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Reproduction for non-government u s e of the information or illustrations contained in t h i s publication i s not permitted without specific approval of the i s s u i n g service.
NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page.
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CONSISTING O F T H E FOLLOWING:
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. . . . . . . . . . ..226 AUK1907 . . . . . . . . . 5 Aug 1967 B.. . . . . . . . . . . Orlginal c Blank . . . . . . . . . Original I . . . . . . . . . . . . Orldnal 11 Blank . . . . . . . . . Orlglnal * ili . . . . . . . . . . .26 Aug 1967 iv . . . . . . . . . . . Origlnal v . . .......... Origlml vl . . . . . . . . . . .26 Aug 1967 vii . . . . . . . . . . . Orlgiml vlll . . . . . . . . . . . . . . . . . . . . . ..2 6 ~Orlgiml . . . . . . Orlginal u 1967 g x Blank . . * l - 1 thru 1-3 . . . . . . .2 6 A u g 1967 1-4 Blank . . . . . . . . Origilrpl 1-6 . . . . . . . . . . . Orlglnal 1-6 Blank . . . . . . . . Origlnal 1-7.. . . . . . . . . . Orlginal 1-8 lank . . . . . . . . Original *2-1 . . . . . . . . . . . 2 6 A u g l 9 6 7 2-2 . . . . . . . . . . . Origf~l * 2-3 thm 2-4 . . . . . . .26 Aug 1967 2-6.. . . . . . . . . . Original * 2 - 6 . . . . . . . . . . .26Aug1967 2-7 thru 2-0 . . . . . . . Orlgi~l *2-10 . . . . . . . . . .26Aug1987 2-11 thru2-14 . . . . . . Orlginnl *2-16 . . . . . . . . . . 26Aug1967 2-16 thru2-27 . . . . . . Origiml * 2-28 . . . . . . . . . .26 Aug 1967 Orlginal 2-29 thru2-33 . . . . . . '2-34 . . . . . . . . . ..26 Aug 1967 Orlgiml 2-36 thru2.-36 . . . . . *3-1 thru 3-3 . . . . . . . 2 6 Aug 1967 3-4 thru 3-6 . . . . . . . Orlginal '3-6 . . . . . . . . . . .26Aug 1967 3-7 thru 3-9 . . . . . . . Orlgirul *3-10 . . . . . . . . . .26 Aug 1967 3-11 . . . . . . . . . . Origi~l *3-12 . . . . . . . . . .26Aug 1967 9-13thru3-16. . . . . . Orldlvl 3-17 thru 3-26 . . . . . . 26 A u 1967 ~ *3-26A thru 3-26F Added . 26 Aug 1967 3-27 thru 3-29 . . . . . . 26 Aug 1967
* Title
*A.
*h
Deleted *3-31 thru3-34 3-36 *3-36 thru 3-37 3-38 * 3-39 thru 3-41 3-42 thru 3-49 * 3-60 thru 3-61 3-62 thru 3-63 3-64 . . . . . a s . 3-66 thru 3-77 * 3-78 3-79 thru 3-80 "3-81 3-82 thru 3-83 3-84 3-66 thru 3-89 * 3-90 3-91 thru 3-92 * 3-93 3-94 thru 3-96 * 3-97 3-98 thru 3-117 *3-118. 3-118 thru 3-128 * 3-130 3-131 *3-132 3-133 thru 3-134 * 3-136 3-136 thru 3-137 $3-138 thru 3-139 3-140 thru 3-141 * 3-142 thru 3-144 3-146 3-146 thru 3-147 3-148 * 3-149 3-160 Blank 4-1 thru4-21 * 4-22 4-23 thru4-36 4-36 Blank 5-1 thru 6-96. 6-86 Blank.
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. . . . . . .26 Aug 1967 . . . . . . . . . .26Aug1867l~ . . . . . .2 O r6i g1967 ..... im . . . . . . Original . . . . . . . . . . 26 Aug 1967 . . . . . . .26 AO rui g1967l . . . . . . ~i m
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. . . . . . Orlglnal u g 1967 . . . . . .2266 AOrlglnnl . . . . . . . . . .. Aug 1967 . . . . . Orlginal . . . . .. .. .......2 6 AOgr1l9g6i7~ l . u . . . . . . . . . . 26 Aug 1967 . . . . . . Original . . . . . . . . . . 26 Aug 1967 . . . . . . Orlginal . . . . . . . . . . 26 Aug 1967 .... . . . . . . . . . .2 6 Aug 1967 . . . . . . Orlginal . . . . . . . . .2 5 AOrlglnal . . . . . Orlglnal ug1967 . . . . . . . . . . .26 Aug 1967 . . . . . . . . . .2 6 AOrlginnl . . . . . u g 1967 . . . . . . . . . . Original . . . . . . . . . .2 6 Aug 1967 . . . . . .26 Aug 1987 . . . . . Originnl . . . . .26 Aug 1967 Original .... . . . . . . . . . . 26 Aug 1967 .......... Origirul . . . .. .. .. . . . . 26 Aug 1967 Original ... . . . . . . . Originall . . . . . . Origlm . . . . . . . . . .26 Aug 1967 . . . . . . Original . . . . . . . Orlglml . . . . . . Origiml . . . . . . . Orlgiml
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Frontispiece
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T a b l e of Contents
I1 1
..................... GENERAL . . . . . . . . . . . . . . . . . . . . . . . . S a t u r n V Mobile L a u n c h e r . . . . . . . . . . . . . . . ................ UMBILICAL EQUIPMENT S a t u r n V Umbilical C a r r i e r s . . . . . . . . . . . . . . S - I C Stage U m b i l i c a l C a r r i e r s . . . . . . . . . . . . S - I C Stage Aft U m b i l i c a l C a r r i e r s . . . . . . . . . . S-IC Stage Intertank Umbilical C a r r i e r . . . . . . . . S -1C I n t e r t a n k U m b i l i c a l Ground C a r r i e r C o n t r o l Test Set . . . . . . . . . . . . . . . . . . . . . S - I C Stage F o r w a r d U m b i l i c a l C a r r i e r . . . . . . . . S-I1 S t a g e U m b i l i c a l C a r r i e r s . . . . . . . . . . . . . . S-I1 S t a g e I n t e r m e d i a t e U m b i l i c a l C a r r i e r . . . . . . . S-I1 S t a g e F o r w a r d U m b i l i c a l C a r r i e r . . . . . . . . . S-I1 S t a g e L O X / L H 2 P r o p e l l a n t Couplings . . . . . . . S - I V B S t a g e / I .U . U m b i l i c a l C a r r i e r s . . . . . . . . S-IVB S t a g e Aft U m b i l i c a l C a r r i e r . . . . . . . . . . S-IVB S t a g e F o r w a r d 1 1. U . U m b i l i c a l C a r r i e r . . . . . SERVICING EQUIPMENT . . . . . . . . . . . . . . . . .
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S -1C P n e u m a t i c Ground S u p p o r t Equipment S - I C P n e u m a t i c Console S - I C P n e u m a t i c Checkout R a c k s S - I C F o r w a r d U m b i l i c a l S e r v i c e Console S-IC Pneumatic Portable T e s t e r s S - I C H y d r a u l i c Supply a n d Checkout Unit H y d r a u l i c P o w e r Unit Motor Control Center S y s t e m Checkout C o n s o l e S-IC GSE H y d r a u l i c P e r f o r m a n c e T e s t e r Console Assembly Manifold A s s e m b l y S-IC I n e r t P r e f i l l Unit . . . . . . . . . . H y d r a u l i c P u m p i n g Unit S y s t e m Checkout Console S-IC F l u s h a n d P u r g e S e r v i c e T r u c k S-IC R J - 1 / E t h y l e n e Glycol Mobile S e r v i c e r
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Table of Contents
MSFC-MAN- 100
TABLE OF CONTENTS Section I11 S-11 Pneumatic Ground Support Equipment S-I1 Pneumatic Consoles (S7.41A. B. C. D) S-I1 LH2 Heat Exchanger (A7-71) S-I1 Pneumatic Console T e s t Set (C7.70) P o r t a b l e Vacuum P u m p Unit (S7-37) Stationary Vacuum P u m p (S7-29) E l e c t r i c a l Container A i r Servicing Unit (S7-34) Hydraulic Accumulator P r e c h a r g e Servicing Unit (S7-38) P u r g e and T h e r m a l Control Nitrogen Servicing Unit (S7.40) P n e u m a t i c Checkout Blanking P l a t e Set (C7-53) P n e u m a t i c Checkout Console Set (C7-603) E l e c t r i c a l Pneumatic Servicing Console (S7-42) S-IVB Pneumatic Ground Support Equipment S-IVB Pneumatic Console "A" (DSV-4B-432 & 432A) S-IVB Pneumatic Console "B" (DSV-4B-433 & 433A) S-IVB Gas Heat Exchanger (DSV-4B-438) S-IVB Pneumatic Console T e s t Set ( D S V - 4 ~ - 2 8 6 & 2 8 6 A ) S-IVB APS Propellant Servicing Unit ((36500- I & - 2 ) S-IVB APS Pneumatic Console (DSV-4B-436A) Page
.. .. .. .. .. .. .. .. ....................... ...... ........ ...... ....... .. .. ....... . .... . . . . . . S-IVBHydraulicPumpingUnit(DSV-4B-358) . . . . . . Nitrogen Fill T r u c k (DSV4- 186) . . . . . . . . . . . . . APS P n e u m a t i c Console P o r t a b l e T e s t Set (DSV-4B-186) . . Vacuum Pumping Unit (DSV4- 187) . . . . . . . . . . . . Battleship Pneumatic Console "A" (DSV-4B-327) . . . . . Battleship P n e u m a t i c Console "B" (DSV-4B-333) . . . . . Battleship Pneumatic Console "C" (DSV-4B-328) . . . . . Propellant T r a n s f e r and Interconnect Kit (DSV-4B472&-473) . . . . . . . . . . . . . . . . . . . . . APS Checkout A c c e s s o r i e s Kit (DSV-4B-493A) . . . . . . APS Instrumentation and Checkout Kit (DSV-4B- . 18748~-1875) . . . . . . . . . . . . . . . . . . . . I . U . P n e u m a t i c Ground Support Equipment . . . . . . . . I . U . Pneumatic Console . . . . . . . . . . . . . . . I . U . Pneumatic Console (500FS) . . . . . . . . . . . I . U . Pneumatic Console T e s t Set . . . . . . . . . . . I . U . Ground Support Cooling Unit . . . . . . . . . . . . Ground Support Cooling Unit Flow Control Valve Box (RM1801A) . . . . . . . . . . . . . . . . . . . . . I . U . Water Accumulator S e r v i c e r . . . . . . . . . . . .
