the fastener shall not be used where disassemblyis required.

14. Threaded fasteners and related Part$

14.1 Threads. Threads shall be in accordance with FED-STD-H28 or MIL-S-7742.Where threaded fasteners are required to mate with or mount threaded commercial”equipment or devices, threads shall be in accordance with FED-STD-H28. Threadsshall be in accordance with ML-S-8879 for applications requiring high stress or highfatigue life. (Caution shall be exercised where a ML-S-8879 LJNJ external thread fas-tener is used due to its incompatibility with the commonly used UNC, UNF, or UNEFthreaded nut or tapped hole.)

14.1.1 ~ Iicatiortl. Threaded parts for airborne applicationsshall be in accordance with MU-S-7742 and as amplified below:

a. Threads for screws, bolts, nuts, and similar devices shall be chosen from the recom-mended selection contained in paragraph titled Recommended Selection ofML-S-7742, unless used for adjustment, when they may be of fine or extra finethread series.

b. When MIL, AN, or other specifications for components such as variable resistorsand switches are in conflict with the requirements of 4.1.2a, the requirements of thespecification for. the component shall apply.


12-7

REQUIREMENT1230 August 1984


MIL-STD-454L

c. For high strength applications, MIL-S-8879 shall be used.

14.2 Th ead size The following thread sizes shaI1 be utilized to the maximum extentpossible:r

.112-40 UNc

.138-32 UNC

.164-32 UNC

.190-32 UNF!“:

.2500-28 UNF

.3125 -24 UNF

.3750-24 UNF

.4375 -20 UNF

.5000-20 UNF

.5625 -18 UNF

.6250-18 UNF

“14.3 screws and bo Its. Screws and bolts shalI conform to the specifications listed~below unless design requirements dictate otherwise:

a. Machine screws shall conform to FF-S-92

b. Cap screws shall conform to FF-S-85 or FF-S-86.

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

d. Self-locking screws shall conform to IvKL-F-18240. Fiber inserts shall not be usedas the locklng device.

e. Tapping screws shall conform to FF-S-107.

f. Bolts shall conform to FF-B-575, MIL-S-1222, MIL-B-6812, MIL-B-7838,ML-B-8831, or NAS498.

14.4 ~. Nuts shall conform to FF-N-836 or MIL-S-1222 and shall be preferably ofthe hexagon style with the following exceptions:

a. Nuts used in conjunction with a mechanical means to prevent rotation,, press-typeunits, i.e., gang channel nuts, floating and self-aligning plate nuts, clinch-type or

“~press-in nuts

b. Plate nuts of the lug style which are generally riveted or spot-welded to sheet struc-ture

c. Nuts designed for a specific purpose, e.g., nuts for honeycomb structure

d. Sheet spring nuts shall hot be used without specific approval of the procuringactivity.

14.4.1 Self-lockine nuts. Self-locking nuts shall conform to ~N-25027.

14.5 Lockwashers. I.mckwashers shall conform to FF-W-84 or FF-W-1OO. Pre-assembled nut and Iockwasher or screw and Iockwasher assemblies are consideredsatisfactory for use, provided they are replaceable by conventional nuts, screws, andlockwashers.


12-8



MIL-STD-454L

14.6 -. Inserts shall be so constructed that they will not loosen when tighteningor loosening the screw or stud. External threaded inserts shall be capable of being re-placed with inserts which have identical internal threads.

14.7 Fla t washerS. Flat washers shall conform to FF-W-92 where applicable.

15. M ter ials and finishe$. AU bolts, screws, nuts, and other fastener hardware shallbe fabricated or corrosion-resistant materials or shall have a finish applied that wiIlresist the corrosive effects of the specified service environment. Fasteners which arecadmium plated in accordance with appropriate class, Type JI, of QQ-P-416 shall notbe subject to embrittlement relief test. Tin plating in accordance with MIL-T-10727may be used in lieu of cadmium plating if soldering to the part is required. StandardMS an AN parts with other suitable finishes will not require refinishing.

15.1 DN film lubricated nuts. For dry-film lubricated nuts, the type and class of plat-ing are optional if the nuts conform to the salt spray requirements for type IIplating in accordance with QQ-P-416.

15.2 ~s. Other materials may be used where uniquely required by thedesign of the equipment. Materials shall not be used which take a permanent set undernormal conditions of stress.

15.3 Thr d 1 ckin~ unds. Thread locking and retaining com-pounds shall conform to MU-S-22473 or ML-S-46163 and shall be applied in sucha manner that the required level of Iocklng or retaining is achieved and maintained.Such compounds shall:

a. Not be used where required electrical conductivity is impaired

b. Not be used where failure of the compound would endanger personnel or damagethe equipment

c. Be compatible with the material and finish to which they are bonded and shall haveno detrimental effect on the material or finish.

d. Not cause or accelerate corrosion.

15.4 Safetv wirine and cotter oins. Application of safety wiring and cotter pins shallconform to MS33540, where practicable. Safety wiring and cotter pins shall not be usedon terminals such as screws and threaded studs required to function as electricalterminals.

15.5. At!? n s. Antiseize compounds shall conform to MIL-T-22361 orlT-S-1732.


REQUIREMENT 1230 August 1984,

12-9


MIL-STD-454L

STRUCTURAL WELDING

1. q. This requirement es~blishe~ criteria for structural welds. Welded electricalconnections are excluded from tlus requwement.

2. p ntocume s ZiDD]kSb]eto Reau reme ~i ntl:

MU-W-6858 Welding, Resistance, Spot and SeamMIL-W-8604 Welding, Fusion: Aluminum Alloys; Process and

Performance ofMIL-W-8611 Welding, Metal Arc and Gas, Steels, and Corrosion and

Heat Resistant Afloys, Process forML-W-18326 Welding of Magnesium Afloys, Gas and Arc, Manual and

Machjne Processes forML-W-461 32 Welding, Fusion, Electron Beam, Process forMIL-STD-22 Welded-Joint DesignsMIL-STD-248 Welding and Brazing Procedure and Performance

QualificationMIL-STD-1261 Welding Procedures for Constructional SteelsMIL-STD-1595 Qualification of Akcraft, Missile, and Aerospace Fusion

WeldersMIL-HDBK-5 Metallic Materials and Elements for ‘Aerospace Vehicle

StructuresANS3/AWS A2.4-79 Symbols for Welding and Nondestructive TestingANSIIAWS A3.O-85 Welding Terms and Definitions


4. Requirements

4.1 Arc and eas welding. Welding by arc and gas methods shall be performed byoperators who have passed the applicable certification tests and have a certificate ofproficiency in accordance with MIL-STD-248 or MIL-STD-1595. For the materialsindicated, welding shall conform to the following specifications:

a. Welding of aluminum alloys: MIL-W-8604

b. Welding of magnesium alloys: MIL-W-18326

c. Welding of steel alloys: MIL-W-8611.

4.2 Resistance weIding. Resistance welding of joints shall conform to the processrequirements of MIL-W-6858.

5. Jrlf~ idance only

5.1 General. The joint areas of all parts to be welded should be cleaned ofcontaminants and materials which may be detrimental to obtaining satisfactory welds.



13-1


MIL-STD-454L

Degradation of materiaI properties in the heat affected zone caused by welding shouldbe considered. Weldments should be stress relieved when induced stress resultingfrom welding, design configuration, or materials welded may be harmful. See

.ANLWAWS 2.4 for welding symbols, AIWWAWS A3.O for welding terms anddefinitions, and MIL-STD-22 for welded joint designs.

5.2 ~esistanc e welding. MIL-HBDK-5 may be used as a guide for spot-to-sheet edgedistances and allowable strengths.

‘5.3 No ncritical am)lications. In ground equipment applications, weldlng procedures inaccordance with MIL-STD-1261 may be used where, if the weld should fail, it willnot compromise personnel or equipment safety or prevent completion of the mission.

5.4 Other methods Other welding methods, such as the electron beam process ofML-W-46132, may be used provided approval is obtained from the procuring activity.

REQUIREMENT 1312 February 1988.

13-2



kEQUREMENT 14

MIL-STD-454L

TRANSFORMERS, INDUCTORS, AND COILS

1. m. ~is requirement establishes criteria for the selection and application oftransformers, inductors, and coils.

2. P nt 1’~ ire nt 14:

ML-T-55631 Transformers, Intermediate Frequency, Radio Frequency andDiscriminator, General Specification for

MILT-83721 Transformer, Variable, Power, General Specification forMIL-STD-981 Design, Manufacturing and Quality Standards for Custom

Electromagnetic Devices for Space ApplicationsMIL-STD-1286 Transformers, Inductors, and Coils, Selection and Use of

3. Pe finitions. Not applicable.

4. ~

4.1, Selection. Selection of transformers, inductors, and coils shall be in accordancewith MIL-STD-1286 and the following paragraphs.

4.1.1 ]nt~ incriminator transf rs. Intermediate,radio frequency and discriminator transformers shall conform to Grade 1, 2, or 4 ofML-T-55631. The use of Grade 3 transformers shall be limited to hermetically sealedor encapsulated assemblies.

4.1.2 Variable transformers. Variable transformers shall conform to MJL-T-83721.

4.1.3 ~ustom electromagnetic devices for sDace armIiCations. Custom electromagneticdevices for space applications shall conform to tiSTD-981.

5. Information for eu idance only. Not applicable.

SupersedesREQUIREMENT 1426 Februaty 1967

14-1



MIL-STD-454L

REQURWMENT 15

METALS, CORROSION RESISTANCIZ

1. m. TMs requirement establishes criteria for the selection and treatment ofmetals as related to their ability to resist corrosion.

MIL-STD-889 Dksimilar MetalsMIL-STD-1516 Unified Code for Coatings and Finishes for DOD Materiel


4. ~eauirements. Metals shall be corrosion resistant or shall be coated ormetallurgically processed to resist corrosion. Materials and processes for metallic partsshall conform to applicable requirements in MIL-STD-889 and MIL-STD-1516.Coatings shall be selected from MIL-STD-1516.

5. ~y. The environmental severity to which the equipmentwill be exposed should be considered in selection of metals. The use of non-corrosionresistant steel alloys, except where specifically required for electronic purposes, shouldbe kept to a minimum.

SupersedesREQUIREMENT 1530 June 1985

15-1

REQUIREMENT1510 September. 1987


MIL-STD-454L

REQUDWMENT 16

DISSIMILAR METti

1: fi+s., Thk requirement establishes. cflteria for the selection and protection ofdlsslmdar metal combinations and other slgrufmant corrosion behavior factors.

2. Do cument aDD1 e tO Reau ement 16.I“cabl ir

MIL-STD-889 Dksimilar Metals

3. Pll)s. Not applicable.

4. Reouirem ents. Selection of metals for use in electronic equipment shall be made inaccordance with the requirements of MIL-STD-889.

5. Jirformation for euidance only. Where electronic design requirements preclude theinsulation of incompatible metal combinations as identified in MIL-STD-889 from oneanother, specific attention should be paid to isolating the combination from exteriorenvironments.



16-1


MIL-STD-454L

REQUEWMENT 17

PRJNTED WIRING

1. mroose. TMs requirement established criteria for the design and treatment ofprinted wiring assemblies.

2. p nOcume ts aDD]icab]e to Reou remei nt 17:

MIL-P-13949 Plastic Sheet, Metal-Clad (For Wlnted Wiring Boards),General Specification for

MIL-P-28809 I%nted Wking AssembliesMIL-P-28870 Assemblies, Electrical Backplane, Prhted Wbing, General

Specification forMTL-I-46058 Insulating Compound, Electrical (For Coating Prkted

Circuit Assemblies)MU--P-46843 Prk_tted Wiring AssembliesMIL-P-50884 Printed Wking, Flexible, and Rigid-FlexMIL-P-5511O I%nted Wiring BoardsMIL-STD-275 Printed Whing for Electronic EquipmentMIL-STD-2118 Flexible and Rigid-Flex Printed Wking for Electronic

Equipment, Design Requirements forMIL-STD-2119 Design Requirements for Printed Wiring Electrical

Backplane AssembliesANSIAPC-DW-425/l 1 Design and End Product Requirements for Discrete Wking

Boards/Plated-Through Hole Connection

3. ~. Not applicable.

4. ,Reouirements

4.1 Rieid Drinted wiring and minted wirine boards. Rigid printed wiring and printedwiring boards for single-sided, double-sided, and multilayer printed wiring shall con-form to MIL-STD-275 and ML-P-55110. The materials used for single-sided, double-sided, and multilayer printed wiring boards shall conform to ML-P-13949.

4.2 R] i~ s emblies. Rigid printed wiring assemblies consisting of rigidprinted wiring boards on which separately manufactured parts have been added shallconform to MIL-P-28809. For Army missile weapon systems, ML-P-46843 shallapply.

4.3 c~ ing. When conformal coating is required? rigid printed wiringassemblies shall be conformably coated with a coating material which conforms toMIL-I-46058.

4.4 Flexible and rieid-flex wirine. Flexible and rigid-flex printed wiring shall conformto MIL-P-50884 and shall ,be designed in accordance with MIL-STD-21 18.


17-1



MIL-STD-454L

4.5 Pkcrete wirine boa rds, Dkcrete wiring boards with plated-through hoIes shall bein accordance with ANSI/IPC-DW-425/l 1. Discrete wiring boards shall not be used forspace application.

4.6 $ackp ane asseI mblies. or kted wirirw. Electrical backplane printed wiring assem-M#_~~;: conform to MIL-A-28870 and shall be designed in accordance with MIL-

5. Jnformatio n for mzidance only

5.1 Prhted wirine boa d size. Whenever cost and technical requirements permit,preferred rigid printed ~iring board sizes should be used. These board sizes willfacilitate the development and use of standardized insertion and extraction tools. The

preferred board sizes and thickness and extractor hole size and location are shown infigure 17-1.

L1Preferred-Ttickness(Inch)

1-l.062.093.125

BO.4RDNO,

AlA2A3A4B]B2B3B4c1C2C3

LC4010204

PRINTEOWIRINGBOAROSIZEINNOMINAL1.015

2,0.3.02.0.4.52,0s6,52,0xB.O5.0x3,05.0.4,55.0.6.55.0.B.O6.5v3.06.5x4.56.5z6,5

L6.5x8.08,0.3,0B.O.4.58,0.8.0

J?/ \

e?7 ,0 0 ~“ 0 0

r,502.005

1 .- —- -— --0

0; ~“~ 0 ‘o

I I--—-0

rJ, I ,, J.1

‘~ I 4~:5i “i- 0 ,

- -—-l.—

?

~t

T

0: 0’ 0

7

4.5 2

2.50t.005 3,0 I

0 0 0

FIGURE 17-1. Preferred minted wirine board sizes.


17-2

EXTRACTORHOLESIZE.125t,005

I


4


MIL-STD-454L

REQUIWMENT 18

DEIWTJNG OF ELECTRONIC PARTS AND MATERIALS

1. mroos~. Thk requirement establishes criteria for derating of electronic parts andmaterials.

2. P~e R irement 18:

MIL-STD-1547 Parts, Materials! and Processes for Space and Launch Vehicles,Technical Requmements for

3. Definitions.. Not applicable.

4. Jleauirements

4.1 ,Derating. Irs the application of electronic parts and materials, the parts andmaterials selected shall be used within their electrical ratings and environmentalcapabilities (e.g., any ambient or hot spat temperatures, voltage, current, or powerdissipation). Derating shall be accomplished as necessary to assure the required equip-ment reliability within the specified operating conditions.

4.2 ~. Electronic parts and materialsused in launch vehicles or space systems shall be derated in accordance with therequirements of MIL-STD-l 547.

5. .Information for eu idance only. Not applicable.



18-1


MIL-STD-454L

REQUIREMENT 19

TERMINATIONS

1. fi~q. TMs requirement establishes criteria for the selection and application oftermmatlons.

2. pocu ments arml icable to Rea uirement 19:

MIL-T-7928 .Terminals, Lug and Splice, Crimp-Style, CopperML-T-15659 Terminal, Lug, Solder, Copper and Phosphor BronzeIWL-T-55156 Terminals: Lug, Splices, Conducto~ Screw Type, General

SDecificatlon forMIL-T-55164 T&rninal Boards, Molded, Barrier, Screw Type, and Associated

Terminal Board Lugs, General Specification forMJL-STD-1277 Splices, Terminals, Terminal Boards! Binding Posts, Terminal

Junction Systems,.Wire Caps; ElectricalMS 27212 Terminal Boards, Assembly, Molded-in Stud, Electric


4. Requirements

4.1 Terminals

4.1.1 Lue terminals. Lug terminals shall conform to one. of the followingtions, and wherever possible shall be selected from MIL-STD-1277.

specifica-

MIL-T-7928 Crimp, Insulated and NoninsulatedML-T-15659 SolderML-T-55156 Screw

4.1.2 ~ ind’n osts. Stud terminals, feed-through terminals and binding posts shall be selected from ‘~-STD-1277.

4.1.3 Number of wires Der terminal or lug. The number of wires terminated in anindividual terminal or lug shall not be greater than three. Multisection turret, bifur-cated, or multi-hole lug terminals shall have not more than three wires per section,tong, or hole. In no case shall the total circular mil area of the terminated wiresexceed the circular mil area capacity of the terminal or lug. If a greater number ofwires is required than those specified herein, approval of the procuring activity shall beobtained.

4.2 ~s.T Terminal boards shall be selected from MIL-STD-1277.


RE&lREMENT 1920 September 1988

19-1


MIL-STD-454L

4.2.1 ~umber of Iues oer terminal. The maximum number of lugs to be connected toany one terminal on a terminal board shall be two for screw-type terminal boardscovered by MIL-T-55 164 and as specified in the detail specification sheets for stud-

‘type terminal boards. Not more than four lugs shall be connected to any one terminalof a board covered by MS27212. Accessories such as stud connectors, straddle plates,jumpers and terminal board lugs shall be counted as lugs for this purpose.

4.3 ~erminal iunction svste m~. Terminal junction systems shall be selected from MIL-STD-1277.

5. Information fo mlidance ortly. Crimping of terminal Iu s should be so accomplished5khat the comecti;ns will meet the resistance (voltage drop and tensile strength

requirements and tests of lvfLT-7928.


19-2

SupersedesREQUIREMENT1930 June 1985


MIL-STD-454L

REQUIREMENT 20

WIRE, HOOKUP, INTERNAL

1. puroose. ‘Ilk requirement establishes criteria for the selection and application ofeIectri&l internal hookup wire.

2. pocu ments aDoIicable to Requirement 2Q

QQ-W-343 Wire, Electrical, Copper (Uninsulated)MIL-W-76 Wire and Cable, Hookup, Electrical, InsulatedMIL-W-5086 Wire, Electric, Polyvinyl Chloride Insulated, Copper or

Copper AlloyMIL-W-5845 Whe, Electrical, Iron and Constantan, ThermocoupleML-W-5846 Wire, Electrical, Chromel and/or Alumel, ThermocoupleMIL-W-5908 Wire, Electrical, Copper and Constantan, ThermocoupleML-W-16878 Wke, Electrical, Insulated, General Specification forMIL-W-19150 Wire, Insulated, Hard Drawn CopperML-W-22759 Wire, Electric, Fluoropolymer-Insulated, Copper or Copper

AlloyMILW-81044 Wh-e, Electric, Crosslinked Polyalkene, Crosslinked

Alkane-Irnide Polymer, or Polyarylene Insulated, Copper orCopper Alloy

ML-W-81381 Wire, Electric, Polyimide Insulated, Copper or CopperAlloy

MIL-W-81822 Wire, Electrical, Solderless Wrap, Insulated andUninsulated, General Specification for

MIL-STD-681 Identification Coding and Application of Hook-Up and LeadWke


4. Requirements

4.1 Selection. Internal hookup wire shall be selected from the types and classesspecified by the documents listed in table 20-1. For solderless wrap applications,shall be selected which are in accordance with ML-W-81822.

wires

4.1.1 MIL-W-76 shall be used for Army applications only.

4.1.2 ML-W-16878 shall not be. used for Alr Force space applications.

4.1.3 MfL-W-22759 wire with only single polytetrafluoroethylene insulation used inAir, Force space and missde applications shall require the approval of the procuringactwlty.

4.1.4 Wires with polyvinyl chloride insulation shall not be used in aerospace applica-tions. Use of these wires in any other Air Force application requires prior approval ofthe procuring activity.

SupersedesREQUIREMENT2029 August 1986 20-1



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2010

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SupersedesR

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20-3

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20-4


MIL-STD-454L

4.2 ~.I Hookup wires in the equipment shall be, insofar as practicable,distinctly coded in color or numbered. Short hookup wire, six inches or less betweentermination points, need not be marked if the path of the short wire can be easily andvisually traced. The unmarked wire must be specified on the drawing. Codes, whenused, shall be in accordance with MIL-STD-681 or as otherwise agreed upon with theprocuring activity. Numbers shall not be used where they would be difficult to read ortrace, such as in compact assemblies.

4:3 J3are wire. Bare hookup wire shall be type S, soft or drawn and annealed, andcoated, and shall conform to QQ-W-343. Bare hookup wire shall not be used unlessinsulated wire is impractical because of circuit characteristics or shortness of wire run.

4.4 ~ermocouole wire. Selection of thermocouple wire shall be in accordance withMIL-W-5845, ML-W-5846, or MIL-W-5908.

5. Jrl~y

5.1 solid or stranded. Stranded wire should be used for conductors and cables whichare normally flexed in use and servicing of the equipment, such as cables attached tothe movable half of detachable connectors and hanging cables attached to removableor movable doors and shields. Leads six inches or less in length may be run as solidwires unless they form interconnections between shock isolation mounted parts andnonshock isolation mounted parts. There are some other instances, such as wirewrapping, where a solid conductor may be required regardless of length.

5.2 Cold flow. Certain insulating materials exhibit a cold flow characteristic. Cautionshould be used in the selection of these materials in applications requiring restrictiveclamping or tying, etc, where this feature may result in exposed or shorted conductors.

SupersedesREQUIREMEtW 2029 August 1986 20-5

,’. ,



MIL-STD-454L

REQUEWMENT 21

CASTINGS

~. fi-. TMs requiremen~ establishes criteria for the design, classification,mspectlon, and repair of castings.

2. p m nt~ “rement 21:

MIL-STD-276 Impregnation of Porous Nonferrous Metal CastingsMIL-STD-2175 Castings, Classification and Inspection of

3. p~. Not applicable.

4. R~s

4.1 Die castines. Die castings shall not be used where the casting might be subject toimpact. Zinc alloy die castings shall not be used where dimensional changes of thecasting could affect use of equipment.

4.2 R Ou castines. When required, castings shall be impregnated in accordance withMIL-S&-:76.

4.3 ~. Castings shall be classified and inspected inaccordance with MIL-STD-2 175.

4.4 -. Inserts which are intended to be cast in place shall be knurled! grooved,or otherwise prepared to secure satisfactory keying of the insert to the casting. Insertsshall be fabricated from a material which is not adversely affected by exposure to themolten casting alloy. When inserts are located near a casting edge, sufficient edgedistance 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, suchas partial alloying, poor bonds, porosity, and cracks shall not be present.

5. Information for euidance only

5.1 Selection and armlication. In any design utilizing metallic castings, considerationshould be given to intended application, the availability of molding and casting alloys,the choice of a suitable casting process (see table 21-I), and the use of ribs and fins.


21-1



MIL-STD-454L

TABLE 21-1. General comDarison of me tallic castine rxocesses.

Type ofcastings

SandDieInvestmenShellmold

Permanenmold

Plastermold

Ability toDimensional reproduceaccuracy fine detail

EI3 3

t : ;

2 2t

2 2

2 1

3“ 3; 1 :3 ; 1 3

3 1 2 3

3 1 ‘, 2 2

1 3 2 3

Legend: 1 = Very good; 2 = good; 3 = fair

5.2 Reoair of unmachined castines. Repair of minor discontinuities or defects in‘unmachined or raw castings should be permitted only when specific approval has beengranted by the contractor Material Review Board (MRB), or is specified on theengineering documentation. Weld repair should be limited to class 3 and class 4castings (class 1 and class 2 repair should require procuring activity approval) and toareas where no severe stress will be encountered. Heat treatable alloys must be fullyreheat treated after welding to meet drawing requirements.

