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IBEElMIL-HDBK-540030 NOVEMBER 1995SUPERSEDINGMIL-STD-540015 JUNE 1992MILITARY HANDBOOKELECTRONIC EQUIPMENT, AIRBORNEGENERAL GUIDELINES FOR.\THIS HANDBOOK,IS FOR GUIDANCEoNLy. DO NOT CITE.THIS DOCUMENTAS A REQUIREMENT.AMSCNIADISTRIBUTIONSTATEMENTA. ApprovedAREA”GDRQfor public release; distributionis unlimited.

MI L-HDBK-5400FOREWORD1. This military handbook is approved for use by al1 Departments and Agenciesof the Department of Defense.,,2. Beneficial comments (recommendations, additions, deletions) and anypertinent data which may “be of use in improving this document should beaddressed to: Commander, Systems Standardization, Code 4.1.4.2B120-3,. NavalAir Warfare Center Aircraft Oivision, Highway 547, Lakehurst, NJ OB733-S1OO,by using the self-addressed Standardization Oocument Improvement Proposal (DOForm 1426) appearing at the end of this document or by “letter.3. This handbook provides guidance for implementing and tailoring guidelinesand documents contained in MIL-HDBK-454 Standard General Guidel ines forElectronic Equipment, which have applicability in the design and production ofelectronic equipment for airborne applications.Included in this handbook arereference’s to the applicable requirements, an index of appl icable documents,and a guide for tailoring and application of those requirements and documentsin conjunction with ‘the various equipment design, development and productionphases.ii.

IMIL-HDBK-5400CONTENTS PARAGRAPH11.11.1.1.’. . . . . . . . . . . . . . . . . . on. . . .Tailoring. . . . .Class ification . . .External cooling . .2.2.12.22.3APPLICATION OOCUMENTi. . . . . . . . . .DocumentsAppli able s Uis”::.,.Copies . . . . . .”. . . . . . . . . . .’ . . . . 1. .’.1.1. .1. .1.2. . . . .2. . . 2.2.2DEFINIT,IONS. . . . . . . . . . . . . . . . . . . .2. . . . . . . . . . . . . . . . 2AccessoryAc j iti,on”a t v t : . . . . . ., . . . . . . . . . . 23.73.83 .“9 Airborne . . . . . . . . . . . . . . . . . .Complete operating equipment . . . . . . .Detail specification.’. . . . .Electron ice. . . . . . . . . . . . . . . . .EquipmentHermeticseal;ngnlj:Ju :1 . . . .Instal 1ation (complete equipment)Intermittent and short time operati& “ : 1Other component definitionsPerformance requirements of tie “equ{prne t“Permanently installed part,”. . . . . . . .Removable assembly.’. . . . .Reordered production equipment . . : . . .,.J.GENERAL GUIDELINES. . . . . . . . . . .”.Untitled . . . . . . . . . . . . . . . . .Tailoring of MI L-HDBK-454 guidelines : . . . .Standard hardware acquisition and reliabilityprogram (SHARP)Requirements,, table: nd igu;e 1 1 j : : 1 1Design and construction. . . ,.,. . . . . . .Untitled .’. . . . . . . . . . . . ‘. . . . . . . . . . .AccessibilityAnti-jamming.llI J1ll11 . . . . . .Castings, metalCorona and electr c l “b;e;kdown “p e e;t o; : :Derating . . . . . . . . . . . . . . . . . . .Electrical overload protection . . . . . . . .Resettable circuit protectors. . . . . . . .Spare fuses. . . . . . . . . . . . . . . . .iii.2. . . 2.3. . . . . .3. . . 3: . . ;. . . . . 4. . . 4.4. . .-4.4. .4. . . . 441 1 1 5. . . 5.5. . . 5. . .”56I 1 n : 6.7. . . . 7. . . “.7. .7j.