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T a b l e of Contents
T A B L E OF CONTENTS ( C o n t ) Section S-111s-IVB Mobile H y d r a u l i c S e r v i c e r (DSV-4B-479) Mobile P n e u m a t i c Checkout Console Mobile P n e u m a t i c T e s t S e t P o r t a b l e P n e u m a t i c R e g u l a t o r s and H o s e Kits H a z a r d o u s G a s Detection S y s t e m Page
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. . . .......... ACCESSEQUIPMENT S-IC A c c e s s E q u i p m e n t ........ S-I1 A c c e s s E q u i p m e n t ........ LH2 T a n k S e r v i c i n g M e c h a n i s m (A7-35) . LH2 T a n k C l e a n Room (A7-39) . . . . .
. . . . . . ........ ........ ........ ........ ........ LHZ T a n k S e r v i c i n g A i r Conditioner (A7-40) . . . . . . . P r o p e l l a n t T a n k s P r e s s u r i z a t i o n S y s t e m (S7-44) . . . . . Engine C o m p a r t m e n t A u x i l i a r y P u r g e Manifold (A7- 57) . . S-IVB A c c e s s E q u i p m e n t . . . . . . . . . . . . . . . I .U. A c c e s s E q u i p m e n t . . . . . . . . . . . . . . .
. . S -IC Handling and A u x i l i a r y E q u i p m e n t S . Haudling and A u x i l i a r y E q u i p m e n t . . I1 S-IVB Handling and A u x i l i a r y E q u i p m e n t . . I . U . Handling and A u x i l i a r y E q u i p m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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............ ............ ... ........ S a t u r n V Umbilical C a r r i e r s ........... S - I C Stage Umbilical C a r r i e r s . . . . . . . . . . . S - I C S t a g e Aft Umbilical C a r r i e r s . . . . . . . . .
S a t u r n V Mobile L a u n c h e r V e r t i c a l A s s e m b l y Building E l e c t r i c a l Equipment and Cabling A r r a n g e m e n t Mechanical Equipment Arrangement S - I C Stage I n t e r t a n k Umbilical C a r r i e r s S - I C I n t e r t a n k Umbilical Ground C a r r i e r Control T e s t S e t S - I C Stage F o r w a r d Umbilical C a r r i e r S-I1 S t a g e Umbilical C a r r i e r s S-I1 S t a g e I n t e r m e d i a t e Umbilical C a r r i e r s S-I1 S t a g e F o r w a r d Umbilical C a r r i e r S-I1 S t a g e LOX/LH2 P r o p e l l a n t Couplings S-IVB S t a g e / I U Umbilical C a r r i e r S-IVB S t a g e Aft Umbilical C a r r i e r S-IVB Stage Forward1I.U. Umbilical C a r r i e r S-IC P n e u m a t i c Ground S u p p o r t Equipment S -1C P n e u m a t i c Cons ole S - I C P n e u m a t i c Checkout Racks S - I C F o r w a r d Umbilical S e r v i c e Console S-IC Pneumatic Portable T e s t e r s S-IC H y d r a u l i c Supply a n d Checkout Unit S-IC H y d r a u l i c P o w e r Unit S-IC M o t o r C o n t r o l C e n t e r S -1C S y s t e m Checkout Console S-IC GSE H y d r a u l i c P e r f o r m a n c e T e s t e r Console A s s e m b l y Manifold A s s e m b l y S-IC I n e r t P r e f i l l Unit H y d r a u l i c P u m p i n g Unit S y s t e m Checkout Console S - I C F l u s h and P u r g e S e r v i c e T r u c k S-IC R J - 1 /Ethylene Glycol Mobile S e r v i c e r S-I1 P n e u m a t i c G r o u n d S u p p o r t E q u i p m e n t S - I I P n e u m a t i c Consoles(S7.41A. B. C. D) S-I1 LH2 H e a t E x c h a n g e r (A7- 71) S-I1 P n e u m a t i c Console T e s t S e t (C7-70) P o r t a b l e Vacuum P u m p Unit (S7- 37)
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Title S t a t i o n a r y Vacuum P u m p (S7-29) E l e c t r i c a l Container A i r S e r v i c i n g Unit (S7-34) Hydraulic Accumulator P r e charge Servicing Unit (S7-38) P u r g e and T h e r m a l C o n t r o l Nitrogen . S e r v i c i n g Unit (S7-40) P n e u m a t i c Checkout Blanking P l a t e S e t (C7-53) P n e u m a t i c Checkout Console Set (C7-603) E l e c t r i c a l P n e u m a t i c S e r v i c i n g Console (S7-42) S-IVB P n e u m a t i c Ground S u p p o r t E q u i p m e n t S-IVB P n e u m a t i c Console "A" (DSV-4B-432 & 432A) S-IVB P n e u m a t i c Console "B" (DSV-4B-433 & 433A) S-IVB G a s H e a t E x c h a n g e r (DSV-4B-438) S-IVB P n e u m a t i c Console T e s t S e t '(DSV-4B-286 & 286A) S-IVB APS P r o p e l l a n t S e r v i c i n g Unit (GS6500- 1 & - 2 ) S-IVB APS P n e u m a t i c Console (DSV.4B.436A) S-IVB H y d r a u l i c P u m p i n g Unit (DSV-4B-358) Nitrogen F i l l T r u c k (DSV4- 186) APS .Pneumatic Console P o r t a b l e T e s t S e t (DSV-4B- 186) Vacuum P u m p i n g Unit (DSV4- 187) B a t t l e s h i p P n e u m a t i c Console "A" (DSV-4B-327) B a t t l e s h i p P n e u m a t i c Console "B" . (DSV-4B-333) B a t t l e s h i p P n e u m a t i c Console "C1' (DSV-4B-328) P r o p e l l a n t T r a n s f e r and I n t e r c o n n e c t Kit (DSV-4B-472 & -473) A P S Checkout A c c e s s o r i e s Kit (DSV-4B-4934) APS I n s t r u m e n t a t i o n and Checkout Kit (DSV-4R- 1874 & -1875) I U P n e u m a t i c Ground Support E q u i p m e n t I U P n e u m a t i c Console I U P n e u m a t i c Console (500FS) I U P n e u m a t i c Console T e s t S e t I U Ground Support Cooling Unit GSCU F l o w C o n t r o l Valve Box I U Water Accumulator S e r v i c e r S-111s-IVB Mobile H y d r a u l i c S e r v i c e r (DSV-4B-479)
Page 3-59 3-61 3-63 3-65 3 - 67 3-69 3-72 3-74 3 76 3 .9 7 3-82 3-85 3-87 3-91 3-94 3-96
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3-98 3- 100 3- 102 3- 104 3- 106 3-108 3-110 3-113 3-1 1 5 3-117 3- 119 3- 124 3- 126 3-131 3-133 3- 136
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L i s t of I l l u s t r a t i o n s
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Title Mobile P n e u m a t i c Checkout Console Mobile P n e u m a t i c T e s t Set P o r t a b l e P n e u m a t i c R e g u l a t o r s and H o s e Kits Hazardous Gas Detector S a t u r n V HGD S e n s i n g Line Configuration Hazardous Gas Detector System Functional Block D i a g r a m
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LH2 T a n k S e r v i c i n g M e c h a n i s m (A7-35) LH2 T a n k C l e a n Room (A7-39) LH2 T a n k S e r v i c i n g A i r Conditioner (A7-40) P r o p e l l a n t T a n k P r e s s u r i z a t i o n S y s t e m (S7-44) E n g i n e C o m p a r t m e n t A u x i l i a r y P u r g e Manifold (A7-57) S-IVB A c c e s s E q u i p m e n t I .U A c c e s s Equipment
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S-IC Handling and A u x i l i a r y E q u i p m e n t S-I1 Handling and A u x i l i a r y E q u i p m e n t S-IVB Handling and A u x i l i a r y E q u i p m e n t I . U Handling and A u x i l i a r y E q u i p m e n t Launch Vehicle Handling and A u x i l i a r y E q u i p m e n t
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MSFC-MAN- 1 0 0
Introduction
INTRODUCTION
T h i s booklet h a s b e e n p r e p a r e d to provide a quick r e f e r e n c e t o S a t u r n V s t a g e p e c u l i a r ground support equipment. I t c o n s i s t s of v i s u a l p r e s e n t a tions and a brief d e s c r i p t i o n of e a c h m a j o r component. I t i s intended t o quickly f a m i l i a r i z e concerned e l e m e n t s with the o v e r - a l l MSFC launch vehicle ground s u p p o r t equipment and i s not intended f o r design usage. T h e booklet h a s b e e n p r e p a r e d i n five sections. Section I contains the i n t r o d u c t o r y m a t e r i a l and a d e s c r i p t i o n of the S a t u r n V mobile l a u n c h e r (ML). Section I1 contains information on the umbilical equipment. Section I11 contains information on the s e r v i c i n g equipment, both fixed and mobile. Section IV contains information on the a c c e s s equipment. Section V contains information on the handling and a u x i l i a r y equipment.
