.

- GEMINI
PROJECT
FEES
COPY

DATE 18 _ J-96_
REV IBED

PROJECT GEMINI

FAMIL_IZATION MANUAL
FOR

sPAcsc_.:_
#:

REPORT SEDIR :300 SERIAL NO. I

/ •

Mc,
DONNELL
_ __

SUBMITTED UNDER COI_"_R_.CT NO. NAS _-170

PREPARED BY _' ?t, APPROVED BY _/J///F_" _'/x-_._/

(_S A I _ C
REPRESENTATIVE
 SEDR 300

INDEX OF EFFECTIVE PAGES

The pages of this Manual currently in effect are

listed below in nu-_rical order.

Page No. Issue

A Basic
B Basic
C Basic
D Basic

i-i Basic
2-1 thru 2-16 Basic
3-1 thru 3-4 Basic
4-1 thru 4-3 Basic
5-1 thru 5-2 Basic
6-1 thru 6-35 Basic

A
 SEDR 300

================================
.........................................................................................................................
_::.:.:.::.:._:..._::..._:,:,_._._
,iiI ,!' i',iiNNOjECT,, ,, QEM

FOREWORD

The purpose of this _nual is to present, clearly and concisely, the description

and operation of the Gemini spacecraft systems and major components as installed

in spacecraft number one. The pr_y usages of the _ual are as a familiari-

zation-indoctrinetio_ aid, and as a ready reference for detailed _nfo_s_ion on

a specific system or component.

The _-_uual is sectionalized by spacecraft systems or major assemblies. Generally_

each section contains a system index illustration and a detailed word descripti_

of the system, its operation and its _-_Jorcomponents.

F. The inforw_tion contained in this _nual is applicable only to spacecraft n-tuber

one and is accurate as of iO July 1963. The m_nual will be revised periodically

or as required by changes to the spacecraft.

 5EDR 300

II II I I III IIiiiiiii II I I II I II I IIII

PAGE
SECTION I

SPACECRAFTMISSION ......................................... l_l

SECTION II

MAJOR STRUCTURALASSE_IES ................................ 2-i

SECTION llI

CABIN INTERIOR ARRAN_ ................................. 3-1

SECTION IV

ENVIRO_2AL CO_W_ROLSYSTEM ............................... _-i

SECTION V

COOLING SYSTEM ............................................. 5-1

SECTION Vl

INS_ATIC_ AND CC_B_JNICATION

SYSTEM ................... 6-1

C
 SEDR 300

I_fRODUCTI_

Initiated by the NASA and _p.lemented by McDonnell Aircraft Corporation, Project

Gemini is the next logical step in the field of ms,ned space exploration. Closely

allied to Project Mercury in concept, and utilizing the knowledge gained fro_ the

Mercury flights, Project Ge_Ini will eventually orbit a two-._u spacecraft consi-

derably more sophisticated than any employed so far.

The normally configured Gemini spacecraft is w_euverable within its orbit and is

capable of rendezvousing with and connecting to a second orbiting vehicle. Depend-

ing upon the specific mission objective, it can stay in orbit up to fourteen days.

Finally, upon re-entry, the re-entry portion of the spacecraft can be controlled in

a relatively conventional landing.

Spacecraft number one, however, with which this _nual is specifically concerned,

will perform a considerably less complex mission. Equipment requirements and

perfon_nce capabilities are therefore relatively l_ted.

D
 SPACECRAFT MISSION

_iiiiiiiii_iiiiiiiiii_ TA B L E O F CO N T EN TS

......................
.....................
• TITLE PAGE

.....................
..........................
°°o*o°°°*°°°°_°**.H°°o_*°
°°°°°°°°.°°o°°°°°_*_*°_*°
°°°°°°°°°°°_°*_°*_._**°_
°°°°°°°°°°°°°°.°°°°°°°_.°_
MISSION DI_SCRIPTION.... ° ..... ° ...... 1l
°°°°°°°°**o,°°°°°°°°°°°°°°°
...........................
°°°°°°°°°°°°°°°°°°°°°°o°°°°
°°°°°°°°°°°°°°°°°°°°°°°°°°°
° ...... °°°°°o°°°°o°°°°°°°.o $PACI_CRAFT DESCRIPTION ..... . ........ 11
_

_HIHHHHH_IIIHHHI_
.... °°°°°°°°°°°°°°°°o°°°°_o
°°°°°°°°°°°°**o.°°°°°°°°°°°
.... °o°°°°°°_o°°°°°°°°°°°°°
°°°°°°°°°°°,°°°°°°°°°°°°°°°
°°°°°°°°°°°°°°°°°°°°°°°°°°°
°°°°°°°°°°°°°°°°°°o°°°°°°°°
°°°°°°°°°°°°°°°°°°°°°°°,°°°
°°°°°°°°°°°°°°°°H°°°*°*°°°
..... °°°°°°°°°°°°°°°°°°°°°.
°°°°°°°°°°°°°°o°°°°°°°°°°°°
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°°°°°°°°°°°°°°°°°°°°°°°°°°.
°°°°°°°°°°°°.°°°°°°°°°°°°°°
°°°°°°°°°° .......... °°°°°°°
°°°°°°.°°°°°°°°°°°°°°°°°°°°
°°°°°°°°°° .......... °°°°°o°
..... °°°°°°°°°°°°°°°°°°°°°°
.... °°°°°°°°°°°°°°°°°°°°°°°
°°°°
°°°°.°° .........
....... °°°°°°°°°°°°°°
°°°°°°°°°°°°°
°°°°°°°°°°° ........... °°°°°
°°°°°°°°°°°°°°°° ........ °°°
HIHHHHIHIHHHHHH
..... °°°°°°°°°°°°°°°°°°°°°°
........... °°°o°°°°°°°°°°°°
HHHH_HHHHHHHHH
HHHH_HH_IHH_HHHI
_HHHHHHHHHHHHH
°°°. ................ °°°°°°°
HHHIH_HIIH_HH_HIH
HHHHHHHHHHHHH_
HHHHHIIHIHHH_HH;
...... °°° ..................
.......... °°°°°°°..°.°°°°°°
................
............ °°.°°°°°°°°
°..............
.............. °°°°°° .......

............... ,° ..........
................
.............. °..........
° ............

....... ° ...................

_ iiiiiiiiiiiiiiiiiiiiiigiiii
_HHHH:H_HHH:_H
 _. " "_, i.:_i_" "

SECTI0_ I SPACECRAFT MISSION

_¢_ION DESCRI_TIO]_

Gemini spacecraft n-m_er one will perform an unmanned orbital mission. The space-

craft will not be separated from the launch vehicle. Recovery will not be attempted.

The pr4_y objective of the mission will be to de_nstrate the structural integrity

of the spacecraft and launch vehicle through launch and a mln_,m of one orbit.
/

Telemetered data eoncernin8 structural integrity, temperature, pressure and vibra-

tin- will be obtained throughout the mission.

/
SPACE_ DESCRIPTION

Spacecraft number c_e conslb_s of production structure for the re-entry module and

adapter. Within the spacecraft, the following equipment is accurately si_-_ated

with regard to size, shape, weight, center of gravity and method of attachment:

Co_mter

IGS Platform

RCS Thrusters
/

OAMS Thrusters (except _ for_ firing thrusters)

/
/

_11 other internal equlpcent is si_ted only with regard to _e_ight,c_nter of

gravity and method of attac_ut.

/
 MAJOR STRUCTURAL
ASSEMBLIES

TABLE OF CONTENTS

- TITLE PAGE
::::::::.':::=:....._-:_
•""!_'.:=...:::.j
-_..._._
iHiii_iii_i_i_"_..:-_ GENERAL INFORMATION ................ 2-1
!!iii!!}iiiii_i_}_ii'-.-':'..'=.
." RE-ENTRY MODULE .................... 2-1
iliHiiiii!iiiiHiiiiiii!ii RENDEZVOUSAND RECOVERYSECTION...... 2-1
iiiiiiiiiiii!iHi!iiiiHiii RE-ENTRYCONTROLSYSTEMSECTION ....... 2-7
ii_iii_i!i!i!iiiiiiiiiiiii CABIN................................. 2-7
iii_i!_!!!iiiiiiiiiiiiiii ADAPTER ............................... 2-12
iiiiHi_iiiiiiiiiiiiiiiiiii RETROGRADESECTION..................... 2-14
_i_iiii!ii!iiiiiiiiiiiiii ADAPTEREQUIPMENTSECTION............. 2-14
i i i i !i i i i i i i i i
iiiiiiiiiiiiii!iiiii!iiiiii

................ °.... ......

