-CATION CHANGE

A Reproduced Copy 1

OF
{NASA-CR-111195) G E M I N I SPACECRAFT X72-80686
PROPULSION SYSTEMS S P E C I F I C A T I O N (U) Sa
T o l p e n (McDonnell A i r c r a f t Corp.) 13 Jul.
1962 98 p
1;0/99

I
I 879-76559
(NASA-cR-111 195) GEHIIBI SPACECRAFT
PROPULSION SYSTEIIS SPECIFICAT~ON (HcDonnell
Aircraft Co.) 98 p Unclas
00/20 11690
D NUMBER) (CATEGORY)-

i
Reproduced for NASA
by the
Scientific and Technical Information Facility
 DATE' 20 February 1962

REVISED 18 J u l y 1262

GEMINI SPACECRAFT
PROPULSION
S Y S T E M S SPECIFICATION
(TI TL E UNC LASSl F IED)

.SERIAL NO. &

MCDONAlELh AIRCRAFT CC3RPORATlQN

b
MATION A f F

IN ANY MANNER T O AN U N A
 PAGE
i
REPORLT 86142
MODEL Gemini

APPRGVAL S%ET

Prepared by:
S. Tolpen - Spec&cations Group

Approved by:
L. 1.1. Parker - Senior S p e c i f i c a t i o n s Engineer
.-P

R
E
, , J . N. E a r n h i l l - Senior Group Engineer Design V

H. 0. L u t z
/
- S x Q r o t e c h n i c s Engineer

-
.
L & fmmTLA I

..-.---, -. - . . ,.. ._.

. , . ,. . .* .. , . ., . ‘ . _.... .... . ”
DATE 20 kebruary 1962 ST. LOUIS, MISSOURI PAGE ii
REVISED 18 Juv
196? REPORT
*% r .
C - . '.+L

REVISED 't. . . MODEL ue:1--:;3

1. GT:IIJERAL
1.1 Scope \

2. APFLICAELE iX)CUMEX':TS
2 01 General
2.2 Do cumects
2.2.1 Contra c tar Fubli c a t i o n s
2.3 Super s e derice

3. OHBIT k.T'TITUbh AND i.Li1\;LUKH SW1EI.i

3 01 General
3 -2 Function
3 .3 Descriptior, and Operaticn
3 04 Design Criteria
3.5 De s i g n Requirements
3.581 I n p u t s and Eluids
3.5.2 Performance
3.5.3 heights
3.5.4 Materials o f Constructicn
3.5.5 Assembly
3.5.6 Interchangeability
3.5.7 Component Life
3.5.8 Ground Checkout
3 86 Environmental Conditions
3.7 S t r u c t u r a l Hequirements
3.7.1 Pressures and Temperatares
3.702 Tabulation of' Operating, Proof and Burst. FresEures f a r
Components

4. RETRQGRA3F, ROCKET SYSTEM

4.1 General
4.2 Function
4.3 Opera t i o n
4.4 De s i g n Requirements
4.4.1 Retrograde Rocket
4.5. Environmental and Load Hequirements
4.S.l Environmental Conditions
&.6 S t r u c t u r a l Requirements
DATE -arv 1962 ST. LOUIS, MISSOURI PAGE iii
REVISED 18 JUlV 1962 REPORT 06b2
R E V l SED -h. MODEL Gemini

TABLE OF' CONTENTS (Continued)

Page

m-EKTRY CQNTRCL SYSTFM 50

General 50
Function 50
Description znd Operation 50
Design Criteria 56
De s i g n Requirements 58
I n p u t s and Fluids 58
Performance 59
heights 60
M a t e r i s l s o f Construction 60
Assembly 60. R
Interchangeability 60 E
Compo fie n t Life 60 V
Ground Checkout 61
Environment.al Conditions 61
S t r u c t u r a l Requirements 61
Pressures and Tenperatures 61
Tabulation of Operating, Proof and Burst
Pressures f o r Componentis 43
6. QUALITY ASSUXXCE 66
6.1 General 66
7. ' RELIHBILSTY 66
7.1 General 66
8. DATA FtI&UI REIENTS 66
8.1 General 66
AFEFEN3M I ELJJIPIvENT LIST 67 I
N
APPEKDIX I1 LIST QE' CHANGES 69 E
W
ALTkRiiATE RETRCGRAJIL ROCKET SYSTEM A1 I
I
 2 0 February 1962 ST. LOUIS, MISSOURI PAGE
i \r