5.3 Rerrair of machined cas tines. Repair of defects in machined castings should bepermitted for class 3 and class 4 castings based on the contractor’s MRB decision.Class 1 and class 2 casting repair should require procuring activity approval. Reheattreatment should be required unless engineering analysis during MRB action candemonstrate it is unnecessary.


21-2



MIL-STD-454L

REQWREMENT 22

PARTS SELECTION AND CONTROL

1. fi~~. This requirement offers guidance as to parts selection and control whichmust be considered when preparing contractual documents. lT DOES NOT ESTAB-LISH REQUIREMENTS AND MUST NOT BE REFERENCED IN CONTRACTUALDOCUMENTS. Parts selection and control must be dkectly specified in the contract orthe system/equipment specification, as appropriate.

2. P mnocu e ts aocdicable to nReauireme t 22:

MIL-STD-965 Parts Control ProgramMIL-STD-1546 Parts. Materials. and Processes Standardization Control and

3.

4.

5.

Management “Program for Spacecraft and Launch Vehicles

p~. Not applicable.

Reauirements. Not applicable.

Information for eu idance onlv

5.1 Parts control uroeram. MIL-STD-965 establishes two procedures covering theSubmission, review, and approval of Program Parts Selection Lkts and than es thereto.The objective is to achieve hfe cycle cost savings and cost avoidances by: ~) assistingequipment or system managers and their contractors in the selection of partscommensurate with contractual requirements, (2) minimizing the variety of parts usedin new design, (3) enhancing interchangeability, reliability, and maintainability ofmilitary equipment and supplies, (4) conserving resources and (5) assuring long termavailability of parts. MIL-STD-965 must be tailored when applied; applicationguidance is offered in the document.

5.2 P~s . (Not applicable toNASA programs) MIL-STD-1546 establishes the criteria and requirements for thepreparation and implementation of a Parts, Materials, and Processes StandardizationControl and Management Program for use during the design: development, fabrication,and test of spacecraft and launch vehicles. The implementation of thk standard isintended to: (1) assure total, integrated, and coordinated management of the selection,app]kation, procurement, control ,and standardization of part:, materials and p~ocesses(l%@, (2) reduce program costs, (3) improve the .Xandardlzation and rehabdlty ofprogram parts, materiak, and processes and (4) assure long term availability of parts.


22-1



MIL-STD-454L

REQUIREMENT 23

ADHESIVES

1. -. This requirement establishes guidance for the selection and application ofadhesives.

2. p ent Iiocum s arm cable to Reau irement 22

MMM-A-121MMM-A-130MMM-A-132

MMM-A-l 34MMM-A-l 38MMM-A-181MMM-A-189M&ll~3i-y7

MIL-A-5540MD--A-8576MIL-A-22397

ML-A-241 79MU-A-25463

MIL-A-46050

MU-A-46146

MU--A-48611ML-A-52194MIL-A-81236MEL-A-81253MU--A-83377

MIL-HDBK-691ASTM StandardASTM D2564-80

Adhesive, Bonding, Vulcanized Synthetic Rubber to SteelAdhesive, ContactAdhesive, Heat Resistant, Airframe Structural, Metal toMetalAdhesive, Epoxy Resin, Metal to Metal Structural BondingAdhesive, Metal to Wood, StructuralAdhesive, Phenol, Resorcinol, or Melamine BaseAdhesive, Synthetic-Rubber, Thermoplastic, General PurposeAdhesive, Rubber Base, General FurPoseAdhesive, Optical, ThermosettingAdhesive, PolychloropreneAdhesive, Acrylic Base, for Acrylic PlasticAdhesive, Phenol and Resorcinol Resin Base (for MarineService Use)Adhesive, Flexible Unicellular-Plastic Thermal InsulationAdhesive, Film Form, Metallic Structural SandwichConstructionAdhesive,” Cyanoacrylate, Rapid Room-Temperature Curing,SolventlessAdhesive-Sealants, Silicone, RTV, Non-Corrosive (for UseWkh Sensitive Metals and Equipment)Adhesive System, Epoxy-Elastomeric, for Glass-To-MetalAdhesive, Epoxy (for Bonding Glass Reinforced Polyester)Adhesive, Epoxy Resin With Polyamide Curing AgentAdhesive, Modified Epoxy Resin With Polyamide Curing AgentAdhesive Bonding (Structural) for Aerospace and OtherSystems, Requirements forAdhesivesWood; Adhesives - Part 22Solvent Cements for PolyvinyI Chloride (WC) Plastic Pipeand Fhtings, Specification for

Code of Federal Regulations, Title 29, Chapter XVII, Part 1910

3. Definitions

3.1 Adhesives. Adhesives are substances capable of holding materials together bysurface attachment. Adhesive is a general term and includes, among others, cement,gkse, mucilage and paste. All of these terms are loosely used interchangeably.

4. R~s. Not applicable.

5.1 ~. The joint should be designed to minimize concentrations of stress.The basic stress shouId be in shear. The weakest design is where the basic stress is incleavage or peel and non-axial loading in tension produces cleavage.

SupersedesFiEQUIREMEti 231 March 1985

23-1


,.

i,


I MIL-STD-454L

5.2 Deleterious effects. The user should ascertain that the formulation of the adhesiveselected will have no deleterious effects on the bonded assembly or nearby items whenthe bonded assembly is in storage, transit or use under the environmental conditionsfor 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 otherharmful results degrading operation of the equipment.

5.3 ADDIication. Care should be taken to avoid starved joints which are the result ofeither absorption of adhesive by a porous material, poor application, inadequatecoverage, or excessive pressure. Where one or both of the adherends are porous,

-successive thin coats of adhesive should be applied to completely seal the surface, andeach coat should be dry before the next coat is applied. This procedure should be used

“;instead of the application of one thick adhesive coat to the porous surface, except inthe case of silicone adhesives. In general, the thicker the adhesive layer, the lower theshear resistance, but the higher the strength to impact and peeling.

5.4 structural com~atibility. Adhesives which are not compatible structurally should beavoided. For example, a brittle adhesive should not be used for glass bonding becauseexcessive shrinkage during setting or curing will load the glass in tension. Forassemblies which may be flexed or subject to impact, a brittle adhesive should not be

used.

5.5 ~s. Certain chemicals have been identified in the Occupational Safetyand Health Act (OSHA) as cancer producing substances (carcinogens). Before usingany materials which might contain carcinogens, they should be evaluated in accordancewith the Code of Federal Regulations, Thle 29, Chapter ~, Parr 1910. Considerationof the toxicity of a substance should be given prior to material selection.

5.6 ~. All thermoplastic adhesives have a tendency to creep under load,especially at elevated temperature, and should not be used in critical structural apphca-tions. Many thermoplastic adhesives have limited or poor resistance 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 bebonded satisfactorily without prior treatment, special adhesives, or both.

5.8 Guide for selection and aor)lication. The following, although not a complete list,may be used as a guide in selecting adhesives and bonding procedures to meet designrequirements in electronic equipment:

MMM-A-121 MMM-A-181 MIL-A-8576 ML-A-46146 ML-A-83377MMM-A-l 30 MMM-A-189 MIL-A-22397 ML-A-48611 IWL-HDBK-691W-A-132 MMM-A-1617 ML-A-24179 ML-A-52194 ASTM STD-Part 22MMM-A-134 MIL-A-3920 MIL-A-25463 ML-A-81236 ASTM D2564MMM-A-138 MIL-A-5540 MIL-A-46050 MIL-A-81253

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


23-2

SupersedesREQUIREMEW 231 March 1985


MIL-STD-454L

REQUDWMENT 24

WELDS, RESISTANCE, ELECTRICAL INTERCONNECTIONS

1. x. This requ~rement establishes criteria for. resistance welds of electrical andelectromc uttercomectlons and part leads. ‘llm requirement does not include structuralwelds.

2. Pocu ments arm licab le to Reau irement 24:

ML-W-8939 Welding, Resistance, Electronic Circuit Modules

3. Jle finitionS. Not applicable.

4. ~. Welds and welding processes shall be in accordance withMIL-W-8939.

S.lf n~ idance onl

5.1 co ntaminant~. All surfaces of leads or parts to be welded should be free of con-taminants which would adversely affect forming of the welded joint.

5.2 E~s Except where needed to meet electromagnetic interferenceor system compatibility requirements, welded electrical connections should not be usedwhere it may be necessary to dkconnect, replace, or reconnect a part or module duringservicing.

5.3 E~. Excess conductor wire should be trimmed sufficientlyclose to provide adequate clearance to prevent possible electrical shorting but not soclose as to cause damage to the welded joint.

5.4 &rain reli ef. .~ch part lead terminating at a connection point shou[d haveallowance for strain relief to minimize tensile or shear stress.

SupersedesREQUIREMEN 241 September 1978


24-1


.\., MIL-STD-454L

REQWREMENT 25

ELECTRICAL POWER

1. ~~~. This requirement establishes criteria for electrical power.

2. Documents applicable to Requirement 25:

MIL-STD-205 Frequencies for Electric PowerMIL-STD-255 E1ectric Voltages, Alternating and Direct Currenth’ffL-sTD-704 Aircraft Electric Power CharacteristicsMIL-STD-1275 Characteristics of 28 Volt DC Electrical Systems in

Military VehiclesIIOD-STD-1399 fnterface Standard for Shipboard SystemsMIL-STD-1539 Electrical Power, Direct Current, Space Vehicle Design

Requirements

3. De finitiorm. Not applicable.

4. ~s

4.1 General. Except as specified below, the electrical power source required forelectronic equipment and associated equipment and for portions of systems employingelectronic equipment shall be in accordance with MIL-STD-205 and MIL-STD-255.

4.2 Airborne. The electrical power requirements for airborne and associated equip-ment shall be in accordance with MlL-STD-704.

4.3 ShiDboar~. The electrical power requirements for shipboard and associated equip-ment shall be in accordance with Type I or Type IIof Section Rl of DOD–STD-1399.

4.4 -. The electrical power requirements for space equipment shall be inaccordance with MIL-STD-1539.

4.5 Groun dvehlcles. The electrical power requirements for military ground vehiclesshall be in accordance with MlL-STD-1275.

5. In~ n~. Not applicable.



25-1

)


MIL-STD-454L

REQUIREMENT 26

ARC-RESISTANT MATERJALS

1.. Puroose. Tttk requirement establishes criteria for the selection and application ofarc-resistant materials used for insulation of electrical power circuits.

2. oc m ntsD u e aDDlicable to Recruirement 2f2:

L-P-516 Plastic Sheet and Plastic Rod, Thermosetting, CastZZ-R-765 Rubbe[, SiliconeMIL-I-1O Insulating Materials, Electrical, Ceramic, Class LMIL-M-14 Molding Plastics and Molded Plastic Parts, ThermosettingMIL-P-79 Plastic Rod and Tube: Thermosetting, LaminatedMJL-P-997 Plastic Material, Lamutated, Thermosetting, Electrical

Insulation, Sheets, Glass Cloth, Silicone ResinMIL-P-15037 Plastic Sheet, Laminated, Thermosetting, Glass-Cloth,

Melamine-ResinMIL-P-19161 Plastic Sheet, Laminated, Glass Cloth, Polytetra-

fluoroethylene ResinMIL-M-24325 Molding Material, Plastic, Epoxy Compounds, ThermosettingMIL-P-25518 Plastic Material, Silicone Resin, Glass Fiber Base,

Low-Pressure I&minatedMIL-P-46112 Plastic Sheet and Strip, PolyimideFED-STD-406 Plastics: Methods of TestingASTM D495-73 Standard Method of Test for H!gh-Voltage, Low-Current Dry

AC Resistance of Solid Electrical Insulation MaterialsCode of Federal Regulations, Title 29, Chapter XVII, Part 1910


4. Requirements. Materials shall conform to table 26-I. The materials listed havepassed the minimum requirements of 115 seconds when subjected to the arc-resistancetest of ASTM D495 or Method 4011 of FED-STD-406, and are listed in approximateorder of arc resistance.


5.1 &~. Materials may be masked, if necessary, during any treatment of theequipment in which they are used which might resuk in degradation of thearc-resistant properties of the material. For parts which may be exposed to other thanhigh-voltage, low-current arcing, the materials should be evaluated for overall thermaland electrical characteristics. Suitability for the specific application and the potentialfor satisfactory performance in elevated humidity, as defined in the detail equipmentspecification, should also be considered.



26-1


MIL-STD-454L

5.2 Ca rcino gens. Certain chemicals have been identified in the Occu ational Safetyfand Health Act (OSHA) as canc:r-producmg substances (carcinogens Before using

any materials which might contain these chemicals, they should be evaluated in accor-dance with the Code of Federal Regulations, TNe 29, Chapter XVII, Part 1910. Con-sideration of the toxicity of a substance should be gwen prior to material selection.

TABLE 26-I. Arc-resistant ma terials.

Mi#!zMs

Ceramic

Plastic(s), thermosetting,Molding

Molding, epoxy compounds

Laminated rods and tubes

Laminated sheets

Glass cloth, melamineresin

Glass cloth, polytetra-fluoroethylene resin

Glass cloth, siliconeresin

Low pressure laminate,silicone resine, glassfiber base

Sheet and rod, cast

Sheet and strip, polyimide

Silicone rubber

5$.~Q. . .

MIL-I-1O

MIL-M-14

MIL-M-24325

MIL-P-79

MIL-P-15037

ML-P-19161

MIL-P-997

MIL-P-25518

L-P-516

MIL-P-46112

ZZ-R-765

All

CMI-5, GDI-30, GDI-30F,MAG, MAI-30, MAI-60,MAJ-1OO, MAT-30, MDG,MME, MMI-5, MMI-30, MSGMSI-30, SDG, SDG-F, SDI-30

MEE

GMG

GME

GTE

GSG

All

E-2

@l

All

REQUIREMENT 26Supersedes

10 September 1987REQUIREMENT2626 September 1977

26-2

\


MIL-STD-454L

REQUIREMENT 27

BATTERIES

1. ~l?!ie. YIS requirement establishes the criteria for the selection and applicationof batteries, utcludmg mstallatlon and markmg criteria.

2. D nt Ii~ irement 27

ML-B-18 Batteries, Non-Rechargeable, DryMIL-B-10154 Batteries, Primary, Water-Activated (Dunk Type)ML-B-11188 Batteries, Storage, Lead-AcidDC)D-B-15072 Batteries, Storage, Lead-Acid, Portable, General

Specification for (Metric)MIL-B-49030 Batteries, Dry (Alkaline)MIL-B-49430 Batteries, Non-Rechargeable, Nickel Cadmium, SealedMIL-B-49436 Batteries, Rechargeable, Nickel-Cadmium, SealedMIL-B-49458 Batteries, Non-Rechargeable, Lithium Manganese DioxideMIL-B-49461 Batteries, Non-Rechargeable, Lhhium Thionyl ChlorideML-B-55118 Batteries, Storage, (Cells), Vented, Nickel-CadmiumMIL-B-55130 Batteries, Rechargeable, Nickel-Cadmium, SealedML-B-55252 Batteries, Magnesium, DryMCL-B-81757 Batteries and Cell:, Storage, Nickel-Cadmium, Aircraft,

General Specification forMIL-B-83769 Batteries, Storage, Lead-Acid, General Specification forDOD-STD-1578 Nickel-Cadmium Battery Usage Practices for Space VehiclesRegulation 700-83, Army Materiel Command


4. Requirements

4.1 w. Batteries shall not be used unless approved by the procuring activity.

4.1.1 Arm}7 EIDrdications. Battery power for Army equipment (development and non-development type) and other-service-developed equipment adopted by the ‘Army shallbe selected in accordance with Afmy Materiel Command Regulation 700-83.

4.1.2 $oace atm tlica ions. Batteries for space applications shall be selected and appliedin accordance with DOD-STD-1 578.

4,1.3 ~lthium batteries. When lithium batteries are to be used in an equipment, direc-tion on their use, transportation, storage, and disposal should be requested through theprocuring activity from the following sources:

For Army: US Army Laboratory Command’”Electronics Technology and Devices LaboratoryATIN: SLCET-PFt Monmouth NJ 07703-5302


27-1



I

MIL-STD-454L

For Navy: Department of the NavyNaval Sea Systems CommandATIN NAVSEA 652Washington DC 20362

For Air Force: Sacramento Air Logistics CenterAlTN: MMIECMcClellan AFB CA 95652

..4.2 Recha reeable ba tteries. Rechargeable batteries shall conform to MIL-B1 1188,DOD-B-15072, ML-B-49436, ML-B-55118, MIL-B-55130, MIL-B-81757,ML-B-83769, or DOD-STD-1578.

4.3 N~ arteries. Nonrechargeable batteries shall conform to MIL-B-18,MIL-B-10154, MIL-B-49030, MIL-B-49430, MIL-B-49458, MIL-B-49461, orMIL-B-55252.

4.4 Installation marking. Connections, polarity, minimum acceptable voltage for equip-ment operation, nominal voltage, and type(s) of batteries required shall be marked asapplicable in a prominent place on or adjacent to the battery compartment.

4.5 Warnine label. Battery-powered equipment, with the exception of equipmentrequiring permanent battery installation, shall be labeled externally as follows:

WARNINGREMOVE BATTERIES BEFORE

SHIPMENT OR INACTIVE STORAGEOF 30 DAYS OR MORE

Examples of equipment requiring permanent battery installation are sonobuoys,missiles, and fuses.

““”5.Information for euidance only. The battery compartment should be provided withdevices }0 firmly secure the batteries. Adequate room should be provided for batteryinstallation, mamtenance, 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, andshould also prevent such materials from entering the electronic compartment. Whenmagnesium dry batteries are used, extra precautions should be observed since these

~ batteries give off heat at high rates of discharge (less than 10 hours) and evolvehydrogen.

IREQUIREMENT2720 September 1988

SupersedesRE”QUIREMEN 2730 June 1985

I27-2


MIL-STD-454L

REQUIREMEW 28

CONTROLS

1. -. This requirement establishes criteria for the selection and application ofcontrols.

2. D~ e irement Z&

MIL-K-3926 Knobs, Control (For Usewith Electronic, Comrtnmications,and Allied Equipment)

MIL-K-25049 Knob, Control, Equipment, AircraftML-D-28728 Dial, Control, Multitum Counters, General Specification for

3. ~s

3.1 ~ cent 01. Operating controls are controls that may be required for useduring the normal operation of the equipment.

3.2 ~ trolS. Adjustment controls are controls that are used for alignmentand. calibration of the equipment and are not used during normal operation of theequipment.

4. R~

4.1 General. All controls shall be marked, indexed, sized, and located so that thecontrol position can be readily identified. Controls shall have fixed guide .marks ifpre-settingof the controls is required. Controls located adjacent to their associateddisplays shall be so positioned that operation of the control will not obscure thedisplay. Controls shall be so connected in the circuit that the controlled characteristics(e.g., sensitivity, volume, orvoltage) increase, with clockwise rotation oftie control asseen from the operating position. In general, movement of a control forward,clockwise, to the right, or up, shall turn the equipment on, cause the quantity toincrease or cause the equipment to move forward, clockw~se, to the right or up.

,4.2 Access ibility

4.2.1 9De ratine controls. Controls necessary for the operation of the equipment shallbe readily accessible, and unless otherwise specified’ shall relocated onthe front panelof the unit.

4.2.2 ~diustmentco ntrols. Adjustment controls that are required’ for periodic align-ment or calibration shall be mounted behind covered openings, such as access doors,on the surfaces of the equipment accessible when installed. When not adjustable byhand, controls shall be designed to accept a common screwdriver blade tip. Controlswhich infrequently require adjustment need not be accessible from the operating panel,butshall bereadily accessible for servicing when the equipment is opened formaintenance purposes.

SupersedesREQUIREMENT28 REQUIREMENT281 February 1977 10 September 1987

28-1


MIL-STD-454L

4.3 M6Chanical characte ristim

4.3.1 -. Mechanical stops shall be provided. for all ad@able controls, except con-

~trols designed for utdimited rotation. Where flexlble control shafts are employed, orwhere stops integral to the adjustable control or the mechanism could be damaged byexcessive torque, stops shall be provided on the driving end of the shaft.

4.3.2 Jmckine devices. Control locking devices shall be capable of retaining the con-trols in any given setting within the range of control. The locklng and unlockhg actionshall be easily and quickly accomplished, and shall not affect the setting of the control.

‘When in the unlocked Dosition. the locking devices shall not interfere with the normal‘floperation of the control. Where vernier c&trols are used, the locklng devices shall

I ‘operate on both main and vernier controls if necessary to prevent damage.

4.3.3 Nontum devices. AH nontuming controls and bodies or cases of turning controls

~shall be equipped with a positive device to prevent their turning in the panel orassembly on which they are mounted.

4.3.4 s~uu Ii Coupling behveen or to shafts shall be accomplished bymeans of metallic or insula~ed couplings rigidly secured.

4.3.5 Control kno bs and handles. Control knobs conforming to ML-K-3926 orMIL-K-25049 shall be used wherever suitable. For knobs not covered by a militaryspecification, color, tactile information, and flammability requirements shall be inaccordance with MILK-3926. Control knobs and handles shall have high impactstrength and shall be firmly secured to the control shafts by use of setscrews whereverthat type of fastener is applicable. Plastic knobs and handles shall have metal insertsfor setscrews and shall not warp or crack.

4.3.6 Multitum counters control dials. Manually operated multitum counters controldials shall conform to MIL-D-28728.

4.3.7 Stability. All controls shall be so designed that the setting, position, or adjust-ment of any control shall not be altered when the equipment is subjected to the serviceconditions specified in the detail equipment specification.

4.3.8 Factorv adiustment controls. The design of equipment shall not include “factory”or sealed adjustment controls, unless specifically approved by the detail equipmentspecification.

5. blLIY

5.1 mAZ!l ion. Controls should be arranged to facilitate smooth andrapid operation. All controls which have sequential relations, which are related to aparticular function or operation, or which are operated together should be groupedtogether along with their associated displays. Controls should be conveniently locatedwith respect to associated visual displays. Controls should. be of such size and sospaced that the manipulation of a given control does not interfere with the setting ofan adjacent control. Adjustment controls with required test points should be groupedand so marked as to provide for simplicity and ease of maintenance.


SupersedesREQUIREMENT281 Februa~ 1977

28-2

L---- I


MIL-STD-454L

5.2 Mec hanical ODeration. Infrequently required controls should be screwdriveradjusted. Play and backlash in controls should be held to a minimum commensuratewith intended operational functions and should not cause poor contact or inaccuratesett~ng. Controls should operate freely and sm.oo+ly without binding, scraping, orcutting. Controls may be lubrmted when lubrlcauon does not interfere with operationand is specified in the detail equipment specification.

5.3 ~aft$ and COUDlin~. Shafts subject to removal may have their couplings securedby two set screws 90 to 120 degrees apart. Fiexible couplings may be used for controlswhere the use of rigid couplings would interfere with the satisfactory operation ormounting of such controls.


28-3



MIL-STD-454L

REQ~ 29

ELECTRON TUBES

1. fi&g.g& This requirement establishes criteria for the selection end application ofelectron tubes.

2. P~ t licabl ir 9:

MIL-STD-200 Electron Tubes, Selection and Use of


Reau iremen~. Electron tubes shall be selected and applied in accordance with$ilHD-2oo.