.... ...° ............... ...°

................ ° ..........

.......................... °

f" ::ii::iiii:::_iii!i::::iliiiiiiii

:::::::::::::::::::::::::::::::::::::::::
 SEDR 300

" ; %!: !!

SECTION II MAJOR STRUCTURAL ASSEMBLIES

GENERAL INFORMATION

The Gemini Spacecraft is basically of a conical configuration, (Figure 2-1), con-

sisting of a re-entry module and an adapter as the two major assemblies. Space-

craft construction is semi-monocoque utilizing titanium for the primary structure.

It is designed to shield the cabin pressure vessel from excessive heating, noise

and meteorite penetration, (Figure 2-2). During spacecraft flight, the spacecraft

adapter is aft with respect to flight path. See Figures 2-3 and 2-4 for space-

craft orientation. TY is considered to be the top fo the spacecraft.

BE-ENTRY MODULE

The re-entry module (Figure 2-5) is separated into three primary sections which

include the rendezvous and recovery section (R & R), re-entry control system

section (RCS) and the cabin section. Also incorporated in the re-entry module

is the heat shield which is attached to the cabin, and a nose fairing which is

the forward section of the rendezvous and recovery section.

RENDEZV0_S AND RECOVERY SECTION

The rendezvous and recovery section (R & R), (Figure 2-5), the forward section

of the spacecraft, is a truncated cone in shape and is attached to the re-entry

control system section With twmnty-four bolts. The R & R section utilizes rings,

stringers, b,11_headsof titanium for its priw_ry structure and the external sur-

face is composed of beryllium shingles.

?-I
 SEDR 300
--. ""_!_
_:__ ,,_ii_ i_!_!_:_i_!_iii
._._!_i_:_:_:_._i_
_._:i!i_._ !_!_!_!
_:!_:.':
._!!!___ ._._
ii_._i_:_.._i_:i_:_:_
__._ :_. _.

'_ SPACECRAFT

ADAPTER _ _ RE-ENTRYMODULE

ADAPTER

MATING ADAPTER RENDEZVOUS

SECTION
_ CABIN
SECTION SECTION SECTION

RADAR

2
RENDEZVOUS AND
MATING
AIRING
LINE
_

RECOVERY SECTION
MATING LINE

RE- ENTRY CONTROL

SYSTEM SECTION/
CABIN MATING LINE

RE-E NI"RY MODULE/ADAPTER

MATING LINE

-- SPACECRAFT/LAUNCH
VEHICLE MATING LINE

Figure 2-1 Spacecraft General Nomenclature

FMGI-25

2-2
 SEDR 300

*_..._.!.:::::::_:_:_::_:;.._:.:_:_:::_:_:_:::_:_::.:_::::_:_::::_:_::.::_.:::_:_::::_:::_:_i_i_i_:._
_ _"

_i:_::;:_.:;::::_:_:
_'_:_ " "':"_ """ "•
:"'"""":::
:::_:
':""::"
....... "" ":'"
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.::.._!_!!:!:!_:..::_
:::::"""":':
_i
^"" ..'":"
I::_:
____LW_
" "....
i!" x_

/ /
/

/
/

/
/

/ " /

! \\ _ _-

'\
_ J

\ \
,., /
j
,
/

Figure 2-2 Cabin Pressure Vessel FMG,-23

2-3
 22667
(LAUNCH AND Of'BIT CONFIGURATION)

• 120,00 DIA.

BY

Figure 2-3 Spacecraft Dimensions FMGI-26

2-4
 _TOPI

TV

--._a t i,) J i

BY

Figure 2'-4 Stations Diagram

FMGI-27

2-5
 SEDR 300

iNGRESS-EGRESS

RE-ENTRY CONTROL
SYSTEM SECTION

DOCKING BAR BASE

HOLE AND PLUG

RETAINING STRAP RENDEZVOUS AND

FAIRINGS 3 PLACES)
(TYPICAL _ RECOVERY SECTION

OBSERVATION WINDOWS

NOSE FAIRING

/--CABIN/ADAPTER __

EQUIPMENT BAY
ACCESS

SMALL PRESSURE

DUMMY R.C.S. THRUST

CH

HEAT SHIELD

-E.C.S. EQUIPMENT DOOR

i_ (TYPICAL 2 PLACES)

DOCKING POINTS

(TYPICAL 3 PLACES)
Figure 2-5 Re-entry Module Structure
FMGI-20

2-6
 -- _ $EDR 300

RE-EI_IRYCONTROL SYS_ SECTION

The re-entry control system (RCS) section is located between and mated to the

rendezvous and recovery section and cabin section of the spacecraft, (Figure

2-5). This section is cylindrical in shape and is constructed of a center meg-

nesium cylinder, eight strln_ers, two bulkheads and eight beryllium shingles for

its outer skin.

CABIN

The cabin (Figure 2-_), similar in shape to a truncated cone, is mated to the

re-entry control system section and the adapter. The cabin has an internal

+/+-_ pressure vessel shaped to provide an adequate crew station with a proper water

flotation attitude. This shape also allows space between it and the outer cc_i-

cal shell for the installation of equipment. Structural design for the pressure

vessel is 12.0 psi ultimate (burst) and S.O psi ultimate (collapsing).

Outlining the basic cabin and equip_nt bays is a heli-arc welded fr-_ section

of ring segments, stringers and iongerons ° Employing titanium as a ma_or struc-

tural _aterial, _h_ cabin incorporates unbeaded skins, seam welded to beaded

outer skins and reinforced by longitudinal and vertical stringers on the surface.

The outer circumferential surface is covered by Rene' _I shingles. Pressure b,,_k-

heads are attached to each end of the cabin. On the top side of the cabin, two

regular hatches are provided of sufficient size to permit normal ingress and egress

for spacecraft checkout and instrumentation setup.

2-T
 j___._ SEDR 300 °

,J

F_

0 0
o o

_. z _
_- _ z
o _z

Figure2-6 Access Doors (Sheet 1 of 2) FMG_-22

2-8
 • SEDR 300 _'____

f--_

/
/

Figure 2-6 Access Doors (Sheet 2 of 2) FMG,-22

2-9
 SEDR 300

SILL STRUCTURE _.

SILL STRUCTURE

(I'YPICAL 12 Pk_CES)--

I LATCFI ASSEMBLY

L
VIEW I_OTATED IS0 ° S_CTION A-A

Figure 2-7 Spacecraft Ingress/Egress Hatches EMG_ - _

2-10
 SEDR 300

El

Equipment Bays. The equi_ent bays are located outside of, and on the flat sides

of, the pressure vessel in the cabin, (Figure 2-5). Two bays are located c_ each

side of the pressure vessel and three bays on the bottc_ side of the cabin_ he-

neath the pressure vessel floor. The bays are structurally designed for mounting

of the equipment not requiring pressurizatic_ or ccm_onents having 8elf_ontained

pressurization.

Door_____s.To enclose the four equil_nent bays, two hinged, structural doors are pro-

vided on each side of the cabin (Figure 2-6). These doors provide access to the

components installed in the equll_nentbays. The main land_-_ @ear _ays are en-

closed by one door on each side of the cabin. The doors, inoperative on spaQe-

s_ craft number one, are attached to the structure by a total of i_9 bolts.

On the bottom of the cabin, equidistant from the centerline end _etween the lend-

ing gear doors, two additional doors are installed. The forward door allows ac-

cess into the unpressurized compartment and the aft door provides access to the

ECS cc_tment which is a protion of the pressure vessel.

Hatches. Two large structural hatches, (Figure 2-7), are incorporated for sealing

the cabin ingress or egress openings. The hatches are s_trically spaced and

are located on the top side of the cabin section. Each hatch is man,,nlly operated

by means of a handle and mechanical latching meachnism and is hinse_ on the out-

board side. An external fitting is incorporate so a handle can be inserted for

latching and ,,nlarching by ground personnel.

2-11
 SEDR 300

|
Windows. Each of the ingress/egress hatches incorporates a visual observation

window I (Figure 2-8). Each window consists of an inner and outer glass assembly.

The outer assembly is a single flat pane and the inner panel assembly consists

of two flat panes. Two heat sensors are installed between the outer and inner

glass assembly. The heat sensors will _n_itor the thermal radiation on the outer

_rlndow.