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SECTION I GENERAL
Section I General
F i g u r e 1- 1.
S a t u r n V Mobile L a u n c h e r
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Section I General
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SATURN V MOBILE LAUNCHER T h e mobile launcher (ML) s e r v e s a s the launch platform f o r the S a t u r n V launch vehicle, and contains operational t e s t and launch equipment used during checkout and launch. This i s equipment which is in'stalled within the b a s e of t h e ML and tower s t r u c t u r e a s well as v a r i o u s i t e m s of mobile servicing equipment located on t h e pad a r e a immediately surrounding the LUT.
The launch platform i s a two-story s t e e l s t r u c t u r e 2 5 f e e t high, 160 f e e t long, and 1 3 5 f e e t wide. The tower mounted on one end of the launch platform extends 380 f e e t above the deck.
S e r v i c e a r m s , varying in length f r o m 35 to 45 feet, c a r r y e l e c t r i c a l , pneumatic, and propellant lines to the launch vehicle. They a l s o provide walkways f o r checkout personnel entering the i n t e r s t a g e a r e a s .
1-2
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Section I General
F i g u r e 1-2.
V e r t i c a l A s s e m b l y Building
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Section 1 General
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Figure 2- 1.
Saturn V Umbilical C a r r i e r s
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SATURN V UMBILICAL CARRIERS A t o t a l of ten umbilical c a r r i e r s and two propellant couplings s e c u r e the v a r i o u s umbilical l i n e s t o the Saturn V vehicle. T h e c a r r i e r s and couplings a r e located a t the vehicle end of the s e r v i c e a r m s extending f r o m the tower o r a t the end of the t a i l s e r v i c e m a s t s a t t h e b a s e of the ML. The c a r r i e r s and t h e supporting b r a c k e t s o r l e g s extending below the c a r r i e r s t r a n s f e r a portion of the weight of t h e s e r v i c e lines t o the vehicle s t r u c t u r e . Eight of the umbilical c a r r i e r s and the two propellant couplings a r e inflight disconnects, disconnecting a t vehicle lift-off. Two of the umbilical c a r r i e r s a r e pre-flight disconnects, disconnecting f r o m t e n t o fifteen seconds p r i o r t o lift-off.
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AFT
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Figure 2-2.
Section I1 MSFC-MAN- 100 Um bilical Equipment S-IC STAGE UMBILICAL CARRIERS The S-IC stage umbilical s y s t e m c o n s i s t s of t h r e e a f t umbilical c a r r i e r s , a n intertank umbilical c a r r i e r , and a f o r w a r d umbilical c a r r i e r . The c a r r i e r s a r e located a t the vehicle end of the s e r v i c e a r m s exterrding f r o m the tower o r a t the ends of the tail s e r v i c e m a s t s on the deck of the ML, and s e c u r e the following s e r v i c e l i n e s to the S-IC stage of the S a t u r n V vehicle: a. b. c. d. e. Electrical. Pneumatic. Gaseous nitrogen (GN2). Gaseous helium (GHe). Liquid oxygen (LOX).
A i r conditioning.
The t h r e e aft c a r r i e r s a r e in-flight disconnects, disconnecting a t vehicle lift-off. The intertank and forward c a r r i e r s a r e p r e -flight disconnects, disconnecting a t T-minus -15 seconds and T-minus -10 seconds respectively.
2-6
MSFC-MAN- 100
Figure 2-3.
MSFC-MAN- 100
Figure 2-3.
MSFC-MAN- 100
Figure 2-3.
Section I1 Umbilic a1 Equipment S-IC STAGE AFT UMBILICAL CARRIERS 1. Functional Description
a . Although the t h r e e aft c a r r i e r s a r e physically s i m i l a r , e a c h c a r r i e r s e c u r e s different umbilical s e r v i c e lines to the S-IC stage of the S a t u r n V launch vehicle.
( 1 ) Aft Umbilical C a r r i e r #1 i s located 12O 39' 22 112" off Position I11 toward Position IV. It consists of various pneumatic couplings, eight e l e c t r i c a l connectors, and a 6-inch LOX connector. The e l e c t r i c a l connectors can be ejected independently of the c a r r i e r a s s e m b l y f o r simulated flight t e s t and checkout purposes. ( 2 ) Aft Umbilical C a r r i e r #2 i s located 12O 39' 22 1/2" off 1 Position I toward Position 1 . It consists of various pneumatic couplings, eight e l e c t r i c a l connectors, and a 6-inch fuel connector. The e l e c t r i c a l connectors can be ejected independently of the c a r r i e r a s s e m b l y f o r simulated flight t e s t and checkout purposes. ( 3 ) Aft Umbilical C a r r i e r #3 i s located 120 39' 22 112" off Position 111 toward Position 11. It consists of various pneumatic couplings and two 4-inch a i r conditioning couplings. This c a r r i e r does not contain any e l e c t r i c a l connectors. The S-IC Aft Umbilical Flight P l a t e contains fluid disconnect b. couplings and connectors. All couplings and connectors on the flight plate a r e rigidly mounted. The c a r r i e r provides f o r coupling and connector alignment during mating. The v e r t i c a l motion of the vehicle during lift-off r e l e a s e s an identical locking mechanism on e a c h aft c a r r i e r , resulting i n disconnection of the t h r e e c a r r i e r s f r o m the vehicle. ( 1 ) P r i m a r y Ejection Method: The four telescoping rods follow the r i s i n g motion of the vehicle. As the vehicle moves upward, m e c h a n i c a l linkage of the t a i l s e r v i c e m a s t withdrawal m e c h a n i s m f o r c e s the yoke of the locking piston away f r o m the vehicle. The locking piston r e t r a c t s , r e l e a s i n g the locking fingers. The f i n g e r s collapse t o a d i a m e t e r s m a l l e r than the minimum diameter of the vehicle plate receptacle. F u r t h e r r e t r a c t i o n of the locking piston r e l e a s e s the t r i g g e r pins. The pneumatically loaded push off foot then f o r c e s the c a r r i e r away f r o m the vehicle plate. After disconnection, pneumatic p r e s s u r e r e l e a s e d f r o m a coupling on the c a r r i e r a s s e m b l y c a u s e s the s p r i n g r e t u r n operational control valve in the t a i l s e r v i c e m a s t t o open. Hydraulic fluid then flows f r o m the t a i l s e r v i c e m a s t r e t r a c t cylinder and the t a i l s e r v i c e m a s t withdraws the c a r r i e r assembly. 2-10
MSFC-MAN- 100
S e c t i o n I1 Umbilical Equipment
( 2 ) S e c o n d a r y E j e c t i o n Method: If p n e u m a t i c f a i l u r e o c c u r s , t h e r i s i n g m o t i o n of t h e t e l e s c o p i n g r o d s f o r c e s t h e f o u r pushoff p i s t o n s a g a i n s t t h e v e h i c l e p l a t e , disconnecting t h e c a r r i e r f r o m t h e v e h i c l e . T h e l o c k i n g p i s t o n is s i m u l t a n e o u s l y r e t r a c t e d t h r o u g h m e c h a n i c a l l i n k a g e . T h e c a r r i e r i s t h e n unlocked f r o m t h e vehicle. A f t e r d i s c o n n e c t i o n , a n e l e c t r i c a l s w i t c h on t h e c a r r i e r a s s e m b l y i s a c t u a t e d , c a u s i n g a n e l e c t r i c a l l y ope r a t e d c o n t r o l valve, p a r a l l e l with t h e pneurrlatic c o n t r o l v a l v e , t o open. T h e t a i l s e r v i c e m a s t t h e n w i t h d r a w s t h e c a r r i e r . If t h e r e i s h y d r a u l i c o r p n e u m a t i c f a i l u r e i n t h e m a s t r e t r a c t i o n s y s t e m , counterweights i n the t a i l s e r v i c e m a s t will complete retraction. 2. Remarks
T h e following p r e c a u t i o n s a r e t a k e n t o p r e v e n t p o s s i b l e explos i v e conditions i n t h e vicinity of t h e c a r r i e r s . T h e s h i e l d of e a c h e l e c t r i c a l c o n n e c t o r i s grounded a. t h r o u g h a c o m m o n w i r e t o t h e vehicle. b. GN2. 3. General a. Weight, pounds ( A p p r o x i m a t e ) Aft U m b i l i c a l C a r r i e r A s s e m b l y # 1 Aft U m b i l i c a l C a r r i e r A s s e m b l y # 2 Aft U m b i l i c a l C a r r i e r A s s e m b l y # 3 T h e e l e c t r i c a l connectors i n e a c h c a r r i e r a r e purged with
b.