MI L-HDBK-5400CONTENTS, (continued) 8.2;.; l power . . . . . . . . . . . . . . . . .7Warm-upt ice. . . . . . . . . . . . . . . . . .’.7Untitled . . . . . . . . . . . . . . . . . . .7Electromagnetic interference control . . . . . . . . . 7Electrostatic discharge control. . . . . . . . . . . 7Enclosures. . . . . . . . . . . . . . . . . .8Standardized avionics enclosures . . . . . . . . . . . 8‘ Other enclosures . . . . . . . . . . . . .’.Fabrication. . . . . . . . . . . . . . . . . . . . .Grounding, bonding and shielding . . . . . . . . . . . 8,“Human,engi neering. : . . . . . . . . . . . . . . .8Interchangeabi lity . . . . . . . . . . . . . . . . .8Interchangeability of reordered equipment. ,. . . . . 8Maintainabil icy. . . . . . . . . . . . . . . . .9. . . . . . . . . 9Marking/.Labels. :IR::IuIIIJ::. . . . . . .9Wire coding for identification . . . . . . . . . . . . gOperational programmarking. . . . . . . . . . . . gIiicrophonias . . . . . . . . . . . . . . . . . . .9Moisture pocket s. . . . . . . . . .9Multi flexing.,.’.,. . . . . . o. oNomenclature assignment. . . . . . . . . . . . . . .Orientation. . . . . . . . . . . . . . . . . . .10’Panels . . . . . . . . . . . . .: . . . . . . .10Control panel s . . . . . . . . . . . . . . . . . .10Electroluminescent panels. . . . . . . . . . . . . 10Ranges. of adjustable parts . . . . . . . . . . . . . . 10Pressurizati on . . . . . . . . . . . . . . . . . .10Reliability. . . . . . . . . . . . . . . . . . .11 ; a;abil icy. . . . . . . . . .,.’. . . . . . . . . . . . . . . . .System;a e y”III;. . . . . . . .-12Personnel safety . . . . . . . . . . . . . . . . .12Test provisions.:.,. . . . . . . . . . . 12Built- in test devices. . . . . . . . . . . . . . . . 12External test points . . . . . . . . . . . . . . .12“.Failure effect . . . . . . . .“.-.12Testability program. . . . .“. . . . . . . . . .12Thermal design . . . . . . . . . . . . . . . . . .13Cooling design data. . . . . . . . . . . . . . . . .13. . . . . . . . . . . . . . . . “13Tool SSetscrew wr n hes”lE. . . . . . . . .13Specialt oils. . . . . . . . . . . . . . . . .13.,iv

IIMIL-HDBK-5400CONTENTS(continued) 44.3.4.14.3.4,.24.3.4.34.3.4 18.24.3.18.34.3.18.4Furnishing and stowing . . . . . ‘. : . . . . . . . . . 13Standardized power supplies. . . . . . . . . . .,. . 13. . . . . . . . . . . . . . . 13WorkmanshippParts selecti;n”:j;j. . . . . . . .114Government furnished baseline (GFB). . . . . . . . . 14Choice of parts. . . . . . . . . . . . . . . . .14. . . . . . 14Nonstandard partsParts control progr;m” J 1 :’: J I :.: ; I . . . . . . 1416.Approval of partsContracts under cat g& : 1 : : : 1 1 : n : 1 1 : I 16Contracts for equipment which fall under categoriesIIand III . . . . . . . . . . . . . . . . . . .16Reordered production equipment . . . . . . . . . . .16Continuation of production . . . . . . . . . . . . . . 16Replacing of approved parts. . . . . . . . . . . . . 17Equipment performance. . . ., . . . . . . . . . . . 17Substitute on of parts. . . . . . . . . . . . . . .17Batteries. . . . . . . . . . . . . . . . . . . .178earings . . . . . . . . . . . . . . . . . . . .17Capacitors . . . . . . . . . . . . . . . . . . . .1.?Fixed, “tantalum, electrolytic. . . . . . . . . ‘. . . 1?Aluminum electrolytic. . . . . . . . . . . . . . . 17Circuit breakers .:. . . . . . . . .17”Manual operation .’. . . . . . . . .17Position identification. . . . . . . . . . . . . . . 18Orientation . . . . . .”. . . . . . . . . .18Connectors, electrical .“,. . . . . . . . . . . . . “. . 18Mounting. of electrical receptacles . . . . . . . . . . 18.Adjacent locations . . . . . . “. . . . . . . . . . JacksControl; k;obs; ha;die;, “d;aisi E : j I J I : 1 I j “1 18Crystals (quartz and oscillator) . . . . . . . . . .“. 18,Fastener hardware. . . . . . . . . . . . . .18. . .Filters, electricalFuses, fuseholders and as;o iated “h rdw re ; j j . . . ::Gears. . . . . . . . . . . . . . . . . . . .19Hydraul ice. . . . . . . . . . . . . . . . . . .19Aircraft . . . . . . . . . . .Missiles.’.Untitled . . . . . . . . . . .Lights and associated items.Indicator lights . . . . . . .Press to test indicator lightsInstrument lights. . . . . .Lamps. . . . . . . . . . . .v. . .”. . . . . . . .’. . . . . .19. .19.19. . . “. 19. .19. . . . 19. .19. .19