Heat Shield. 'fheheat shield is a dish-shaped structure co_posed of silicc_e

elastlsuer impregnated phenolic fiberglass honeycomb. Xt is an ablative device,

90 inehas in diameter with a spherical radius of l_ inches. The heat shield is

basically designed to protect the re-entry module from extreme ther,_ conditions

f_ during re-entry into the atmosphere. Due to the particular mission of spacecraft

n,m_er one, however, the adapter will not separate from the cabin to expose the

heat shield. The device is attached to the large diameter end of the cabin struc-

ture by utilizing eighteen 1/4 inch bolts.

Shingles. The external surface of the spacecraft is made up of beaded Rene' 41

shingles. The shingles protect the spacecraft structure from excessive heat and

provide additional rigidity. The shingle outer surfaces will be covered with a

black oxide film to preserve thermal balance.

AD_

In the spacecraft n,1_er one configuration, the adapter functions only to mate

the spacecraft to the launch vehicle.

f_

2-12
 SEDR 300

i IJ J I |

f--_ OUT F.RGUkSS

GASKET _,/.---GAS KET

FP,Aht_ _ SRAME

PANE_ --O'.RING

DETAIL A-A

HATCH OUTER
ML _EF)

OUTER WINDOW ASSY

INNER ML _EF)
OUTER WINDOW ASSEMBLY

INNER WINDOW ASSY

GLASS PANES

ZI_6.50

OBSERVATION WINDOW ASSEMBLY

MIDDL

INNER WINDOWASSEMBIY
STAT-O-SEAL

BOLT

_£gure 2-8. Observation Window

FMGt-_0

2-13
 SEDR 300

Imir___ i_::_::_!/i_i_i_i_i_ii_i_ii!__._muaam'_"__ ial

The adapter, (Figure 2-1), is a truncated cone shaped, semi-monocoque structure

consisting of circumferential aluminum rings spliced together with extruded mag-

nesium alloy stringers to form the basic structure. The forward end of the adapter

is coupled to the aft end of the re-entry module by utilizing three titanium re-

taining straps_ (Figure 2-9). The skin is formed of magnesium sheets which ere

integral with the magnesium coolant loops. These loops serve no function other

than structural on spacecraft n,,m_erone.

RE_OGRAI_ SECTION

The retrograde section is the smaller diameter end of the adapter and is mated

to the cabin section. An alm,_uum alloy "I" beam is used for structural rigid-

ity and for mounting the d,,,..yretrograde rockets in this section.

ADAP_R E_IPM_ SECTION

The adapter equipment section is the larger diameter end of the adapter. This

section utilizes al,,m_numalloy tubing in a truss beam arrangement for mounting

of equipment •

Spacecraft - Launch Vehicle Mating. The spacecraft is mated to the Titan II

launch vehicle through a continuous, machined al-mlnum alloy ring, (Figure 2-10).

This ring, 120 inches in diameter3 mates with the launch vehicle mating ring.

Twenty bolts secure the rings together. To provide for ali£_-_nt, the launch

vehicle incorporates one steel 3/16 inch diameter alignment pin and four index

marks.

2-1k
 .... SEDR 300
":_a'_i
__ I_,}t__._.
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_'_:_._._..':_
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%,

SHAPED CHARGE
/ "'"-.,.- " ASSEMBLY (REF)
/" INERT

(TITANIUM)

PICKUP
\
\.
SPHERICAL WASHER "_..
SPACER "\_.
%

"_. ii iiiii
--% ....
FAIRING

NUT ............. i.'" ..... S (REP)

(REP) \_
---.Q ........
"-.... i
_...... ! •,.
- . .....
A / "--_ " "

....
"_" STRAP

(TITANIUM) -_"_-" ""'_... "" ":-, "-._;

• '_'" \ RE-ENTRY MODULE"

REP)

J i i"//_(FAIRING (REF) STRAP

ASSEMBLY

SHAPED CHARGE

REEN,RYMODOLEJ
..........................
•
STRAPASSEMBLY (REE)
(TYP2 PLACES)

RETAINING STRAP ASSY

ADAPTER (REP)J__
,_ HEAT SHIELD (REF)J / I

S_"CTIO N A-A
Figure 2-9 Re-entry Module-Adapter Retaining Straps

FM_I-19

2-15
 :_ SEDR300

:__* " "i_._ ii _ ._!i'_.,..ii__l__

I_ }i _ "
I II I BB it ii

/
/
OXI01ZER TANK
(REF)

QUAD 2 _\
QUAD 4 / _'

/
QUAD 1 _. VEHICLE

--E. "Z 2-- " _/- ;-

y__ SPACECRAFT TO

ATTACHMENT BOLT
HOLES

T
LAUNCH VEHICLE

FIBERGLASS FAIRIN G-_

TION
MATING SECTION

SEPARATION ASSEMBLY RX !'b LX

sj QDAD 1 AO 2

SPACECRAFT

- ..... M/_TING LiNE o

LAUNCH
VEHICLE
RING ATTACH --
BOLT
BY

SECTION A-A

(TYPICAL 20 PLACES)

p_

Figure 2-10 Spacecraft Laurrch Vehicle Mating FMa_-,S

 CABIN INTERIOR
ARRANGEMENT

TABLE OF CONTENTS

TITLE PAGE

:::::""==::"="=-- GENERAL 3 1
iiiiiiii_i}i:-'Hiii_._'_"_
_!_ff_ff_ff_F_ PA LLETS ................................ 3 -1
!iiiiiiiiiiiiiiiiii:_ili!._ STATIC SYSTEM .......................... 3-1
i_iiiiiiiiiiiiiii_iiiiiiiii
:::::::::::::::::::::::::::
PITOT SYSTEM .......................
3-4

i!i !i }i i i }i i i i }i}!
i i i i !i i !i!i i i i iH
_ii _i i !_ii i i!i i i i
:::::::::::::::::::::::::::

......................... o.
...... o......
...,...°...o..°..°,°°°,°.°o o....°.....,..
°..°....°°°,.°.°.o, ........
.........
........... ° ....... • .........
° ...............
................ . ..........
.... °......
....°°o.°....o.,,,.. ,.° ..... o..............
.................... .°,o.oo
:::::::::::::::::::::::::::
:::::::::::::::::::::::::::
:::::::::::::::::::::::::::
:::::::::::::::::::::::::::
:::::::::::::::::::::::::::
:::::::::::::::::::::::::::
:::::::::::::::::::::::::::
:::::::::::::::::::::::::::
:::::::::::::::::::::::::::
:::::::::::::::::::::::::::
:::::::::::::::::::::::::::
:::::::::::::::::::::::::::
:::::::::::::::::::::::::::

:::::::::::::::::::::::::::
:::::::::::::::::::::::::::
 G SEDR300

SECTION III CABIN I_TERIOR ARRANGE_

The instrumentation paJ_ets, pressure transducers, temperature sensors and

acceler_neters are installed in the cabin. The instrumentation equipment

will allow flight data to _e telemetered to the ground station. The cabin

will be purged and sealed prior to launch.

p_T.TRTS

The left and right pallets (Figure 3-1) are essentially platforms on which in-

strumentation and oowm_nioation equipment is mounted. The pallets and a bal-

last assembly are installed on the seat rails, which are located on the large

pressure bulkhead. The pallets are restrained fr_ an upward or downward motion

by a single point attac_-_nt located on the floor of the cabin beneath the pal-

lets •

STATIC SYS_

The static system is used for an altitude sensing source up to approximately

i00,000 feet for the static transducers, located on the s_l pressure bulk-

head in the cabin. The atmospheric pressure is sensed by four static ports

(Figure 3-2), sy_netricall¥ spaced around the forward end of the conical section

of the spacecraft. Through telemetry, the altitude is transmitted to a ground

station.

3-1
 SEDR 300

RIGHT I -LEFT iNSTRUMENTATION PALLET

f_ OUTER MOLD LINE

CABIN PURGE
FITTINGS

Figure 3-1. Cabin Equipment EMGN5

3-2
 SEDR 300

**":." " ' ..... _: ." _l " _ii ":: '" "'_'.
_,.::
_ .., ....._ ::_::_..'._:: _.

DETAIL A.-A

SMALL PRESSURE __1

BULKHEAD \\

DETAIL B-B

\ -

\ -

i
/ /
i/
STATIC PORTS
(TYPICAL 4 pLACES)-

Figure 3-2 Static and Pitot System FMGI-28

3-3
 SEDR 300

The pitot system (Figure 3-2) is not used for this particular mfssicm. The

system is installed but will be plugged at the small pressure bulkhead in the

cabin.

