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1
SPACECRAFT 8 ATTITUDE CONTROL
ANOMALY REPORT
I
NATIONAL AERONAUTICS AND SPACE ADMINISTRATION
MANNED SPACECRAFT CENTER
HOUSTON, TEXAS
JUNE 27, 1966
NASA PROGRAM GEMINI WORKING PAPER NO. 5050
Approved by:
S. H. Simpkinson
Manager, Office of Test Operations
Charles W. Ma thews
Manager, Gemini Program Office
FOREWORD
Section Page
FOREWORD iii
1.0 PURPOSE 1
2.0 SUMMARY 1
APPENDIX A A-l
APPENDIX B B-l
APPENDIX C C-l
APPENDIX D D-l
APPENDIX E E-l
vi
TABLES
Table Page
FIGURES
Figure
2.0 SUMMARY
5. 2 Systems Analyses
5.2.1 Propulsion system.- A review of valve design, testing pro-
cedures, and system tests was conducted. Acceptance test data for
TCA 8, and the history- of- failure records of all Gemini thruster sole-
noid valves during manufacturing, development, qualification, and reli-
ability testing were examined. The probability that the failure can be
attributed to a short circuit within the valves is considered remote.
The coil windings are insulated from the bobbin by two layers of
mica and a silicon varnish in addition to the wiring insulation. The
coil is insulated from the valve case by fiberglass wrappings and
silicon varnish. The coil lead wires are insulated by Teflon sleeving
in addition to the normal insulation and are also potted with Sylgard
in the valve riser to within a very short distance of the solder pins ;
on the electrical receptacle. Soldered connections to the receptacle
are protected by Teflon sleeves extending from the receptacle into the
potting compound.
A review of »n pertinent valve test results for this thruster
was acconiplished and no unusual data were noted. Each valve of this
type received a 1000- volt rms dielectric- strength test, a 500- V dc
insulation- resistance check, and a coil- resistance test after completion
of solenoid assembly. These tests were then repeated during acceptance
testing except that a 500-V rms level was used during the dielectric
test. Coil- resistance and dielectric- strength (500-V rms) tests were
conducted again during engine pre-delivery acceptance and in PIA testing.
During all 500-V rms dielectric-strength tests, the potential was ap-
plied for 1 minute with an allowable maximum current of 500 |jA. The
minimum allowable insulation resistance is 500 Mf> During dielectric-
strength testing performed in PIA tests, the flow of current between
the pins of the electrical receptacle and the oxidizer valve case was
47 pA, and similarly for the fuel valve, the current was 39 |jA- The
coil resistances were 43.1 ohms and 42.7 ohms on the oxidizer and fuel
valves, respectively, and were within the 42 (±2) ohm limits. X-rays
taken during manufacturing of the fuel and oxidizer valves for TCA 8
show that these valves were assembled normally in the riser to the re-
ceptacle, the most suspected area.
Relevant valve failures encountered on all configurations (25 and
100-pound thrusters) and modifications (Spacecraft 2 through 6 types)
were reviewed by the spacecraft contractor, the thruster manufacturer,
and the NASA. These revealed only one failure which could have produced
the anomaly. A metal chip between the coil and solenoid case caused a
short circuit which would have had the effect of either grounding the
power supply or of actuating the valve, depending upon attachment of
the coil lead. This type of failure would normally be detected by means
of the dielectric-strength testsj however, this particular valve did not
have the chip and burr controls that were exercised on the valves used
for Spacecraft 4 and subsequent spacecraft. The sample size investi-
gated was in excess of 2000 valves. During pre-delivery acceptance
testing, a total of 11 thrusters were rejected for failure to pass the
dielectric requirements previously discussed. None of these thrusters
were ever close to the point of indicating an incipient short circuit
to ground.
5.2.2 Attitude control and maneuver electronic (ACME).- The OAME
circuitry was reviewed and it was determined that a short circuit in the
driver transistors or in the circuitry between the driver transistors
and the output or AGE terminal connectors (connectors 5J2 and Jl — see
fig. 2) could cause TCA 8 to fire. A malfunction in other portions of
the ACME could cause inadvertent thruster firings, but would fire a pair
of thrusters rather than a single thruster.