REVISED 18 JUlY 1962 REPORT ;:(,! I3

REVISED MODEL

LIST OF -"IGURES AND TABLES

Figure. -Pape
.
1 Thrust Chamber Assembly (TCA) Arrangement 4

. 2 O r b i t A t t i t u d e and Xaneuver System

Schematic (Two Day Nission) .
5

3 O r b i t A t t i t u d e and Maneuver System 6

Schematic (Fourteen Day Mission)

4 Orbit A t t i t u d e and Maneuver System 7

Component I n s t a l l a t i on

5 Component Package ItA1l Schematic 9

6 Orbit A t t i t u d e and Pkneuver System 11
Pressure Regulation Group

7 Pressure Psgulator 12
8 Component Package ItEtt Schematic 13
9 Component Package Wt Schematic 14
10 Component Packages and ttDtt Schematic . 16
11 Typical Thrust Chamber (25 l b . OMIS) . .
17
12 Propellant Line G u i l l o t i n e 19

13 Propellant Temperature and Pressure I n d i c a t o r 21

and S e l e c t o r Switch

1L P r o p e l l a n t Display 22

Gemini Spacecraft Vibration Spectra Quipment

Category A 33
1.6 G e m i n i Spacecraft Vibration Spectra Equipment
Category B 34
17 Gemini Spacecraft Acoustic Environment Spectrum
( I n t h e Adapter) 35
 ?

DATE 20 February 1962 ST. LOUIS, MISSOURI PAGE V

REVISED -&&b 1962 REPORT 86h2

REVISED MODEL Gemini

LIST OF FIGURES AM> TABLES (Continued)

Figure No. Page

18 Gemini Spacecraft Acoustic Environment

Spectrum ( I n t h e Re-entry Module i n t h e . .
. Pressurized Cabin) 36
19 Gemini Spacecraft Design L i m i t Load Factors
Area I1 (Main Cabin Section) 37
20 Retrograde Rocket Arrangement 39
21 Retrograde iiocket Assembly 40
22 Retrograde Rocket Performance, Weight, and N
Design Parameters 42 E
W
23 Retrograde Rocket System I n s t a l l a t i o n 43
24 L i m i t Loads f o r Retrograde Rocket 49
25 Re-entry Control System Schematic 51
26 Re-entry Control System Component I n s t a l l a t i o n 52

27 G e m i n i Spacecraft Acoustic Environment Spectrum

( I n t h e Re-entry Module External t o t h e
Press u r i z e d Cabin) 65

* Table. No.

I Design Environmental Conditions f o r Orbit

A t t i t u d e and h n e u v e r System Equipment Located
PaRe

i n .the Adapter 31
I1 Design Environmental Conditions f o r O r b i t
A t t i t u d e and Maneuver System and Re-entry Control
System Equipment Located i n the Re-entry Module R
i n t h e Pressurized Cabin 32 E
V
I11 Design Environmental Conditions f o r Retrograde
Rocket System Equipment Located i n t h e Adapter 156
IV Design Environmental Conditions f o r Re-entry
Control System Equipment Located i n t h e Re-entry
Module Ekternal t o the Pressurized Cabin 64
DATE ? ST. LOUIS, MISSOURI PAGE vi
REVISED REPORT 8642
R E V lSED MODEL Gemini

LIST OF EFFECTIVE PAGES

TITLK PAGE R
i --
vii E
v
1 71
A 1 -A16
 DATE l.962 ST. LOUIS, MlJSOURt PAGE A
REVISED REPORT 86k2
REVISED MODEL

INDEX OF REVISIONS

PAGES A F F E C T E D
DATE REMARKS REVISED B Y APPROVED
REVISED ADDED REMOVED

Complete Revision S. Tolpen L oM. Parker

N
E
W
a

MAC 2 3 l X ( R E V 2 3 JUN 6 ! )
DATE 30 k ' w 1962 ST. LOUIS, MISSOURI PAGE A
REVISED 18 'Fh3 REPORT 85h2
REVISED
MODEL Gemini