34
 ENVIRONMENTAL
CONTROL SYSTEM

TABLE OF CONTENTS

TITLE PAGE

ii[ii::_
_._.
'_::_2
"_'_:_
'_ SYSTEM DESCRIPTION .................. 4-1
!ii_!ii_...:i:#-_!i_i_ SYSTEM OPERATION ................... 4-1
iHiiiiiiiiii_!_i_'_-_ SYSTEM UNITS ........................ 4-2

....... °,°°_°°°°,_°°°°°°+..

......... °...... °..°°°°,,_°

...... • ...... °°.°..,°°.°,.°

..°°.. .....................

ii!iiii_iiiiiiiiiiiiiiiiiil

iiiiiigiiiiig_iiiiiiiiiii!i
.......................... °
.................... °...°..
....................... .°..
............... ° ...........

..°. .......................
 SEDR 300

SECTI_ IV ENVIROR_ENTAL CONTROL S_

SI_ rR.SCRIPTION

The Envlrom-_+ntal Comtrol System (ECS), as reflected in spacecraft c_e func-

tions cml¥ to establish and maintain a differential pressure of approximately 5.5

psl between the interior of the cabin and ambient atmosphere. _s pressure is

required during launch to prevent structural da-mge to the spacecraft. No pro-

vlslcn is made to replenish or to clvoulate the gaseous contents of the cabin.

The differential pressure is established as the spacecraft ascends, reaching the

specified pressure at appraximately 25,000 feet. The pressure is established by

_ the aetiun of the cabin pressure relief valve.

During prepsratious for launch, the cabin is sealed with cabin pressure equal to

-m_lent atmospheric pressure. The cabin is then purged with oxygen. During ini-

tial spacecraft ascent, cabin pressure is automatically relieved to match the de-

creasing atmospheric pressure. _hen the spacecraft reaches approximately 25,000

feet_ however, where atmospheric pressure is apprc_w_tely 5-5 psia, the cabin

pressure relief valve closes. Except for normal leakage, that pressure is main-

tained throughout the reminder of the _ssiou.

4-1
 SEDR 300

CABIN PRESSURE REr.'r_' VALVE

(seeFigure4-1)
_e cabin pressure relief valve c_tains duplicate circuits for all i_nctic_s.

Each of the duplicate circuits has a spring-loaded-closed poppet controlled by

a servo element. This servo element controls a spring-loaded metering valve

which determines the pressure within a diaphra_ chaz_r behind the poppet, thus

controlling poppet positlo_. A s,_11 inlet bleed orifice aR_ts cabin pressure

to the diephra_ c_-_er at all t_s. After the poppet opens, a larger orifice

to the cabin is uncovered thus ensuring quick closing of the poppet.

CABIN _ FIT_NGS

An inlet and an outlet fitt_ is installed in the lo_er portion of the ECS com-

_nt. These fittlnKs are used to purge the spacecraft cabin prior to launch.

The fittings are self-sealing.

4-2
 I___ • , SEDR 300

':_'._4_.._."._
_ ._:. : ,:"_!:
_ ;i ':._i_
:._i_.::_!.
_ :_ • :.

CABIN PRESSURERELIEF VALVE

SPRING (TYP}
SENSING

METERING VALVE

(TYP) _ NSING CHAMBER (TYP)

CABIN PRESSURE(TYP)

AND FILTER (TyP)

CHAMBER (TYP)

[ABIN OIAPHRAGM (EYP)

SERVO ELEMENT (TYP}

'\-- POPPET VALVE

POPPET VALVE

I ABIN

I AMBIENT

--\ SCREEN ASSEMBLY MANUAL SHUTOFF VALVE

Figure 4-1. Cabin Pressure Relief Valve

FMG]-30
 COOLING SYSTEM

TABLE OF CONTENTS

_oo+o°o+°++_::::::

ii__i-_.7-_
_ -_::
-_ _÷Z. TITLE PA G E

iiiiiiiiiiii._iii:._._-_-i SYSTEM DESCRIPTION .................. 5-1

i_iiiiiiiiiiiiiiiiiiiiiiq
iiiiiiiiii_i_i_iiiiiiiiiiii

' iiiiii!ii_!!_iiiiii_H_iii
 __ __!_!!_!_ii
• :_:_
i_i_i_i_!_i_!_!_lii
_ _i_i_i__i_i_
i_i_i_Ii_°_
_ _!_

SECTION
V COOLING
SYSTEM

SYS_ E_SCRIPTION

(See Figure 5-i)

The cooling system consists of a series of coldplates installed on the instru-

mentation pallets in the cabin. Equipment reT,_ing cooling is mounted direct-

ly on the coldplates. During launch preparation, coolant is circulated through

the coldplates from an external source to obtain maximum pre-cooling. At launch,

the external source of coolant is disconnected. Cooling is then obtained only by

transfer of heat from the equipment to the pre-cooled coldplates.

5-1
 SEDR 300

Figure 5-1. Spacecraft Cooling System EMG_-3_

5-2
 INSTRUMENTATION AND
COMMUNICATION
SYSTEM

TABLE OF CONTENTS

"--"=::_
.........
- "-"
o°°..o**_°.°°°_**°_**_
TITLE PAGE

iiiiiiiii_!i_i_.-.'-'#a_-i SYSTEM DESCRIPTION .................. 6-1

!iiiiiiiiiiiiiiiiiiiiiiii-i
.oo°oo°°o°oo..°oo.°°°o°oo°°
SYSTEM OPERATION ................... 6-7
:::::::::::::::::::::::::::

iiiiiiii_ii_iiiii_iiii_ii_ SYSTEM UNITS ........................ 6-8

!iiiiiiiiiiiii
°o°...°.°o°°°°°oo.°°°oo°°°°

iiHiiiiiii!iiiiiiii!iiiiii
iii_iiiiiiiiii_i_ii!iiii!_
iiiiiiiiiii!iiHii!iiiiiiil
iiiiiiiiiiiiiiiiiiiiiiii!ii
.°.°o.°...... ..............

....... °..° ................

°.° ........................
....... ° ...................
..° ........................

...................... °.._.
..°°.°.° ...................
 SEDR 300

SECTICR VI INS_TION AND CC_ICATION

S_ _SCRIPTION

The Instrumentation and C_ication System (Flgures 6-1 and 6-2) serves as

the only co._=u_cation link between the ground and the Gemini Spacecraft. A

block dia6ram of the Instrumentation and C..m-_nicationSystem is shown in

Figure 6-3, and the location of the components in the spacecraft is shown

in Figures 6-1 and 6-2.

The system-my be divided into three sub-systems: Communication, Instrumenta-

tion, and Electrical Power. The Cv.._._ieationsub-system, consisting of a C-

Band Radar Beacon, Phase Shifter, DC-AC Inverter, three C-Bend Ante---e, three

Telemetry Transmitters, _Au_Iriplexer,-nd a UHF Stub Antenna, serves as an in-

stx--._ntationsignal ,,d spacecraft position data l_n_ between the spacecraft

and ground.

The C-Band Radar Beacon, with its Power Divider, Phase Shifter, Inverter, and

Antennas, facilitates ground radar tracking of the spacecraft during its entire

mission.

The Telemetry Transw_tters, in conjunction with the _A_driple_er and the U_

Stub Antenna provide a means of transmitting the data monitored by the instru-

mentation sub-system to the ground station for evaluation and analysis.

6-1
 SEDR 300

" _i_i::!_ _. ."'::::! :! :::::"_:_!. ._"--:_ _::_ :,_

Figure 6-1. Instrumentation and Comm_ _ication System FMGI-13

6-2
 SEDR 300

TELEMETRY TRANSMITTER
(MID FREQUENCY)-

DC-AC
(HIGH FREQUENCY)

..':;:_7;:";S;'.
"c"_AND
_._.DAR ,, ij'"_
jJ • ;_M

tt t! (LOWFR£QUENCY

/'f

IZ /
;..'f ,

e i

/
DC-DC CONVERTER NOo2

RELAy
PANEL /
"'
/
SWITCH AND CIRCUIT BATtlERY
BREAKER PANEL

Figure 6-2 Spacecraft Left Pallet (Sheet 1 of 2) eMGI-1

6-3
 SEDR 300

SPECTRUM ANALYZER
(SYSTEM NO1

HIGH LEVEl. SPECTRUM ANALYZER

C (SYSTEM NO.

LOW LEVEl.