This analysis limited the area of possible failure within the OAME
to the following:
(a) A short circuit in relay KL06
(b) A short circuit in diode CR20
(c) A short circuit to ground in the wiring connecting relay KL06,
diodes CR20 and CR3, and the pin in connector 5J2 leading to the thrus-
ter 8 solenoid valves
8
5« 3 Quality Evaluation
5. 3-1 Test histories.- A list of postulated failure modes was de-
rived as part of the anomaly investigation. The test histories of com-
ponents which could contribute to postulated failure modes were reviewed
to determine if there was any history of failures similar to the postu-
lated failure modes. The results of this analysis was negative. The
only spacecraft system test failures similar to the Gemini VTII postur
lated failures were experienced during the SEDR 371-^ and 383-7 tests.
In both instances, test histories of TCA's indicated inadvertent fir-
ings caused by cable clamps short circuiting a wire bundle.
5.3«2 Special evaluation of quality control.- A special quality
evaluation of the spacecraft wiring was conducted on the Spacecraft 6
and Spacecraft 7 reentry sections and on the Spacecraft 9 adapter-
assembly electrical harnesses. The purpose of these evaluations was to
10
determine the adequacy of the quality of the wiring harness, the wire
protective techniques, the Inspection criteria, and the effectiveness
and timeliness of the wiring-harness inspections. The following are
examples of some of the discrepant conditions that were found:
(a) Wire "bundles laying against structure edges, rivet heads, nuts,
"bolt heads, and coaxial-cable fittings. In these cases, neither the wire
"bundle nor the edge, et cetera, was covered to prevent contact and con-
sequent wire insulation damage.
(b) Excessively long ground wires
(c) Wire "breakouts from wire "bundles where the wire "broken out was
under tension
(d) Excessive harness lengths.
As a result of this evaluation, the following actions were taken:
(a) Reworked discrepant conditions in Spacecraft 9 adapter
assembly
C"b) Established more stringent criteria for wire installation and
inspection
(c) Established a formal physical spacecraft inspection, prior to
shipment, to reinforce in-process inspection during spacecraft fabri-
cation
(d) Established a more rigid spacecraft receiving inspection at
Kennedy Space Center and implemented formal shakedown inspections at
specific milestones in the preflight test plan
(e) Established a special NASA spacecraft acceptance inspection
team to perform detailed spacecraft inspections with the results of
these inspections being reported at the Spacecraft Acceptance Review
(SAR) Board meetings.
Ground rules covering critical wiring installation aspects were
documented and coordinated between the NASA Gemini Program Office and
the spacecraft contractor. Beginning on April 28, 1966, approximately
200 contractor personnel involved in the manufacturing, inspection, and
engineering of the Gemini spacecraft are being refamiliarized with these
ground rules in k hours of class training each.
5.3.3 Design changes.- Design changes resulting from the Space-
craft 8 anomaly investigation were as follows:
11
(a) CAMS thruster disabling: A single switch which will provide
the crew with a rapid means of disabling »"n QAMS thrusters has been
incorporated into the OAMS circuitry.
(b) Circuitry protection: All exposed electrical circuitry in the
OAME package has been coated with a soft conformal epoxy to protect
against possible inadvertent electrical short circuits.
(c) Wiring configuration: Grommet material has been added to the
structure in six general areas to increase clearance of wire bundles.
The Z-10J fairing has been trammed to increase clearance between the
fairing and the wire bundle. Engineering orders have been issued to
remove the tape from the TCA heater and solenoid wiring.
(d) Wire-bundle changes: Specially selected clamps are being used
exclusively for Gemini wire-bundle retention.
5.3'^ Flight procedures.- Flight procedures have been re-evaluated
and revised to provide the crew with optimum operating procedures for
a.n. known possible flight emergencies. A copy of these procedures is
attached as Appendix E.
12
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APPENDIX A
PILOT'S REPORT
APPENDIX B
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-300
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HCME bia s power t urned of for 1.6 >econds. TCA 8 st II fires. (07:13:3 1.6) — -
!