1. GENERAL

1.1 SCOPE.- This s p e c i f i c a t i o n d e s c r i b e s t h e Propulsion Systems f o r t h e

G e m i n i q a c e c r a f t (M.A.C. Model 133P) t o be constructed by t h e
McDonnell A i r c r a f t Corporation (M.A.C. } f g r t h e Iiational Aeronautics and Space
I
R
Administration (USA) under Contract NAS 9-170. 'i'he Propulsion S y s t e m c o n s i s t E
o f a n O r b i t Attitilde and l k i e u v e r System, Retrograde Rocket System, and Re-Entry V
Control System. Included i n t h i s document i s a d e f i n i t i o n of t h e function,
operakion, design requirements, and perforrnance c h a r a c t e r i s t i c s of the s y s t e m
and t h e i r components, as well a s the r e l i a b i l i t y and q u a l i t y assurance t e s t
program t o be performed t o a s s u r e t h a t t h e s e o b j e c t i v e s are m e t . This document
i s n o t t o be u s e d . f o r i n s p e c t i o n purposes.

2. APPLICABLE w cumNrs
2.1 GENEHAL.- It i s the Contractor's i n t e n t , r e l e v a n t t o t h e use of I
R
governiient s p e c i f i c a t i o n s i n t h e design and a d m i n i s t r a t i o n tzf t h e
Propulsion -Istens, t o u t i l i z e e x i s t i n g specif.ications where p r a c t i c a b l e . I n E
cases where t h e s u b j e c t matter i s applicable b u t t h e s p e c i f i c requirements are v
not compatible due t o t h e advanced design of these systems, t h e s p e c i f i c a t i o n s
and documents referenced are followed only t o t h e e x t e n t t h a t the i n t e n t of such
requirements a r e m e t .
I
2 03. DOCUPlEENrS.- Government s p e c i f i c a t i o n s , stardards, and p u b l i c a t i o n s
are l i s t e d i n M.A.C. Report 8357.

2.2.1 CONTRACTOR PUBLICATIONS.- The following Contractor-prepared publi-

c a t i o n s a r e applicable t o t h i s system s p e c i f i c a t i o n .

M.A.C. Drawing 52-50700 S p e c i f i c a t i o n Control Drawing f o r

Retrograde Rocket - Model 133P
Capsule

M.A. C. Drawing 52-50702 S p e c i f i c a t i o n Control Drawing

! 'Retrograde Rocket - Gemini
Space c r a f t
R
M.A.C. Qrawing 52-52700 S p e c i f i c a t i o n Control Drawing E
M.A.C. Model 133P Re-Entry V
Control System

M A .C. h a w i n g 52-52701 S p e c i f i c a t i o n Control h a w i n g

M.A.C. Model 133P Orbit A t t i t u d e
and Kaneuver Systern

MOA C . . Hepar t 8580-3 Project G e m i n i R e l i a b i l i t y Plan

 20 February 1962
- ST. LOUIS, MISSOURI PAGE .A
REVISED If? *Tuly REPORT 86/12
REVISED m-
. MODEL Gemini

2.2.1 CONTFACTOR PUBLICATIWS. - (Continued)

K . k C. %port 8580-7 Q u a l i t y Assurance Provisions (Plan
. f o r P r o j e c t G e m i n i Space System

M.A.C. Report 8580-8 Model 133P Gemini Program Docu-

mentation P l a n R
. M.A.C. Report 8611 . G e m i n i Spacecraft Performance
E
v
Specification

M.A.G. Report 8637 Gemini Spacecraft Guidance and

Control System S p e c i f i c a t i o n

M.A.C. Report 8757 Preservation, Packaging and

Shipping of Gemini P a r t s and
Equipments

2.3 SUPEFSEDENCE.- If any o f t h e s p e c i f i c a t i o n s , standards, drawings,

and publications which form a p a r t of t h i s system s p e c i f i c a t i o n
are superseded during the l i f e o f t h e c o n t r a c t of which t h i s system s p e c i f i c a -
t i o n i s a p a r t , t h e l a t e r i s s u e may be used.
DATE 20 February 1962 ST. LOUIS, MISSOURI PAGE 3
REVISED REPORT A
REVISED MODEL . Gemini

3. ORBIT ATPITUDE AND MANEWER SYSTEM

3.1 GENERAL.- The Orbit Attitude and Mneuver System (OAMS) i s a

l i q u i d b i p r o p e l l a n t rocket engine propulsion system c o n s i s t i n g of
s i x t e e n fixed-mount Thrust Chamber Assemblies ( E A ' S ) operating on s t o r a b l e
hypergolic p r o p e l l a n t s supplied by a c o l d gas pressurized p o s i t i v e expulsion f e e d
system. The s i x t e e n E A ' S a r e located i n the adapter and a r e arranged as s h o - i
i n Figure 1.