.\
).

INSTRUMENTATION _1
ASSEMBLY NO 1

ASSEMBLY NO 2
INSTRUMENTATION

ASSEMBLY
NO 3" \x

\ \
\ I_V_OCOUPLE RBEEI_:NCE

JUNCTION

\
PACKAGE NO I

Figure 6-2 Spacecraft Right Pallet (Sheet 2 of 2) FMG|-]A

6-4
 SEDR 300

____*_:_:._,._::::_ _ :::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::::
:_ _:_'__._--'_..,._._:_::_, _,_"_

z_

- _,_-

r , 1TI
__a _ ,--a -

Zo_
_ _o

Z _ _
_o z_? z>__ z_oZ
_._0 _0
.... _ _,_. _,<
u_ <

T"_- --F'-F
z z _
O_ O_ _

_ Z_. z_ Qz_

_ eo:

_ o _ _ _ _ _ _ ZzO
_

_ _ o _ o _
FMGI-29

Figure 6-3 Instrumentation & Communication S,'stem Block Diagram

6-5
 $EDR 300

_he Znstz,-_%ion su'_-syste:, con_)_.n_ _w._at;u:e sensors, In'essuze _-ens-

(lucers, _11)_ti(m pick-ups, a_e].e _z_m_ters, an(1 microphones, In'ovt(les a means

Of _o_Litorlngthe physical co_itio_s and reactions of the spacecraft. _ese

signals are fed to various Voltage Controlled Oscillators (VCO) which =o_ulate

the tele_try transmitters that transmit the obtai_ data to a suitable

static. _he instru_enta%ion pick-up _evices are located throushout the space-

craft.

_e Electrical Power sub-system _asic_ly consists of _e _i_ _atter_, several

control relays an_ interconnecting wiring. The electrical power sub-syste_ sup-

plies _r _irectly, o_ indirectly, for _ instrumentation an_ c_,-Ication

f_

c_nts.

6-6
 SEDR 300
• ._._*_._}_._i_i!!_i_i_i_i_ii_i_i_:_::_:_:_i!_ii_i_:..:_!}_`_.._
_ ' ..,.. ._

S_S_ OPERA_O_

The Instrumentation and C_cation System is _uall_ actuated prior to launch.

From the beginning of the Pre-Lau_ch Phase of the spacecraft mission through um-

bilical release the lustx,r_ntation and Communication System may be controlled

fr_a the blockhouse. Capability exists: to turn the telemetry transmitters

and the C-Band Radar _eacon on and off; to apply main power either fro_ the

spacecraft's win battery or from the blockhouse, and to monitor C-_a_d _eacon

i_put po_r, bus power, and battery current. The blockhouse control and _o_i-

tar feature is _de available by the Re-Entry module umbilical connector and

various power c_trol relays in the spacecraft.

Prior to sealing the h-tch al_ circuit breakers are placed in the on position.

Prior to lift-off power is applied from the blockhouse and the C-_ Radar

_eacon and telemetry transmitters are turned on. At -m_ilical release the

power source is switched from blockhouse power to spacecraft _in battery power.

_ata c_er_i_ spacecraft temperatures, pressures, vibrations and accelerations,

c_ti_uously _itore_ by the i_stz,_-_ntati_ system, is transmitted throughout

the spacecraft's mission.

entire system, i_stx,,_ntati_ and cr_._...t_icatlons,

will be operat_-_ through-

out the entire misslo_ of the spacecraft or as l_ted by the _attery life. Pri-

importance of data acquisition and trac_-_ capability is placed on the per-

i_ starti_ with lauach and ending with i_serti_ of the spacecraft into its

6-7
 SEDR 300

%.
• • •

.SYS_ UNITS

CO_RUNICATION

C-Band Radiatin_ Elements. Purpose: The C-_ Radiating R3ements are used to

provide radiation coverage and reception for the C-Band Radar Beacon. The an-

tennas are located at the swatI end of the conical section of the spacecraft

forward of the small pressure bulkhead.

Physical Characteristics: The physical representation of the C-Band Radiating

Elements and their approx_te location in the spacecraft is sho_n in Fi@ure 6-4.

The radiating ele=ents are mounted flush with the outside skin of the spacecraft

and spaced 120° apart. The antenna unit is appr_imately 2.18 inches lc_g and

has a maximm vertical dimension of 3.41 inches. Each element has a TNC connec-

tor for connecting the antennas to the phase shifter and power divider. Each

radiating element weiEb_ approx_w_tely 3.5 ounces.

Electrical Characteristics: The C-Band Radiating Elements receive a properly

coded signal from a ground tracking station which, when found acceptable by the

C-Band Radar Beacon_ triggers the transmitter to reply with a _ kilowatt peak

pulse modulated signal at a frequency of 5765 MC by means of the C-Bana Radiat-

ing Elements. The combination of the three antenna elements gives a radiation

pattern which extends in a1_ directions except forward and aft of the SpaceCTCft.

Phase Shifter. Purpose: The Phase Shifter compensates for areas of low_ or no

radiation coverage het_en lobes of the three C-__nd Ant_---_ radiation patterns.

_ The Phase Shifter, Power Divider, and the three radiating elements cc_prise an
 SEDR 300

i_:._._,,_,_,,___.:..i::::-..:
..........
........':'._..'.......'i.......
'i"i.,_,_i_i!
_,_
:_ii.._...°_-:.
_":_'_::
::::_i::"": :" _ _

_'_-_._'_._._i!_.i.".._#_::_ _ :_!_i!ii::_::_:_::_:_:::::::_:::_::!_i_ii_!..`.!_!_._.._.:.%_
'"

f_

Figure 6-4 C Band Radiating Elements _M¢-_-_

6-9
 SEDR300

antenna system which provides essentially complete coverage for all orbital

attitudes.

Physical Characteristics: The physical representation and approximate location

of the Phase Shifter is shown in Figure 6-5. The phase shifter is located on

the small Pressure b,1_head outside the cabin and has a total length of approxi-

mately 4 3/4 inches and a diameter at the small end of about 1 1/2 inches. The

ph_e shifter contains three connectors to connect the phase shifter to the power

divider, to a C-Band Radiating Element, and to a DC to AC inverter. The phase

shifter weighs apprc_tely 20 ounces.

Electrical Characteristics: The sehe-_tic of the pbA-e shifter is shown in

Figure 6-5. A 26 VAC 400 eps input to the phase shlfter, obtained from a DC-AC

inverter, is half wave rectified and applied across a coil wound around a

ferrite material. Due to the characteristics of the ferrite material, the RF

signal from the power divider is delayed 0 to 180° +-200 at the rate of _00

cycles per second. The changing phase shift of the RF power on one of the C-

Band Radiating Elements with respect to the other two shifts the lobe of that

antenna by approxlwately + 45 degrees; thus, giving the effect of an -1-_st

ideal circular radiation pattern around the longitudinal axis of the spacecraft.

DC to AC Inverter. Purpose: The DC to AC Inverter is used to power the C-Band

Phase Shifter.

Physical Characteristics: The DC to AC Inverter is shown in Figure 6-6. The

inverter is approx1_tely 1.7 incheshigh, 1.5 inches wide, and 3 inches i_.

6 -i0
 _'O C BAND
RADIAIING
ELEMENt

O
2.5:1

STEP-UP _

TO POWER
DIVIDER

Figure 6-5 Phase Shifter FMG1-2

6-11
 SEDR 300

R4 i RS R

YEL 1"1 BRN _

IO PHASE
SHIFTER

-
,
B
I

ORN _ RI
R3 G

YEL_,,

12
BRN

RED _
R6
GRN 13

_._ :_
BRN

BLU
RED

c_T
-
,0 _

RT
1
_ c_

i II Q4

,_ _ C4 YEL J CR2
I(

I BLU / R8 RII RI2

BENDIX
,_ PT1M-I 0-6P(101)

Figure 6-6 DC-AC Inverter FMG1-5

6-12
 SEDR 300

The inverter is _unted on the left hand pallet of the spacecraft. One s_ngle

connector is used for both input and output vol_es. The weight of the inver-

ter is appro_mtely 0.6 pounds.

Electrical Characteristics: A DC input voltage is supplied to the inverter

(Figure 6-6) frc_ the spacecraft main battery. The inverter provides a 26

VAC, 400 cps output required for operation of _ phase shifter. The inverter

is designed to work into a capacitive load; therefore, a two _icroforad capaci-

tor is placed across the output terminals of the inverter to co_ensate for the

inductive input of the phase shifter.