5. Informs tion for euidance only. Not applicable.

SupersedesREQUIREMEW 291 August 1976


29-1


MIL-STD-454L

REQWREMENT 30

SEMICONDUCTOR DEVICES

1. N-E.. T?Iis requirement establishes criteria for the selection and application ofsemiconductor dewces.

2. ~ n

MIL-S-19500 Semiconductor Devices, General Specification forMfL-sTD-7ol Lkts of Standard Semiconductor Devicesh’lllATD-1547 Parts, Materials, and Processes for Space and Launch

Vehicles, Technical Requirements for

3. ~efinition$. Not applicable.

4. R~

4.1 Selection and application. Semiconductor devices shall be selected and applied inaccordance with MIL-STD-701, and, for Space Division, AFSC (SD), MIL-STD-1547.

4.1.1 JANS level. JANS level devices shall be used in space, launch, and reentryequipment applications for Space Division, AFSC (SD). When JANS parts are notavailable, parts shall be specified/procured in accordance with the requirements ofMIL-STD-1547.

4.1.2 JANTX and JANTXV levels. JANTX, JANTXV, or JANS level devices shall beused in Army Missile Command, Army Laboratory Command, Naval Ah’ ‘SystemsCommand and Alr Force applications other than SD space, launch, and reentry equip-ment.

4.1.3 JAN level. When J.ANTX, JANTXV, or JANS level devices are not available,JAN level may be used, subject to procuring activity approval. The JAN product shallalso be tested in accordance with JAN requirements of table Ill (Group A) and tableIV (Group B) of MIL-S-19500.

4.1.4 ~ ductors. When MIL-S-19500 devices are not available, othersemiconductors may be used, subject to procuring activity approval. AH devices shallbe screened and tested as in 4.1.3 above.

4.2 SealinP. All semiconductor devices used in equipment shall be hermeticallysealed in glass, metal, metal oxide, ceramic, or combination of these. Use of plastic(organic or polymeric) encapsulated or sealed devices requires the approval of the pro-curing activity.

5. Iriforrnation for euidance onbi. Semiconductor devices are susceptible to electrostaticdischarge damage. Appropriate discharge procedures should be observed prior tohandling these parts, and design selections of desired devices should include aconsideration of the effectiveness of the input or other protective elements included inthe device design.

SupersedesREQUIREMENT 30 REQUIREMENT3029 August 1986 .20 September 1988

30-1

i


MIL-STO-454L

REQWREMENT 31

MOISTURE POCKETS

1. ... This requirement establishes criteria for the treatment and drainage ofmoisture pockets.

2. DOCUments aDol cabi le to Requirement 31. Not applicable.


4. Reau emeir nt~. Where moisture pockets are unavoidable in unsealed equipment,provision shall be made for drainage of such pockets. Desiccants or moisture-absorb-ent materials shall not be used within moisture pockets.

5. Information for euidance on~

5.1 Pockets. wells. and traot Pockets, wells, traps, and the like in which water orcondensate could collect when the equipment is in normal position should be avoided.

5.2 Sealed eau iDment. In sealed equipment or assemblies such as waveguides, the useof desiccants or other methods, such as gas purging, is permitted.


ii


31-1


MIL-STD-454L

REQUDWMENT 32

TEST PROVISIONS

1. ~J?Me. Thk requirement establishes criteria for test provisions.

2. Documents arpl icabl e to Reo uirement 3Z

MIL-sTD-415 Test Provisions for Electronic Systems and AssociatedEquipment, Design Criteria for

MIL-STD-2165 Testability Program for Electronic Systems and Equipments

3. p~s. Not applicable

4. ~eauirementa

4.1 BElsil -in .. Built-in test devices shall maintain their accuracy under alloperating conditionsv~equlred by the equipment under test. These devices shall beprovided with connections or access for their operational checkout or calibration.

4.2 J3xternal test uoints. Protection shall be provided in the test point circuitry toprevent equipment damage caused by the external grounding of test points.

4.3 Failure effect. Unless otherwise specified, provisions for testing shall be sodesigned that any failure of built-in test devices will not degrade equipment operationor cause equipment shut down.

4.4 Tet Drevisions. Test provisions to provide means for monitoring performance,calibration, and fault isolation shall be in accordance with MfL-STD-415.

5. n~y idance on!

5.1 fi t bilit~. When specified by the procuring activity, a testabilityprogram should be implemented in accordance with MIL-STD-216S.

SupersetfesREQUIREMENT 3215 March 1978

32-1



MIL-STD-454L

REQWREMENT 33

RESISTORS

1. fi~e. This requirement establishes criteria for the selection and application ofresistors.

2. Docume ts aDo cab e ton Ii I Requirement 33:

MIL-T-23648 Thermistor (ThermalIy Sensitive Resistor), Insulated,General Specification for

MIL-STD-199 Resistors, Selection and Use of


4. Reau emir ents

4.1 selection. Resistors shall be selected and applied in accordance with MIL-STD-199.

4.2 Thermistors. Thermistors shall conform to MIL-T-23648.

5. I forma im ton for euidance onlv. Not applicable.

SupersedesREQUIREMENT3330 April 1984

REQUIREMENT3320 September 19f38


MIL-STD-454L

REQUWIWENT 34

NOMENCLATURE

1. x. ~s requirement establishes criteria for nomenclature (item name andtype deslgnatlon).

2. Pocume t aDD cab e ton Ii 1 Requirement 34

MIL-STD-196 Joint Electronics Type Designation Systems


4. Rea uirement~. Item names and type designations for electronic equipment shall beestablished in accordance with h41L-STD-196.

5. Informs tion for euidance only. The assignment of type designations does notconstitute approval of equipment or the use of a particular item in a specific set anddoes not waive any requirements of the contract involved, nor does the approval of theequipment constitute approval of the type designation assignment.

SupersedesREQUIREMENT 3415 March 1978

REQUIREMENT3412 Februaw 1988


MIL-STO-454L

REQUIREMENT 35

RELL4BIIJTY

I. ~~x. Thk requirement offers guidance as to reliabllity requirements whichmust be considered when preparing contractual documents. IT DOES NOTESTABLISH REQUIREMENTS, AND MUST NOT BE REFERENCED IN CON’IR4C-TUAL DOCUMENTS. Reliability program tasks, quantitative requirements, andverification or demonstration requirements must be directly specified in the contract orthe systetdequipment specification, as appropriate.

2. PoclJ ments armlicable to Reo uirement 35:

MIL-STD-721 De@i~ons of Terms for Reliability and MaintainabilityMIL-STD-756 Rehabdlty Modelin and PredictionMIL-STD-781 Reliability Design &alification and Product Acceptance

Tests: Exponential DktributionMIL-STD-785 Reliabihty Program for Systems and Equipment Development

and ProductionMIL-STD-1629 Procedures for Performing a Failure Mode, Effects and

Criticality AnalysisMLL-I-JDBK-217 Reliability Prediction of Electronic Equipment


4. R~ ir nt Not applicable.

5. ~y idance onl

5.1 ~eliabilitv Droeram. Reliability engineering and accounting tasks aimed atpreventing, detecting, and correcting reliability design deficiencies, weak parts, andworkmanship defects and providing reliability related information essential toacquisition, operation, and support management should be included in contact require-ments with the objective of establishing and maintaining an efficient reliability programaccording to life cycle phase. MIL-STD-785 is the overall program document for thearea. It is sectionalized into individual task statements and requires extensive tailoringwhen it is applied. Detailed application guidance as to the nature of the tasks andwhen they should be imposed is’provided. Other reliability documents which may beinvoked through MIL-STD-785 or which may be cited directly as a basis for contractrequirements include MIL-STD-721, MIL-STD-756, MIL-STD-781, MIL-STD-1629,and MIL-HDBK-217.

5.2 ~ iv iremen S. Quantitative reliability requirements and verification ordemonstration requirements should be established appropriate to program phase.

SupersedesREQUIREMENT 3530 JUly 1982

35-1



MIL-STD-454L

REQUINMENT 36

ACCESSIBILITY

1. m. ‘Ilk requirement establishes criteria for accessibility.

2. ~ocuments ?QQ!&@j~ti

MIL-STD-280

IvIII.ATD-721MIL-STD-1472

3. Definitions

Definition of Item Levels, Item Exchangeabtlity, Models, andRelated TermsDefinitions of Te.pns for. Reliability and M~@ainabilityHuman Engmeermg Design Crltena for MdItary Systems,Equipment and Facilities

Accessibility is as defined in MIL-STD-721.

3.2 ~P embly. Pan, subassembly, and assembly are as definedin MIL-STD-~80.

4. ~eou irements

4.1 &r&ss. Each article of equipment and each major subassembly forming a partthereof shall provide for the necessary access to its interior parts, terminals, and wiringfor adjustments, required circuit checking, and the removal and replacement of mainte-nance parts. Accessibility for testing and replacement does not apply to parts locatedin nonrepairable subassemblies or assemblies. For routine servicing and maintenance,unsoldering of wires, wire harnesses, parts or subassemblies shall not be required inorder to gain access to terminals, soldered connections, mounting screws and the like.Inspection windows shall be provided where necessary. Sizes of openings, maximumreach requirements, and allowable sizes and weights of replaceable assemblies shallconform to limits established in MIL-STD-1472.

4.2 co nnections. Connections to parts inside a removable container shall be arrangedto permit removal of the container without threading connection leads through thecontainer.

4.3 .&$s. Parts which are identified as replaceable parts shall not be mounted bymeans or rivets, spot welding, or hard curing compounds. No unsoldering or solderingof connections shall be necessary when the front panel or any subchassis is removedfor maintenance purposes. Design shall be such that where plug-in modules orassemblies are used, they can be easily inserted in the proper location when correctlyoriented without damage to equipment or parts being engaged.

SupersedesREQUIREMENT 36 REQUIREMENT36

12 Februafy 198829 August 1986

36-1


MIL-STD-454L

4.4 ~ r Accessibility to chassis, assemblies, or parts contained within cabinets,consoles or other enclosures shall be provided from outside the basic equipmentthrough the use of access doors, by mounting such items on withdrawal slide:,swinging doors, through cable extenders and cable retractors, provisions for circuitcard extenders which will allow part or module operation in the open position, or otherarrangements to permit adequate access for properly servicing the eqtupment.

,Automatic or manually operated locks shall be provided to lock the chassis in theservicing position. When withdrawal slides are used they shall be of guided sectionalconstruction with tracks and rollers. Complete removal and access for servicing ofelectronic equipment contained within cabinets, consoles or other enclosures shall be

:provided from either the front or rear of the equipment. Guide pins or locating pins,!or the equivalent, shall be provided for mechanical alignment during mounting.‘Shipboard equipment shall have complete access for maintenance and servicing fromthe front .of the equipment.

4.5 $olt ogether racks and enclosu res. For Navy ship and shore applications, whenbolt-toge~er racks are required, fastening shall be provided to bolt adjacent rackstogether at the top with external brackets and through the bottom of the rack to a baseor foundation. Bottom mounting shall be accessible from the front with minimum dis-assembly of internal parts or subassemblies.


5.1 co mDatibili ty.,Equipment should be designed for optimum accessibility compatiblewith operating, mamtenance, electromagnetic compatibility, and enclosure require-ments.

5.2 f!ULS. If, in order to check or remove a part, it is necessary to displace someother part, the latter part should be so wired and mounted that it can be moved with-out being disconnected and without causing circuit detuning or instability.



36-2


MIL-STD-454L

REQWREMH4T 37

CfRCUIT BREAKERS

1: z. Thk requirement establishes criteria for the selection and application ofcmcutt breakers.

2. Docum~le to Rerys ement 37:ir

MIL-STD-1498 Circuit Breakers, Selection and Use of

3. Pefinition~. Not applicable.

4. ~eauirements

4.1 Selection and app Iication. Circuit breakers shall be selected from IWL-STD-1498.Trip-free circuit breakers shall be used. Nontrip-free circuit breakers shall be usedonly when the application requires overriding of the tripping mechanism for emergencyuse.

4.2 .Manual oueration. Circuit breakers shall be capable of being manually operatedto the ON and OPF positions. Circuit breakers shall not be used as ON-OPF switchesunless such breakers have been specifically designed and tested for that type ofservice.

4.3 Position identification. Circuit breakers shall have easily identified ON, OFF andTRIPPED positions except that the TRIPPED position may be the same as the OPFposition with no differentiation between OFF and TRIPPED being required.

4.4 Orientation. Circuit breakers shall operate when permanently inclined in anydirection up to 30 degrees from the normal vertical or normal horizontal position. Thetrip point of an inclined unit shall not vary more than t 5 percent of the currentspecified for normal position mounting. Circuit breakers used on flight equipment andportable test equipment shall operate within the limits of the detail specification whenthe equipment is in any position or rotation about its three principal axes.

5. ~b i nly. Not applicable.


37-1



MIL-STD-454L

REQUJNMENT 38

QUARTZ CRYSTALS AND OSCILLATOR UNITS

1.. EUQQSQ WIS requirement esmblishes criteria for the selection of quartz crystalumts and crystal oscillators.

2. DOWments aDD]iCab]eto Requirement 3&

MCL-O-5531O Oscillators, CrystalMIL-S131-683 Crystal Units, Qu~, and Holders, Crystal

3. p~. Not applicable.

4. R~x

4.1 Quartz CNS tals. Quartz crystal units shall be selected in accordance with MIL-STD-683.

4.2 c~s. Crystal oscillator units shall conform to MIL-O-5531O.

5. ~ idance only. Not applicable.



38-1,. -,

f’ I


MIL-STD-454L

REQUIWMENT 39

FUSES AND FUSE HOLDERS

1. puroose. TMs requiremen~ establishes criteria for the selection and application offuses, fuseholders, and associated hardware.

2. P m Ii~ ire ent 39:

MIL-STD-1360 Fuses, Fuseholders, and Associated Hardware, Selectionand Use of

3. Definitions. Not applicable

4. ~eau irement~

4.1 selection and app Iication. Fuses, fuseholders, and associated hardware shall beselected from MIL-STD-l 360.

4.2 ~~ e fuseh Ider The load shall be connected to the fuseholderterminal that terminates in the removable cap assembly.

5. l~v idan e onl

5.1 J3ranch circuits. Fusing should be so applied that fuses in branch circuits willopen before the fuses in the main circuit.

5.2 ~. Fuses are thermally activated devices. In general, time1-hdelay fuses are most susceptible to ambient temperature extremes; current limiters theleast.

5.3 @LQ. Fuse ratings are in terms of RMS, not average, linecurrents measured using true RMS reading instruments. Direct current lines havutg apulsating component should be measured using a true RMS reading instrument.


REQUIREMENT 39.20 September 1988

39-1


MIL-STD-454L

REQUIREMHW 40

SHUNTS

1. -g. TMs requirement establishes criteria for the selection of external metershunts.

2. Documents armlicable to Reau irement 4Q:

MIL-S-61 Shunt, Instrument, External, 50 millivolt (Lightweight Type)MIL-I-1361 Instrument Auxiliaries, Electrical Measuring; Shunts, Resistors,

and Transformers

3. PQs. Not applicable.

4. Reauirements. External meter shunts shall conform to MIL-S-61 or fvfIL-I-1361,as applicable.

5. Informs tion for euidance only. Not applicable.


40-1



MIL-STD-454L

REQUIRHWNT 41

. SPRINGS

1.. -g Thk requirement establishes criteria for the design, selection, and applica-tion of springs.

2. DQ t icabl ir 4:

QQ-B-750

QQ-C-530

QQ-C-533

QQ-C-585

QQ-C-586

QQ-S-766QQ-W-321QQ-W-423QQ-W-470MIL-S-7947ML-S-13282MIL-S-13572MIL-C-19311

NIILS-22215MU-S-46049

MIL-C-81021ASTM A29-84

‘ASTM A682-79

ASTM A684-81

ASTM B522-80

Bronze, Phosphor, Bar, Plate, Rod, Sheet, Strip, Flat Wkeand Structural and Special Shaped SectionsCopper-Beryllium AIIoy, Bar, Rod, and Wire (Copper AlloYNumbers 172 and 173)Copper-Beryllium Alloy Strip (Copper Afloy Numbers 170and 172)Copper-Nickel-Zinc Alloy Plate, Sheet, Strip and Bar (CopperAlloy Numbers 735, 745, 7S2, 762, 766, and 770)Copper-Nickel-Zinc AIIoE Rod Shapes, and Flat Productsand Finished Edges (Flat Wire, Strip, and Bar)Steel Plates, Sheets, and Strip, Cofrosion ResistingWke, Copper Alloy.Wire, Steel, Corrosion-ResistingWire, Steel, Carbon, Spring, MusicSteel, Sheet and Strip (1095) Aircraft QualitySilver and Silver AlloySpring, Helical, Compression and ExtensionCopper-Chromium Alloy Forgings, Wrought Rod, Bar- and Strip .(Copper Alloy Numbers 182, 184 and 185)Silver-Copper-Cadmium-Nickel AlloySteel. Carbon, Strip, Cold Rolled, Hardened and Tempered,Spring Quality -Copper-Cobalt-Beryllium Alloy (Copper Alloy No. 175), StripSteel Bars, Carbon and Alloy, Hot Wrought and ColdFinished, General Requirements forSteel, Carbon, Strip, Cold Rolled Spring Quality, GeneralRequirementsSteel, Carbon, Strip, Cold Rolled Soft, Untempered SpringQualityGold-Silver-Platinum Electrical Contact Alloy, Specificationfor

Metals Handbook, Vol I (1978), American Society for Metals


4. ~rement$

4.1 Helical smin~. Helical springs shall conform to ME-S-13572.


4..

,.~,

:,. ,,.

REQulREMEm’4j::::”

10 September 1987

1 .4’-’


MIL-STD-454L

4.2 Elsxtr ical contact x. Electrical contact springs shall use materials selectedfrom table 41-1.

4.3 Cabon steel *“. Carbon steel springs shall be suitably plated or finished toresist corrosion.

5.

‘,5.1 co rrosion res istine steel. Corrosion resisting steel springs are preferred where.. electrical conductivity is not a consideration and where they are adequate for the‘purpose intended. “

5.2 Fatigue limits. Fatigue limits of the springs should not be adversely affected bycorrosion? operating temperature, and other environmental conditions in service.Fatigue hmits should be consistent with the maximum specified operating cycles forthe respective part or equipment or, if such is not specified, with the maximum dutycycle to be expected during the equipment service life.

5.3 Electrical cond uctivity. Electrical conductivity of contact-springs should not beadversely affected by corrosion, operating temperature and other environmentalconditions in service.

5.4 Enclosure. Where practicable, springs should be enclosed in housings or otherwisecaptivated in order to prevent broken pieces from entering and adversely affecting theequipment.

5.5 Heat treatment. Springs made of materials that achieve their desired properties byheat treatment, such as copper-beryllium alloys, annealed carbon steels, CRES steels,or heat resisting alloys, should be heat treated to the specified temper after forming.

5.6 Grain orientation. Flexure and forming of springs should be designed to occurperpendicular to the grain of the material. Deviation from the perpendicular should notexceed 45 degrees.

5.7 Documents for sDecifvine materials. When the materials listed in tables 41-1,41-II, and 41-IU are used, they should conform to the specifications listed for eachmaterial.

IREQUIREMENT 41

I10 September 1987

41-2


L.


MIL-STD-454L

TABLE 41-1. Materials for electrical soring ao~.

Material

Copper-nickel-zinc alloy

Copper-nickel-zinc alloy

Copper-beryllium alloy

Copper-beryllium alloy

Copper alloy

Copper-cobalt-berylliumalloy

Copper-chromium alloy

Phosphor bronze

Platinum-iridium alloy

Silver-copper alloy

Silver-copper-cadmium-nickel-alloy

Palladium-copper alloy


Form

Plate, sheet, strip androlled bar

Rod, shapes and flat productswith finished edges (flatwire, strip and bar)

Bars, rods, and wire

Strip

Wire, spring

Strip

Bar, rod, and strip

Bar, rod, plate, sheet, strip,and flat wire

Strip

Ba; ro~, plate, sheet, strip,

Rod, sheet, strip, and wire

Materialspecification

QQ-C-585

QQ-C-586

QQ-C-530

QQ-C-533

QQ-W-321

IvHL-C-81O21

MIL-C-19311

QQ-B-750

ASTM B522

MIL-S-13282

MIL-S-22215

Metals Hand-book, Vol I


41-3


MIL-STD-454L

TABLE 41-II. Corrosion resistine stee I for SDri~.

MaterialMaterial

Form specification

Steel, CRES Wire QQ-W-423Strip QQ-S-766

,.!.

TABLE 41-III. Carbon steel for smin~~

MaterialMaterial Form specification

Steel, high carbon Wire, spring, music QQ-W-470 l/

Steel, carbon and alloy Strip, cold rolled ASTM A682(for springs) untempered spring ASTM A684

Steel, carbon and alloy f~~i~d, square ASTM A29(for springs)

Steel, carbon, strip Cold rolled, hardened MIL-S-46049and tempered spring

Steel, carbon (1095) Sheet and strip A-annealed

‘[

MIL-S-7947

1condition 1 H-hard tempercondition 3 cold finished

~/ QQ-w-470 springs require heat treatment immediately after forming toprevent stress embrittlement.

SupersedesREQUIREMENT 41 RE”QUIREMEtW4110 September 1987 30 August 1984

41-4

i


MIL-STD-454L

REQUIRH@NT 42

TUNING DJAL NfECI-L4NISMS

1. fi~?. Thk requirement establishes criteria for the design of tuning dialmecharusms.

2. p~ irement Q.

MIL-S-3644 Shaft Assembly, FlexibleMS33558 Numerals and Letters, Aircraft Instrument Dial, Standard

Form of

3. Pefinitiom. Not applicable.

4. B~

4.1 ~. The division marking and lettering on tuning dials shall be suitably etched orprinted with characters of style MS33558. Dial markings shall be legible at a distanceof two feet from any point within a solid angle of 60 degrees defined by a surface ofrevolution 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 lubberline or pointer tip shall not exceed the width of the graduation marks. Except fordigital tuning indicators, for which only one calibration number will be seen, dials shallbe marked so that at least two calibration numbers on each band can be seen at anydial settutg.

4.2 Balance and friction. Weighted tuning knobs shall be counterbalanced. Friction intuning dial mechanism shall allow smooth and easy adjustment of the operating knobover the entire operating range of the mechanism, but shall have sufficient resistanceor shall incorporate a positive lockhtg device to maintain the setting under all specifiedservice conditions. Friction shall be achieved through dry or elastic resistance ratherthan by fluid resistance.

4.3 FI iblex e control shafts. Flexible shaft assemblies conforming to MIL-S-3644 shallbe used when a flexible mechanical connection is required between the tuning knoband the tuned device.

5. lnfmmat or rzudance o yion f i nl

5.1 Tunine ra tiQ. The tuning ratio used should be the optimum which will permit bothrapid and precise setting.

SupersedesREQUIREMENT 421 February 1977 42-1



MIL-STD-454L

REQUIWMENT 43

LUBRICANTS

1. -s. Thk requirement establishes criteria for the selection and application oflubmxmts.

2. Pocu ments an vlicable to Reau irement 43

W-L-800 Lubricating Oil, General Purpose, Preservative (Water-Dkplacing, Low-Temperature)

W-P-236 Petrolatum, TechnicalMCL-L-2105 Lubricating Oil, Gear, Multi-PurposeMIL-L3150 Lubricating 011, Preservative, MediumMIL-L-3918 Lubricat@g Oil, Instrument, Jewel BearingMIL-L-6085 Lubricating Od, Instrument, Aircraft, Low VolatilityMIL-L-6086 Lubricating 0]1, Gear, Petroleum BaseML-L-15719 Lubricating Grease (High-Temperature, Electric Motor,

Ball and Roller Bearings)MIL-L-17331 Lubricating Oil, Steam Turbine (Noncorrosive)MIL-L-17672 Lubricating Oil, Hydraulic and Light Turbine,’

NoncorrosiveMIL-G-23827 Grease, Aircraft and Instrument, Gear and Actuator ScrewMIL-G-24139 Grease, Multi-Purpose, Quiet ServiceDOD-G-24508 Grease, High Performance, Multi-purpose (Metric)MIL-G-81 322 Grease, Aircraft, General Purpose, Wide Temperature RangeCode of Federal Regulations, Title 29, Chapter XWI, Part 1910


4. Requirements

4.1 w Lubricants shall conform to one of the following:

W-L-800 , IWL-L-6085W-P-236

MIL-G-23827MIL-L-6086 MIL-G-24139

MIL-L-2105 MIL-L-15719h41bL-3150

DOD-G-24508MIL-L-17331

MIL-L-3918MIL-G-81322

MIL-L-17672

4.2 $ilicones. Silicone compounds shall not be used as lubricants.

