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E stablished 1981Advanced Test EquipmentRentalsNOT MEASUREMENTwww.atecorp.com 800-404-ATEC(2832)SENSITIVEMIL-HDBK-540030 NOVEMBER 1995SUPERSEDINGMIL-STD-540015 JUNI; 1992MILITARY HANDBOOKELECTRONIC EQUIPMENT, AIRBORNEGENERAL GUIDELINES FOR'·THIS HANDBOOK IS FOR GUIDANCEONLY. DO NOT CITE.THIS DOCUMENTAS A· REQUIREMENT.AMSC N/AAREA GDRQ. DISTRIBUTION STATEMENT A. Approved for public release; di stribution is unlimited.

Mil-HDBK-5400FOREWORD1. This military handbook is approved for use by all 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 4.1.4.28120-3,. NavalAir Warfare Center Airct·aft Division, Highway 547, Lakehurst, NJ 08733-5100,by using the self-addressed Standardization Document Improvement Proposal (DDForm 1426) appearing at the end of this document or by letter.3. This handbook provides gui.dance for implementing and tailoring guidelinesand documents contained in Mll-HOBK-454 Standard General Guidelines forElectronic Equipment, whi.ch have applicability in the design .and production ofelectronic equipment for airborne applications. Included in this handbook areref rence·s to the applicable requ.irements, an index of applicable documents,and a guide for tailoring and application of those requirements and documentsin conjuncti n with the var1ous equipment design, development.and productionphases.·ii

MIL-HDBK-5400CONTENTSPAGEPARAGRAPHI.1.11.1.11.1. 21.2I. 2 .I2. .2 .I2.22.33.3 4.4 .I4 .I. I4.1.24.1.34.2. 4. 2 E. . .ScopeApplicationTailoring . .Classification .External cooling'IIIII2APPLICATION DOCUMENTSDocuments . . . . Applicable issuesCopies . .2222DEFINITIONSAccessory.Acquisition activityAirborne· . . . . . . .Complete operating equipmentDetail specificationElectronics . . . . . . . .Equi ment. .Hermetic sealing . . . . . . ,Installation (complete equipment) .Intermittent and short time operationOther component definitions . . . . . .Performance requirements of the equipmentPermanently installed part· . .Removable assembly . . . . . .Reordered production equipment22222GENERAL GUIDELINES. .Untitled . . . . . . . . . . ·. . . .Tailoring of MIL-HDBK-454 guidelines.Standard hardware acquisition and reliabilityprogram (SHARP). . . .Requirements, tables and figuresDesign and construction.Untitled : . . .Accessibility . . . . .Anti-jamming . . . . : .Castings, metal . . . . . .Corona and electrical breakdown preventionDerating . . . . . . . . . . .·Electrical overload protectionResettable circuit protectorsSpare fusesiii33333334444444455555667777

M1L-HDBK-5400CONTENTS. (cent i 2.114.2.11.14.2.11.24. 14.2.17.2·4. 2.17. 3.24.2.23.34.2.244.2.25' 24.2.28.34.2.294.2.304.2.30.14. 2.31 .4.2.31.14.2.31.2\'·Electrical pojer . . . . . . . . . .Warm-up time . . . . . . . . . . . .Untitled . . . . . . . . . . . . . .Electromagnetic interference controlEl ctrostatic discharge controlEnclosures . . . . . . . . . . .Stan'dardized avionics 'enclosuresOther enclosures . . . . . . · . .Fabrication . . . . . . . . . . Grounding, bonding and shieldingHuman .engineering . . . . . . .Interchangeability . . . . . . . . . . .Interchangeability of reordered equipmentMaintainability . . . . . . .Mar:ki ng , . . . . . . . . . .Labels . . . . . . . . . . . .Wire coding for identificationOperational program·markingMicrophonics . . . . . .Moisture pockets . . . .Multiplexing . . . . . .Nomenclature assignmentOrientation . . . . . .Panels . . · . . . . . . .Control panels . . . . .Electroluminescent panelsRanges. of adjustable partsPressurizationReliabilityRepairabilitySafety . . . .System safety .Personnel safetyTest provisions .Built-in test devicesExternal test points·. Failure effect . . .Testability programThermal design . . .Cooling design dataTools . . . . . .Setscrew wrenchesSpeci'al toolsiv7777. 212121213. . 13. '1313. 13