Power Divider. Purpose: The Power Divider is used to give equal power distri-

bution to the three C-Baud Radiating Elements.

Physical Characteristics: The physical representation of the power divider is

shown in Figure 6-7. The paver divider is located on the small pressure bulk-

head outside the cabin and measures fro_ the left side antenna connector to the

beacon co_ncector approx_tely 3.8 inches. _he distance between the two

screws is approx4_tely 4 inches. The power divider coatai_s two t,m4,_ ad_ust-

_nts, and 4 connectors of which one connects to the C-__nd Beacon, two connect

to the left and top antenna, and the fourth oue c_m_eets to the phase shifter

that is in series with the right a_te_na. The power divider weighs appr_ctmately

6._ pounds.

Electrical Characteristics: The power divider is basiea_ly a cavity type power

splitter. Dur_n_ beacon transmission the power is delivered to the power divider.

6-13
 $EDR300

TO PHASE SHIF1BR
(RIGHT ANTENNA

TUNING STUB CAPS

RADAR BEACON

Figure 6-7 Power Divider

PMG_-9

6-14
 SEDR 300

""_*:_._:_:_::i::_._
...................
_;_:""_:_'_::
_:
.....
_i!i
.........
_ _!_ _:::_:__i!::!il___:....
__iii!i:iii:_
'""" - ":::::"
_ :_:_:!i!:!ii:_:_i
- "'"::'"- '' _?':'_!_'_'_!_:_'i_'_'':"
__ _ I
I

The power divider then splits the power in such a re,net as to deliver the same

amount to each of the C-Band Radiating Elements. The power divider compensates

for the loss of power due to the phase shifter in series with the right antenna.

The power divider also curtains a double stub tuning feature to ccenpensate for

_smatch _etween the C-Band Beacon and the C-Band Radiating Elements and Phase

Shifter. T_nin_ is accc_pllshed by means of a self-lo_kin_ tuning shell lo_a%ed

underneath each ten_ng stub cap.

C-Band Radar Beacon. Purpose: The C-Band Radar Beacon provides tracking cape-

bility of the spacecraft during its entire mission.

Physical Characteristics: The C-Bend Radar Beacon is a sealed unit and measures

apprc_mtely 7.6_ x 6.1_ x 3.02 inches. In reference to Figure 6-8, the beacon

has power, antenna, and test connectors. Located on the rear of the beacon are

various adjustments for transmitter, pre-selector, and local oscillator tuning.

Solid state modular circuitry is used throu6hont the beacon with the exception

of the transmitter magnetron and the local oscillator cavity. The beacon is

•punted on the left cabin pallet and weighs apprn_-tely 8.3 pounds.

Electrical Ch-racteristics: Basically, the C-Band Radar Beacon is a transp(mder

which upon reception of a properly coded interrogation signal from a ground radar

tracking station, transmits a pulse modulated sis_ml back to the tracking station.

By measuring the elapsed time between transmission and reception at the track_

station, and compensating for the t_e delay of the beacon, the position of the

spacecraft can be detez_...:ned. The block diagram of the beacon is shown in Figure

'_ 6-9. The si_ml arriving at the antenna is routed by means of the directional

6 -15
 SEDR300

• • ... .:::.<_ :

[_ PRESELECTOR TDNING TUNING

Figure 6-8 "C" Band Radar Beacon FMG;--_

6-16
 SEDR 300

......_4 ._.%._:_:_:_:_:_:
_._:':i:_::_:_::
..... _:::::_:::_'_::!::'_:::::'::::::_8::::
......................
:.::=::::::: :_::_i¢i:_
__i !_ !!:i!_ _: :__i:_ '_ _

ANTENNA

PEAK POWER

DIRECTIONAL PEAK POWER -- TRANSMITTER

COUPLER AMPLIFIER PRF

RECEIVER_ RECEIVER TEST POINTS

O TRANSMITTER PRE

@ MONIToRPEAK
POWER I

TRANSMITTER AND LOCKOUT OVER [NTERRO

-OATION

OVER '_
@ TRANSMITTER
FI_QUENCY INTERROGATION
I
I
i

,
CIRCULATOR MIXER I.F. -_ AMP DECODER DELAY COINCIDENCE DELAY
(DIPL_XER)

PRE-SELECTOR

RECEIVER
CIRCULATOR
(MIXER)
I IMMUNITY

FREQUENCY

®®@ l
LOCAL VARIATION VARIATION
OSC. CORRECTION CORRECTION

®_CE_VER
FREQUENCY
_; ,%
SLOPE #] SLOPE #2

LINE POWER VARIOUS

_l FILTER SUPPLY VOLTAGES

Figure 6-9 "C" Band Radar Beacon Block Diagram

FMGI-7

6-17
 SEDR 300

._::
..._.:..'_ ._ ........... ::::::::
........:.......:........:::::..,
...:..... .:.. ." _ _: _.

coupler to one half of a dual ferrite circulator. The characteristics of the

ferrite circulator are such as to isolate the transmitter from the receiver;

thus, providing the capability of utilizing a single antenna, or antenna system

for both reception and transmission. The beacon utilizes a superheterodyne re-

ceiver to provide the required reception. The receiver is tunable by maans of a

three stage pre-selector over a range of 5600 MC to 5800 _C. The assigned re-

ceiver center frequency is 5690 MC. The output of the pre-selector is combined

with the local oscillator frequency in the crystal wd_er which pro_ucee an o_t-

put IF frequency of 80 MC. The local oscillator is of the metal-ceramic triode

cavity type and the _xer contains a ferrite circulator for isolation _et-_een the

local oscillator, mixer, and pre-selector. The output of the mixer is then amp-

f_ lified by three tuned IF amplifier stages followed by a video detector an_ a

video pre--mD_lifier. Additional amplification is obtained by a pulse =-_.lifier.

The purpose of the decoder is to initiate triggering of the transmitter after a

correctly coded signal has been recelved. The system delay in co, unction with

the delay variation correction circuitry provides for a constant fixed delay use_

in determinin_ the exaot position of the spacecraft. The beacon incorporates a

CW immunity circuit that prevents the transmitter fr_ being triggere_ by rand_

noise. The noise level is reduced below the triggerin_ level of the transmitter

by controlling the gain of the pulse amplifier. The tran-_itter utilizes a mag-

netron and provides a One kilowatt peak l_,l,emodulated signal at a frequency of

576_ MC to the power divider. The beacon is powered by a I)C-DCconverter employ-

ing a magnetic amplifier and silicon controlle_ rectifiers. _e converter pro-

vides voltage regulation for input voltage variations between 18 and 32.5 VDC.

G-8
 $EDR 300

,_ _ _7__.:._._._. _'+_:::::::::::::::: _:.::::::_::::..._::::

:::::::::::::::::::::::
_:::::::_:::_::
:::_:::!
_:!:::_:::::_:_:_:_
_.._:_
_._._._._ _ __ _ _ __k_ • __,=_,_

The input to the converter is filtered by a pi-type filter to mi_Ize any line

voltage disturbances.

Tele_etr_ Transmitters. Purpose: The three telemetry transmitters provide a

radio frequency (RF) link from the spacecraft to ground co-H-_nicationfacili-

ties for transmission of various data obtained by the instrumentation sub-system.

Physical Characteristics : The three telemetry transmitters are identical ex-

cept for the operating frequency. The physical construction and approx_-_te

location of the transmitters in the spacecraft is shown in Figure 6-10. The

transmitters are approximately 2.75 inches high, 2.25 inches wide, and 6.5

inches long. The three trs_smitters are mounted on the left cabin pallet.

_ Each transmitter contains three connectors : a DC power connector, a RF out-

put power connector, and a video input power co_ector. Each transmitter weighs

approximately _I ounces.

Electrical Characterist_cs : The three FM transmitters are frequency modulated

and operate continuously to provide an output po_ _"of a minimum of two watts.

The low frequency tran_tter, operating at 2_0._ MC, transmits data concerning

vibration, acceleration, acoustic noise, pressure, and scanner fairing break-

wire continuity. Temperature and vibration data is tran_Itted by the mid fre-

quency transmitter at 2_6.S _. The high frequency transmitter transmits data

concerning vibration, te_perature_ acoustic noise, pressure and scanner fairin_

brea_-wire continuity at a frequency of 259.7 _C.