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Figure 2-4.
MSFC-MAN- 100
Functional Description
The Intertank Umbilical C a r r i e r contains two 6-inch liquid a. oxygen ( L O X ) f i l l and d r a i n couplings. The c a r r i e r i s r e m o t e l y disconnected and withdrawn f r o m the vehicle a t approximately T - m i n u s - 1 5 s e c onds. In c a s e of a hold o r a b o r t , the c a r r i e r c a n be automatically r e c o n nected to t h e vehicle to replenish o r d r a i n the LOX tank. Ejection: The LOX lines a r e drained and then purged with GNz b. just before engine ignition. The c a r r i e r a s s e m b l y i s pneumatically d i s connected by applying GN2 a t 750 psig to the locking m e c h a n i s m . The locking piston i s r e t r a c t e d , r e l e a s i n g the locking f i n g e r s to a d i a m e t e r s m a l l e r than the minimum d i a m e t e r of the vehicle plate r e c e p t a c l e . Pneum a t i c p r e s s u r e simultaneously actuates a switch i n the locking m e c h a n i s m , indicating the locking f i n g e r s a r e r e l e a s e d . A solenoid valve then c a u s e s the r e t r a c t cylinder to withdraw the c a r r i e r a s s e m b l y f r o m the vehicle. After the c a r r i e r a s s e m b l y i s c l e a r of the vehicle d r i f t envelope, a switch i s actuated, initiating s e r v i c e a r m rotation. The s e r v i c e a r m i s then hydraulically rotated to the tower and locked.
2.
Remarks
The i n t e r i o r of the c a r r i e r i s purged with GN2 a s a precaution to prevent possible explosive conditions in the vicinity of the c a r r i e r . 3. General a. b. Weight, pounds (Approximate) 5, 850 Envelope Dimensions, inches (Approximate) 110 x 63 x 180
B-H 1077
F i g u r e 2-5.
MSFC-MAN- 100
Functional Description The I n t e r t a n k Umbilical Ground C a r r i e r Control T e s t s e t i s r e a. q u i r e d to s i m u l a t e ML c o n t r o l of t h e S-IC i n t e r t a n k u m b i l i c a l ground c a r r i e r . The s e t i s used i n m a n u a l o r automatic m o d e s t o check out p r o p e r o p e r a t i o n of the i n t e r t a n k umbilical ground c a r r i e r . The t e s t s e t p r o v i d e s nlanual c o n t r o l of a l l valves except t h e c a r r i e r latch, lock r e l e a s e , and purge v a l v e s . The t e s t s e t i s portable, with the upper half of t h e s e t u s e d t o b. s t o r e t h e two 18 foot c a b l e s and the lower half containing t h e c i r c u i t r y f o r monitoring and controlling t h e intertank umbilical ground c a r r i e r . I t contains switches and i n d i c a t o r s f o r operation of t h e i n t e r t a n k u m b i l i c a l ground c a r r i e r on initial installation and following component r e p l a c e m e n t t o indic a t e p r o p e r a d j u s t m e n t and c o r r e c t . o p e r a t i o n of the c a r r i e r . The m a n u a l mode of operation provides individual c o n t r o l of t h e c. solenoid valves i n t h e i n t e r t a n k umbilical ground c a r r i e r . This p e r m i t s the c a r r i e r to be stopped a t any point of t r a v e l . After t h e c a r r i e r h a s stopped, the p r e s s u r e r e g u l a t o r s o r l i m i t s w i t c h e s c a n be adjusted. d. T h e a u t o m a t i c m o d e o f connectionis u s e d t o c h e c k o u t p r o p e r o p e r a t i o n of t h e i n t e r t a n k umbilical ground c a r r i e r through a complete connection sequence. The switch lights on the t e s t s e t illuminate i n s e q u e n c e to indicate p r o p e r operation of t h e solenoid valves and l i m i t s w i t c h e s i n t h e c a r r i e r . Automatic r e t r a c t i o n i s used t o check out p r o p e r o p e r a t i o n of t h e c a r r i e r through a complete r e t r a c t sequence. Facility Requirements Power 2 8 vdc
3.
Demand 10 amps
4.
2-15
MSFC-MAN- 100
F i g u r e 2-6.
2-16
M S F C - M A N - 100
Figure 2-6.
S e c t i o n I1 Umbilical Equipment
MSFC-MAN- 100
F i g u r e 2-6. 2-18
S - I C S t a g e F o r w a r d U m b i l i c a l C a r r i e r ( S h e e t 3 of 3 )
MSFC-MAN- 100
The F o r w a r d Umbilical C a r r i e r contains v a r i o u s pneumatic a. couplings, eight e l e c t r i c a l connectors, and one 4-inch a i r conditioning coupling. It i s a p r e -flight disconnect, disconnecting a t approximately T - m i n u s - 10 seconds p r i o r to lift-off. The S-IC F o r w a r d Umbilical Flight P l a t e contains fluid d i s b. connect couplings and e l e c t r i c a l connectors. All couplings and c o n n e c t o r s on the flight plate a r e rigidly mounted. The c a r r i e r provides f o r coupling and connector alignment during mating. The c a r r i e r provides both p r i m a r y and s e c o n d a r y methods of ejecting the s e r v i c e lines f r o m the vehicle. ( 1 ) P r i m a r y Ejection Method: The c a r r i e r a s s e m b l y is ejected pneumatically f r o m the vehicle by applying GN2 a t 750 psig to the locking m e c h a n i s m . The r e l e a s e pin r e t r a c t s , r e l e a s i n g the locking m e c h a n i s m . Pneumatic p r e s s u r e simultaneously f o r c e s four pushoff pistons against the vehicle plate, disconnecting the c a r r i e r f r o m the plate. A lanyard routed f r o m the c a r r i e r to the pneumatically d r i v e n block and tackle r e t r a c t i o n device then pulls the c a r r i e r to the s e r v i c e a r m .
( 2 ) Secondary Ejection Method: If pneumatic f a i l u r e o c c u r s , the lanyard a c t u a t e s a m e c h a n i c a l r e l e a s e linkage on the c a r r i e r that d i s connects the umbilical c a r r i e r . As the lanyard i s withdrawn, the r e l e a s e a r m of the mechanical r e l e a s e linkage m o v e s outward, contacting the m a n u a l r e l e a s e knob on the locking m e c h a n i s m , and retricting the r e l e a s e pin. The locking m e c h a n i s m i s r e l e a s e d , and the pulloff a r m s on the s i d e s of the c a r r i e r Force the c a r r i e r away f r o m the vehicle plate. Additional lanyard motion then pulls the c a r r i e r to the s e r v i c e a r m . 2.
Remarks
The following precautions a r e taken to prevent possible explosive conditions i n the vicinity of the c a r r i e r . The shield of each e l e c t r i c a l connector i s grounded through a. a common w i r e to the vehicle.
b. 3.
MSFC-MAN- 100
F i g u r e 2-7.
The S-I1 stage umbilical sys tem consists of a n intermediate umbilical c a r r i e r , a forward umbilical c a r r i e r , and two propellant f i l l and drain couplings. The c a r r i e r s and couplings a r e located a t the vehicle end of the service a r m s extending from the tower and secure the following service lines to the S-I1 stage of the Saturn V vehicle:
a. Electrical.
b. c. d. e
f
Pneumatic. Gaseous nitrogen (GN2). Liquid oxygen (LOX). Liquid hydrogen (LH2). Air conditioning. Hydrogen vent.
.
.
g.
The c a r r i e r s and the couplings provide primary and secondary methods of ejecting the service lines from the vehicle a t lift-off.
MSFC-MAN- 100
Figure 2-8.