4.3 f&aDhite b ase lubricants. Graphite base lubricants shall not be used.

5. Information for guidance only

5.1 =. The number of different lubricants should be held to a minimum.



43-1

/,, ,


MIL-STD-454L

5.2 VolatiliQ. Low volatility lubricants should be used where practical.

5.3 @mpat ibility. The lubricant should be chemically inert with regard to thematerials it contacts.

5.4 c arcinoeens. Certain chemicals have been identified in the Occu ational SafetyYand Health Act (OSHA) as cancer-producing substances (carcinogens . Before using

any materials which might contain these chemicals, they should be evaluated in. accordance with the Code of Federal Regulations, Tkle 29, Chapter XVD, Part 1910.

Consideration of the toxicity of a substance should be given prior to material selection.


MIL-STD-454L

REQ~ 44

FIBROUS hL4TERIALS, ORGANIC

1. me. ‘Ilk requirement establishes criteria for the selection and application oforganic fibrous materials.

2. P~ Iicabl Reauir nt 44:

V-T-276V-T-285V-T-291V-T-295CCC-C-428

MCL-W-530

MIL-C-572lvlLT-3530

MIL-W-4088MIL-C-9074MIL-W-27265

Thread, CottonThread, PolyesterThread, LinenThread, NylonCloth, Duck, Cotton; Fire, Water, Weather, and MildewResistantWebbing, Textile, Cotton, General Purpose, Natural or inColorsCords, Yarns, and Monofilament, Organic Synthetic FiberThread and Twine, Mildew Resistant or Water RepellantTreatedWebbings, Textile, Woven NylonCloth. Laminated. Sateen. RubberizedWeb&g, Textile: Woven’Nylon, Impregnated

Code of Federal Regulations, Title 29, Chapter XVII, Part 1910

3. D~ Not applicable.

4. Requirements

4.1 Webbing

4.1.1 -. Cotton webbing shall conform to MIL-W-530, class 4 or 7. Class 7shall be used when webbing will come in contract with natural or synthetic rubber orclass 4 when prolonged contact with the skin may occur.

,4.1.2 _ Nylon webbing shall conform to MIL-W-4088 or class R ofMIL-W-27265.

4.2 ~. Cotton duck used for protective enclosures shall conform to type I ortype II ~f ~CC-C-428. Medium texture number 4 shall be used for heavy dutyservice and hard texture 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.

4.3.1 ~. Cotton and linen thread shall be treated in accordance withMIL-T-35 30. Type I, class 2 mildew inhibking agent shall be used when thread willcome in contact with natural or synthetic rubber or type I, class 1 when prolong con-tact with the skin may occur.



44-1


MIL-STD-454L

4.4 m. Laminated, two-ply rubberized cotton sateen shall conform toMIL-C-9074. This sateen shall not be used when prolonged contact with the skin mayoccur.

4.5 c~ ent$. Cords, yams, and monofilament shall conformto ML-C-572. Types PVCA, AR, VCR, and CTA shall not be used where they maybe exposed to fungus attack.


“5.1 Shrinkaee. Fabric and thread should be preshrunk or allowance should be made.: for shrkkage in order to provide for satisfactory fit of finished items both before and

after they are immersed in water and then dried.

5.2 ~. Certain chemicals have been identified in the Occu ational Safetycf’and Health Act (OSHA) as cancer producing substances (carcinogens Before using

any materials which might contain these chemicals, they should be evaluated inaccordance with the Code of Federal Regulations, Thle 29: Chapter ~, Part 1910.Consideration of the toxicity of a substance should be gwen prior to materialselection.


44-2



MIL-STD-454L

REQWREMENT 45

CORONA AND ELECTRICAL BREAKDOWN PREVENTION

1. -e. TIis requirement establishes criteria for the prevention of corona andelectrical breakdown.

2. D~ et Ii eauirement 45:

ASTM D149-81 Dielectric Breakdown Voltage and Dielectric Strength ofSolid Electrical Insulating Materials at Commercial PowerFrequencies

ASTM D1868-81 Detection and Measurement of Partial Discharge (Corona) ~.Pulses in Evaluation of Insulation Systems

3. Definitions

3.1 co rona (air~. A luminous discharge due to ionization of “the air surrounding a con-ductor caused by a voltage gradient exceeding a certain critical value, called the partialdischarge (corona) inception voltage (CIV).

3.2 ~wI’ vo ta . The lowest rms voltage atwhich continuous partial discharges above some stated magnitude (which may definethe limit of permissible background noise) occur as the applied voltage is graduallyincreased.

3.3 P~w. The highest rms voltage atwhich partial discharges above some stated magnitude no longer occur as the appliedvoltage is gradually decreased from above the inception voltage. .

3.4 j3reakdown. A disruptive discharge through insulation, involving a sudden andlarge increase in current through the insulation because of complete failure underelectrostatic stress. Also called puncture.

4. R~ ir ent

4.1 0 rona rmevention. The CEV shall be at least 150 percent of the peak circuitvoltage, correspond~ng to the maximum specified steady-state rms SUPPIy voltage. Thkrequirement applies:

a. When the equipment is terminated with the cabling or other accessory equipmentwith which It N intended to be used and

b. When the equipment is operated under the specified environmental service condi-tions and

c. When the equipment is supplied with the specified power source frequencies andvoltages inchdng commonly recurring transients.

SupersedesREQUIREMENT 45 REQUIREMENT 4515 March 1978 12 Februaty 1988

45-1

/


MIL-STD-454L

4.2 J51ectrical breakdown Drevention. The equipment shall be ‘designed and manufac-tured with electrical clearance spacing,’ leakage (creepage) distances, and insulationcharacteristics adequate to prevent electrical breakdown. ‘Ilk requirement applies

mrtder all specified environmental service conditions including service life and using thespecified operating voltages (including transients). Liquid dielectrics, gases other than

“air, or pressurization to prevent electrical breakdown shall not be used unless approvedby the procuring activity.

.5. hformat on foi r euidance only

5.1 J3ffects of corona. Corona occurring at the interface of an insulator and a metalcan damage or reduce the life of an insulating system. In general, inorganic insulatingmaterials are more resistant to the damaging effects of corona than organic insulatingmaterials. Corona also generates electrornag-netic interference and liberates ozone, atoxic, oxidant gas.

5.2 Insulation svsterns. Corona can occur within cavities between an insulatingmaterial and a metal surface which are in contact. Therefore, care should be exercisedto avoid cavities at such interfaces where high voltages are encountered.

5.3 Netal Darts. Sharp edges and points should be avoided on metal parts which areincluded in high intensity electric fields.

5.4 Corona testing.. There are many factors which determine whether or not coronawill occur, including temperature, humidity, ambient pressure, test specimen shape,rate of voltage change and the previous history of the applied voltage. Test methodssuch as ASTM D1 868 may be used but the. test results lack accuracy and repeatabilityand require great care due to the personnel hazards involved.

5.5 Electrical breakdown testing. The breakdown voltage of a given insulatingmaterial is dependent upon electrode size and shape, insulator thickness, temperature,humidity, rate of voltage application, voltage waveform and voltage frequency. Whentesting, care must be exercised to assure that the insulating material is evaluated underthe actual environmental conditions which apply to the equipment and that theoccurrence of corona or localized heating do not mask the true breakdown voltage. Atest usable at power frequencies (25 to 800 Hz) is ASTM D149.


45-2

/’



MIL-STD-454L

REQUINWENT 46

MOTORS AND ROTARY POWER CONVERTERS

1. J+m’oose. This requiremertt establishes criteria for the selection and application ofmotors and rotary power converters.

2. P m ntocu e s aDolicable to Reau emeir nt 46:

CC-M-1807

MIL-D-24MIL-G-3111MIL-G-3124MIL-M-4818ML-M-4819MIL-M-4820MJL-M-7969

NIIL,-M-8609

MIL-F-9397ML-M-13786

MIL-M-l 3787

MIL-M-17059

MIL-M-17060

MIL-M-17413

MIL-M-17556

MIL-M-19097MIL-M-19160MIL-M-19167MIL-M-19283MIL-M-19633

MIL-B-23071


Motors, Alternating Current, Fractional and IntegralHorsepower (500 HP and Smaller)Dynamotors, General Specification forGenerator, Electric, Dkect Current (Naval Shipboard Use)Generator, Alternating Current, 60 Cycle (Naval Shipboard Use)Motor-Generator, Skid Mounted, Type MD-2Motor-Generator, Skid Mounted, Type MD-3Motor-Generator, Skid Mounted, Type MD-4Motor, Alternating Current, 400 Cycle, 115/200-VoltSystem, Akcraft, General Specification forMotors, Direct Current, 28 Volt System, Aircraft, GeneralSpecification forFrequency Converter, Mobile, Type MC-1AMotors, Fractional Horsepower, Dkect Current andUniversal [for Communication and Other Electronic and SpecialMilitary Applications)Motors, Alternating Current, Fractional Horsepower,Squirrel Cage (for Communication and Other Electronic and SpecialMilitary Applications)Motor, 60 Cycle, Akernatin Current, Fractional

7Horsepower (Shipboard UseMotors, 60 Hertz, Akematirrg Current, Integral Horsepower(Shipboard Use)Motors, Direct Current, Integral Horsepower, NavalShipboardMotor, Direct Current, Fractional Horsepower, (ShipboardUse)Motor-Generators, DC to AC, Sh~pboard ServiceMotor-Generator, 60 Hertz AC to 400 Hertz AC, Shipboard ServiceMotor-Generator, AC to DC, Shipboard ServiceMotor-Generator, DC to DC, Shipboard ServiceMotor-Generator, 60 Cycle AC to 400 Cycle AC (voltage andFrequency Regulated) Shipboard ServiceBlowers, Miniature, for Cooling Electronic Equipment, GeneralSpecification for


46-1


MIL-STD-454L

3.” p~s. Not applicable.

4. Reau irement~

.4.1 Motors - altematine current. Alternating current motors shall conform toCC-M-1807, ML-M-7969, ML-M-13787, MIE-M-17059 or MIL-M-17060, exceptthat any motor used with a miniature blower for cooling electronic equipment shall bein accordance with MIL-B-23071.

,4.2 Mom rs - direct curre nt. Direct current motors shall conform to ME-M-8609,MIL-M-13786, MIL-M-17413 or M3L-M-17556.

4.3 M~ r . Motor-generators shall conform to one of the following:

ML-M-4818 M3L-M-9397 MIGM-19167

MIL-M-4819 MIL-M-19097 MIL-M-19283

MIL-M-4820 MCL-M-19160 MIL-M-19633

4.4 Generators – altematine current. Alternating current generators shall conform toML-G-3124.

4.5 Generators - direct current. Direct current generators shall conform toMJL-G-3111.

4.6 Dvnamotors. Dynamotors shall confo~ to MIL-D-24.


REQUIREMENT-4620 September 1988

46-2

SupersedesREQUIREMENT 4626 Februafy 1987


MiL-sTc)-454L

REQUINMENT 47

ENCAPSULATION AND EMBEDMENT (PCMTJNG)

1. fi~e. This requirement establ~shes criteria for encapsulating and embeddhg(potting) a part or an assembly of discrete parts. Conforrnal coating of printed circuitassemblies is excluded from thk requirement.

2. Pocume ntS aDDIicable to Reauiremen t 47:

MIL-S-8516 Sealing Compound, Polysulfide Rubber, Electric Connectorsand Electric Systems, Chemically Cured

MIL-I-16923 Insulating Compound, Electrical, EmbeddingMIL-S-23586 Sealing Compound, Electrical, Silicone Rubber,

Accelerator RequiredMIL-M-24041 Molding and Potting Compound, Chemically Cured,

Polyurethane (Polyether Based)MIL-I-81550 Insulating Compound, Electrical, Embedding, Reversion

Resistant SiliconeCode of Federal Regulations, Title 29, Chapter XVII, Part 1910

3. Jlefinitions

3.1 Encapsulation. A process for encasing a part or an assembly of discrete partswithin a protective material which is generally not over 100 roils tilck and does notrequire a mold or container.

3.2 E~~ A process for encasing a part or an assembly of discreteparts within a protective material which is generally over 100 roils thick, varies inthickness, fills the connecting areas within an assembly, and requires a mold or con-tainer to confine the material while it is hardening. Potting is an embedding processwhere the protective material bonds to the mold or container so that it becomes inte-gral with the item.

4. ~. Encapsulation and embedment materials shall be of a nonreversiontype and shall be selected from the following specifications: MU--S-8516,.MIL-I-16923, MIL-S-23586, MU-M-24041, and MTL-I-81550. The materials selectedshall be capable of filling all voids and air spaces in and around the items beingencased. For Air Force applications, approval for use of any material other thantransparent silicone in accordance with MIL-I-81550. shall be requested through theprocuring activity from the Ak Force Wright Aeronautical Laboratories, AlTN:MLSE, Wright-Patterson AFB OH 45433-6503.

5. hforrnation for euidance only

5.1 Selection. The following points should be considered when selecting an encapsula-tion or embedment material:

a. Need for precautions due to hazardous characteristics of the material


47-1



MIL-STD-454L

b. Electrical, mechanical and thermal properties, including tear resistance, resistance toflame, 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 p&ts

i. Durometer hardness

j. Adhesion to substrates (and priming)

k. Temperatures of application and curing

L Repairability

m. Dielectric constant

n. Volume resistivity

o. Reversion resistance, including hydrolytic stability

p. Vkcosity

q. Solvent affects

r. Compatibility with parts or assemblies to which applied.

5.2 A~~ Iication. The encapsulation or embedment of microelectronic modules andequipment modules should be avoided, except where specifically indicated by therequirements of a particular application. In such instances, the module design shouldbe completely verified for the particular encapsulation or embedment materials and

“processes to be employed. Any changes in module design, materials, and processesmay require re-evaluation of the modules. In particular, extreme temperature agingand temperature cycling tests should be performed to verify adequacy of the design.Wherever economically feasible, the module to be encapsulated or embedded should bedesigned as a throw-away unit.

5.3 Ca rcino eens. Certain chemicals have been identified in the Occu ational safety~ Before usingand Health Act (OSHA) as cancer-producing substances (carcinogens

any materials which might contain these chemicals, they should be evaluated inaccordance with the Code of Federal Regulations, Tkle 29, Chapter XVII, Part 1910.Consideration of the toxicity of a substance should be given prior to material selection.



47-2


MIL-STD-454L

REQUIREMENT 48

GEARS

1. m. This requirement ‘establishes criteria for the selection and application ofgears.

2. Docu ments aDDIicable to Reau irement 4&

index &nerican Gear Manufactiers Association (AGMA)

3. Definiticms. Not applicable.

4. Beau iremen~. Gears not operating in a lubricant bath shall be made of corrosionresistant materials. Gears operating in a lubricant bath containing a corrosion inhibitingadditive may be made of noncorrosion resistant materials.

5. Itlf~y idance on

5.1 DJ2 . Gears should be designated, dimensioned, tolerance and inspectedin accordance with the applicable AGMA specifications.

5.2 PI? ring.. Planetary or epicyclic gearing is preferred to wormgearing.

.5.3 Nonmetallic eears. Nonmetallic gears may be used when ‘tiey meet load, life, andenvironmental requirements of the applicable specification.

StmersedesREQUIREMEN 481 February 1977

48-1

REQUIREMENT’ 4810 September 1987


MIL-STD-454L

REQUIf@WNT 49

HYDRAULICS

1. ~~e. Thk requirement establishes ~riteria for the design and installation of ahydrauhc system when It functions as an integral part of an electronic system.

2. Pocu ments atm Iicable to Requirement 49:

MIL-H-5440

MIL-H-8891

ME-H-25475

ANSI B93.4M-1981

Hydraul~c Systems, Aircraft, Types I and II, Design,lnstallat!on, and Data Requirements forHydrauhc Systems, Manned Flight Vehicles, Type III,Design, Installation, and Data Requirements forHydraubc Systems, h@sile, Design, Installation, Tests,and Data Requirements, General Requirements forFluid Power Cylinders, Dimension Identification Code forFluid Power, Glossary of Terms forCylinder Bore and Piston Rod Sizes for Fluid PowerC~lindersElectric Resistance Welded Mandrel Drawn Hydraulic Line

ANSI B93.5-1979

ANSI B93.6-1972

ANSI B93.7-1968

ANSI B93.8-1968

ANSI B93.9M-1969

ANSI B93.1O-1969

TubingUse of Fke-Resistant Fluids for Fluid Power Systems,Practices for theMounting Flanges and Shafts for Positive Displacement Fluid~’rwer Pumps and Motors, Dimensions and Identification Code

Mounting Surfaces of Sub-Plate Type Hydraulic Fluid PowerValves, Dimensions forBore and Rod Size Combinations and Rod End Configurationsfor Cataloged Square Head Industrial Fluid Power CylindersSvmbols for Marking Electrical Leads and Ports on FluidP~wer Valves -Static Pressure Rating Methods of Square Head Fluid PowerCylinders

ANSI B93. 1lM-1981 Seamless Low Carbon Steel Hydraulic Lhe TubingANSI SAE J514f Hydraulic Tube FittingsANSI SAE J518c Hydraulic Flanged Tube and Hose Connections, 4 Bolt, Split

Flanged Type

3. p efinition~. Not applicable.

4. Reau irements

4.1 ~~ i~ht vehicles. The design and installation of hydraulicsystems for aircraft or manned flight vehicles shall conform to the applicable type andclass or system described in MIL–H-5440 or IWbH-8891.


49-1



MIL-STD454L

4.2 Ivfksiles. The design and installation of hydraulic systems for missiles shallconform to the applicable type and class of system shown in MIL,-H-25475.

5. _atio for eu idance o~ . The following documents contain additionalinformation on hydraulic design:

., ANSI B93.1ANSI B93.2ANSI B93.3ANSI B93.4MANSI B93.5ANSI B93.6ANSI B93.7

ANSI B93.8ANSI B93.9MANSI B93.1OANSI B93.llMANSI SAE 1514ANSI SAE J518

REQUIREMENT 49

cSupersedesREQUIREMENT 4910 January 1983

49-2

/, ,.’./’I


MIL-STD-454L

REQUIREMENT 50

INDICATOR LIGHTS

?. .fi2.u. ‘Ilk requirement establishes criteria for selection and application ofmdtcator hghts and associated Kerns.

2. Jlocume IltSaDDIicable to Rea uiremen t 5Q

w-I_-oolll Lamp, Incandescent, (Electric, Miniature and Subminiature,Tungsten Fdament)

W-L-00116 Lamps, Fluorescent (General Specification)ML-L-3661 Lampholder, Indicator Eights, Indicator-IJght Housings, and

Indicator-Light hnses, General Specification forMIL-L-6363 Larmps, Incandescent, Aviation Service, General Requirements

MIL-L7806 Light, Panel, Plastic Plate LightingMIL-L-7961 Ulghts, Indicators, Press to TestMIL-L-15098 Lamp, G1ow, General Specification forMIL-S-19500 Semiconductor Device, General Specification forMIL-STD-1472 Human Engineering Design Criteria for Military Systems,

Equipment and Facilities


4. ~eauirements

4.1 Liehts and accessories. Indicator lights, indicator light housings, Iampholders,lenses, and lamps shall be selected in accordance with table 50-1.

4.2 Visual diso]av and ]eeend liehts. Visual display and legend lights shall complywith the requirements in MIL-STD-1472.

4.3 L~). LED’s when used as indicator lights shall conformto the applicable detail specifications of MIL-S-19500.

‘5. Information for mlidance only. Not applicable.



50-1


MIL

-ST

D-454L

Su

persed

es

RE

QU

IRE

ME

NT

50R

EQ

UIR

EM

EN

T50

20S

eptem

ber

198826

Feb

ruary

1987

50-2,.

.....4


MIL-STD-454L

REQUIREMENT 51

METERS, ELECTRICAL INDICATING

1. x. Thk requirement establishes criteria for the selection and application ofelectrical meters.

2. P~1 me

MIL-M-7793 Meter, Time TotalizingMLL-M-16d34 Meter, Electrical Indication (Switchboard and Portable Types)MTL-M-16125 Meters, Electrical, FrequencyMIL-I-81219 Indicator, Elapsed Time, ElectrochemicalIvlL-STD-1279 Meters, Electrical Indicating, Selection and Use of


4. Rea uirement~.Meters shall be selected and applied in accordance withMILATD-1279 . Meters required other than those listed in MIL-STD-1279 shallconform to one of the follawing specifications: MIL-M-7793, MlL-M-l 6034,MIC,-M-16125, ML-I-81219.

5. b~y. For analog meters,. the normal operating value ofthe quantity to be indicated should be between 1/3 and 3/4 of full scale deflection,wherever practicable.


51-1

“-’>



MIL-STD-454L

REQWREMENT 52

THERMAL DESIGN

1. -. This requirement establishes criteria for thermal design.

2. p nocume ts aoulicable to Reau ement 5ir 2:

F-F-300 Filter, Air Conditioning, Viscous-impingement and Dry Types,Cleanable

MIL-F-16552 Filter, Air Environmental Control System, Cleanable,Impingement (High Velocity Type)

MIL-B-23071 Blowers, Miniature, for Cooling Electronic Equipment,General Specification for

MIL-HDBK-251 Reliability/Design, Thermal Applications

3. Definitions

3.1 ~uxiliarv heatine or cooling. External heating or cooling devices not normally panof the equipment configuration.

3.2 Cold date. A heat transfer surface cooled by forced air or other heat transfer‘,fluid to which heat dissipating parts are mounted,

3.3 co ntaminant. Any foreign substance contained in air or other heat transfer fluidwhich adversely affects coaling performance, such as dust particles, lint, oil, sludge,etc.

3.4 D2 ineement. Passing cooling air over parts without the use of cold platesor heat exchangers.

3.5 E~. Water condensed from the cooling air and carried along with thecooling air.

3.6 External source SUDD coo e alied lin ir. Forced air supplied from a conditioningsource such as an air conditioner or aircraft environmental control system which is notnormally a part of the electronic equipment.

3.7 Fo ced a ir coo lin~. The dissipation of heat to cooling air, including ram air, sup-plied b; a source ‘with sufficient pressure to flow through the unit.

3.8 Heat excharwer. An air-to-air or liquid-to-air fimed duct arrangement which isused to transfer dissipated heat from a hot recirculating fluid to the cooling fluid byconduction through the finned surfaces.

3.9 ~a~ral cooling. The dissipation of heat to surroundings by conduction,convection, radiation, or any combination thereof without the benefit of externalcooling devices.



52-1


!,

I

MIL-STD-454L

3.10 &. An element or component used in the production of art. electronic equip-ment or subsystem, such as a microcircuit, diode, transistor, capacitor, resistor, relayswitch, or transformer.

a3.11 fiessu re droD (dinferential m-essure). Resistance to flow usually measured as thestatic pressure difference across the electronic equipment from inlet to coolant outlet.