3.2 FUNCTION.- The O W , i n conjunction w i t h t h e A t t i t u d e Control and

Maneuver E l e c t r o n i c s (ACME), various sensing devices and t h e h m d
c o n t r o l l e r s and f o o t pedals, provides a t t i t u d e and maneuver c o n t r o l of t h e
s p a c e c r a f t from t h e time of spacecraft separation from t h e launch vehicle u n t i l
retrograde. A t retrograde, t h e OAMS is j e t t i s o n e d and s p c e c r a f t a t t i t u d e con-
t r o l i s provided by t h e Re-Entry Control System (RCS) from retrograde t o deploy-
ment of t h e drogue chute o r paraglider.

The OAMS i s capable of two types of missions: a two day mission

during which a rendezvous w i t h t h e t a r g e t vehicle (Agena) i s c a r r i e d out, or a
f o u r t e e n dsy o r b i t i n g mission. The system responds t o e l e c t r i c a l s i g n a l s from R
t h e Orbit A t t i t u d e and Maneuver Electronics ( O M ) which i s a psrt of t h e A C B . E
I n response t o t h e e l e c t r i c a l s i g n a l s , t h e OAMS produces rocket t h r u s t f o r c e s
f o r a t t i t u d e c o n t r o l and maneuver of t h e spacecraft.

Translation of t h e spacecraft i s c o n t r o l l e d by t h e crew through use

of the maneuver hand c o n t r o l l e r . Attitude i s c o n t r o l l e d automatically by t h e
ACME o r manually by t h e crew through t h e ACME. Control by t h e crew i n p i t c h
and r o l l i s accomplished w i t h t h e a t t i t u d e hand c o n t r o l l e r and i n y a w w i t h the
f o o t pedals (a d e t a i l e d discussion of t h e guidance and c o n t r o l modes of operatio2
i s contained i n M.A.C. Report 8637).

The a f t - f i r i n g maneuver chambers are used t o provide t h r u s t f o r

s p a c e c r a f t s e p a r a t i o n from t h e launch vehicle i n normal missions and f o r high
a l t i t u d e a b o r t s (see Section 3.3 of M.A.C. Report 86.11).

Pitch, r o l l , and yaw torques are obtained by f i r i n g pairs of TcA's.

T r a n s l a t i o n a l a c c e l e r a t i o n i s obtained by f i r i n g appropriate TAC's s i n g l y or i n
pairs according t o the d e s i r e d d i r e c t i o n of motion. TCA's used f o r a t t i t u d e
c o n t r o l have a nominal motor a x i a l t h r u s t of 25 pounds, those used f o r transla-
t i o n a f t have a motor a x i a l t h r u s t of 85 pounds, and those used f o r t r a n s l a t i o n
forward, l e f t , r i g h t , up, o r down have a motor a x i a l t h r u s t of 100 pounds.

3.3 DESCRIPTIC?? AlE 3PERATION.- The components a r e arrayed as s h a m

schematically i n Figure 2 f o r t h e two day mission and Figure 3 f o r
t h e f o u r t e e n day mission and a r e i n s t a l l e d as shown i n Figure 4. I n general,
system operation may be described as follows. Cold gas i s s t o r e d under pressure
& TE
20 February 1962 PAGE - 4
EVlSED
18 July 1962 REPORT 86L2
ST. LOUIS, MISSOURI
GEMSNI
EVlSED MODEL ___-
-. ^._ I..

THRUST CHAMBER ASSEMBLY (TCA) ARRANGEMENT

RE-ENTRY COt4TROL SYSTEM

...$a'
.-.~.~~::~~~...~~".~..
-:.-:.
-
1
..

.a
:
&+*.