MIL-HDBK-5400CONTENTS .6I::1.14.4.24.4.34.4.44.4.4.14.4.5.)Visual display and legend lights . . . .Night v“ision compatibility . . . . . . .Meters . . . . . . . . . . . . . . . . .Microelectronic devices. . . . . . . .Motors . . . . . . . .”. . . .Motors, alternating current. . . . . .Motors, direct current . . . . . . . . .“Readouts and displays. . . . . . . . .Readouts . . . . . . . . . . . . . . . .Display s . . . . . . . . . . . . . . . .Relay s . . . . . . . . . . . . . . . . .Resistors. . . . . . . . . . . . . . .Semiconductor devices. . . . . . . . .Servodevices, rotary . . . . . . . . . .Sockets, shields and mounting pads . . .Sockets. . . . . . . . . . . . . . . . . . . . . . .ShieldsMounting ads”lIH:J. . . .SpringsStandard ilec r&{c ”modul s’(5EMs)’ 1 I HSwitches . . . . . . . . . . . . . .Mounting . . . . . . . . . . . . . . . .Rotary switches. . . . . . . . . . . .Toggle switches. . . . . . . . . . . .Terminations . . . . . . . . . . . . . .Number of wires per terminal or lug. .Number of lugs per terminal” . . .’. . .Number of wires in a connector contact .Transformers, inductors and coils. . .Tubes, electron: . . . . . . . . . . . .Waveguides and related item: . . . . . .Wire and cable . . . . . . . . . . . . .Wire andcable, internal . . . . . . . .Wiring practices, internal. . . . . .Wire and cable, external interconnectionExternal wiring practices. . . . . . .Cable, coaxial (RF). . . . . . . . .Printed wiring . . . . . . . . . . . .Material select ion . . . . . . . . . . .Choice of materialsPolyvinyl chloride (PVC)’rna e;i;l : n HStandard material s. . . .Nonstandard materials . . . . . . . . .Approval of nonstandard materials. . .Adhesives. . . . . . . . . . . . . . .vi.:.:.;.j.: : : : ; ;;. . .21. . .21. . .21. . .21. .22. . . . . 22. . . . . 22. . . . 22. . . . . 22. . .22. . . . . 22. . .22. . .22. . . . . 2?. . . . . 23. . . . . 23. . . . . . . . . . .23. . . . . 23. . . . . 24. . .24. . . - . 24. . . . . 24. . .24. . . . 20. . . . 20. . ’.20. . . . . . . . . . . 20. .20. .20. .20. .20. .20. .20. . . . 21. .21. . . . 21.21. . . . 21.’ .21