4. JZeauirementS

4.1 F3Z ir ing. Forced air cooling shall be used only when natural cooling isnot adequate. Exhaust and recirculating fans and blowers shall be driven by ac brush-Iess motors or by properly shielded dc motors. Miniature blowers shall conform to,MIL-B-23071. Air filters shall be provided for air intakes for fan and blower cooledunits when required to protect internal parts. Filters, when used, shall conform toF-F-300 or ML-F-16552, and shall be removable for. cleaning without disassembly ofthe equipment. All ventilation openings shall be designed and located to comply withelectromagnetic interference, undesired radiation and enclosure requirements. Akexhaust shall be directed away from operating personnel.

4.1.1 )3xtemal sou rce. For equipment designed for use with external source suppliedcooling air, which may contain entrained water or other contaminants detrimental tothe equipment, precautionary measures shall be taken to avoid direct impingement oninternal parts and circuitry by channeling or use of heat exchangers. +

4.1.2 Aircraft atm Iication. Equipment that is intended for use in aircraft and requiresforced air cooling shall be designed using cold plates or heat exchangers so that noneof the cooling air will come into contact with internal parts, circuitry, or connectors.The only exception to this requirement is equipment that will be used solely in envi-ronments such as in the cockpit or air conditioned cabins, where surrounding air ispermitted to be drawn into the equipment for direct coohng of heat-producing parts.

4.2 Other cooline methods. Prior approval of the procuring activity shall be obtainedwhen heat densities or other design requirements make the use of air for coolingimpractical and alternate methods, such as liquid, evaporative, change of phasematerial, or heat pipes, are required.

5. Information for euidance only. The design factors which should be considered indetermining the required fan or blower characteristics include such factors as amountof heat to be dissipated, the quantity of air to be delivered at the pressure drop of theenclosed equipment, the allowable noise level, the permissible level of heat that maybe exhausted mto the surrounding environment, and other pertinent factors affectingthe cooling requirement of the equipment. Induced drafts and ventilation by means ofbaffles and internal vents should be used to the greatest practicable extent. Whenpracticable, ventilation and air exhaust openings should not be located in the top ofenclosures or in front panels. When it is impractical to avoid direct impingement oninternal parts and circuitry by channeling or use of heat exchangers, the water andcontaminants should be removed from the cooling air by suitable water and contami-nant removal devices.


SupersedeaREQUIREMENT 5210 September 1987

.752-2


MIL-STD-454L

5.1 J3xtemal source. For equipment designed for use with external source suppliedcooling air, minimum differential pressure (pressure drop) of the cooling air throughthe equipment heat exchanger or cold; plate should be maintained, consistent withadequate cooling.

5.2 Desion euidance. MIL-HDBK-251 may be used as a guide for detail informationon thermal design of electronic equipment.

.,

SupersedesRE”QUIREMEN 5210 September 1987

REQUIREMENT 5212 Februafy 1988 .,

52-3


MIL-STD-454L

REQUIWMENT 53

WAVEGUWES AND RELATED DEVICES

1. figs. Ttds requirement establishes criteria for the selection and application ofwavegludes and related devices.

2. Jl~ en Requirement 5Y

ML-G-24211MIL-S-55041MIL-STD-1327

MIL-STD-1328

MIL-STD-1 329MIL-STD-1352MIL-STD-1358MIL-STD-1636MIL-STD-1637

MIL-STD-1638MIL-STD-1639

NIIL-STD-1640MIL-STD-2113MU.-STD-2162

MTL-HDBK-216MJL-HDBK-660

Gaskets, Waveguide Flange, General Specification forSwitches, Wavegulde, General Specification forFlanges, Coaxial and Waveguide; and Coupling Assemblies,Selection ofCouplers, Directional (Coaxial Line, Waveguide, and PrhtedCircuit), Selection ofSwitches, RF Coaxial, Selection ofAttenuators, Fixed and Variable, Selection ofWaveguides, Rectangular, Ridge and Circular, Selection ofAdapters, Caaxial to Waveguide, Selection ofDummy Loads, Electrical, Waveguide, Coaxial, and Stripline,Selection ofWaveguide Assemblies, Rigid and F1exible, Selectian ofPower Dividers, Power Combiners, and Power Dkider/Combiners, Selection ofMixer Stages, Radio Frequency, Selection ofRadio Frequency Circulators and Isolators, Selection ofAmplifiers, Radio Frequency and Microwave, Solid State,Selection ofRF Transmission Lines and FittingsFabrication of Rigid Waveguide Assemblies (Sweep Bends andTwists)


4. .Requ emenir ts. Waveguides and related devices shall be selected in accordance withthe standards appearing in table 53-I and shall conform to a specification listed in thetable or to a specification imposed by the listed standard.

5. in formation for eu idance only

5.1 ~u nd fitti . ~HDBK-216 should be used as a technicalinformation guide for RF transmission hnes and fktings.

5.2 .Rieid wavecu ide ass emblies. MIL-HDBK-660 should be used as a guide to thefabrication of rigid waveguide assemblies where bends and twists are required tosatisfy a particular application.



53-1


MIL-STD-454L

TABLE 53-I. ~veeuides and related devices.

Item Description Applicable Document

kdapters Coaxial to Waveguide MIL--STD-1636

4mplifier, RF and Microwave DIP, Coaxial, TO, and MIL-STD-2162Flatpack

attenuators Fixed and Variable MIIATD-1352Coaxial and Waveguide

circulators RF-SM4 and Waveguide ‘ MU-STD-2113

~ouplers Directional Coaxial MIL-STD-1328Waveguide and Prtd Ckt

Soupling Assemblies Quick-Dkconnect for MIL-STD-1327Subminiature WaveguideFlanges

Dummy Loads Waveguide, Coaxial MIL-STD-1637and Stripline

Flanges Waveguide and Coaxial h41L-STD-1327

Gaskets Pressure Sealing for MIL-G-24211Use With Cover Flangesand Flat Face

[solators RF-SMA and Stripline MIL-STD-211 3

Mixer Stages RF-DIP, Flatpack, MIL-STD-1640TO and Connector

Power Dividers, Combiners Solder Terminals, MIL-STD-1639and Divider/Combiners Plug-In, Flatpack,

TO and Connector

Switches .Waveguide to Waveguide MIL-S-55041Manual and Electro-mechanically Operated

RF Coaxial MIL-STD-1329

Waveguide Assemblies Flexible and Rigid MLL-STD-1638

Waveguides Rigid Rectangular MIL-STD-1358Rigid Circular! Singleand Double IUdge


53-2

/’,



MIL-STD-454L

REQUIREMHW 54

MAINTAINABILITY

1. Puroose. ~is requirement offers guidance as to maintainability requirements whichmust be considered when preparing contractual documents. IT DOES NOTESTABLISH REQUIREMENTS, AND MUST NOT BE REFERENCED ~CONTRACTUAL DOCUMENTS. Maintainability program tasks, quantitative require-ments, and verification or demonstration requirements must be directly specified in thecontract or the systemlequipment specification, as appropriate.

2. D~ nt Requirement 54:

MIL-STD-470 Maintainability Program Requirements for Systems and EquipmentsMIL-STD-471 Maintainability VerificationlDemonstratiort/EvaluationMU-STD-721 .Definitions of Terms for Reliability and MaintainabilityMLL-HDBK-472 Maintainability Prediction

3. D efinitiorrS. Not applicable.

4. ~~s. Not applicable.

5. h~y

5.1 M in ina ta abilitv Drozram, Maintainability engineering and accounting tasks aimedat preventing, detecting, and correcting maintainability design deficiencies andproviding maintainability related information essential to acquisition, operation, andsupport management should be included in contract requirements with the objective ofestablishing and maintaining an efficient maintainability program according to life cyclephase. MIL-STD-470 is the overall program document for the area. Other maintain-ability documents which may be invoked through MIL-STD-470 or which may be citeddirectly as a basis for contract requirements include MfL-STD-471, MIL-STD-721,and MIL-HDBK-472.

5.2 Qua ntitative requirements. Quantitative maintainability requirements andverification or demonstratiori requirements should be established as appropriate toprogram phase.

SupersedesREQUIREMENT 5430 July1982

54-1

REQUIREMENT 5412 Februav 1988


MIL-STD-454L

REQUIREMENT 55

Enclosures

1. fiJ?uQ. Tfds requirement establishes criteria for the design and construction ofenclosures.

2. DOCUments aDplicable to Reau iremerrt 5&

MIL-C-172

MIL-M-81288MIL-STD-108

EIA RS-31O-C-77

3. p~s

Cases, Bases, Mounting, and Mounts, Vibration (For UseWith Electronic Equipment in Aircraft)Mounting Bases, Flexible Plastic FoamDefinitions of and Basic Requirements for Enclosures forElectric and Electronic EquipmentRacks, Panels, and Associated Equipment

3.1 J%closureS. Enclosures are housings such as consoles: cabinets, and cases, whichare designed to provide protection and support to mechamsms, parts, and assemblies.

4. RXl_aWLuir e ts

4.1 Casesa nd mountine bases for airborne eau ioment. Materials, bonding, shieldingand performance requirements of MIL-C-172 shall apply to all cases. Mounting basesshall conform to MIL-C-172 or ML-M-81288, as applicable.

4.2 p~. Enclosures shall be designed in accordance withMIL-STD-108, table I forthe degree of enclosure best suited to the application.Moisture absorbent materials such as open-celled foam shall not be used to fillmoisture pockets.

4.3 Materials: Materials used shall be corrosion and deterioration resistant or coatedto resist corrosion and deterioration.

4.4 Racks and DaneIs. The internal clearance and. the equipment mounting holes ofracks and panels shaUbe in accordance with EIARS-310-C.

4.5 Te st reou irement$. Enclosures shall be tested as specified in MIL-STD-108.

5. b formation for euidance only

5.1 Cas es for aerosDace eround SUDDOrteauioment. The detailed equipmentspecification or contract for the particular equipment will specify the type of case to besupplied by the contractor. Transit cases and combination type cases may not berequired for ship, depot, or field shops wherever the area of use is protected orcontrolled for human occupancy.

SupersedesREQUIREMENT 5530 April 1984

REQUIREMENT 5510 September .1987

55-1..


MIL-STD-454L

5.2 Desicca tSn . Where moisture build up in sealed equipment cannot be tolerated, theuse of desiccants or dehydrating agents should be considered.

5.3 Materials. Materials for the enclosure should be the lightest practical consistentwith the strength required for sturdiness, serviceability and safety.

1----REQUIREMENT ’5510 September 1987


55-2


MIL-STD-454L

REQUIMMENT 56 (

ROTARY SERVO DEVICES

1. ~~e. This requirement establishes criteria for the selection and application ofrotary servo devices such as servomotors, synchros, electrical resolvers, tachometergenerators, encoders, and transolvers.

2. p mn~ Ii uire ent S&

MIL-S-22432MIL-S-22820

MIL-T-22821M3L-R-50781MU-E-81512

MIL-S-81 746MIL-S-81963

MIL-T-83727MIL-E-85082MIL-STD-71OMIL-STD-1451IW!L-HDBK-214M3L-HDBK-218MIL-HDBK-225MUA3DBK-231

3. Definitions. Not

4. Reau irements

Servomotors, General SpecificationServomotor-Tachometer Generator AC, General SpecificationforTachometer Generator AC, General Specification forResolver, Electrical, Linear, General Specification forEncoder, Shaft Position to Digital, Contact Type, AltitudeReporting, General Specification forServtorqs, General Specification forServo Components, Precision Instrument, Rotating, CommonRequirements and Tests, General Specification forTransolvers, General Specification forEncoders, Shaft Angle to Digital, General Specification forSynchros, 60 and 400 CycleResolvers, Electrical, Selection ofSynchrosApplication of Electrical ResolversSynchros, Description and OperationEncoder, Shaft Angle to Digital

applicable.

4.1 Rotarv servodevices. Rotary Servo devices shall conform to MIL-S-81963 asapplicable.

4.2 ServomotorS. Servomotors shall conform to ME-S-22432.

4.3 ~vnchros. Synchros shall be selected and applied in accordance withMIL-STD-710.

4.4 J31ectrical resolvers. Electrical resolvers shall be selected and applied inaccordance with MIL-STD-1451.

4.5 J31ectrical linear resolverS. Electrical linear resolvers shall conform toMIL-R-50781.

4.6 Ta~. Tachometer generators shall conform to MIL-T-22821.

SupersedesREQUIREMENT 56 REQUIREMENT 5630 June 1979 20 September 1988

56-1


MIL-STD-454L

4.7 Tra nsolvers. Transolvers shall conform to ML-T-83727.

4.8 J3ncoders. Encoders shall conform to MIL-E-85082 for general application. Foraltitude reporting applications, encoders shall conform to MJL-E-815 12.

4.9 Semomo tor-tachometer e~ . Servomotor-tachometer generators shallconform to MIL-S-22820.

4.10 ~ervtoras. Servtorqs shall conform to MIL-S-81746.

:5. Informat oni for euidance only

5.1 Svmhro reference dti MIL-HDBK-214 provides technical reference data onstandard synchro types for new design and on synchros required for maintenance ofexisting equipment.

5.2 Additional info rmation. The following documents contain addhional informationfor appli~ation:

MIL-HDBK-218 (Resolvers)

MIL-HDBK-225 (Synchros)

MIL-HDBK-231 (Encoders)



56-2


MIL-STD-454L

REQUIRH@NT 57

RELAYS

1. ~~w. TMs requirement establishes criteria for the selection and application ofrelays.

2. P~ nt i to R ir 7:

ML-R-83516 Relays, Reed, Dry, General Specification forMIL-STD-1346 Relays, Selectlon and Application

3. ~. Not applicable.P

4. Requirements

4.1 Selection. Unless otherwise specified, the order of precedence for relay selectionshall be as follows:

a. Relays listed in MlL-STD-l 346. Reed relays shall conform to MIL-R-83516.

b. DESC selected item drawing relays, subject to procuring activity approval.

c. Other relays, subject to procuring activity approval. Sufficient detail must bepresented (e.g., contact loads, coil voltages of requested relay vs the standard part) tojustify the use of the nonstandard part.

4.2 ~. Relays shall be applied in accordance with MLL-STD-l 346. The useof reed relays in airborne applications requires procuring activity approval.

5. ~forrna tionfor euidance onlv. Not applicable.


REQUIREMENT 57,20 September 1988”, ~

57-1


MIL-STD-454L

REQUIREMEfi 58

SWITCHES

1. .fi~e. Thk requirement establishes cri~eria for the selection and application ofswitches and associated hardware. Tlms requirement is not applicable to RF coaxialswitches.

2. Pocuments a~~ licable to Requ irement 5&

ML-S-12285 Switch, ThermostaticMIL-S-15743 Switches, Rotary, EnclosedMIL-S-18396 Switches, Meter and Control, Naval ShipboardMIL-S-83731 Switch, Toggle, Unsealed and Sealed Toggle, General

Specification forMIL-STD-1 132 Switches and Associated Hardware, Selection and Use of


4. Reauirement$

4.1 SS Iication. Switches andassociated hardware shall be selected andapplied in accordance with MIL-STD-1132. Switches required other than those listedin MIL-STD-1132 shall conform to one of the following specifications: MCL-S-12285,ML-S-15743, MJL-S-18396, and IvKL-S-83731.

5. 1~ idanc nly. Not applicable.



58-1

,.,


MIL-STD-454L

REQWREMENT 59

BRAZING

1. x. This requirement establishes criteria for brazing.

2. Pocume t aDdn icable to Reau irement 59:

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


Rea uirements. Brazing of steel, coppe~, copper alloys, nickel alloys, aluminum, and~iuminum alloys shall be in accordance with MIL-B-7883.

5. Inf ati~v. Electrical connections of stranded or insulated wireor those having construction which may entrap fluxes should not be brazed.



59-1

;...


MlL-STD-4S4L

REQWREMENT 60

SOCKETS AND ACCESSORIES

1. m. This requirement establishes criteria for the selection and application ofsockets and accessories for plug-in parts.

2. ~cume ts app cab e ton Ii I Requirement 6Q

MIL-S-12883 Socket and Accessories for Plug-In Electronic Components,General Specification for

MfL-S-24251 Shield, Retainer (Bases), and Adapters, Electron Tube, HeatDissipating, General Specification for

MIL-M-38527 Mounting Pads, Electrical-Electronic Component, GeneralSpecification for

MIIA-83502 Sockets, Plug-In Electronic Components, Round Style,General Specification for

MJbS-83734 Sockets, Plug-in Electronic Components, Dual-in-line (DIPs)and Single-in-line packages (SIPS), General Specification for


4. R~s

4.1 Sockets. Sockets for plug-in electronic parts shall be of the single unit type andshall conform to MIL-S-12883, MIL-S-83502 or MD--S-83734. The use of socketsfor microcircuits requires approval of the procuring activity.

4.2 -. Heat dissipating tube shields shall conform to MIL-S-24251.

4.3 Mountine r)ads. Where mounting pads are required for use with small electricalor electronic devices, they shall conform to MIL-M-38527.

5. Jnf nnati n f~y

5.1 use of sockets. The use of sockets in mission related and ground support equip-ment should be kept to a minimum, due to the possibility of intermittent connectionsduring shock, vibration, and temperature cycling.

5.2 ~hi I~s. Shield bases, for use with heat dissipating shields, should bemounted on clean, smooth, metallic mating surfaces, to minimize the contact resistance(thermal and electrical) between the base and the supporting chassis.


60-1



MIL-STD-454L

REQWRFMENT 61

ELECTROMAGNETIC INTERFERENCE CONTROL

I m. Thk requirement establishes criteria for electromagnetic interference con-trol.

2. Docume ts armn Iicable to Reau ireme nt 61:

MIL-STD-461 Electromagnetic Emission and Susceptibility Requirements for theControl of Electromagnetic Interference

MIL-STD-462 Electromagnetic Interference Characteristics, Measurement of

MIL-STD-469 Radar Engineering Design Requirements, ElectromagneticCompatibility

MIL-HDBK-253 Guidance for the Design and Test of Systems Protected Against theEffects of Electromagnetic Energy

NTIA Manual National Telecommunications and Information AdministrationManual of Regulations and Procedures for Radio FrequencyManagement

3. ~~. Not applicable.

4. Requirements

4.1 General. Electromagnetic interference requirements shall be as specified in NIU--.STD-461.

4.2 Radar eauiDment. Radar systems and equipment shall also conform to the provi-sions of section 5.3 of the NTIA Manual as specified in the contract and to MIL-STD-469. In the event of conflict, the following descending order of precedence shallprevail: NTIA Manual, MIL-STD-469, MIL-STD+61.

4.3. Ies& Tests and test methods shall be as specified in MIL-STD-462. For radarequipments and systems, MIL-STD-469 shall apply.

5: ~forrnation for guidance only IWL-HDBK-253 provides guidance for the designand test of electronic systems which are to be immune to the detrimental effects ofelectromagnetic energy.

SupersedesREQUIREMENT 6130 July1982

61-1


/.


MIL-STD-454L

REQWIWMENT 62

HUMAN ENGINEERING

1. .. . Thks requirement offers guidance as to human engineering requirementswhich must be considered when preparing contractual documents. IT DOES NOTESTABLISH REQUIREMENTS, AND MUST NOT BE REFERENCED IN CONTRAC-TUAL DOCUMENTS. Human engineering requirements and related test andevaluation requirements must be directly specified in the contract or thesy.sternlequipment specification, as appropriate.

2. Pocu ments armIicable to Requirement 62:

ML-H-46855 Human Engineering Requirements for Military Systems,Equipment and Facilities

MIL-STD-1472 Human Engineering Design Criteria for Mditary Systems,

3.

4.

5.

Equipment-and Fa~ilities

Jlefinitions. Not applicable.

Rea uirements. Not applicable.

lnformat ion for eu idance oI-Ily. Human engineering applied during development andacquisition of military systems, equipment, and facilities serves to achieve the effectiveintegration of personnel into the design of the system. The objective of a humanermineerinz effort is to develoD or improve the crew/ectuipment/software interface and

to ~chieve ~equired effectivene& of hu”man performanc~ d-uring system operation,maintenance and control and to make economical demands upon personnel resources,skills, training, and costs. MIL-H-46855 is the overall requirements document for thearea. It must be tailored when applied; application guidance is offered in thedocument. MTL-STD-1472 provides design criteria which may be selectively appliedas requirements or guidance.

SupersedesREQUIREMENT 6230 Jldy1982

62-1



MIL-STD-454L

REQUIREMENT 63

SPECIAL TOOIS

1. z. Thk requirement establishes criteria for the selection and application ofspecial tools.

2. ~3.P ir Not applicable.

3. Pefinitions

3.1 s.JX.@&Xl Is. Tools, including jigs, fixtures, stands, and templates, not listed inthe Federal Supply Catalog.

4.1 Atmroval. The use of any special tool shall be subject to the approval of theprocuring activity.

4.2” ~~ towing. Special tools needed for operation and organization levelmaintenance shall be furnished by the contractor and shall be mounted securely ineach equipment in a convenient and accessible place, or in a central accessible locationfor an equipment array requiring such tools..

5. ?~y. The design of equipment should be such that theneed for special tools for tuning, adjustment, maintenance, replacement, andinstallation is kept to a minimum. Only when the required function cannot be providedby an existing standard tool should special tools be considered. Necessary tools shouldbe identified as early as possible.


63-1



MIL-STD-454L

REQWNWfENT 64

MICROELECTRONIC DEVICES

1.. -. ~is requirement establishes criteria for the selection and application ofmlcroelectromc dewces. These criteria are based on the objectives of achievingtechnological superiority, quality, reliability, and maintainability in military systems.

2. Docume ts atm cabn Ii Ie to Requirement 64:

MCL-M-3851OMIL-STD-785

MIL-STD-883MIL-STD-975

MIL-STD-1547

MIL-STD-1562DOD-STD-1686

Microcircuits, General S edification fortReliability Program for ystems and Equipment Development

and ProductionTest Methods and Rocedures for MicroelectronicsNASA Standard Electrical, Electronic and Electro-mechanical Parts LktParts, Materials and Processes for Space and LaunchVehicles, Technical Requirements forLkts of Standard MicrocircuitsElectrostatic Discharge Control program for Protection ofElectrical and Electr&ic Parts, Ass~mblies and Equipment(Excluding Electrically Initiated Explosive Devices)

MIL-Bti-l 03 List of Standardized Military Drawings (SMDS).MIL-HDBK-217 Reliability Prediction of Electronic Equipment

IEEE 1076-1987 VHSIC Hardware Description Lenguage (VHDL)VHSIC Interoperability Standards. Includes specifications for the TM-bus, ETM bus,

Pi bus, and VHSIC Electrical Specification. (Copies availablefrom Naval Research Laboratory, Code 5305, Washington, DC20375-5000).

Tester Independent Support Software System (TISSS) Specifications(Copies available from TISSS Program Office, R4Dt.YRBR,Griffiss Air Force Base, NY 13441-5700).

3. Definitions

3.1 Microelectronic devices. Monolithi~, hybrid, rf and microwave (hybridlintegrated)circuits, multichip microcircuits, and microcircuit modules.

3.2 Verv hieh soeed integrated circuits (VHSIC . A, technology development program(1980-1989)-for the design and manufacture of ~igh speed digital integrated circuitswith 1.2S and 0.5 micrometer feature sizes for military applications. Many VI-MC’Sincorporate Built–In-Test and later VHSIC’S will incorporate interoperability features.Table 64-II describes VHSIC characteristics.

3.3 Mlcrowave/millimeter wave monolithic integrated circu s (MIMK)it Program toestablish the capabilities to design, develop, manufacture and test analog microwave/millimeter wave integrated circuits for use in military systems.



64-1


MIL-STD-454L

!3.4 Advance d microcircuit tec hnology. Microcircuit fabrication and design technologywhich is newly available for prototype designs and will be available for production in

‘the near future (2-5 years). VHSIC and MfMIC are examples. For digital microcircuits,the performance capability can be approximately characterized by the minimum featuresize, the clocking frequency, and the functional throughput rate. (See 5.1)

‘.3.5 ~SIC hardware descrirXion larwua~ WHDL]. A high level computer language:developed under the VHSIC program for ~escribing the signal structure of electronichardware (chips, modules, and subsystems). The language describes the signal flowand the structure of the device in terms of the basic circuit models, fundamental logic

,blocks, and higher level functional assemblies of logic blocks.