..' .:.
a
.:
e:.
..?*

RE-ENTRY MODULE

LEGEND:
- RING A (2188.77)
---- RING (2183.17)

16 - 25 LB. THRUST CHAMBERS

I
0

f
6' 35 '(TY P.) 0
0

.
0
FUNCTION TCA NO. w 0

0 -

PITCH UP 5 AND 6
PITCH DOWN 1 AND 2
YAW RIGHT 3 AND 4
YAW L E F T
R O L L CLOCK WISE
7 AND
3 AND
8
7
I 14.9R (TY P.1

R O L L COUNTERCLOCKWISE 4 AND 8
T Y 3.98 A T 2;:-
CODE

25 LB. 0 4
NOTES: 1 85 LB. . 0 4
10 DIRECTIONS REFERENCED TO ASTRONAUTS' ORIENTATION.
100 L3. e 4
2. ARROWS INDICATE FLOW OF EXHAUST GASES.
Figure 1
31 Ell /REV 2 5 AUG 61 )
 ~ & h ; W W ~ ~ E -
,20 February 1962
DATE ST. LOUIS: MISSOURI C-e;c

REVISED
18 July 1962 iitL 'Y- __

7:,

ORBIT ATTITUDE A N D MANEUVER S Y S '

SCHEMATIC- 2 DAY MfSSiON
PRESSURANT GROUP ---
COM PONE NT

t PRESSURANT STORAGE
1
LEGEND
THRUST CHAMBER ASSEMBLY
CONNECTED
NOT CONNECTED
TEMPERATURE (TRANSMITTED TO INSTRUMENT
PAN E L INDICATOR 1
PRESSURE (TRANSMITTED TO INSTRUMENT
PANEL INDICATOR)
MANUAL VALVE

CARTRIDGE-ACTUATED VALVE (NORMALLY CLOSED)

CARTRIDGE-ACTUATED VALVE (NORMALLY OPEN)

PRESSURE TRANSDUCER

R E L I E F VALVE

SOLENOID VALVE (NORMALLY CLOSED)

PRESSURE SWITCH

BURST DIAPHRAGM

CHECK V A L V E

FILTER
GROUND TEST CONNECTION

MOTOR O P E R A T E D V A L V E

FLOW LIMITING ORIFICE

25 LB. THRUST TCA (YAW, PITCH, 8, ROLL)

100 LB. THRUST TCA (TRANSLATE FORWARD)

PROPELLANT L I N E GUILLOTINE
100 LB. THRUST TCA (TRANSLATE RIGHT, LEFT, UP,
OR DOWN)
85 LB. THRUST TC;. (TRANSLATE AFT)
ATTITUDE A N D MANEUVER SYSTEM
SCHEMATIC- 2 DAY MISSION
PRESSURANT GROUP
.. OXIDIZER/FUEL GROUP
a ---I. e

.
. r
..
..
..
I--
COMPONENT : FUEL

L-COMPONE :
PACKAGE
)VE RBOAR D
i R ASSEMBLY VENT

1
TRANSMITTED TO INSTRUMENT
IR)
qSMITTED TO INSTRUMENT
3R)

rUATED VALVE (NORMALLY CLOSED)

rUATED V A L V E (NORMALLY OPEN)

qSDUCER

i GM

COMPONENT
CONNECT ION PACKAGE
Ug"
TED VALVE

ORIFICE

TCA (YAW, PITCH, & R O L L )

r T C A (TRANSLATE FORWARD)

,INE GUILLOTINE
T TCA (TRANSLATE RIGHT, LEFT, Up,

T ich (TRANSLATE AFT)

Figure 2
lROUP TCA GROUP

IMPONENT
4CKAGE
sn

R
.
e
E
V

..
I
I
I

I
I.
I PE L L A N T
IUS

DMPONENT
PACKAGE
#IC”

.
.
W
 DATE
20 February 1962 ST. LOUIS, MISSOURI PAGE ___I
6
REVISED
18 July 1962 RkPORT
.
-_
c