MSFC-MAN- 100
The Intermediate Umbilical C a r r i e r i s located 73O f r o m a. Position I toward P o s i t i o n 11. I t contains 30 pneumatic couplings, 12 e l e c t r i c a l c o n n e c t o r s , and two a i r conditioning couplings. The e l e c t r i c a l connectors can be ejected independently of the c a r r i e r a s s e m b l y f o r simulated flight t e s t and checkout p u r p o s e s . The c a r r i e r provides p r i m a r y and s e c o n d a r y methods of b. ejecting the s e r v i c e l i n e s f r o m the vehicle a t lift-off. : (1) P r i m a r y ~ j e c t i o n ' ~ e t h o dThe c a r r i e r i s disconnected f r o m the vehicle a f t e r the rise-off switches have been actuated. The c a r r i e r a s s e m b l y i s ejected pneumatically by applying GN2 a t 1250 psig simultaneously to the pushoff pis tons. The r e l e a s e pins then r e t r a c t , r e l e a s i n g the locking m e c h a n i s m . The pushoff pistons a r e f o r c e d . a g a i n s t the vehicle plate, disconnecting the c a r r i e r f r o m the vehicle. (2) Secondary Ejection Method: If p r i m a r y pneumatic f a i l u r e o c c u r s , a pneumatically d r i v e n lanyard a r r a n g e m e n t a c t u a t e s the mechanical r e l e a s e linkage, t h e r e b y disconnecting the c a r r i e r f r o m the vehicle.
( 3 ) If both p r i m a r y and s e c o n d a r y pneumatic f a i l u r e s o c c u r , the upward motion of the vehicle tightens the lanyard and c a u s e s the m e c h a n i c a l r e l e a s e linkage to actuate and' disconnect the c a r r i e r f r o m the vehicle.
2.
Remarks
The following precautions a r e taken to prevent possible explosive conditions i n the vicinity of the c a r r i e r s : a. The shield of e a c h e l e c t r i c a l connector i s grounded through a common w i r e to the vehicle. b. with G N 2 . 3. General a. b. Weight, pounds (Approximate) 500 Envelope Dimensions, inches (Approximate) 70 x 75 x 15 The e l e c t r i c a l connectors i n the c a r r i e r a r e purged
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F i g u r e 2-9.
MSFC-MAN- 100
The F o r w a r d Umbilical C a r r i e r c o n s i s t s of v a r i o u s a. pneumatic couplings, eight e l e c t r i c a l c o n n e c t o r s , and two 7 -inch GH2 vent couplings. The e l e c t r i c a l connectors can be ejected independently of the c a r r i e r a s s e m b l y for simulated flight t e s t and checkout p u r p o s e s . b. The c a r r i e r provides p r i m a r y and s e c o n d a r y methods of ejecting the s e r v i c e l i n e s f r o m the vehicle a t lift-off. ( 1) P r i m a r y Ejection Method: After the vehicle r i s e -off switches have been a c t u a t e d , the c a r r i e r i s ejected pneumatically by applying GN2 a t 1250 psig simultaneously to each locking m e c h a n i s m and the pushoff pistons. The r e l e a s e pins then r e t r a c t , r e l e a s i n g the locking m e c h a n i s m . The p r e s s u r i z e d pushoff pistons then f o r c e the c a r r i e r away f r o m the vehicle, and the pneumatic withdrawal cylinder moves the c a r r i e r to the s e r v i c e a r m .
(2) Secondary Ejection M c thod: If p r i m a r y pneumatic f a i l u i e o c c u r s , a pneumatically d r i v e n lanyard a r r a n g e m e n t actuate's the mechanical r e l e a s e linkage, disconnecting the c a r r i e r f r o m the vehicle.
( 3 ) If both p r i m a r y and s e c o n d a r y pneumatic f a i l u r e s o c c u r , the upward motion of the vehicle tightens the lanyard and c a u s e s the mechanical r e l e a s e linkage to disconnect the c a r r i e r f r o m the vehicle
2.
Remarks
The following precautions a r e taken to prevent possible explosive conditions in the vicinity of the c a r r i e r s . The shield of e a c h e l e c t r i c a l connector i s grounded a. through a common w i r e to the vehicle. The c a r r i e r i s purged between the e l e c t r i c a l connectors b. and the fuel tank vent line with GN2.
3.
General a. b.
Section I1 U m b i l i c a l Equipment
MSFC-MAN-100
S-ll STAGE UMBILICAL CARRIERS
F i g u r e 2-10.
2-26
MSFC-MAN- 100
F i g u r e 2 - 10.
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a. The two 8-inch propellant couplings a r e identical. They s e c u r e the liquid hydrogen (LH2) and liquid oxygen (LOX) s e r v i c e lines t o the S-I1 stage of the vehicle. Debris valves a r e used on t h e s e couplings t o prevent d e b r i s f r o m contaminating the propellant lines at disconnect. b. Since the couplings a r e independent of the main c a r r i e r , they r e q u i r e t h e i r own r e l e a s e systems, both p r i m a r y and secondary. (1) P r i m a r y Ejection Method: The two propellant couplings a r e ejected by appling G H at 750 psig simultaneously to the locking ~ mechanisms and pushoff pistons. The r e l e a s e pins then r e t r a c t , releasing the locking mechanism. The pushoff pistons then eject the two couplings f r o m the vehicle. A lanyard attached t o the r e l e a s e pin of each locking mechanism pulls the couplings and attached propellant lines t o the s e r v i c e arm. (2) Secondary Ejection Method: If pneumatic f a i l u r e o c c u r s , the lanyards r e l e a s e the locking mechanisms by r e t r a c t i n g the r e l e a s e pins and then pull the couplings t o the s e r v i c e a r m . 2. General a. b. Weight, pounds (Approximate) 125 (each) Envelope Dimensions, inches (Approximate) 21 x 17 x 30 (each)
MSFC-MAN- 1 0 0
S e c t i o n I1 Umbilical Equipment
F i g u r e 2-1 1.
S - I V B S t a g e / I . U. U m b i l i c a l C a r r i e r s
Section I1 MSFC-.VAN- 100 Umbilical Equipment , *, S-IVB STAGE /I. U. UMBILICAL CARRIERS
...
The S -1VB stage /I. U. umbilical s y s t e m c o n s i s t s of the S-IVB a f t umbilical c a r r i e r and the S-IVB f o r w a r d / I . U. umbilical c a r r i e r s b r a c k e t e d together a s a common unit. The c a r r i e r s a r e located a t the vehicle end of the s e r v i c e a r m s extending f r o m the tower and s e c u r e the following s e r v i c e l i n e s to the S -1VB stage /I. U. of the S a t u r n V vehicle: a.
b.
Electrical. Pneumatic. Gaseous nitrogen (GN2). Liquid oxygen (LOX). Liquid hydrogen (LH2). A i r conditioning Hydrogen vent. A i r bearing s p h e r e .
c, d. e.
f.
g. h.
M S F C - M A N - 100
S e c t i o n I1 Unlbilical Equipment
F i g u r e 2-12.
S - I V B S t a g e Aft U m b i l i c a l C a r r i e r
2-31
S e c t i o n I1 Umbilical Equipment
MSFC-MAN- 100
a . T h e Aft U n l b i l i c a l C a r r i e r c o n t a i n s v a r i o u s p n e u n l a t i c c o u p l i n g s , s i x e l e c t r i c a l c o n n e c t o r s , a n d t w o 4 - i n c h LOX a n d LM2 c o u p l i n g s . T h e e l e c t r i c a l c o n n e c t o r s c a n be e j e c t e d i n d e p e n d e n t l y of t h e c a r r i e r a s s e m b l y f o r s i m u l a t e d flight t e s t a n d c h e c k o u t p u r p o s e s . T h e LOX a n d LH2 c o u p l i n g s a r e c o n t a i n e d i n t h e m a i n c a r r i e r a n d d i s c o n n e c t a s a unit. a b. T h e c a r r i e r p r o v i d e s p r i n ~ a r y n d s e c o n d a r y m e t h o d s of e j e c t i n g t h e s e r v i c e l i n e s f r o m t h e v e h i c l e a t lift-off. ( 1 ) P r i m a r y E j e c t i o n Method: T h e c a r r i e r i s u n l o c k e d f r o m t h e v e h i c l e by t h e two s i d e - m o u n t e d p n e u n l a t i c l o c k i n g n ~ e c h a n i s n l s a f t e r the vehicle rise-off switches have been actuated. T o r e l e a s e the l o c k i n g m e c h a n i s m s , GN2 a t 1250 p s i g i s s i m u l t a n e o u s l y a p p l i e d t o e a c h m e c h a n i s m a n d t h e pushoff p i s t o n s . T h e r e l e a s e p i n s r e t r a c t , u n l o c k i n g t h e c a r r i e r f r o m t h e v e h i c l e . T h e p r e s s u r i z e d pushoff p i s t o n s t h e n f o r c e the c a r r i e r away f r o m the vehicle, and the pneumatic withdrawal cylinder moves it to the service a r m .
( 2 ) S e c o n d a r y E j e c t i o n Method: If p r i m a r y p n e u m a t i c f a i l u r e o c c u r s , a pneuulatically driven l a n y a r d a r r a n g e m e n t a c t u a t e s t h e nlechanical r e l e a s e linkage, thereby disconnecting the c a r r i e r f r o m the vehicle.
( 3 ) If b o t h p r i m a r y a n d s e c o n d a r y p n e u m a t i c f a i l u r e s o c c u r , t h e r i s i n g m o t i o n of t h e v e h i c l e t i g h t e n s t h e l a n y a r d a n d c a u s e s t h e rmechanical r e l e a s e l i n k a g e t o a c t u a t e a n d d i s c o n n e c t t h e c a r r i e r f r o m t h e vehicle.