4. J?eauirementS

4.1 Selection

4.1.1 ~chnoloey. At each stage in new and re-engineered system designs, i.e.,concept studies, demonstration and validation, and full scale development, theadvanced microcircuit technologies which meet reliability, Performance, and costrequirements of the application-shall be evaluated for use ‘in the production phase.

4.1.2 Reliability. Microelectronic devices in military systems in full scale developmentand production shall, as a minimum, conform to MJL-M-385 10, product assurancelevel class B. Class S shall be used for space applications. A plan shall be in place toassure that microelectronic components meet this requirement by full scaledevelopment. This plan shall include a requirement for resubmission of parts liststhrough DESCA4PCAG prior to procurement of parts to be used in actual productionto assure that all evaluations are based on the most recent standardization status.

‘4.1.3 Order of mecedence, Unless otherwise specified, the order of precedence shallbe as follows:

: a. Microcircuits listed in table I of MIL-STD-1562.

b. Other MIL-M-3851O microcircuits not listed in tables III, IV and V oflylIL-STD-1562.

.c. Other microcircuits listed in table II of MIL-STD-1562 as preferred for new design,subject to procuring activity aPProval.

d. Active Standardized Military Drawing (SMD) or DESC drawing microcircuits notlisted in tables Ill, IV and V of MLL-STD-1562, subject to procuring activity approval

e. Other microcircuits (see 4.1.4), subject to procuring activity approval.

4.1.4 Oua lified devices. When the contract or purchase order for new design orredesign of military hardware specifies the use of MIL-ST&883 class B or Smicrocircuits, and there is a class B or S device on QPL-38510 of the required genericchip and package type or case outline: the qualified class B or S microcircuit shall bethe only device authorized in that design.


64-2



MIL-STD-454L

4.1.4.1 Class S devices. For space applications, when class S arts per QPL-38510are not available or cannot be qualified by the manufacturer, %e requirements ofMIL-STD-975 or MILSTD-1547 shall apply in accordance with procuring activitydirection.

4.1.4.2 Class B deviceS When a qualified class B device does not exist and an activeSMD (or DESC drawingj device of the required generic chip and package type or caseoutline does exist, the SMD (or DESC drawing) device shall be the preferred deviceauthorized for that design.

4.1.5 Other microcircuits. For other than QPL-38510 microcircuits, the followinginformation shall be included in the nonstandard part approval request (except whereidentification of a military detail specification, SMD or DESC drawing number satisfiesthis requirement or other direction is given):

a. Device nomenclature, marking, configuration, functional requirements, parametersand 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 mirtimum, devices shall be procured to all the requirements ofMIL-STD-883 paragraph 1.2.1. Hybrid and microwave microcircuits shall be procuredto the requirements of MJL-M-385 10, Appendix G. The applicable MIL-M-3851Odetail specification, SMD (or DESC drawing) or vendor/contractor document shall bespecified for electrical performance, mechanical, and final electrical test requirements.Current and valid generic data may be substituted only for Groups C and D ofMethods 5005, 5008, and 5010 of MIL-STD-883. Group C generic data must be ondate codes no more than one year old and on a die in the same microcircuit group(see appendix E of MIL-M-3851O) with the same material, design and process, andfrom the same wafer fabrication area as the dle represented. Group D generic datamust be on date codes no more than one year old and on the same package type (see3.1.3.12 of MIJ.--M-3851O) and from the same plant as the package represented.

d. An evaluation of the projected availability and product assurance status for the timeof production and through the projected life of the system.

4.1.6 Electrostatic sensitive Darts. Microcircuits are susceptible to electrostaticdischarge (ESD) damage. Microcircuit susceptibility is classified in DOD-STD-1686(and Test Method 3015 of MIL-STD-883). Microcircuits from the least susceptibleclass shall be selected and a lower class microcircuit shall not be used when a higherclass microcircuit is available in the same order of precedence which meetsperformance requirements. The ESD susceptibility of microcircuits is listed inQPL-3851O for JAN devices or MJL-BUL-103 for SMD or DESC drawing devices.When the dewce susceptibility information is not available, it can be determined usingTest Method 3015 of MIL-STD-883 or Appendix B of DOD-STD-1686.

4.2 Programmable devices. Use of programmable devices, regardless of type, requiresapproval of the procuring activity.

Supersedes “REQUIREMENT 6410 September 1987


,64-3‘.


MIL-STD-454L

4.3 Fusible link devices When fusible link devices (PROMS, PALs, PLDs, etc) areprogrammed by the user: parametric and functional electrical tests in accordance withMIL-STD-883, Method 5005, Oroup A, Subgroups 7 and 9 as a minimum, shall beperformed after programming to verify the specific program configuration and

:effectiveness of link fusing. Ttds testing shall be done on a 100VObasis.

4.4 ~ackae~. Microcircuit devices used in equipment shall be hermetically sealed inglass, metal or ceramic (or combinations of these) packages. No organic or polymericmaterials such as lacquers, varnishes, ,coatings, adhesives, or greases shall be usedinside the microcircuit package, unless otherwise specified. No desiccants shall becontained in the microcircuit package, unless otherwise specified.

4.5 J3evice des ien and test docu mentation

4.5.1 S C docu mentation in VHDL. Digital Application-Specific Integrated Ckcuits(ASICS$’~esigned after 30 September 1988 shall be documented by means of structuraland behavioral VHSIC Hardware Description Language (VHDL) descriptions inaccordance with IEEE 1076. Behavioral VHDL descriptions shall describe theinput/output behavior at a sufficiently detailed level to permit the behavioraldescription to be used within a larger VHDL model for test generation and fault

,grading of the containing model.

4.5.2 Fau It coveraee. Fault coverage shall be reported for the manufacturing-levellogic tests for all digital microcircuits designed after 30”.!3eptember 1988. Faultcoverage shall be based on the equivalence classes of single,, permanent, stuck-at-zeroand stuck-at-one faults on all lines of a TISSS-compatible structural VHDL model,where the structural model is expressed in terms of gate-level primitives or simpleatomic functions (such as flip–flops). Large, regular structures such as R4MS andROMs shall not be modeled at the gate level, but rather documentation shall beprovided that these structures are tested using appropriate algorithms (such as

,# alloping patterns for a RAM).

4.6 co st considerations. Microelectronic devices shall be selected on the basis ofoverall life cycle cost.


5.1 Technoloev Drowession. The use of advanced microcircuit technology should beconsidered and evaluated in the design of all systems/equipment. For critical weaponsystems applications, and for system development schedules projected to be longerthan four years, the performance advantages provided by advanced technologies, suchas VHSIC and MIMIC, should be evaluated early in the system development phases foruse in the procurement stage.

5.1.1 Roiected availability. The projected availability of advanced digital (VHSIC)technologies for use in progressive stages of system development is provided in table64-I to aid in performing this evaluation.

I .‘.


SupersedesREQUIREMENT 64IO September 1987

64-4


MIL-STD-454L

TABLE 64-I. Jlieital tec hnoloev ~eress ion prediction.

I Year I Concept I D&V II FSD III P&D

1987

1988

1989

1990

1991

1992

1993

1994

.5 - 1.0 1.0 -1.25

.5 - .8 .8 -1.0

.5 - .7 .7 -1.0

.4 - .6 .5 - .8

.4 - .5 .5 - .6

.3 - .4 .4 - .6

.25- .3 .3 - .5

.25 .3 .4L

D&V Demonstration and Validation

FSD: Full Scale Development

P&D: Production and Deployment

I, II, III: System Development Milestones

1.0- 1.25

1.0- 1.25

.8- 1.0

.6- 1.0

.6- .8

.5- .7

.4- .6

1.25 -1.5

1.0 -1.25

1.0 -1.25

.8 -1.0

.7 - .8

.6 - .7

.5 - .6

5.1.2 Performance characteristics. The numbers in table 64-I represent the “minimumfeature size” which generally characterizes the performance and characteristics ofdigital technology. (See table 64-II.)

5.2 Reliability urediction. When required, microcircuit reliability predictions should beprepared in accordance with MIL-HDBK-217.

5.3 ~lcrocircuit obso Iescence. Due to rapid technology advances, many military andcommercial microcircuits listed in specifications and catalogs are either obsolete or.arenearing obsolescence. The use of these devices will affect the mission objectives of theusing equipment. For Navy equipment current information on microcircuits that maybe nearing obsolescence may be obtained from the Naval Avionics Center, Code 435,Jstdianapolis, Iirdiana 46219-2189, telephone (317) 353-3767.

5.4 s~. Upon specific request and approval by theprocuring activity to waive the requirements of 4.1, non-hermetic microcircuits may beconsidered for use in ground fixed (GF) or ground benign (GB) environments asdefined in IvIbHDBK-217, provided they meet all the requirements of the equipmentspecification: temperature and humidity are completely controlled in transit, storage,and application, and provisions have been made for logistic availability.

SupersedesREQUIREMENT 64 REQUIREMENT 6410 September 1967 20 September 1986

/.64-5


MIL-STD-454L

TABLE 64-IL Pe rformance characteristics - dieital microelectro nic~.

Characteristic

Min feature size

Temperature range

Min clock frequency

FrR

Testability

BIT fault coverage

stuck at

stuck open (CMOS

Test bus

Interoperability

Units

micrometers

degrees Celsius

MHz

gate I-Iz/sq cm

%

%

1.25

-55 to 125

25

5 exp 11

98% of detec-table faults

95”

ETM or TM””

yes

D.5

-55 to 125

100 on chip

1 exp 13

98% of detec-table faults

95

75

ETM or TM**

yes

●Required after July 1989

““IAW VHSIC Interoperability Standard

5.5 Testability. New and upgraded systems should exploit chip level built-in-testII features to enhance the testability and operational availability of the module or system.

When advanced digital modules or boards are developed, microcircuits incorporatingthe VHSIC ETM-BUS or VHSIC TM-BUS should be used. (See VHSIC Interoperability

, Standards.)

5.6 L!fe cvcIe cost evaluation. The following factors should be considered inestimating life cycle costs associated with selection of microcircuit devices ortechnologies: a) effect of built–in-test on repair, maintainablli~, operationalavailability, and reconfigurability; and b) value of VHDL descriptions of chips,modules, and boards in resupply, multiple source development, and design upgrade.


64-6,,

SupersedesREQUIREMEtNl 6410 September 1987


MIL-STD-454L

REQWREMENT 65

CABLE,COAXIAL(m)

1. fi@QQSQ:Thk requirement establishes criteria for the selection and application ofcoaxial radio frequency (s$ cable.

2. Docu ments at.mIicable to Reauirement 65:

MJL-C-17 Cable, Radio Frequency, Flexible and Semirigid, GeneralSpecification for

MIL-L-3890 Lines, Radio Frequency Transmission (Coaxial, AirDielectric)

MIL-C-22931 Cable, Radio Frequency, Semirigid, Coaxial, Semi-AirDielectric, General Specification for

MIL-C-23806 Cable, ~dio Frequency, Coaxial, Semirigid, FoamDlelectrlc, General Specification for

MIL-HDBK-216 RF Transmission Lines and Fittings

3. J3ef inition~. Not applicable.

4. B~$

4.1 cable selection. Selection of coaxial cable shall be in accordance with MIL-C-17,MLL-L-3890, ML-C-22931 or MII-C-23806. Other types of cable may be usedprovided they are selected from specifications acceptable for the specific applicationand approved by the procuring activity.

4.2 ~. Cables with polyvinyl chloride insulation shall not be usedAin aerospace applications. Use of these cables in any other Air Force applicationrequires prior approval by the procuring activity.

5. hformation for eu idance only

5.1 Atmlication eu eidanc MIL-HDBK-216 may be used as a technical informationguide to applications of transmission lines and fittings.

5.2 !22s. For use above 400 MHz and in critical rf circuits, elements suchas environmental requirements, short leads, and grounding should be considered indesign apphcation, along with critical electrical characteristics such as attenuation,capacitance, and structural return loss.



65-1

,,i,


MIL-STD-454L

REQUDWMENT 66

CABLE, MULTICONDUCTOR

1. ~~e. ~Is requirement establishes, c~iteria for selection and application ofe~eclmcal multlconductor cable for use wdun electroruc equipment.

2. POcuments atmlicable to Requirement 66

QQ-W-343QQ-w-423MU--C-17

MIL-C-442MIL-C-3432

MIL-W-5086

ML-W-5845MU-W-5846MIL-W-5908MU-C-7078

MIL-W-8777

MIL-C-13777

MIL-W-22759

MU--C-23437MIL-C-24643

MIL-W-25038

MIL-C-27072MILC-27500MJL-C-55021

MIL-W-81044

MIL-W-81381ASTM B33-74

Wire, Electrical, Copper (Uninsulated)Wire, Steel, Corrosion-ResistingCables, Radio Frequency, Flexible and Semirigid, GeneralSpecification forCable

Tire), Two Conductor, Parallel

Cable ower and Special Purpose) and Wire, Electrical(300 and 600 Volts)Wke. Electric, Polyvinyl Chloride Insulated, Copper orCopper Alloy - “Wire, Electrical, Iron and Constantan, ThermocoupleWire, Electrical, Chrome] and/or Alumel, ThermocoupleWire, Electrical, Copper and Constantan, Thermocouple~o;le, Electric, Aerospace Vehicle, General Specification

Wire, Electrical, Silicone-Insulated, Copper, 600 Volt,.,3.0 -,LUu b

Cable, Special Purpose, Electrical: General Specificationfor

Wire, Electrical, Insulated, General Specification forCable, Electrical, Special Purpose, Shore UseCable, Electrical, Shielded, 600 Volt (for NonflexingService)Wire, Electric, Fluoropolymer-Insulated, Copper or CopperAlloyCable, Electrical, Shielded PairsCable and Cord, Electrical, Low Smoke, for Shipboard Use,General Specification forWire, Electrical, High Temperature and Fire Resistant,AircraftCable, Special Purpose, Electrical, MulticonductorCable, Electrical, Shielded and Unshielded, AerospaceCable, Twisted Pairs and Triples, Internal Hookup, GeneralSpecification forWire, Electric, Crosslinked Polyalkene, CrosslinkedAlkane-imide Polymer, or Polyarylene Insulated, Copper orCopper AlloyWire, Electric, Polyimide-Insulated, Copper or Copper AlloyTinned Soft or Annealed Copper Wire for Electrical Purposes

REQUIREMENT 66 REQUIREMENT 6610 September 1987 12 Februaty 1988

66-1


MIL-STD-454L

3. Pe finitions. Not applicable.

4. Jteau ementsir

‘4.1 &lection and am Iication. Selection and application of multiconductor cable shallbe in accordance with table 66-L

4.2 ~ Iio d or stranded. Either solid or stranded conductors may be used (withkr therestrictions of the particular wire or cable specification) except that (a) with theexception of thermocouple and flat cable wire: only stranded wire shall be used inaerospace applications, and (b) for other apphcatlons stranded wire shall be used whenso indicated by the equipment application. Specifically, with the exception of flat multi-conductor flexible cable, stranded wire shall be used for wires and cables which arenormally flexed in use and servicing of the equipment, such as cables attached to themovable half of detachable connectors.

4.3 Am Iication restrictions

I 4.3.1 MIL-W-16878 shall not be used for Ak Force aerospace equipment.

4.3.2 Cables with polyvinyl chloride insulation shall not be used in aerospaceapplications. Use of these cables in any other Air Force application requires priorapproval of the procuring activity.

4.3.3 ML-W-22759 wire with only single polytetrafluoroethylene insulation used inAk Force space and missile applications shall require the approval of the procuringactivity.

5. Information for euidance orrly. Not applicable.


66-2

SupersedesREQUIREMENT 66

) 10 September 1967


MIL

-ST

D-454L

Su

persed

es.,

RE

QU

IRE

ME

NT

6610

Sep

temb

er1967

66-3

RE

QU

IRE

ME

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6612

Feb

ruary

1968


MIL

-ST

D-454L

II

sup

ersedes

RE

QU

IRE

ME

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66R

EQ

UIR

EM

EN

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ebru

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.10S

eptem

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1987

66-4,.

i“’


MIL

-ST

D-454L

Su

persed

esR

EQ

UIR

EM

EN

T66

IoS

eptem

ber

1987

RE

QU

IRE

ME

~66

Iz

Feb

ruary

1988

66-5


MIL-STD-454L

REQ~ 67

hLARIGNG

1. fi~e. This re~uirement establishes criteria for external and internal markings onequipment, assembhes and component parts. Marking for safety, shipping and handlingis not withh the scope of thk requirement.

2. p Ii~ nt 67:

L-S-300

MIL-M-13231NflI,-P-15024MIL-N-18307

MIL-S-81963

MIL-STD-12

MIL-STD-130MIL-STD-155MIL-STD-195MIL-STD-196MIL-STD-280

IvflL-sTD-411MIL-STD-783MIL-STD-1189IvIIIATD-1285IEEE 200-1975

Sheeting and Tape, Reflecting, Nonexposed I-ens, AdhesiveBackingMarKlng of Electronic ItemsPlate, Tags and Bands for Identification of EquipmentNomenclature and Identification for Electronic, Aeronauticaland Aeronautical Suppoti Equipment, Including Ground SupportEquipmentServo-Components Precision Instrument, Rotating, CommonRequirements and Tests, General Specification forAbbreviations for Use on Drawings, Specifications, Standards andin Technical Documents.Identification Marking of U.S. Military PropertyJoint Photographic Type Designation SystemMarking of Connections for Electrical AssembliesJoint Electronics Type Designation SystemDefinitions of Item Levels, Item Exchangeability, ‘Models, andRelated TermsAircrew Station SignalsLegends for Use in Akcrew Stations and on Akborne EquipmentBar Code Symbology StandardMarking of Electrical and Electronic PartsElectrical and Electronic Parts and Equipments, ReferenceDesignations for

3. D~. Not applicable.

4. Beau irements

4.1 ~~. At the manufacturer’s option, patent information may beincluded on equipment, subject to the following restrictions:

a. The identification plate may contain patent information when approved by the pro-curing activity.

b. The location of and method used to mark patent information shall not conflict withany specified equipment requirements, such as marking, enclosure iritegrity, controland indicator locations, etc.


REQUIREMEN 6720 September 1966

67-1


MIL-STD-454L

c. Patent information shall not be !ocated on or in equipment having a security classifi-cation of confidential or higher, wKh the exception that patented items used in securityclassified equipment, when marked, shall be marked in such a manner that patent in-formation will be visible only when the item is removed or dkassembled for repair orreplacement.

4.2 $vmboloey

4.2.1 Reference desienat ions. Except for external comectors and csibles~ referencedesignations shall be employed to identify the location of each item for Its particularcircuit application. The identification and markmg of reference designators for parts

and equipment shall be in accordance with IEEE 200. On subminiaturized assemblies,such as printed or etched boards or other forms of assembly where space is at apremium, the reference designations need not be marked. In lieu thereof, referencedesignation marking shall be shown by means of pictorial diagrams, line drawings,photographs, or other media to provide for circuit identification (by means of referencedesignations) in the appropriate handbooks for the equipment. It shall not bemandatory to mark the reference. designations of parts in nonrepairable subassemblies.Connectors may be further identified on that side of the panel to which the matingconnector attaches, by a name denoting the function of the cable attached thereto.External cables shall be assigned reference designations Wll W2: etc, in accordancewith IEEE 200. The numerical portions of the reference designations shall beconsecutive, where practicable.

4.2.2 A?l reviation n Ieeends. Abbreviations and legends shall conform to MIL-STD-12, MIL-STD-411, or MIL-STD-783, as applicable.

4,3 Markisw methods. Equipment, parts and assemblies shall be permanently markedor identified. Permanency and legibility shall be as required in MILATD-130.

,,4.3.1 Direct marking. Markings may be applied directly to a part or an assembly by‘die or rubber stamping, etching, engraving, molding, casting, forging, decalcomania

transfer, stenciling, or silk screening.

4.3.2 -. Information and identification plates shall conform to and shall bemarked in accordance with MIL-P-15024.

4.3.2.1 ~1 Iates. The ID plate shall be fastened in such a manner asto remain firmly affixed throughout the “normal life expectancy of the item to which itis attached. Type G, adhesive-backed metal, ID plates shall be used on hermeticallysealed items, magnesium cases, or other items where mounting of a plate by mechani-cal fasteners is impractical.

4.3.2.2 P elate Iota oti n. Plates shall be located so that they are not obscured byother parts.

.?


67-2



MIL-STD-454L

4.3.3 ~arkine eab les. cords and wires. The following methods shall be used to markcables, cords 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 artached or captivated

d. Adhesive tag or tape that will withstand the applicable environmental requirements.

4.4 Bar codes. Bar codes shall conform to MIL-Sl_D-l 189.

4.5 ~ ms. Each item which is type designated in accordance withMIL-STD-196 or MIL-STD-155 shall contain an identification marking in accordancewith MIL-N-18307 for Navy and Air Force or MIL-M-13231 for Army. These itemsare systems (electrical-electronic), sets, groups, and some units and assemblies, asdefined in MIL-STD-280.

4.6 Fus e holders. The current rating of fuses shall be marked adjacent to the fuseholder. In addition, “SPARE” shall be marked adjacent to each spare fuse holder.

4.7 co nnections. Marking adjacent to plugs, jacks and other electrical connectors shallidentify the connected circuits to preclude cross connections. The connections toelectrical parts such as motors, generators and transformer shall be marked inaccordance with MIL-STD-195.

4.8 &lerv~ nd markine$. Servo-component marking andconnection identification shall conform to MIL-S-81963.

4.9 ~. Markings shall be provided on the front of eachexterior and interior panel and panel door, also on control mounting surfaces of eachchassis, subpanel, etc, to clearly (though necessarily briefly) designate the functionsand operations of all controls, fuses, and indicating devices mounted thereon,protruding through, or available through access holes therein. All markings shall belocated on the panel or chassis in correct relationship to the respective designateditems.

4.10 $ocket$ The chassis shall be marked to identify both sockets and parts, modulesor assemblies to be plugged into the sockets. The side of the chassis upon which itemsare plugged into sockets shall be marked, adjacent to each socket, with the referencedesignation for the item. The reverse side of the chassis shall be marked, adjacent toeach socket, with the reference designation used in the circuit diagram and table ofparts to identify the socket itself. If space does not permit marking of reference desig-nations for sockets and parts, modules, or assemblies mounted in sockets, a locationdiagram shall be placed where it is visible when viewing the chassis, and shall displaythe markings described herein.

4.11 ~ d wires. All cables, cords and wires which require disconnectionto remove units for servicing and maintenance shall be uniquely identified.



67-3


I MIL-STD-454L

4.12 Prhte d wirine boa d$ Markings on printed wiring boards shall not interfere withelectrical operation. wh~n ink is used, it shall be non-conductive. Markings shall beconsidered when leakage (creepage) distances are determined.

4.13 Replaceable parts a d assemb es[i Replaceable parts and assemblies shall bemarked for identification ?n accordance” with MIL-STD-1285 or MIL-STD-1 30, as

applicable.

4.14 ~rammable item . Equipments which are software programmable shallindicate the identifying number and revision of the software program which has beenloaded into memory. The meferred method is to provide either a local or a remotedisplay which is u~der th~ control of the software program. However, when the use ofa display is not practical, the equipment enclosure shall be marked with theinformation as follows:

I4.14.1 Reproduction and production equipment shall be marked with the identifyingnumber and revision of the software mouam. The identifyisw number shall be

L

preceded by the words “software pro~rafi”..-

4.14.2 Development equipment shall be marked in a manner similar to preproductionand production equipment, except that means shall be provided to easily change therevision letter by the use of a matte surface for hand marking or by using self-adhesive labels. The use of the revision letter or number and a patch letter or numberis permissible.