MIL-HDBK-5400CONTENTS (continuediPAGEPARAGRAPH4.2.31.-34.2.324.2.334.34. 24.3.10.34.3.114.3.124.3.134. 3.144.3.154.3 .164. 3.174.3.17.14.3.17.24.3.17.34. 3.184.3.18.14.3.18.24.3.18.34.3.18.4Furnishing and stowing. Standardized power suppliesWorkmanship . .Parts selection. .Government furnished baseline (GFB)Choice of partsNonstandard partsParts control programApproval of parts.Contracts under category I.Contracts for equipment which fall under categories. . .I I and I I IReordered production equipmentContinuation of productionReplacing of approved partsEquipment performanceSubstitution of partsBatteries.Bearings.CapacitorsFixed, ·tantalum, electrolyticAluminum electrolyticCircuit breakers . ,.Manual operation.Position identificationOrientation·.Connectors, electrical .Mounting.of electrical receptacles.Adjacent locations.Jacks. . . .Controls (knobs, handles, dials)Crystals (quartz and oscillator)Fastener hardware.Filters, electrical.Fuses, fuseholders and associated Lights and associated items.Indicator lightsPress to test indicator lightsInstrument }171717 .1718. .1818181818181818191919191919191919191919

MI L-HDBK-5400CONTENTS (continued)PAGEPARAGRAPH4.3.18.5&·':tlAI'O-y ., . 3 .30.1. 5.64.44.4.14.4.24.4.34.4.44.4.4.14.4.5-Visual display and legend lightsNight v·ision compatibility .Meters. . .Microelectronic devices.Motors . .Motors, alternating currentMotors, direct current·Readouts and uctor devicesServodevices, rotary.Sockets, shields and mounting padsSocketsShieldsMounting padsSprings.Standard electronic modules (SEMs)SwitchesMountingRotary switchesToggle switchesTerminations . .Number of wires per terminal or lugNumber of lugs per terminal·.Number of wires in a connector contactTransformers, inductors and coilsTubes, electron : . . . . . .Waveguides and related itemsWire and cable . . . . . . Wire and cable, internalWiring practices, internal.Wire and cable, external interconnectionExternal wiring practicesCable, coaxial (RF). . . .-Printed wiringMaterial selection. . .Choice of materials.Polyvinyl chloride (PVC) materialsStandard ma'terials.Nonstandard materialsApproval of nonstandard 32424242424

MIL HDBK-5400CONTENTS 04.4.114. 4.124.4.134 .4.144.4 .15.4.54. 5.14. 5. l.J4.5.1.24. 5. 1. 2 14 . 6 2 5. 1. 6.2.6.34.6.2.7Arc-resistant materials . . . . . . .Con forma 1 coating. . . . . . .Dissimilar materials . . . . . . . . .Encapsulation and embedment materialsFibrous material, organic . . . . . .Flammability of materials . . . . . .Fungus-inert materials . . . . . . . . . . . .Insulators, insulating and dielectric materialsLubricants . . . . . . . . . . .Metals, corrosion resistantProcesses and finishes . . . . .Protective platings and coatingsMaterials . ·. . . . . . . . . .Aluminum alloy . . . . . . . . . Surface, general· . . . . . . . . .Surfaces, bonde and grounded ·. ·.Surfaces, extreme wear·resistantMagnesium and magnesium alloysZinc and zinc-plated parts . .Finishes . . . . . . . . . . .Cases and front panels . . . .Fasteners and assembly screwsOther standard finishes.Environmental service requirementsMIL-STD 810 environmental tests.Untitled . . . . . . . : . . . . .Equipment operational requirementsTemperatureOperating . . . . . . . . . . .Nonoperating . . . . . . . . . .Altitude . . . . . . . .' . . . .Temperature-altitude combinationHumidity . . . . . . . . . . . .Vibration . . . . . . . . . . .Equipment normally.mounted . . . . . . . . . . .Equipment designed for installation in propelleraircraft . . . . . . . . . · . . . . . . . . . . .Equipment designed for installation in jet aircraftEquipment nesigned for installation in helicoptersMinimum integrity testShock . . . . . . .Equipment . . . .Mount1ng base (crash safety)Bench handling.·Sand and 2828282829292929293535353535353535353636363636