2.
Remarks
T h e following p r e c a u t i o n s a r e t a k e n t o p r e v e n t p o s s i b l e e x p l o s i v e c o n d i t i o n s i n t h e v i c i n i t y of t h e c a r r i e r . a. t h e vehicle.
b.
T h e s h i e l d of e a c h e l e c t r i c a l c o n n e c t o r i s g r o u n d e d t o
T h e i n t e r i o r of t h e c a r r i e r i s p u r g e d i n f o u r l o c a t i o n s
with GN2.
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3.
General a.
b.
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Section I1 U m b i l i c a l Equipment
S-IVB STAGE FORWARD /I. U. UMBILICAL CARRIER Functional D e s c r i p t i o n T h e S-IVB F o r w a r d Umbilical C a r r i e r contains eight a. e l e c t r i c a l c o n n e c t o r s and one 6-inch GH2 vent coupling. T h e e l e c t r i c a l c o n n e c t o r s c a n b e e j e c t e d independently of t h e c a r r i e r a s s e m b l y f o r s i m ulated flight t e s t a n d checkout p u r p o s e s . T h i s c a r r i e r i s connected t o t h e I. U. Umbilical C a r r i e r by s i d e b r a c k e t s and they a r e disconnected a s a unit. b. T h e I . U. Umbilical C a r r i e r c o n s i s t s of five pneumatic couplings, s i x t e e n e l e c t r i c a l c o n n e c t o r s , and one 6-inch a i r conditioning coupling.
c. T h e S-IVB f o r w a r d c a r r i e r and I. U. c a r r i e r a r e held t o g e t h e r by s i d e b r a c k e t s a t t h e end of one c o m m o n s e r v i c e a r m . T h e ends of t h e b r a c k e t s , which extend down p a s t t h e f o r w a r d c a r r i e r , s e r v e a s pivot points f o r the c a r r i e r a s s e m b l i e s when they a r e d i s c o n n e c t e d .
( 1 ) P r i m a r y Ejection Method: T h e S-IVB f o r w a r d c a r r i e r and I . U. c a r r i e r a r e disconnected f r o m t h e vehicle a f t e r t h e vehicle rise-off s w i t c h e s have b e e n actuated. T o r e l e a s e t h e locking m e c h a n i s m , GN2 a t 7 5 0 p s i g i s simultaneously applied t o t h e f o u r pushoff p i s t o n s contained i n t h e I. U. c a r r i e r . The r e l e a s e pin r e t r a c t s , unlocking t h e c a r r i e r s f r o m the vehicle. T h e pushoff pistons a r e f o r c e d a g a i n s t t h e vehicle p l a t e , r e l e a s i n g t h e c a r r i e r s f r o m t h e vehicle. T h e pneumatic w i t h d r a w a l c y l i n d e r then m o v e s the c a r r i e r s t o the s e r v i c e a r m . ( 2 ) Secondary E j e c t i o n Method: If p r i m a r y pneumatic f a i l u r e o c c u r s , a pneumatically driven l a n y a r d a r r a n g e m e n t a c t u a t e s t h e m e c h a n i c a l r e l e a s e linkage, disconnecting t h e c a r r i e r s f r o m t h e vehicle. ( 3 ) If both p r i m a r y and s e c o n d a r y pneumatic f a i l u r e s o c c u r , t h e upward motion of t h e vehicle tightens t h e l a n y a r d and c a u s e s t h e m e c h a n i c a l r e l e a s e linkage t o a c t u a t e and disconnect t h e c a r r i e r s f r o m the vehicle.
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Remarks
The following precautions a r e taken to prevent pos sible explosive conditions in the vicinity of both c a r r i e r s . a . The shield of e a c h e l e c t r i c a l connector i s grounded through a common w i r e to the vehicle.
b.
3.
2'
135
100
70 x 1 9 x 1'
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JST
I
T A I L SERVICE MAST NO. 12 INTERFACE PLATE
I
T A I L SERVICE MAST NO. 32 INTERFACE PLATE
I
T A I L SERVICE MAST NO. 34 INTERFACE PLATE
1
H O L D DOWN ARM Ill INTERFACE PLATE
F i g u r e 3 - 1. 3-2
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The S -1C Pneumatic Ground Support Equipment supplies p r e s s u r e a. regulated nitrogen and helium g a s e s to the S-IC stage t o s a t i s f y both o p e r ational and t e s t and checkout requirements. The equipment, located i n the M L b a s e , c o n s i s t s of the pneumatic console, the pneumatic checkout r a c k s , the f o r w a r d umbilical s e r v i c e console, and the portable t e s t e r s . The pneumatic console consists of two groups of r a c k s with f o u r b. r a c k s in each group. The pneumatic checkout r a c k s consist of four r a c k s in one group. The forward umbilical s e r v i c e console i s i n a s e p a r a t e cabinet. The portable t e s t e r s c o n s i s t of two t e s t e r s , e a c h in i t s own "suitcase", f o r the pneumatic console, and four t e s t e r s , two t o a "suitc a s e " , f o r the pneumatic checkout r a c k s . In addition, t h e r e i s a s e p a r a t e t e s t s e t f o r the forward umbilical s e r v i c e console. 2. Facilitv Requirements a. Power (1) 110 vac, 60 c p s , single phase (2) 28 vdc Demand To be determined To be determined
b.
Gaseous Media Nitrogen a t 3800 psig minimum t o 6600 psig m a x i m u m . (1) Helium a t 3800 psig m i n i m u m to 6600 psig maximum. (2)
3-3
Section 1 1 1 Yervicing E q u i p m e n t
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F i g u r e 3-2.
S-IC P n e u m a t i c C o n s o l e
The S-IC Pneumatic Console c o n s i s t s of a p r i m a r y regulation a. module and eleven s e c o n d a r y regulation modules. The p r i m a r y regulation m o d a l e r e g u l a t e s facility g a s e s t o provide stable input to the s e c o n d a r y regulation modules. The secondary regulation modules supply operating p r e s s u r e s d i r e c t l y t o the S-IC s t a g e and t o the pneumatic checkout r a c k s .
(6)
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The valve control module supplies nitrogen t o operate t h r e e (7) LOX f i l l and d r a i n valves, the fuel f i l l and d r a i n valve, the LOX i n t e r connect valve no. 2, and the LOX and fuel prevalves. Delivered flow r a t e to each valve i s approximately 6.0 pounds p e r minute a t approximately 725 psig. The control p r e s s u r e bottle fill module p r e s s u r i z e s t h e (8) stage nitrogen s t o r a g e s p h e r e s during two p r e s s u r i z a t i o n cycles. The f i r s t cycle c a l l s for a p r e s s u r e of approximately 1500 psig p r i o r t o fuel loading. The second cycle c a l l s f o r approximately 3250 psig, the d e s i r e d in-flight supply. Delivered flow r a t e i s 36. 0 pounds per minute. The high and low p r e s s u r e t e s t module supplies high p r e s (9) s u r e nitrogen a t approximately 3300 psig and 42.0 pounds p e r minute and low p r e s s u r e nitrogen a t approximately 750 psig a t 6.0 pounds per minute t o the pneumatic checkout r a c k s . ( 10) The fuel bubbling module injects nitrogen a t approximately 105 psig a t 0.60 pounds p e r minute and a flow of 15, 000 scirn into the fuel suction duct during LOX loading and replenishing. This nitrogen agitates the fuel and r e d u c e s t e m p e r a t u r e and density variations i n the fuel. (11) The LOX dome purge module prevents contaminants f r o m e n t e r i n g the LOX injection p a r t s of the F - 1 engine and gas generator. The module provides two nitrogen purge r a t e s a t s e p a r a t e t i m e i n t e r v a l s . The lower purge r a t e , 95 psig and 75. 0 pounds p e r minute, i s initiated whene v e r the c o v e r s a r e removed f r o m the engines o r when the fuel i s aboard the stage. The higher purge r a t e , 755 psig and 525.0 pounds p e r minute, i s initiated just p r i o r t o engine ignition and provides a blowout of t h e LOX i n j e c t o r s i n c a s e of engine cutoff and abort. 2. General a. b. Weight, pounds (Approximate) Location i n M L ( B a s e ) 6000 Compartment A - 13
Ill
3-6
M S F C - M A N - 100
Figure 3-3.
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Figure 3-3.
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The S-IC Pneumatic Checkout Racks provide p r e s s u r e regulated a. nitrogen gas f o r t e s t and checkout of p r e s s u r e switches and pneumatically actuated valves i n the S-IC stage propulsion systems. The r a c k s regulate, control, and monitor the gaseous media required to check out the S-IC stage. Normal operation i s by commands f r o m the computer; c e r t a i n functions can a l s o be commanded by the launch crew i n the Launch Control Center (LCC) when required. The S-IC Pneumatic Checkout Racks consist of four r a c k s which directly to the stage to check operation of various p r e s supply s u r e switches and pneumatically actuated valves.
b.
Pneumatic Checkout Rack #1 provides regulated GN2 to the c. following stage components f o r the following purposes :
(1)
a t 47 psig.
(2)
a t 25 psig.