4.14.3 The marking requirement does not apply when changes to the softwareprogram are accomplished by making a hardware change (for example, when the soft-ware program resides in fusible link devices such as PROMS). In such cases, themarking requirements applicable to a hardware change shall apply.

5. Jrlformation for m idance only

5.1 Reflective markers. Where reflective markers are required reflective polyester tapein accordance with L-S-300 may be used.


67-4



MIL-STD-454L

READOUTS AND DISPLAYS

1. m. This requirement establishes criteria for the selection of readouts anddisplays.

2. pocu ments armlicableto Reauirement6&

MIL-R-28803 Readouts,Segmented, General Specification forMIL-D-87157 Displays, Diode, Light Emmmg, Solid State, General Specification

for

3. P~$. Readouts and displays are devices which are designed primarily toconvert electrical information into alphanumeric or symbolic presentations. Thesedevices may contain integrated circuitry to function as decoders or drivers.

4. Reouirement$

4.1 ~ descent readouts. Incandescent type readouts shall conform toMIL-R-28803.

4.2 ~ disulavs. Vkible light emitting diode displays shall conformto ML-D-87157, quality Ievel A or B.

5. ~ idance onlv. Not applicable.


REQUIREMEN 6820 September 1986

68-1


~REQUIREMENT 69

MIL-STD-454L

INTERNAL WIRING PWCTICES

1. m. This requirement establishes criteria for internal wiring practices.

2. n~:

~T-152 Treatment, Moisture and Fungus Resistant, of Communications,Electronic and Associated Electrical Equipment

MIL-V-173 Varnish, Moisture-And-Fungus Resistant (For Treatment ofCommunications, Electronic, and Associated Equipment)

MIL-I-631 Insulation, Electrical, Synthetic-Resin Composition, Non-RigidMILT-713 Twine, Fibrous: Impregnated, Lacing and TyingMD-A-3158 Insulation Tape, Electrical Glass-Fiber (Resin Filled); and ~”

Cord, Fibrous-G1assMIL-I-3190 Insulation Sleeving, Electrical, Flexible, Coated, General

Specification forMIL-T-7928 Terminals, Lug: Splices, Conductors: Crimp Style, Copper,

General Specification forMIL-1-22076 Insulation Tubing, Electrical, Non-Rigid, Vinyl, Very Low

Temperature GradeMIL-I-23053 Insulation Sleeving, Electrical, Heat Shrinkable, General

Specification forMIL-S-23190 Straps, Clamps, and Mounting Hardware, P1astic and Metal for

Cable Harness Tying and SupportMJL-T-43435 Tape, Lacing and TyingMIL-C-55543 Cable, Electrical, Flat Multiconductor, Flexible, UnshieldedMIJ-=STD-108 Definition of and Basic Requirements for Enclosure for

Electric and Electronic EquipmentMIL-STD-1130 Connections, Electrical, Solderless, Wrapped


4. Reauirement$

4.1 c~$ k tan Clearance between solder connectionsor bare conductors, such as o: ter~inal strips, s“mnd offs or similar connections, shallbe such that no accidental contact. can occur between adjacent connections whensubjected to service conditions specified in the equipment specification. For electricalclearance and leakage distances, see table 69-I.

4.2 Throue h hole motection. Whenever wires are run through holes in metalpartitions, shields, and the like: less than 1/8 inch in thickness, the holes shall beequipped with suitable mechamcal protection (grommet) of insulation. Panels 1/8 inchor more in thickness either shall have grommets or shall have the hole edges roundedto a minimum radius of 1/16 inch.


69-1

REQUIREMENT’ 6912 February 1988


MIL-STD-454L

TABLE 69-L J31 ri I r n~ r istances .

Voltage ac

(rms) or dc Condition

To 150 ABc

d==’-+

1+c

600-1000tc

Clearance

(inches)

1/161181J4

1/161/8114

1/161/8114

1/81/41/2

Leakage Distances (inches)

Enclosure I I Enclosure 1

1/16 1/161/8 1/4318 3/4

1/16 1/161/8 1/4112 314..

1/8 1/81/4 1/41/2 3/4

318 1/2314

1 1/2 ;

condition A. For use where the effect of a short circuit is limited to the unit, andwhere normal operating power does not exceed 50 watts.

condition B. For use where short circuit protection in the form of fuses, circuitI breakers, etc, is provided, and where normal operating power does not exceed 2000

watts.

co nditionC .For use where short circuit protection in the form of fuses, circuitbreakers, etc. IS provided, and where normal operating power exceeds 2000 watts.

Enclosu re I. Enclosure I is an equipment enclosure which has no openings, or in whichthe openings are so constructed that drops of liquid or solid particles striking theenclosure at any angle from 00 to 150 from the downward vertical cannot enter theenclosure either directly or by striking and running along a horizontal or inwardlyinclined surface. (“Drip-proof enclosure for other than motors, generators, and similarmachines”. of MIL-STD-108 meets the description).

.J3nclosure fi. Enclosure II is any equipment enclosure which affords less protectionthan enclosure I.

Supersedes

REQUIREMENT 69 REQUIREMENT 69

12 February 1988 ,/ 29 August 198669-2


MIL-STD-454L

4.3 Wkim arramze ment. Wiring shall be arranged to permit bundling by one or moreof the following methods or permanently mounted in cable ducts.

4.3.1 -. Twine shall be in accordance with Type P of MIL-T-713. Tape shaflconform to MILT-43435. Cordage shall be in accordance with Type SR-4.5 ofMIL-I-3158.

4.3.2 m. Tape for binding shall be as specified in MIL-T<3435.

4.3,3 Ieev”~. Sleeving insulation shall conform to MIL-I-631,MIL-I-3190, MIL-I-22076, or MIL-I-23053.

4.3.4 Wraop ine and tvi~. Plastic devices for wrapping and tying of wires shallconform to MIL-S-23190.

4.4 solderless wram ed wire connections. Solderless wrapped wire connections shall bein accordance with MlL-STD-l 130. Procuring activity approval is required for Navyairborne and Army missile applications.

4.5 Cla mDed connections In no case shall electrical connections depend upon wires,lugs, terminals, and the like, clamped between a metallic member and an insulatingmaterial of other than a ceramic or vitric nature. Such connections shall be clampedbetween metal members, preferably, such as an assembly of two nuts, two washersand a machine screw.

4.6 ~g. Unpotted connectors furnished as integral wired inparts of articles of equipment shall have a piece of insulating tubing placed over eachwire in the connector. The tubing shall be long enough to cover the contact and atleast 1/2 inch of insulation of the wire attached to it but in no case shall the length ofthe tubing exceed 2 inches. The minimum length of 1/2 inch may be reduced to 3/16inch where restricted volume does not permit longer tubing (such as in miniaturizedelectronic subassemblies). The tubing shall fit tight] y over the contact or be tiedsecurely enough so that it will not slide off. If bare wire is used, the tubing shall belong enough to extend at least 1/4 inch beyond the contact, metal shell or clamp,whichever projects the farthest. This paragraph does not apply to connectors with bodyinsulated crimp-on contacts, to insulation displacement connectors or mass solderedflat cable connectors, nor does it apply to wire wrapped connectors in accordance withh’nL-sp-l130.

5. Inf~ idance on]

5.1 Wirin~t. All wiring should be arranged in a neat and workmanlikemanner. The use of preformed cables and wiring harness is preferred to thepoint-to-point method of wiring. Wires should be bundled and routed to minimizeelectrical coupling. Unless suitably protected, wire or cable attached to sensitivecircuits should not be placed adjacent to a disturbing circuit.

5.2 Internal wiring. Stranded wire is preferred; however, solid wire may be used inthe equipment, provided such wire is so insulated or held ii place that it does not failor show excessive motion likely to result in failure when the equipment is subjected to

SupersedesFtEQUIREMENT 69 REQUIREMENT 6929 August 1986 12 Februa~ 1968

69-3


MIL-STD-454L

vibration and shock encountered under the specified service condhions. Anuninterrupted wire is preferable to a junction. The following descending order ofpreference exists when junctions are used, and the choice of the listed junctions should

j-be determined by consideration of reliability factors, maintenance factors, and..manufacturing procedures:

a. Permanent splices.

- b. Bolted connections.

c. Comectors.

5.3 Wirine Drotection. The wiring should be secured and protected against chafing dueto vibration or movement (such as slide out racks or d$awers). For securing. of wiring,polyamlde clamps or wrapping and tying devices with integral mounting facdmes oradhesive bonding are preferred. Metal clamps, if used, should be cushioned. Individualconductors thus secured should lie essentially parallel.

5.4 Cable duc ts. where cable ducts are employed, provisions should be made for theremoval of any wre that may become faulty. For example, covers may be employedat intervals to aid in the removal of a faulty wire.

5.5 J3end radius. The bend radius of polyethylene cable should not be less than fivetimes the cable diameter to avoid establishing a permanent set in the cable.

5.6 -g. Flexible plastic sleeving, either nonflammable, self extinguishing, orflame retardant, should be used on cables subject to flexing, such as panel doorcables. The sleeving should be secured under cable clamps at each end, and the cableshould be formed and secured so that the cable will not be subject to abrasion in itsnormal flexing motion. In cases where abrasion cannot be avoided, additionalprotection should be provided.

5.7 Panel do or cable$ Wiring to parts on a hinged door should be in a single cable ifpossible, arranged to ~ex without being damaged when the door is opened and closed.

5.8 M. Wkes and cable should be as short as practicable, except that sufficientslack should be provided to:

a. Prevent undue stress on cable forms, wires and connections, including connectionsto resiliently supported parts.

b. Enable parts to be removed and replaced during servicing without discomectingother 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 slideor support travel without breaking connections. Units which are difficult to connectwhen mounted, should be capable of movement to a more convenient position for

REQUIREMENT 6912 Februa~ 1988

Supersedes.,, REQUIREMENT 69

i 29 “August198669-4


MIL-STD-454L

connecting and dkconnecting cables. When drawers or racks are fully extended androtated, if rotatable, the cable bend radius should not be less than three times thecable assembly diameter. When flat molded cable assemblies are used, the bend radiusshould not be less than ten times the cable assembly W]ckness.

e. Permit replacement of the connected part at least twice. Exceptions to tfis provisionare cases where rf leads must be as short as possible for electrical reasons, when freedpath rotating is specified, or the amount of slack is limited by space available.

f. Ensure freedom of motion of lugs or terminals normally intended to have somedegree of movement.

5.9 m. Wke and cable should be properly supported and secured to preventundue stress on the conductors and terminals and undue change in position of the wireor cable during and after subjection of the equipment to specified service conditions,or after service or repair of the equipment in a normal marmer. When shielding onwire or cable is unprotected by an outer insulation, adequate support is necessary toprevent the shleldlng from coming in contact with exposed terminals or conductors.Twine or tape should not be used for securing wire and cable.

5.10 ~. Cables and separable harnesses should be of thetwo-connector type. The two connectors should be of the same number of contacts andall contacts should be. wired point-to-point (i.e., pin 1 to pin 1, pin A to pin A, or pin1 to pin A and up in sequence). A minimum number of connector types and contactconfigurations within a type should be used consistent with non-crossmatingrequirements and circuit and spare considerations.

5.11 so Iderless crimD cormection~. Solderless crimp connections should meet thefollowing requirements:

a. Insulated, solderless lugs are preferred and should conform to ML-T-7928.

b. Where thermal or other considerations prevent the use of insulated lugs,non-insulated solderless lugs conforming to IvILL-T-7928 should be used, provided theyare covered with an insulating sleeve.

5.12 ~. Prior to attachment of terminals to prepared lengths of cableswhich “contain materials that will support fungus, the’ ends should be protected againstentrance of moisture and fungus by treatment with a fungicidal varnish conforming toMIL-V-173 m accordance with MIL-T-152.


69-5



MIL-STD-454L

REQUIREMENT 70

ELECTRICALFILTERS

1. fiJ2u: Thk requirement establishes criteria for the selection and application ofelectrical falters.

2. n~ “rement 7Q

MILSTD-1395 Filters and Networks, Selection and Use of

3. De finitionS. Not applicable.

Reau eme nts. ‘Electrical filters shall be selected and applied in accordance withks&-1395.


SupersedesREQUIREMEtW 701 September 1982

REQUIREMENT 7020 September 1988 “

70-1


MIL-STD-454L

REQUEWMENT 71

CABLE AND WIRE, INTERCONNECTION

1. h-e. TMs requirement es~blishes cr$aia for the selection and application ofelectric cable and wire used for mtercorrnectlon between units.

2. Docume ts aDon Iicable to Requirement 71

QQ-w-343QQ-W-423MlL-c-l 7

MIL-W-76MIL-C-442MIL-C-3432

MIL-W-5086

MIL-W-5845MIL-W-5846MIL-W-5908MIL-C-7078MIL-W-8777MIL.-C-13777MIL-W-16878MIL-W-19150MIL-C-19547MI.L-C-21609

MIL-C-22759

ML-C-23437MIL-C-24643

MIL-W-25038

MIL-C-27072MIL-C-27500MIL-C-55021

MIL-W-81044

MIL-W-81381


Wire, Electrical, Copper (Uninsulated)Wke, Steel, Corrosion-ResistingCables, Radio Frequency, Flexlble and Semi-rigid, GeneralSpecification forWire and Cable. Hookum Electrical. InsulatedCable, Two Conductor, ParallelCable (Power and Special Purpose) and Wire, Electrical(300 and 600 Volts)Wire, Electric, Polyvinyl Chloride Insulated, Copper orCopper AlloyWke, Electrical, Iron and Constantan, ThermocoupleWke, Electrical, Chromel and Alumel, ThermocoupleWire, Electrical, Copper and Constantan, ThermocoupleCable, Electric, Aerospace Vehicle, General Specification forWke, Electrical, Silicone-htstrlated, Copper, 600 Volt, 200”CCable, Special Purpose, Electrical: General Specification forWke, Electrical, Insulated, General Specification forWire, Insulated, Hard Drawn CopperCable, Electrical, Special Purpose, Shore UseCable, Electrical, Shielded, 600 Volt (for NonflexingService)Wire, Electric, Fluoropolymer-htsulated, Copper or CopperAlloyCable, Electrical, Shielded PairsCable and Cord, Electrical, Low Smoke, for Shipboard Use,General Specification forWke, Electrical, High Temperature and Fire Resistant,General Specification forCable, Special Purpose, Electrical, MulticonductorCable, Electrical, Shielded and Unshielded, AerospaceCables. Twisted Pairs and Tri~les. Internal Hookup, GeneralSpecification for

.

Wire, Electric, Crosslinked Polyalkene, CrosslinkedAlkane-imide Polymer, or Polyarylene Insulated, Copper orCopper AlloyWke, Electric, Polyimide-Insulated, Copper or Copper Alloy

71-1



MIL-STD-454LI

MS25471 Wire, Electrical, Silicone Inmdated, Copper, 600 Volt,200”C, Polyester Jacket

MS2711O Wire, Electrical, Silicone Insulated, Copper, 600 Volt,200”C, PEP Jacket

ASTM B33-74 Thned Soft or Annealed Copper Wire for Electrical Purposes

3. PefinitiwI

‘3.1 Interconnect irre wire. Insulated, single-conductor wire used to carry electric:current between units.

3.2 h~ab~. Two or more insulated conductors contained in a commoncovering or one or more insulated conductors with a gross metallic shteld outer con-ductor used to carry electrical current between units.

I

I 4. ~eauirements

4.1 Wire selection. Selection of wire for interconnection between units shall be inaccordance with table 71-1.

4.2 Multiconductor cable selectl‘on. Selection of multiconductor cable for interconnec-

1 tion between units shall be in accordance with table 71-II.

4.3 ADD licationrestrictions

I 4.3.1 IvllGW-76 shall be used for Army application only.

I 4.3.2 MIL-W-16878 shall not be used for Ak Force aerospace equipment.

4.3.3 Cable or wire with polyvinyl chloride insulation shall not be used in aerospace

1

applications. Use of these wires or. cables in any other Alr Force application requiresprior approval of the procuring actlwty.

4.3.4 MIL-W-22759 wire with only single polytetrafluoroethylene insulation used inAk Force space and missile applications shall require the approval of the procuringactivity.

I 4.3.5 Use of aluminum wire requires specific approval by the procuring activity.

5. Jnforma tion for euidance only

5.1 Pulsed or rf sienals. AN interconnecting cables carrying pulsed or rf signals shouldbe coaxial cables or waveguides and should be terminated, when possible, in thecharacteristic impedance of the transmitting media.

L REQUIREMENT 7112 February 1988

71-2



)uIR

EM

EN

T71

IOS

eptem

ber

1987

—L%

r

RE

QU

IRE

ME

~71

12F

ebru

ary1988

71-3


MIL

-ST

D-454L

RE

QU

IRE

ME

NT

7112

Feb

ruary

198871-4

RE

’QU

IRE

ME

tW71

IOS

eptem

ber

1987

“.=

11—

1-1IIIIIII

IIIIllIIIIIIIIIIII

II

II11II

r1


MIL

-ST

D-454L

~.

>&

oJ

Wz

-z

Su

persed

esR

EQ

UIR

EM

EN

T71

10S

eptem

ber

1987

RE

QU

IRE

ME

NT

7112

Feb

ruary

198871-5


I

L

-R

EQ

UIR

EM

EN

T71

12F

ebru

ary1988

7

KSu

persed

esR

EQ

UIR

EM

EN

T71

10S

eptem

ber

1987-6


MIL

-ST

D-454L

w.4t-

Su

persed

esR

EQ

UIR

EM

EN

T71

IoS

eptem

ber

198771-7

RE

QU

IRE

ME

NT

7112

Feb

ruafy

1988

c


MIL

-ST

D-454L

I

RE

QU

IRE

ME

NT

7112

Feb

ruaty

1988

Su

persed

esR

EQ

UIR

EM

EN

T71

10S

eptem

ber

198771-8?

,..’


MIL-STD-454L

REQUIWMENT 72

s~sm~~

1. n-. This requirement establishes criteria for the selection and application ofsubstitute parts.

2. Docume nt aDoIicable to Requirement 72

DOD-STD-480 Configuration Control - Engineering Changes, Deviations andWaivers

.3. p~s. Not applicable.

4. R.~s

4.1 Militan varts. Substitution of parts covered by military specifications andstandards that include substitutability or supersession information is acceptable. Thistype substitution does not require submission of engineering change proposals,deviations, or waivers in accordance with DOD-STD-480.

4.2 ~s. When the equipment design specifies a commercial part, amilitary specification part may be substituted when the form, fit and functionalcharacteristics of the military part are equal to or better than those of the specifiedcommercial part under equivalent environmental conditions. This type substitution issubject to applicable configuration control procedures of DOD-STD-480 and shall bedocumented on a parts substitution list as described by DOD-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 thespecified part may be substituted after approval is obtained from the applicableacquisition activity. This type of substitution is subject to the applicable configurationcontrol procedures of DOD-STD-480 and shall be documented on a parts substitutionlist as described by DOD-STD-480.

4.4 Jnitial~ monstratio Substitutepartswithquality/reliabilitycharacteristicssuperiortothose specified in the parts Iist shall not be used in equip-ment to be subjected to initial qualification or demonstration tests.

5. Info rmation for eu idance only.


Not applicable.

72-1 ‘



MIL-STD-454L

REQUIREMENT 73

STAND- ELECITtONIC MODULES

1. ~j?u?. ‘Ilk requirement establishes criteria for the selection and application ofstsndsrd electronic modules (SEM).

2. :

MIL-M-28787 Modules, Standard Electronic, Oeneral Specification forMILATD-1378 Requirements for Employing Standard Electronic ModulesMIL-STD-1389 Design Requirements for Standard Electronic Modules

3, p~s. Not applicable.

4. Reouirement~. Requirements for the design and application of standard electronicmodules shall .be in accordance with MlL-STD-l 389 and MIL-STD-1 378. Standardelectronic modules shall be in accordance with MK-M-28787.

5. Irlf~ nly. Not applicable.

SupersedesREQUIREMENT 7310 September 1979 .,. -

73-1



MIL-STD-454L

REQUIREMHW 74

GROUNDING, BONDJNG, AND SHIELDING

1.. _. .Thk requirement establishes grounding, bonding, and shieldktg interfacecnterla for mstallatlon of e[ectrortic equ}pment.

2. D nt~ irem 74:

MIL-B-5087

MIL-STD-188-124MIL-STD-131O

MUATD-1542

MII.AXD-1857

~t~~~, Electrical, and Lightning Protection, for Aerospace

Grounding, Bonding, and ShieldingShipboard Bonding, Grounding, and Other Techniques forElectromagnetic Compatlbdity and Safety ShieldingElectromagnetic Compatibility (EMC) and Grounding Requirementsfor Space System FacilitiesGrounding, Bonding, and Shielding Design Practices


4. Beau irements.. Grounding, bonding, and shielding provisions shall be incorporatedinto equipment design, as necessary, to enable installation of equipment into theapplicable platform or facility. The grounding, bonding, and shielding installation andinterface requirements are specified in the following documents:

Aerospace ground support facilities MIL-B-5087Aircraft and space vehicles MIL-B-5087Ground telecommunications C-E equipment MTL-STD-188-124Shipboard equipment MIL-STD-131OGround space systems facilities MIL-STD-1542Other Army ground equipment MIL-STD-1857

5. Jrl~. Not applicable.


74-1

REQUIREMENT 7412 Februafy 1988


MIL-STD-454L

REQWREMENT 75

ELECTROSTATIC DISCHARGE CONTROL

1. z. ‘Ms requirement offers guidance regardhg the handling and control ofelectronic parts and assembhes that are susceptible to damage or degradation fromelectrostatic discharge. lT DOES NOT ESTABLISH REQUEWMENT S AND MUSTNOT BE REFERENCED LN CONTRACTUAL DOCUMENTS. Requirements for theestablishment and implementation of an electrostatic discharge (ESD) control programin accordance with DOD-STD-1 686 must be directly specified in the contract or equip-ment specificaUon.

2. Documents ~~ Iicabl irement ~

MIL-M-3851O Microcircuits, General Specification forMIL.-STD-883 Test Methods and Rocedures for MicroelectronicsDOD-STD-1686 Electrostatic Dkcharge Control Program for Protection of

Electrical and Electronic Parts, Assemblies, and Equipment(excluding electrically initiated explosive devices)

DOD-HDBK-263 Electrostatic Discharge Control Handbook for Rotection ofElectrical and Electronic Parts, Assemblies, and Equipment(excluding electrically initiated explosive devices) .

Definitions.Definitionsof applicableterminology may be found in MIL-M-3851O,kSTD-883, DOD-STD-1686, and DOD-HDBK-263.

4. Rll nt~. Not applicable.

5. Information for eu yidance onl

5.1 ESD con trol mom. DOD-STD-1686 establishes the requirements for theestablishment, implementation, and monitoring of an ESD control program, includlngidentification of electrostatic discharge sensitive (ESDS) items, classification of ESDsensitivity levels, control program elements, extent of program element applicability toeach acquisition, protective measures to be employed in equipment design, handling,storage, and packaging of ESDS items, protected work areas, personnel training, ESDaudits and program reviews, and tailoring. Ap endix A of DOD-STD-1686 establishes

!the criteria and procedure for classifying ESD parts by test. Appendix B ofDOD-STD-1686 identifies and classifies ESDS items. DOD-HDBK-263 providesguidelines for the establishment and implementation ‘of an ESD control program inaccordance with DOD-STD-1686.

5.2 ~tn “delines for My program designed for theprevention of ESD damage to ESDS p~~s an: a~sernblies should be based on thefollowing considerations:

a., Identification of ESDS parts and assemblies and determination of sensitivity”


75-1



MIL-STD-454L

b.

c.

d.

e.

f.

&

hli~mization of static charge generation.