6-19
,,:._.:.:,:,,,:.,,:.:.:,:,:,: .............. . .... , . _:.:.: ,,:

Figure 6-10 Telemetry Transmitter

FMGI-]4

6-20
 SEDR 300

IJl I

. UPIFQuadri_lexer. The UHF Quadriplexer provides isolatic_ between three tele-

metry transmitters operating simultaneously into a c_ antenna.

Physical Characteristics: The physical representation and approximate location

of the quadriplexer is shown in Figure 6-11. The quadriplex_r is mounted on the

left cabin pellet and is approximately 6.7 inches wide, _.12 inches high, and

5 inches deep. The quadriplexer contains five connectors: the UHF stub antenna

connects to JS, the mid frequency, low frequency, and _gh frequency telemetry

transmitters connect to Jl, J2_ and J_ respectively. Connector J3 is not used

in the spacecraft number one configuration. The quadriplexer weighs approximately

three pounds.

Electrical Characteristics: Figure 6-11 shows the schematic of the qua_riplexer.

Basically, each channel consists of a high Q cavity tuned to the corresponding

transmitter frequency. All channels are isolated from each other without appre-

ciably attenuating the RF signals passing throu_ it. Each channel has the capa-

bility of being retuned in case the transmitter frequencies or the functio_ of

the quadriplexer change. The outputs of the telemetry transmitters are fed into

Jl, _2 and _ of the quadriplexer and brought out with a sin@le antenna connector

thus eliminating the need for an antenna for each transmitter.

UHF Stub Antenna. Purpose: The U_F Stub Antenna provides s_w_taneous radia-

tion coverage for the three telemetry transmitters.

6 -21
 SEDR 300
__11111__¢__i_-__ ;.. _ u

/tt_"
, _ L II O J_
MID TM

LO TM

R&RUHF
J_ 0
STUB ANTENNA [

T I_ 0 J3
_J_,_ /

_ II oJ_

Figure 6-11 UHF Quadriplexer FMG,-_

6-22
 • "_!i;_'_i.:.,:_ii_!__!::__:_i
_i_i_
_::___
_!!!!!!
;!!:i_i____ii:_i_i_
_i_:_
_i_ _!_
__'_:_:_ii! ""
_(: : :!:i:_:_:_:i:!:!:i:_:!:_:!:_:_:_:_!_!_i_i:i:::!:3!;

Physical Characteristics: Figure 6-12 shows the UHF Stub Antenn- and its approxi-

mate locatio_ o_ the nose of the spacecraft. The ante_, is mounted c_ the R & R

_ section and extends about six inches forward from the spacecraft nose fairing.

The antenna has an ann,_!ar slot in which a variable capacitor is _ounted and is

approx_tely 11.2 inches in length, 0.63 inches in diameter, and is for the major

portiou of the length hollow. The antenna cont-_s one connector to mate with the

output of the quadriplexer.

Electrical Characteristics: The D_F Stub Antenna provides sim_taneous radia-

tion coverage for the three telemetry transmitters. The v_riable capacitor placed

across the annular slot provides broad-band tuning capability of the antenna. The

radiation pattern of the antenna is identical to that of a q,,-rterwave stub.

INS_ATION

Te_rature Sensors. Purpose: Resistive element temperature sensors and ther-

mocouples are provided to sense various spacecraft temperatures and to convert

these temperatures into proportional electrical signals.

Physical Characteristics: A basic thermocouple is shown in Figure 6-13. Although

various physically different terminations are used, the basic construction consists

of two elements of which one is AI,-._I,and the other Chr_nel. The three different

types of resistive element temperature sensors are also shown in Figure 6-13. The

0 - 300° F sensor measures_ excluding the mounting flange, approx_-_tely 0.4 inches

high, 0.75 inches wide, and 1.5 inches long; the 0 - _00O F sensor is appr_x1._tely

6-23
,4_, $EDR 300

PLUG

"IUNING ::

A ,_ ENNA MAS

PLUG

EPON RESIN

qG FLANGE

SULATOR

Figure 6-12 UHF Stub Antenna

IMGI-3

6-24
 SEDR 300

I I I

0.5 inches hi_h, 0.5 inches _rlde, and 2 inches long; and the 0 - 600 ° F sensor

is apprc_w_tely 0.3 inches high, 0.7_ inches wide, and 1.5 inches long. Figures

6-13 _hru 6-15 identify and show the location of all thermocouples and resistive

element temperature sensors. The sensing element of the resistive element tem-

perature sensors are made of pure platinu_ wire encased in ceramic insulation.

Electrical Characteristics: _asic-_ly, the resistive element tez_erature pick-

up consists of a bridge circuit which is energized by the +_ VDC regulated out-

put of _._ DC-DC converters. One leg of the bridge is made of platinum wire.

The characteristics of the platinum wire causes a proportional resistance change

for a c_ in temperature; thus, unbalancing the bridge and providing an out-

put proportional to the change in temperature. Two resistive element temperature

se_so_s provide a reference temperature for all thermocouples by _itorlng the

temperature of the reference Junction.

Ther_oco_ples are used for measurements of temperatures exceeding I0000 F where

rapid response to a large temperature change is necessary. The outputs of the

ther_ocouples and resistive element temperature sensors are 0 - 20 millivolts

and are supplied to the low level c_tator for sampling.

Pressure Transducers. Purpose: Two types of pressure transducers are provided

to sense various spacecraft pressures and convert these pressures into propor-

ti_l electrical outputs.

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Physical Characteristics: The pressure transducers ere shown in Figure 6-13.

f

The transducers are appr_x4mtely 1.25 inches high, 1.25 inches wide, 1.75

inches long. The mechanical portion of the transducer is a bellows which is

physically attached to a wiper of a potentic_eter. The transducer weighs ap-

prcad_ately O.31 pounds. Figures 6-13 thru 6-15 with their corresponding charts

show the ne_e and location of all pressure transducers.

Electrical Characteristics: The pressure transducer potenti_eters are powered

by the +_ VXX_regulated output of the DC-DC converters. Basically, a change in

pressure causes the bellows either to contract or expand by a proportional a_nt

which moves the _riper of the potentio_eter that is physically connected to the

bellows; thus, providing an ontput voltage proportional to a pressure chan_.

The derived output ranges fr_n 0 - 5 VDC and is supplied to the high level cc_-

mltator input for s--_14-_. The ran@es of the pressure transducers are 0 - 15

PSlA and 0 - 6 _S_.

Vibration .Pick-U_s. Purpose: Force _alance servo accelero_eters and crystal

type accelerc_ters are provided to monitor various structural spacecraft vi-

bratic_s and to convert these vibrations into proportional electrical signals.

Physical Characteristics: Low and high frequency vibration pick-ups are provided.

The low vibratio_ pick-up consists of a force balance servo acceler_neter end a

filter shown in Figure 6-13. The accelerometer is appr_Imately 3 inches lon_,

1.2 _nches wide, and 1.2 inches high; and the filter bias unit is approximately

1.8 inches high, I.I inches wide, and 2 inches loz_. The high vibration pick-

_ ups consist of a crystal type acceler_neter followed by an a_plifier. Both

6-z9
 .... SEDR 300

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units are shown in Figure 6-13. The accelercm_ter is 0.625 inches hexagon shaped

at the bott_ and 0.785 inches high; and the a_pllfier is appro_-_tely 1 _neh

high, i.I inches wide, and 2.5 inches ic_. The _eight of the acceler_meter is

approx1_tely 1.1 ounces, and the Amplifier weighs apprn_tely 3 ounces.

Electrical Characteristics: Low frequency vibrati_ measurements, ran_ from

1 to 30 cps, are acco_lished by a force balance servo accelero--ter and a filter.

The acceler_ter together with the filter offers a frequency response from i to

_0 cps with an _n_inite attenuatic_ at 0 cps. _ne accelerc_eter is esaential_y

a torque balance closed loop system utilizing a pendulous mass supported by an

extremely low frictice_Jmeel bearing. _asically, a elect_tic posltlc_ de-

_ rector notes the slightest _ov_nt of the _ass, caused by a c_uge in velocity

of the spacecraft, and applies a directly proportional electrical signal to a

servo a_lifier. The Output of the servo a_li_ier is applied to a _r_e gen-

erator which tends to restore the mass to its equilibrium position. B_ measur-

i_ the amount of current required for the mass to reach its equilibrit_ position,

the acceleration may be determined. Since the primary interest in this case is

low frequency vlhratic_s, the output of the accelerometer is fed through a i to

30 cps filter. The c_tput of each filter is applied to a VCO. The output of

the accelercm_ter is 0 - 5 VDC, directly prol_ic_al to the a_llt_de of vibra-

ti_. T_e mid (20 cps to 600 cps) and high frequency vibrations (up to 2000 cpe)

are monitored by a crystal type accelerc_eter fo_ by an a_lifier.

crystal accelerc_eter provides an electrical si_..1 Output proportional to the

_mount of acceleration. _he output of the aecelerc_eter is then a_lified to a

6-3o
 5EDR 300

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z sufficient amount to drive the various voltage controlled oscillators. A?] vi-

bratio_ pick-ups are pop,red by the DC-DC converters.