(3)
Pneumatic Checkout Rack # 2 provides regulated GN2 to the d. following stage components f o r the following purposes :
(1)
a t 50 psig.
( 2 ) Calibration verification of the purge s y s t e m p r e s s u r e switches a t '190 psig.
(3)
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P n e u m a t i c Checkout R a c k #3 p r o v i d e s r e g u l a t e d GN2 t o t h e e. following s t a g e components f o r t h e following p u r p o s e s : C a l i b r a t i o n v e r i f i c a t i o n of the c o n t r o l p r e s s u r e s y s t e m (1) p r e s s u r e s w i t c h e s a t 3 , 2 0 0 psig. C a l i b r a t i o n v e r i f i c a t i o n of t h e c o n t r o l p r e s s u r e s y s t e m (2) p r e s s u r e s w i t c h e s a t 750 psig. (3) T e s t a c t u a t i o n of the GOX flow c o n t r o l v a l v e a t 1, 500 psig.
C a l i b r a t i o n v e r i f i c a t i o n of the " T h r u s t OK" p r e s s u r e (2) s w i t c h e s a t 1 , 7 7 5 psig. 2. General a. b. Weight, pounds ( A p p r o x i m a t e ) Location i n ML (Base) 3,600 C o m p a r t m e n t B - 13
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Figure 3-4.
S - I C F o r w a r d U m b i l i c a l S e r v i c e C o n s o l e a n d T e s t Set
3-11
S e c t i o n I11 S e r v i c i n g Equipment
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"
T h e f o r w a r d u m b i l i c a l s e r v i c e console c o n s i s t s of t h r e e n i t r o g e n a. r e g u l a t i o n m o d u l e s and a n e l e c t r i c a l d i s t r i b u t i o n d r a w e r . F a c i l i t i e s a i r at 1248 (-2 50) SCIM and 50 p s i g i s supplied to t h e console f o r continuous t p u r g e of t h e cabinet i n t e r i o r . E s c a p e of p u r g e a i r f r o m t h e cabinet i s c o n t r o l l e d by a c a l i b r a t e d bleed. The f o r w a r d u m b i l i c a l s e r v i c e console m o d u l e s and t h e i r p r i m a r y b. functions a r e a s follows: The c a m e r a l e n s p u r g e module s u p p l i e s heated n i t r o g e n a t (1) 350 p s i g and 4 . 0 pounds p e r m i n u t e , and a t 100 psig and 0.75 pounds p e r m i n u t e , t o the c a m e r a s y s t e m f o r l e n s p u r g e and s t r o b e light purge. The c a m e r a e j e c t s p h e r e f i l l module s u p p l i e s n i t r o g e n a t (2) 3000 p s i g and 10 pounds p e r m i n u t e ( m a x i m u m ) t o a s t o r a g e c o n t a i n e r f o r c a m e r a ejection. I t a l s o s u p p l i e s n i t r o g e n regulated t o 3000 psig t o t h e c a m e r a l e n s p u r g e module. T h e COX tunnel purge module supplies n i t r o g e n a t 3000 (3) psig and 81 pounds p e r m i n u t e t o t h e f o r w a r d u m b i l i c a l plate f o r GOX tunnel purging. 2. General a. b. Weight, pounds ( A p p r o x i m a t e ) Location i n ML (Base) 3,000 C o m p a r t m e n t A - 13
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B-H 1082
HELIUM I TESTER
F i g u r e 3-5.
S - I C P n e u m a t i c P o r t a b l e T e s t e r s ( S h e e t 1 of 3 )
3-13
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NITROGEN I TESTER
F i g u r e 3-5.
14
S-IC P n e u m a t i c P o r t a b l e T e s t e r s (Sheet 2 of 3 )
F i g u r e 3-5.
S - I C P n e u m a t i c P o r t a b l e T e s t e r s (Sheet 3 of 3 )
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T h e S - I C P n e u m a t i c P o r t a b l e T e s t e r s a r e provided f o r checking a. continuity of e l e c t r i c a l components of the pneumatic c o n s o l e and checkout r a c k s . Two t e s t e r s a r e used f o r t e s t i n g the pneumatic c o n s o l e , e a c h i n i t s own " s u i t c a s e " , and f o u r t e s t e r s a r e u s e d f o r t e s t i n g the checkout r a c k s , two t o a " s u i t c a s e " . In addition t o t h e s e , a s e p a r a t e t e s t e r i s p r o v i d e d , i n i t s own " s u i t c a s e " , f o r t h e f o r w a r d u m b i l i c a l s e r v i c e c o n s o l e . T h e pneumatic console t e s t e r s c o n s i s t of a s e l e c t o r s w i t c h , v o l t b. m e t e r , t o g g l e s w i t c h e s , and i n d i c a t o r lights mounted on a panel in a "suitcase". T h e s e l e c t o r switch and v o l t m e t e r a r e used t o t e s t p r e s s u r e t r a n s d u c e r s i n t h e console. E l e c t r i c a l power i s applied t o solenoid v a l v e s i n t h e c o n s o l e by t h e toggle s w i t c h e s . Position s w i t c h e s on t h e v a l v e s c o n t r o l l i g h t s on t h e t e s t e r panel indicating when the valves a r e opened o r c l o s e d . O t h e r lights on t h e t e s t e r panels i n d i c a t e w h e t h e r p r e s s u r e s w i t c h e s a r e actuated o r deactuated. The p r e s s u r e s w i t c h e s and t r a n s d u c e r s a r e a c t u a t e d by applying p n e u m a t i c p r e s s u r e to the s y s t e m .
A s e p a r a t e t e s t e r i s provided f o r e a c h of the four p n e u m a t i c c. checkout r a c k s . E a c h t e s t e r c o n s i s t s of a v o l t n l e t e r , toggle s u i t c h e s , and i n d i c a t o r l i g h t s mounted on a panel. The v o l t m e t e r s a r e used to c h e c k t h e output of t h e checkout r a c k p r e s s u r e t r a n s d u c e r s and s e r v o a m p l i f i e r s . T h e v o l t m e t e r d i a l s a r e c a l i b r a t e d in p s i and indicate line p r e s s u r e s . E l e c t r i c a l power i s applied t o solenoid v a l v e s i n the checkout r a c k s by the toggle s w i t c h e s . P o s i t i o n s w i t c h e s on t h e v a l v e s c o n t r o l lights on t h e t e s t e r p a n e l s indicating v a l v e s a r e open o r closed. O t h e r lights on the t e s t e r p a n e l s i n d i c a t e w h e t h e r the p r e s s u r e s w i t c h e s a r e actuated o r d e a c u a t e d . The p r e s s u r e s w i t c h e s and t r a n s d u c e r s a r e a c t u a t e d by applying p n e u m a t i c p r e s s u r e t o the s y s t e m .
d. T h e f o r w a r d u m b i l i c a l s e r v i c e console t e s t e r i s used t o t e s t t h e two r a c k s of t h e s e r v i c e c o n s o l e t h a t supply g a s e s to the forwarcl s t a g e u m b i l i c a l and contain t h e following n>odules: (1) (2) (3) C a m e r a e j e c t s p h e r e fill module C a m e r a l e n s p u r g e module GOX - tunnel p u r g e m o d u l e .
2.
45 (each) 23 x 19 x 12
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LAUNCHER OFF-ML
-- II
F i g u r e 3-6.
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a. T h e S-IC H y d r a u l i c Supply a n d Checkout Unit i s r e q u i r e d f o r functional g i m b a l of t h e f o u r o u t b o a r d engines of t h e S-IC s t a g e , checkout of t h e S - I C " T h r u s t OK" p r e s s u r e s w i t c h e s , a n d c o n t r o l of t h e engine v a l v e s of t h e five F-1 engines d u r i n g i n i t i a l f i r i n g a n d t h r u s t buildup. S i x p r i m a r y s y s t e m s a c c o m p l i s h t h e s e functions; t h e y a r e t h e fuel, s e r v o h y d r a u l i c , p n e u m a t i c , cooling w a t e r , h y d r a u l i c w a s t e , a n d electrical systems. ( 1 ) T h e f u e l s y s t e m s u p p l i e s fluid, a t a c o n t r o l l e d p r e s s u r e o v e r a wide r a n g e of flow r a t e s , t o t h e f u e l s y s t e m of t h e S-IC b o o s t e r . P r e s s u r e s r a n g e f r o m 0 t o 2500 p s i g a n d flows r a n g e f r o m 0 t o 2 6 0 gpm. ( 2 ) T h e s e r v o h y d r a u l i c s y s t e m p r o v i d e s high p r e s s u r e h y d r a u l i c fluid t o o p e r a t e t h e s e r v o v a l v e s on t h e t h r e e m a i n p u m p s . T h e s e v a l v e s c o n t r o l t h e d i s p l a c e m e n t of t h e t h r e e m a i n p u m p s t o m a i n t a i n a c o n s t a n t output p r e s s u r e d e s p i t e c h a n g e s i n flow demand.