MIL-HDBK-5400CONTENTS 5.46.6.16.26.36.46.5Fungus . . . . . . .Salt atmosphereExplosive conditions\I·'DETAIL GUIDELINES. . . . . . . .Detailed mechanical and electrical designTechnical data . . . . . . . . . . . . .Quality assurance . . . . . . . . . . .Responsibility for tests and inspectionsGovernment verification. .Failure criteria . . . . . . . . . . . .Problem/failure reporting and corrective actionDesign qualification testsFirst article testsScope of tests . . . . . . .Qu'al ity conformance testsPreparation for deliveryNOTES . . . . . . . . . .Intended use . . . . . . . .Details for inclusion in equipment specificationsand contracts . . . .Use of helium . . . . . . . .Publications . . . . . . . . .Subject term (keyword) 41FIGURES1234Operational requirements for class I airborne electronic equipment (temperature vs altitude)Operational requirements for.class 2 airborneelectronic equipment (temperature vs altitude)Operational requirements for class 3 airborneelectronic equipment (temperature vs altitude)Operational requirements for class 4 airborneelectronic equipment (temperature vs altitude). 31323334TARLESIIIIllIVvGeneral design and constructionParts selection . . . .Materials selectionProcesses and finishesEnvironmental conditionsviii615242730

MIL-HDBK-5400CONTENTS (continued)PAGEAPPENDIX AAPPENDIX SA-IAPPLICABLE DOCUMENTS .SAMPLE TAILORING GUIDEB-1. . 1-1INDEX-.ix

MIL-HDBK-54001.SCOPE1.1 Scope. Thl s handbook contains general guidelines for electronic·equipment for operatiqn in pilot d aircraft and helicopters,· missiles,boosters and allied vehicles. Detail electrical and mechanical design,performance and test requirements should be as specified in the det'a i 1specification or contract. This handbook is for guida!'lce only. This handbookcannot be cited as a requirement. If it is, the contractor does not have tocomply.1.1.1 Application. This handbook should not be invoked on a blanket. basis; however, each guideline should be assessed in terms of need. Thishandbook is a compendium of general guidelines, the majority of which havebeen selected from MIL-HDBK-454. for specific applicability to airborneelectronic equipment. Individual deta.il specifications or- contract shouldinvoke only those requirements which are applicable and necessary to thatspecif,ic equipment'.1.1.2 Tailoring. A tailoring guide, Appendix 8, is included to assistthe acquisition activity and the contractor in· a·pplying MIL-HDBK-5400guidelines to the various phases of equipment design, development andproduction.·1.2 Classification. Suggested-classification for design and manufacture·of electronic equipment is as follows (see 6.2).Class 1 - Equipment designed for 15.20 km {50,000 feet} altitude ·and contin4ous sea level operation over the temperaturerange of -54 to 55 C ( 71 C intermittent operation}.Class1A Equipment designed for 9.12 km (30,000 feet} altitude andcontinuous sea level operation over the temperature rangeof - 4 to 55 C ( 7l C intermittent operation).Class iB- Equipment designed fo'r 4.56 km (15,000 feet) altitude andcontinuous sea level operation over the temperature rangeof -40 to 55 C ( 71 C intermittent operation).Class 2 - Equipment designed for 21.28 km (70,000 feet) altitude·and continuous sea level.operation over the temperaturerange of -54 to 71 C ( .95 C i.ntermi ttent operation).Class 3 - Equipment designed for 30.40 km (100,000 feet) altitudeand continuous sea level operation over.the temperature.range of -54 to -i-95 C ( 125 C intermittent operation):Class 4 - Equipment designed for 30.40 km (100,000 feet} altitudeand continuous sea level operation over the temperaturerange of -54 to 125 C ( 150 C intermittent operation).1------··--------------------