- In tial cond tions: A CS on fl ght contr ol mode 3. OAMS 1attitude control
i
power off (07:00:25)
i i i GATV elemetry indicate; ACS is urned ol
:
(07:12::•8.6)—,
-20 I 1
r - TCA 8 stops firing. Telemetry indicates TCA Son or remai nder of m ission ( 37:02:37. '1) [— TCA 8 starts iring agj in (07:0 ':20.31
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07:00 07:01 07:02 07:03 07:04 07:05 07:06 07:07 07:08 07:09 07:10 07:11 07:12 07:13 07:14 07:15
Ground elapsed time, hr:min
(a) Docked.
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Ground elapsed time, hr:min.
Figure 5,1.5-20. - Attitude control anomaly - time history.
C-l
APPENDIX C
PROPULSION SYSTEM
(Excerpted from Section 5.1.8 of the
Gemini Program Mission Report for Gemini VIII)
C-2
The A-ring was turned off at 7:19:38 g.e.t. after 79.7 seconds of
firing time accumulated over k pulses. The B-ring was then used to
achieve control, with the command pilot using 126 pulses and an accumu-
lated firing time of 306.Jj- seconds, until 7:31:25-7 g.e.t. when the
c-6
B-ring was turned off. A check of the B-ring system operation from
9:01:49 to 9:07:27 g.e.t. in pulse and orbit rate-command modes showed
nominal performance. A final check of the A-ring operation in rate-
command, pulse, direct, and reentry rate-command modes, performed from
9:52:19 to 9:54:07 g.e.t., also provided nominal data.
c-7
Angular acceleration,
Thrust, Ib
Engine
deg/sec
numbers
Preflight Flight Preflight Flight
QAMS
1-2 45.7 43 3-7 3-5
3-4 46.1 44 3-7 3-5
5-6 ^5.8 44 3-7 3-5
7-8 46.4 ^3 3-7 3-6
RCS
A-ring
1-2 46.9 44 3-5 3-3
3-4 47.1 44 3-5 3.4
5-6 47.0 44 3.5 3-4
4-8 46.9 47 1.7 1.7
RCS
B-ring
1-2 46.9 44 3-5 3.3
3-7 47-3 47 1-7 1-7
5-6 47.1 44 3-5 3.3
4-8 47.0 47 1-7 1.7
a
Typical values determined at various times through-
out the mission.
C-8
<
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D-l
APPENDIX D
ELECTRICAL SYSTEM
(Excerpted from Section 5.1.7 of the
Gemini Program Mission Report for Gemini VTII)
D-2
The following four facts stand out from the preceding data:
(c) The only times after the malfunction started when common-
control-bus data, spacecraft-dynamics data, and telemetry bi-level data
agree that thruster 8 was off was during the times when the thruster 8
circuit breaker was opened.
From the above facts, it may be deduced that the failure was
electrical rather than mechanical, and was complex in nature.
From figure 5«l«7-7 it can be seen that the thruster will fire
±f,
(a) False inputs are sent to the valve drivers
D-5
(a) The flight crew reported switching from the primary to the
secondary drivers without a successful commanded response from
thruster 8.
(b) A failure in this portion of the circuitry will not explain
the low-grade accelerations characteristic of a single thruster valve
operating.
(c) If it were possible to have a high-resistance short suffic-
ient to drop out only one solenoid (2.0 volts across the solenoid),
then the telemetry voltage would be greater than 15 volts. Hence,
telemetry would have indicated off rather than on as it did during
periods of low-grade accelerations.
It is evident from the above that the failure was in the solenoids
or in the spacecraft wiring between the solenoids and the junction of
the two solenoid ground returns.
CONTROL
SYSTEMS
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Prepared by Flight Crew Support Division NI,OPERATIONS HANDBOOK
Checked tor. Mission Operations Branch 10 Rev QrU
Approved by Date 5/10/66 I Section ^74.1
HSC Form 1097B (Dec 63) NASA • Manned Spacecraft Center
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