( 3 ) T h e p n e u m a t i c s y s t e m u s e s GNZ f o r supplying a low p r e s s u r e blanket on t o p of t h e m a i n h y d r a u l i c r e s e r v o i r a s a f i r e p r o t e c t i o n d e v i c e , providing p r e c h a r g e gas t o t h e a c c u m u l a t o r s i n t h e f u e l a n d . s e r v o o i l s y s t e m s , a n d p r o v i d i n g g a s p r e s s u r e f o r t h e o p e r a t i o n of t h e t h r e e l a r g e s e l e c t o r v a l v e s which c o n t r o l t h e m a i n h y d r a u l i c fluid loop.
( 4 ) T h e cooling w a t e r s y s t e m i s e s s e n t i a l t o t h e p r o p e r o p e r a t i o n of t h e unit t o p r e v e n t o v e r h e a t i n g .
( 6 ) T h e e l e c t r i c a l s y s t e m provides power t o operate the various p u m p m o t o r s on t h e h y d r a u l i c power unit, p r o v i d e s c o n t r o l c i r c u i t s f o r s e l e c t i n g t h e m o d e of o p e r a t i o n a n d providing n e c e s s a r y i n t e r l o c k s and control programming, provides a n electronic s e r v o s y s t e m which c o n t r o l s t h e d i s p l a c e m e n t of t h e m a i n p u m p s t o m a i n t a i n a u n i f o r m output p r e s s u r e , a n d p r o v i d e s i n s t r u m e n t a t i o n f o r m o n i t o r i n g t h e o p e r a t i o n of c r i t i c a l functional e l e m e n t s .
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The unit i s activated a t approximately T-minus -8 h o u r s and b. continues t o o p e r a t e until it i s automatically shut down a t approximately T - p l u s - 5 seconds by the " T h r u s t OK" p r e s s u r e switches. The S-IC hydraulic supply and checkout unit c o n s i s t s of the c. hydraulic power unit, the motor control c e n t e r , and the s y s t e m checkout cons ole. 2. Facility Requirements a. Power ( 1 ) 480 vac, 60 cps, 3 phase ( 2 ) 120 vac, 400 c p s , single phase ( 3 ) 28 vdc Cooling water 125 gpm a t 60 psig and 45O F. Gaseous Nitrogen (GN2) 3,000 psig m a x i m u m Demand 600 a m p s 5 amps 25 a m p s
b.
c.
3.
4.
3- 19
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T h e H y d r a u l i c P o w e r Unit contains t h e 800 g a l l o n f u e l r e s e r a. v o i r , t h r e e high p r e s s u r e pumps d r i v e n by 150 hp m o t o r s , the s u p e r c h a r g e pump, and a s s o c i a t e d f i l t e r s , valves, a c c u m u l a t o r s , and o t h e r hydraulic components. The hydraulic power unit i s connected to the S-IC s t a g e by a hydraulic line, with a p r e s s u r e t r a n s d u c e r located a t the booster end of t h i s l i n e providing the p r e s s u r e sensing input t o t h e s e r v o s y s t e m which controls the output p r e s s u r e of t h e hydraulic power unit. The unit i s built i n t h r e e m o d u l e s , Module I containing t h e r e s e r v o i r and a s s o c i a t e d f i l l and d r a i n connections, and Modules I1 and I11 containing the high p r e s s u r e pumps and a s s o c i a t e d hydraulic components. This m o d u l a r c o n s t r u c t i o n f a c i l i t a t e s shipment and installation of the unit. The hydraulic power unit p e r f o r m s t h r e e m a i n functions; s t a g e , b. f l u s h , and d r a i n .
(1) The s t a g e function i s the p r i m a r y operating function when t h e unit i s connected to the booster. Fluid i s drawn f r o m t h e r e s e r v o i r through a f i l t e r t o the s u p e r c h a r g e pump. T h i s pump i n c r e a s e s t h e p r e s s u r e of the fluid f o r application to the m a i n pumps, and f i l t e r s t h e fluid through t h e f i r s t and second s t a g e f i l t e r s . The high p r e s s u r e fluid f r o m the t h r e e m a i n pumps p a s s e s through two s t a g e s of f i l t r a t i o n and i s applied t o t h e u m b i l i c a l line. F l u i d i s r e t u r n e d f r o m the b o o s t e r to the heat exchanger and f r o m the heat exchanger t o the r e s e r v o i r .
(2) The f l u s h function i s used t o c i r c u l a t e the fluid through t h e unit a t r e l a t i v e l y low p r e s s u r e to purify the fluid a s i t p a s s e s through t h e f i l t e r s . After the fluid i n the unit h a s been flushed, t h e unit m a y a l s o be used to f l u s h the fluid i n the b o o s t e r .
( 3 ) The d r a i n function i s used to d r a i n the f u e l r e s e r v o i r , to r e duce a l l possible e x c e s s weight before moving the ML. T h e fluid i s pumped to a n outside r e c e i v e r using the s u p e r c h a r g e pump, down to a p p r o x i m a t e l y 170 gallons. Additional fluid m a y be d r a i n e d , i f n e c e s s a r y , by u s e of a m a n u a l d r a i n valve.
II
2.
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Reservoir (1) Fluid capacity, gallons (Approximate) ( 2 ) Fluid ( 3 ) Fluid specific gravity Dimensions, inches (Approximate) Location i n M L ( B a s e )
c.
d.
3.
3-22
MSFC-MAN- 100
F i g u r e 3-8.
Motor Control C e n t e r
3-23
MSFC-MAN- 100
Functional Description
a. The Motor Control Center contains c i r c u i t b r e a k e r s , t r a n s f o r m e r s , r e l a y s , and safety interlocks f o r distributing e l e c t r i c a l power to the hydraulic power unit and the s y s t e m checkout console. It i s divided into four modules. The f i r s t module contains c i r c u i t b r e a k e r s and e l e c t r i c a l controls f o r the incoming line and auxiliary equipment, such a s the s u p e r c h a r g e pump, s e r v o pump, and recirculating pump. The o t h e r t h r e e identi c a l modules contain c i r c u i t b r e a k e r s and control c i r c u i t s f o r each of the t h r e e 150 hp high p r e s s u r e pump m o t o r s . To energize the s y s t e m , c i r c u i t b r e a k e r s i n the motor control b. c e n t e r m u s t f i r s t be closed. Single phase c i r c u i t b r e a k e r s o p e r a t e the m o t o r control c i r c u i t s which protect the m o t o r s against overheating, and i n c o r r e c t phasing. The motor control c i r c u i t s a l s o control s p a c e h e a t e r s in the m o t o r s and i n the m o t o r control c e n t e r cabinets. In addition, they include t i m e delay r e l a y s which prevent overloading the line by s t a r t i n g a l l m o t o r s a t once. T h r e e phase c i r c u i t b r e a k e r s apply driving power to the various pump m o t o r s . T h e s e c i r c u i t b r e a k e r s a r e located on the f r o n t panels of the motor control center and, when closed, lock these panels shut a s a safety m e a s u r e . M e t e r s a r e located on the f r o n t of the m o t o r control c e n t e r panels f o r monitoring line voltage and c u r r e n t in the various c i r c u i t s . Hour m e t e r s a r e included f o r each pump motor to m e a s u r e individual running t i m e s . 2. General a. b. c. 3. Weight, pounds (Approximate) Dimensions, inches (Approximate) Location i n ML ( B a s e ) 10,000 204 x 112 x 42 Compartment A-2
MSFC-MAN-100
B-H 1087
F i g u r e 3-9.
S y s t e m Checkout Console
3-25
MSFC-MAN- 100
a
1.
a . The S y s t e m Checkout Console contains two s e r v i c e panels and s i x d r a w e r s . The upper l e f t s e r v i c e panel contains the p r i m a r y c o n t r o l s and i n d i c a t o r s f o r operating t h e Hydraulic Supply and Checkout Unit. The upper right monitor panel contains s e c o n d a r y c o n t r o l s and i n d i c a t o r s . The s i x d r a w e r s i n t h e b a s e of the console contain r e l a y s , a m p l i f i e r s , c o n t r o l c i r c u i t c a r d s , and interconnecting wiring. One d r a w e r i s left empty f o r t h e installation of communications equipment by NASA. The two panels and s i x d r a w e r s of the console may be r e p l a c e d a s modules t o f a c i l i t a t e maintenance.
b. Numerous indicator lights located on both the s e r v i c e panel and t h e m o n i t o r panel provide indication of n o r m a l o r a b n o r m a l s y s t e m o p e r a t i n g conditions. All f i l t e r s i n the s y s t e m have p r e s s u r e switches connected to t h e m to s e n s e a clogged condition. T h e s e p r e s s u r e switches a c t i v a t e i n d i c a t o r s on t h e monitor panel. T e m p e r a t u r e , p r e s s u r e , and r e s e r v o i r l e v e l i n d i c a t o r s on the monitor panel a l l indicate a b n o r m a l conditions. R e s e t switches a r e provided f o r s e v e r a l of t h e s e i n d i c a t o r s s i n c e f a l s e warnings m a y o c c u r during s t a r t u p .
2. General
a. b. c.
1,100 52 x 53 x 26 C o m p a r t m e n t A-2
3.
3-26
MSFC-MAN-100
CONSOLE ASSEMBLY
F i g u r e 3-9A.
S-IC GSE H y d r a u l i c P e r f o r m a n c e T e s t e r
3-26A