Reduction of stored charges (grounding)

Isolation of ESDS parts (Faraday shielding and line transient protection)

Proper handling, storage, and transportation of ESDS parts and assemblies

Persomel training and certification

Rotected work areas.


.

.

75-2



MIL-STD-454L

ApplieeQWMw&J&kUfl!mL

t4MM-A-121MMM-A-l30

F-F-300L-P-5 16L-S-300V-T-276V-T-285V-T-29 1V-T-295W-L-00111W-L-00116CC-M-1807FF-B-171FF-B-185FF-B-187FF-B-195FF-B-575FF-N-836FF-fi-556FF-S-85FF-S-86FF-S-92FF-S-I 07FF-S-200FF-S-210FF-H-84FF-W-92FF-W-10012Q-B-750CQ-C-530QQ-C-533w-c-585QQ-C-586QQ-P-416QQ-S-’I66QQ-w-32IQQ-W-343QQ-W-423QQ-W-470TT-S-1 732VV-L-800W-P-236ZZ-R-765CCC-C-428

5211, 2667444444445050466

:6121212121212121212121212414141414112414120, 66, 7141, 66, 71411243432644

SupersedesINDEX 112 February 1988

.,

11-1’

MMM-A-l32MMM-A-l34MKM-A-138WMM-A-181MNfrl-A-l89MWM-A-1617

MIL-I-1OMIL-M-14MIL-C-17MIL-B-18MIL-D-24MIL-S-61MIL-W-76MIL-P-79MIL-T-152MIL-C-172MIL-V-173MIL-C-442MIL-W-530MIL-C-572MIL-I-631MIL-J-641MIL-P-642MIL-T-713MIL-P-997MIL-S-1222MIL-I-1361MIL-L-2105MIL-G-3111MIL-G-3124?41L-L+?150MIL-I-3158MIL-I-3190MIL-C-3432MIL-T-3530MIL-S-3644MIL-L-3661MIL-I-3825MIL-L-3890MIL-L-3918MIL-A-3920

Applies

2323232323232323

11, 2611, 2665, 66, 7127464020, 7111, 264, 69554, 6966, 71444411, 6910

:11, 2612404346

::11, 6911, 6966, 71444250

;;4323

INDEX 120 September 1988


J

ML-STD-454L

I MIL-K-3926MIL-B-3990MIL-u-4088MIL-M-4818MIL-M-4819MIL-M-4820MIL-I&5086MIL-B-508THIL-H-5440MIL-A-5540MIL-F-5591MIL-R-5674MIL-B-5687MIL-W-5845MIL-w-5846MIL-W-5908MIL-L-6085MIL-L-6086MIL-L-6363MIL-B-6812MIL-W-6858MIL-C-7078MIL-I-7444MIL-S-7742MIL-M-7793MIL-L-7806MIL-B-7838MIL-B-7883MIL-R-7885MIL-T-7928MIL-S-7947MIL-L-7961MIL-M-7969MIL-S-8516MIL-A-8576MIL-w-8604UIL-M-8609MIL-U-8611UIL-W-8777MIL-R-8814NIL-B-8831MIL-s-8879MIL-H-8891MIL-W-8939MIL-w-8942MIL-B-8943MIL-w-8948

i,.

AppliesJO Ream

2864446 :46 f46 !20, 66, 711, 74

49231212620,20,20,434350

66, 7166, 7166, 71

12

::, 7111,2 1

515012591219, 6941504647231346.

% 7112~121249.2k66,

6(

INDEX 120 September 1988 . /..

11-2

MIL-C-9074MIL-F-9397MIL-B-1O154MIL-C-10544ML-T- 10727t41L-B-l 1188IUL-S- 12285MIL-C-12520MIL-S-12883MIL-T-13020MIL-M-13231MIL-S-13282UIL-B- 13506MIL-S-13572MIL-C-13777MIL-M-13786MIL-M-13787MIL-P-13949MIL-P-15024MIL-P-15037MIL-P-15047DOD-B-15072MIL-L-15098MIL-1-15126MIL-T-15659MIL-L-15719MIL-S-15743MIL-M-16034MIL-M-16125MIL-F-16552MIL-w-16878MIL-I-16923MIL-M-17059MIL-M-17060MIL-I-17205MIL-L-17331MIL-B-17380MIL-M-17413ML-M-17556MIL-L-17672MIL-I- 18057MIL-P-18177MIL-F- 18240MIL-N-18307MIL-W-18326MIL-S-18396MIL-I-18746

Applies

44462710122758

6!

:;4164166, 714646

J11, 261127501119435851515220, 66, 71474646114364646431111

:135811



HIL-M-19097MIL-li-19150MIL-M-19160MIL-P-19161MIL-I-19166MIL-M-1916’7MIL-M-19283MIL-C-19311MIL-S-19500MIL-C-19547MIL-M-19633MIL-C-216091.!IL-I-22076MIL-S-22215MIL-T-22361MIL-A-22397MIL-S-22432MIL-S-22473MIL-W-22759MIL-S-22820MIL-T-22821MIL-A-22895MIL-C-22931MIL-F-22978MIL-I-23053MIL-B-2307IMIL-S-23190MIL-I-23264MIL-C-23437MIL-S-23586MIL-I-23594MIL-T-23648MIL-C-23806MIL-G-23827MIL-I-24024MIL-M-24041liIL-I-24092MIL-G-24139HIL-A-24179MIL-G-24211M.IL-R-24243MIL-S-24251UIL-M-24325MIL-I-24391MIL-G-24508MIL-C-24643MIL-N-25027

SupersedesINDEX 1

Applies

4620, 714611, 26114646,4130, 5066, 714666, 7111, 69411223561220, 66, 71565623651211, 6946, 5269

::, 714711

12 February 1988

336543

:;66, 7112

11-3

>

MIL-STD-454L

Applies~k2h9rr&

l!IL-W-25038 66, 71MIL-K-25049 28ML-A-25463tUL-ti-25475 $ML-P-25518 26?UL-C-27072 66, 71ML-W-27265 44MIL-R-27384MIL-C-27500 :, 71UIL-P-28717 52ML-D-28728 28ML-M-28787 73luL-R-288b3 68MIL-P-28809 17MIL-A-28870 7, 17MIL-M-38510 64, 75MIL-M-38527 60tUL-C-39006/22 2MIL-C-39006/25 2MIL-C-39018MIL-T-43435’MIL-S-46049MIL-A-46050MIL-I-46058MIL-P-46112MIL-W-46132MIL-A-46146MIL-S-46163MIL-P-46843MIL-I-46852MIL-H-46855MIL-A-48611MIL-B-49030MIL-B-49430MIL-B-49436MIL-B-49458MIL-B-49461MIL-R-50781MIL-P-50884MIL-A-52194HIL-C-55021MIL-S-55041MIL-P-5511OMIL-C-55116MIL-B-55118MIL-B-55130MIL-T-55156

INDEX 1

6:4123172613231217

t!;23272727272756172366, 71531710272719

20 September 1988


MIL-STD-454L

.RQwWnU&

MIL-T-55164MIL-C-55181MIL-B-55252MIL-O-55310MIL-A-55339MIL-C-55543MIL-T-55631MIL-C-81021ML-W-8 1044MIL-I-81219MIL-A-81236MIL-A-81253MIL-M-81288MIL-G-81322MIL-h’-8l38lMIL-E-81512MIL-I-81550MIL-B-81744MIL-s-81746MIL-B-81757MIL-B-81793MIL-U-81822HIL-B-81934MIL-B-81936MIL-S-81963MIL-A-83377MIL-S-83502MIL-C-83503MIL-R-83516‘MIL-T-83721‘MIL-T-83727MIL-S-83731UIL-S-83734MIL-B-83769MIL-E-85082MIL-D-87157

FBD-STD-H28FED-STD-406

Applies

19102738

;144120, 66, 71512323554320, 66, 7156.476

56276206656, 672360105714565860275668

1226


11-4

AppliesRQwwlMLtLmurlt

HIL-STD-12 67FUL-STD-22 13MIL-STD-108 55, 69MIL-STD-130 67MIL-STD-1;5 67MIL-STD-188-124 74MIL-STD-195 67MIL-STD-196HIL-STD-198MIL-STD-199MIL-STD-200MIL-STD-202MIL-STD-205MIL-STD-248MIL-STD-255MIL-STD-275MIL-STD-276MIL-STD-280MIL-STD-411MIL-STD-415MIL-STD-461MIL-STD-462MIL-sTD-469MIL-STD-470MIL-STD-471DOD-STD-480MIL-STD-681MIL-STD-683MIL-STD-701MIL-STD-704MIL-STD-710MIL-STD-721MIL-STD-756MIL-STD-781MIL-STD-783MIL-STD-785MIL-STD-81oMIL-STD-883MIL-STD-889MIL-STD-965MIL-STD-975MIL-STD-981MIL-STD-1130MIL-STD-1132MIL-STD-1189

34, 67

3:29

325132517217, 8, 36, 676732616161545472203830255635, 36, 5435

64, 7515,16226414695867

SupersedesINDEX112 February 1988


MIL-STD-454L

AppliesRmWwLtk~

t41L-STD-l261 13MIL-STD-1275 25MIL-sl’D-127’f 19MIL-STD-1279 51HIL-STD-1285 67MIL-STD-1286 14KXL-STD-131O 1, 74MIL-STD-1327 53MIL-STD-1328 53MIL-STD-1329 53llIL-sTD-1334 6

‘MIL-STD-1346 57MIL-STD-1352 53MIL-STD-1353 10MIL-sTD-1358 53MIL-STD-136o 39MIL-sTD-13’78 73MIL-STD-1389 73!41L-STD-1395 70DOD-STD-1399 25MIL-STD-1451 56MIL-STD-1472 1, 36, 50, 62ML-sTD-}498 37MIL-STD-1516 15MIL-STD-1539 8, 25MIL-STD-1542 74MIL-STD-1546 22MIL-STD-1547 18, 30, 64MIL-STD-1562 64DOD-STD-1578 27MIL-STD-1595 13MIL-STD-1629 35MIL-STD-1636 53MIL-STD-1637 53MIL-STD-1638 53MIL-STD-1639 53kUL-STD-l64o 53t41L-sTD-1646 10DOD-STD-1686 64, 75MIL-STD-1857 74DOD-STD-2000-1 5DOD-STD-2000-2 5DOD-STD-2000-3 5MD-STD-2000-4 5MIL-STD-2113 53MIL-STD-2118 17MIL-STD-2119 7, 17MIL-STD-2120 10


11-5

MIL-STD-2162MIL-STD-2165MIL-STD-2175MS25471M2711oMS27212US33522MS33540MS33557!4S33558

Applies

22171711912121242

MILADBK-5 13MIL-HDBK-214 56MIL-HDBK-216 53, 65MIL-HDBK-217 35, 64MIL-HDBK-218 56MIL-IiDBK-225 56MIL-HBDK-231 56MIL-HDBK-251 52MIL-HDBK-253 61DOD-HDBK-263 75MIL-HDBK-472 54MIL-HDBK-600 1MIL-HDBK-660 53MIL-HDBK-691 23

GOVT DOQMEKIS

MIL-BUL-103 64CFR, Title 10, Ch I,

Part 20 1CFR, Title 21, Ch 1,

Subch J 1CFR, Tit10 29, ch XVII

Part 1910 1, 4, 11,23, 26, 43, 44, 47

NTIA Manual 61

Tester Independent SupportSoftware Syetem (TIsSS)Specs 64

VHSIC InteroperabilityStandards 64



MIL-STD-454L

Applies&MWW@dLU@29!I&

NQBGOVT DQGUMEUS

AGM.ASpecificationsANSI B93.1-64ANSI B93.2-71ANSI B93.3-68ANSI B93.W-81ANSI B93.5-79ANSI B93.6-72ANSI B93.7-68ANSI B93.8-68ANSI B93.9M-69ANSI B93.1O-69ANSI B93.1 lM-81ANSI C95.1-82ANSI C95.2-82ANSI N2.1-69ANSI 235.1-72ANSI 235.2-68ANSI 235.4-73ANSI Z53.1-79ANSI/AUS A2 .4-79ANSI/AWSA3.0-80ANSI/IPC-DW-425/11ANSI/SAE J514fANSI/SAE J518C


48494949494949494949494911111111313174949

.) ,

11-6

AppliesEQEmLl&fQlA9mt

ASM Metals Hdbk,VO1 1-1978

ASTMStd - iiOOd,Part 22

ASTNA29-84ASTMA682-79ASTNA684-81ASTt4B33-74ASTNB522-80ASTM D149-81ASTM D495-’I3ASTM D568-7’7ASTt4D635-81ASTM D1OOO-82ASTM D1868-81ASTM D2564-80EIA RS 297A-70EIA RS 31OC-77IEEE 200-1975IEEE 1076-1987NAS 498NAS 547NFPA 70-1987UL 94

41

2341414166, 7141452633

4;23

;;676412121, 83

● New/changed this iesue



Abbreviations .Access devicesAccessibility .Adapters

Rf connectorIiaveguide . .

Mhesives . . .

Ee9nQ.

. . . . . . 67

. . . . . .

. . . . . . ;;

. . . ... . 10. . . . . . 53. . . . . . 2i

Anti-seize compound . . . . 12Arc-resistant materials . . 26Attenuators, rf . . , . . . 53Barriers, electrical . . . 1Batteries . . . . .Bearing assembliesBearings . . . . .BeardDiscrete wiring .Printed circuit .

Bolts.. . . . . . .Bending . . . . . .Brazinz . . . . . .Cabine~s . . . . .Cable, coaxial . .Cable, multiconductcr

. . . . 27

. . . . 9

. . . . 6

. . . . 17

. . . . 1712

: ; “1; 74. . . . 59. . . . 55. . . . 65

Interconnection .Internal . . . .

Capacitors . . . .Carcinogens . . . 1

26,Castings . . . . ,Circuit breakers .clamps, . . . . .Cleaning , . . . .Clearance . . . . .Coaxial cable . . .coils’ . . . . . . .Conformal ccsting ,Connect ionsClamped . . . . .

.Crimp . . . . . .Marking of . , .Soldered . . . .Welded . . . . .Wire wrap . . . .

ConnectorsElectrical . . .

. . . . 71

. . . . 662

“4; ;1; 23’43, U4, 47

: : “8: :;... . 60.,. .. . . . 6:... . 65. . . . 14. . . . 17

. . . . 69

. . . . 69

. . . . 67

. . . . 5

. . . .

. . . . :;

. . 1, 10

MIL-STD-454L

lie9nQ.

Filter pin, . . . . . 10, 70Rfcoaxiel . . . . ...10

Containment . . . . . . . . 9Controls . . . . . . . . .28Insulation of’. . . . . . 1Flexible shsfts for . 28, 42

CcolinS . . . . . . . ...52Corona prevention . . . . . 85Corrosion protection . 15, 16Converters, rotary power . 46Couplers, directional . . . 53Creepage distance . . . . . 69Crimping tocls . . . . . . 19Crystal units . . . . . . . 38Derating, electronic parts 18Devicee, microelectronic . 64Devices, semiconductor . . 30Dial mechanisms, tuning . . 42Dials, control . . . . . . 28Discharging devices . . . . 1Displays . . . . . . ...68Dissimilar metals . . . . . 16Dynamot.ors . . . . .’. . .46ElectricalBreakdown . . . . . . ..U5Connections . 5, 10, 24, 69Filters .i . . . . . ..7OInsulating materials . . 11Meters . . . . . . ...51Overload protection . . . 8Power . . . . . . . . . . 25

.ElectromagneticInterference contrcl . . 61

Electronic part derating . 18Electron tubes . . . . . . 29ElectrostaticDischarge control . . . . 75Sensitive parts . 30, 64, 75

Embedment . . . . . . . . .47Encapsulation . . . . . . . 47Enclosure . . . . 1, 36, 55Fabric . . . . . . . ...44Fastener hardware . . . . 12Fasteners, threaded . . . 12Fibrous meter$al, organic . 44

SupersedesINDEX 229 August 1986

INDEX 212 February 1983

12-1


MIL-STD-454L

W?nQ.

Finishes . . . . . . ...15Flammability . . . . . . . 3Flanges, waveguide . . . . 53Fungus inert materials . . 4Fungus protection . . . 4, 69Fuse holders . . . . . . . 39Fuses . . . . . . . . . 8, 39Gear trains . . . ... . ..48Gears . . . . . . . . . ..48Generators . . . . .’. . . 46Grounding . . . . . . 1,6,74Guards, electrical . . . . 1Handles . . . . . . . . . .28Hardware, faatener . . . . 12Heating . . . . . . . . . .52Hookup wire . . . . . ...20Human engineering “.. . . . 62Hydraulics . . . . . . . . 49Identificationmarking . . 67Indicator lights . . . . . 50Inductors . . . . . . . . .14Insulating materials,electrical . . . . . . . II

Interchangeability’ . . . . 7Interferenceelectromagnetic . . . . . 61

Interlocks . . . . . . . . 1Internal wiring practices . 69

..-

Item names, nomenclature . 34Jacks, telephonelteat . . . 10Knobs, control . . . . . . 28Lacing . . . . . ...9.69LsMPs . . . . . . . . . ..5OLeakage distance . . . . . 69Legenda . .. ’.. . . ...67Light emitting diodes . . . 50Lights, indicator . . . . . 68Lines, rf transmission 53, 65Load, dummy, rf . . . . . . 53Locking devices . . . . 12, 28Lubricants . . . . . . 6, 43Lug terminals . . . . . . . 19Maintainability . . . . . . 54MarkingBattery installation . . 27Cables.cords and wires . 67Fuse . . . . . . . . 39, 67


12-2

ka_&2.

General . . . . . ... . . 67Identification . . . . . 67Radioactivematerial . . 1Warning . ... ... . . . 1

MaterialsArc-resistant . . . . . . 26Electrical insulating . . 11Fabric . . . . . . ...44Fibrous organic . . . : . 4UFlammable . . . . . ...3Fungus inert . . . . . . 4Glaas fibers . . . . . . 1POtting . . 6......47Toxic . . . . . . . . ..l

Mercury . . . . . . . . ..lMetal, alloys . . . . . . . 15Metals, dissimilar . . . . 16Meters

Electrical .. . . . . . 51Shunts . . . . . . .. ..4O

Microelectronicdevices . . 64Mildew treatment , . . . . 44ModulesMarkingof . . . . ...67Microcircuit , . . . , . 64Standard electronic . . . 73

Moisture pockets . . . . . 31Motor-generators . . . . . 46Motors . . . . . . . . . . 46Multiconductor cable

Interconnection . . . . . 71Internal . . . . . ...66

Nomenclature . . . . . . . 34Nonstandard parts . . . . . 22Nuts . . . . . . . . . ..l2Obsolescence, microcircuit 64Organic fibrous material . 44Oscillators, crystal . . . 38Overload Protection,

electrical . . . . . . . 8Pads, rnountin.g . . . . . . 60Panels, enclosure . . . . . 55Parts selection and

control . . . . . . . 7, 22Plastic material,insulating . . . . . .

Plugs, telephone . . . .

SupersedesINDEX 2

11

. 10

29 August 1986


MIL-STD-454L

Il!2dsb

Potting . . . . . . ..lo.47Power, electrical . . . 1, 25Printed wiring . . . . . . 17Markingof . . . . ...67

ProtectionElectrical overload . . . 8High voltagelcurrent . . 1

Pvt . . . . 11, 20, 65, 66, 71Quartz crystal units . . . 38Racks . . . . . . . . ...55Radiation (laser,microwave, X-ray) . . . . 1

Radioactive material . . . 1Readouts . . . . . . . . .68Reference designations . . 67Relays . . . . . . . ...57Reliability . . . . . . . . 35Prediction . . . . . . . 64

Resistance welds . . . . . 24Resistors . . . . . . . . .33Resolvers . . . . . . . ..56Rf connectors . . . . . . . 10Rotary power converters . . 46Rotary servo devices . . . 56Safety (personnel hazard) . 1Screws . . . . . . . . ..l2Semiconductor devices . . . 30Servo devices . . . . . . . 56Setscrews . . . . . . . ..12Shafts, control . . 12, 28, 42ShieldingElectrical . . 1,9,74Magnetic. :~. . . . . 60

Shields . . . . . . . . ..6oShock, electrical,effects of....... .1

Shunts (meter) . . . . . . 40Signs, accident prevention 1Sleeving . . . . . . . 11,69Sockets . . . . . . . . . .6oSoldering . . . . . . ...5Special tools . . . . . . . 63Splices . . . . . . . . ..”9Springs . . . . . . . . ..41Standard electronic modules 73Standard items . . . . . . 7Stops........’...28

SupersedesINDEX 229 August 1986

12-3

kLNQ.

Stress relief . . . . . . . 24Structural welding . . . . 13Substitutability . . . . . 72SwitahesEattleshort . . . . . . . 1General (except rf) . . . 58Interlock . . . . . . ..lRf . . . . . . . ..l.53Safety . . . . . . . ..lThermostatic . . . . . . 58Waveguide . . . . . . . . 53

Symbology . . . . . . ...67Synchros . ., . . . ...56Tachometers . . . . . . . . 56TapeElectrical . . . . . 11, 69Lacing . . . . . . ...69Reflective . . . . . . . 67

Terminal boards, strips . . 19Terminal lugs . . . . ... . 19Terminations . . . 1, 19, 69Test equipment . . . . . . 32Test points . . . . . . 10, 32Thermal design . . . . . . 52Thermistors . . . . . . . . 33Thermocouples . . . . . 10, 20Thread..........44Threaded fasteners . . . . .12Threads . . . . . . . . ..l2Toola, special . . . . . . 63Toxic materials . . . . . . .1Transformers . . . . . . . 14Transmission lines, rf . . 53Transolvers . . . . . . . . 56Tube clampa . . . . . . . . 60Tube shields . . . . . . . 60Tubes, electron . . . . . . 29Tuning dial mechanisms . . 42Type designations . . . . . 34Varnish, insulating . . . . 11Vehicles, ground . . . . . 25Harning labels . . . . 1, 27Washers, . . . . . . . . . . 12iiaveguides . . . . . . . . 53Webbing . . . . . . . ...44Welding, structural . . . . 13Welds, resistance . . . . . 24


-.


I

I

!

I

I

NIL-STD-454L

Subiectt RanQ.

WireHookup . . . . . . ...20Interconnection . . . . . 71Stranded . . . . . ...66

Wire identlftcation . . . . 20wiring

Connector . . . . . . . . 10Harness . . . . . . . 9, 69Internal . . . . . ...69Printed . . . . . . . ..l7Rigid-flex . . . . . . . 17

Workmanship . . . . . . . . 9

● New/changed in this issue

/


12-4

SupersedesINDEX 229 Atigust1986

,. .


IIIi

I

IIII

IIII

III

i

IIII

I1

III

II

STANDARDIZATION DOCUMENT IMPROVEMENT PROPOSAL(~ Imtrncti - Rpwie S&s)

DOCUMENT NUMBER 2 DOCUMENT TITLE

[L-STD-454LNAME OF WBUITWEO ORGANIUTION & TVFE OF OROANIZATlON (M-k e)

❑ VE”oo,

❑ U&”

MmERg@+.(anu4 Cw. sE,a, ZIP C*)

❑ UAPEUFACTURER

❑ OTHER ,.9PCWY)-

FROSLEM AREAS

. ?mv’wh N“rnhw ,nd w*rdi”#:

b. R8MUI— wordino :

c. _/RstiEJIA for R_mmuim ,

REMARKS

wAuE OF 6UBMITTER b t, Pbwt MI) - G@gul b. WORK TELEPI+DNE NUMBER (W- Arn~) - OotiOMl

MAILING ADDR= @kE, Cttv, 8bb, ZEP COM - ~ m DATE OF SIJOMISSION (YYMMDD)

.J’!,

-m --- .. A- --- ,-.. -.. -. ..-,. -,----- ,..,●eE VIOLS EOITIGN B O#bOLE?E.