Accelerom_ters. Purpose: Three acceler_meters are provided to measure space-

craft axis accelerations and to convert "g" forces into a proportional electri-

cal signal.

Physical Characteristics: The physical characteristics of the acceler_m_ters

are identical to the force balance servo accelerameters described under vibra-

tion pick-ups.

Electrical Characteristics: The operating characteristics of these accelero-

meters are identical to th_ force balance servo accelerometers described under

vibration pick-ups except that the response is extended to 0 cps.

Acoustic Noise Pick-Ups. Purpose: Two microphones are ,itilized to pickup any

acoustic noise in the spacecraft cabin and to convert this noise into propor-

tional electrical signals.

Physical ChAracteristics: The acoustic noise pickup system consists of two

mlcrophones, 2 amplifiers, 2 low-pass filters, and 2 spectrum analyzers. The

spectrum analyzers are located on the right cabin p_llet of the spacecraft.

For location of the other ccm_oonents refer to Figure 6-1.

Electrical Characteristics : Noise picked up by the microphones in the cabin is

amplified and then fed to a spectrum analyzer. Each spectrum analyzer consists

6-31
 _-_ SEDR 300

:::::::::::::::::::::::::::::
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of nine filters of which each passes an octave band of frequencies between 37.5

cps and 9.6 Kcps. The outputs of the spectrum analyzer are converted to propor-

tional 0 to 5 VDC signals and supplied to the high level co,.,,,_tator

input for

sampling.

Scanner Fairin_ Break Wires. Purpose : Two break wires are utilized to _w__itor

the environmental cc_ditio_ of the horizon scanner scanner.

Physical Characteristics: This monitor, or sensing system, consists of two pieces

of wire attached to the structure of the scanner fairing. The characteristics of

the wires are such that they will break in the event of excessive elongation or

vibration of the scanner fairing.

Electrical Characteristics : 0_e end of each wire is placed across an E_ of ap-

prox1,_tely _.2 VDC obtained from a voltage divider In the Instrumentatic_ package.

The other end of the wire is continuously sampled by the high level o.......
_tator.

A broken wire will be detected by the high level co_._,-,tator

in the form of no in-

put voltage.

DC-DC Converter. Purpose: The two DC-DC converters supply regulated DC voltages

to the instrumentation components and reference voltages to the high and low level
c_tators.

Physical Characteristics : Both DC-DC converters are identical physically and elec-

trically. The conVerters are mounted o_ the left cabin pallet of the spacecraft.

Each converter is approximately 5.5 inches high, 5.5 inches wide and T inches long.

._ Each converter has a test cc_nector and a connector for input and output voltages

and weighs approx_w_tely 7 pounds.

6-32
 _,_ SEDR 300 _:
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Electrical Characteristics : The DC-DC converters are essentially voltage regu-

lators. The converters operate on main bus voltage variations between 18 and

_0._ VDC. Each converter provides three different regulated outputs, -2_ VDC_

+_ VDC, and + 5 VDC. The DC-DC converters apply power to all instrumentation

sub-system components.

C_,_tators. Purpose: A low and high level commutator provide a _eans of s-wDl-

in_ various _-st_tati_n signals.

Physical Characteristics: Both c_._,tators are located on _? right cabin

pallet of the spacecraft. The low level c_tator is appro_tely 3.9 inches

high, 5 inches wide, and 5-9 inches long. The _gh level c_._!_._,ta_or
weighs ap-

pro_tely 2.9 pounds, and the low level c_,_._,_ator

weighs abont 6.7 pounds.

Electrical Characteristics : Each co._.-,tatoris pulse amplitude modulated and

has the capability of _._Itoring 88 inputs at the rate of I i/_ samples per

sec_. _he low level commutator samples input signals between 0 and 20 _i_-

volts; _ly, 63 th_ocouple outputs and 16 resistive element temperature sen-

sor inputs. To _-_-_ze errors due to c_.._...._

mode disturbances, the l_w level

c_,_,tator accepts a double ended input; _t is, the inputs are balanced to a

c_ return and read the difference between the _h and low signal input wires.

The high level c_,tator samples input signals between O _ 5 VDC, these are:

pressure transducer signals, acoustic noise si_mls, scanner fairing break wire

si_mls, and main bus power. The high level commutator accepts a single ended

input_ that is, the input is referenced to a co_ return.

6-33
 SEDR 300
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Instrumentation Assemblies. Purpose: The instrumentation assemblies proviae an

output frequency variatiun for a correslx_ding input voltage variation.

Physical Characteristics: In reference to Figure 6-1, the number 3 instrumen-

tation assembly contains 7 volta6e controlled oscillator (VCO) modules; _e _r,

and one hardline amplifier. Each VCO module is approximately 1.3 inches wide,

1.6 inches high, and 0.8 inches deep. _he number 2 inst_---_ntation assembly con-

tains _ VCO modules 3 o_e mixer I and one h-rdline amplifier. The number 1 instru-

mentation assembly c_-e 9 VCO modules, one m4wer_ and o_e h-rdline amplifler.

All three instz,,w_ntatlonassemblies are locatea on the right cabin psllet

of the spacecraft. Each VCO m_ule weighs appr_4_-tely 2.2 ounces.

Electrical C_-racteristies: The _er 3 instrumentation assembly accepts 6 vi-

_ratic_ pick-up signals3 and the output of the low level c_.,._-,,tator.
Each of the

inputs to the inst_-_ntation assembly is fed to a VC0. The VCO's provide an out-

put frequency variation for a corresponding input voltage variation. The VCO,

operat_-_ at an assigned center frequency deviates from this center frequency with

a deviatio_ in input voltage. The outputs _f the VCO's are cc_bine_ in a m_er,

the output of which is used to modulate the mid frequency telemetry transmitter.

The outputs of the VCO's are also applied to a _-r_llne amplifier used during

_round checkout of the spacecraft. The mm_er 2 instrumentation assembly receives

an ix_mt for each c_e cf its _ VCO modules frc_ the low level c_.-_tator, the high

level c_tator, and 2 vibration pick-ups. The outputs of the VCO's after mlxin6

modulates the high frequency telemetry transmitter. A har_line amplifier is also

 SEDR 300

provided for the number 2 _nstr_ntatic_ assembly. The D,_er I ins_r_nentati_n

asse_l_ receives its VCO _puts fro_ _ vibration pickoups, _ acceler_ters, and

the high level cow,tator. The m_ed VCO outputs _f the _,1_er 1 inst_-_-ntati_n

assembly is used to modulate the low frequency telemetry transmitter; a hardline

a_plifier provides capability for ground checkout.

Electrical Power, Purpose: The Electrical Power Sub-System supplies power di-

rectly, or indirectly to all instx-_-_ntationand co_mication system cn_!x_nents.

Physical Characteristics: The _aJor components of the electrical power sub-system,

a battery, relay panel_ and switch and circuit breaker panel, are located on the

left cabin pallet of the spacecraft. The battery is approx_wtely 5.9 inches

high, 6.38 inches wide, and 8.3 inches lo_g and weigh, appr_-_tely 17 pounds.

Electrical Characteristics : A _5 aw_ere_our 16 cell battery, having a n_-al

terminal voltage of 24 VDC, serves as the only power source for the spacecraft.

The switch and circuit breaker panel c_tains a main power switch used to arm,

or disarm the power bus, and 7 circuit breakers to provide circuit protectio_

for the DC-DC converter _i and _, Telemetry Transmitters _i, _ and _, the C-

Baud Radar Beacon, and the DC-AC Inverter. The relay panel's main power re1_y

and four control relays are utilized for ground control prior to launch. The

_, power relay, when energized frc_ the blockhouse, disconnects the battery

fr_n the power bus; thus, making it possible to utilize blockhouse power prior

to launch. The four control relays provide cape_ility of controlling the on-off

functions of the three telemetry transmitters and the C-Band Radar Beacon fro_

the blockhouse.