REVISED
MODEL c;: :,sI; I
-

ORBIT ATTITUDE A N D MANEUVER SYSTEM

SCHEMATIC-14 DAY MISSION
PRESSURANT GROUP
COMPONENT --
PACKAGE K

r- COMPONENT
t PRESSURANT STORAGE PACKAGE
T1 TANKS (H-) "E"
TO
3VER BOAR D
THRUST CHAMBER ASSEMBLY VENT
CONNECTED
NOT CONNECTED
TEMP E RAT U R E (T R AN SMIT T E D TO INS T R U ME N T L
PANEL INDICATOR)
PRESSURE (TRANSMITTED TO INSTRUMENT
P A N E L INDICATOR)
MANUAL V A L V E

CARTRIDGE-ACTUATED V A L V E (NORMALLY CLOSED)

CARTRIDGE-ACTUATED V A L V E (NORMALLY OPEN)

PRESSURE TRANSDUCER

R E L I E F VALVE

e SOLENOID VALVE (NORMALLY CLOSED)

PRESSURE SWITCH

BURST DIAPHRAGM

I-1 CHECK V A L V E

FILTER

7
- GROUND TEST CONNECTION

MOTOR OPERATED VALVE

FLOW LIMITING ORIFICE

25 LB. THRUST TCA (YAW, PITCH, 8 ROLL)

100 LB. THRUST TCA (TRANSLATE FORWARD)

Figure 3

MAC 231C fREV I AUG 6 1 1

WJDE AND MANEUVER SYSTEM
4EMATIC-14 DAY MISSION
o XI DI ZER/FUEL G R o uP
PRESSURANT GROUP
--'I
m1
I a
r
..
..
f

. I
*
n
I..
?
. I--1 --
3
STO RAG E
COMPONENT
PACKAGE

TO
PRESSURE
REGULATOR

IVE R BOAR D
\ COMPONENT
PACKAGE
"D"
jEMBLY

t
ISMITTED T O INSTRUMENT
L -T FUEL TANK

T E D T O INSTRUMENT

c-
-
ED V A L V E (NORMALLY CLOSl

ED V A L V E (NORMALLY OPEN'

tER
r
ORMA @ CLOSED)
p2

.
e

COMPONENT .
IECTION PACKAGE
"8" ..
..
v
VALVE

IC E 1

I
..
(YAW, P I T C H , 8. R O L L )

A (TRANSLATE FORWARD)
.
...
.
- Figure 3
ROUP TCA GROUP

- a
. .
1 _

..'

I
I ,

)MPONE N T
KKAGE
)'*

3PELLANT
(KS

OMPONENT
PACKAGE
"C"

.
 OAT E 20 February 1962 7
ST. LOUIS, MISSOURI PAGE

REVISED 18 July 1962 REPORT 86L2

REVISED 1 MODEL GEMIIJI

z
0
II

c
4
2
2
c
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z
II

c
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W
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e
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0
V
z
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s
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LI1
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s
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3
-
c
c
c
a
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I

m
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MAC 231C (REV 1 AUG 6 0

~
DATE ST. LOUIS, MISSOURI PAGE

REVISED l8 1962 REPORT 0642

REVISED MODEL A. .

3.3 DESCRIPTION AND OPERATION .- (Continued)

i n t h e pressurant storage tank and held t n e r e i n by a normally closed c a r t r i d g e -

actuated valve. khen t h e system i s t o be a c t i v a t e d , t h e c a r t r i d g e valve i s
opened and t h e pressurant flows t o the pressure r e g u l a t i o n grclup. The gas
pressure i s reduced a t t h e r e g u l a t o r t o a p r e s e t value and t h i s r e g u l a t e d
pressure i s imposed upon each o f the propellant t a n k s t o p r e s s u r i z e t h e pro-
p e l l a n t s . These tanks are of t h e f l e x i b l e collapsing bladder type f o r p o s i t i v e
expulsion of the p r o p e l l a n t s i n t h e gravity-free environment of space. Simul-
taneously with t h e f i r i n g of t h e above mentioned valve, s i m i l a r valves located
downstream from t h e p r o p e l l a n t tanks are opened. The system, with valves open
and p r o p e l l a n t s pressurized, i s ready f o r a f i r i n g command. The f i r i n g command
i s received a t t h e t h r u s t chamber propellant valves which open i n response,
p e r m i t t i n g p r o p e l l a n t flow t o t h e t h r u s t chamber. The sinultaneous i n t r o d u c t i o n
of both propellants t o t h e t h r u s t chamber p r e c i p i t a t e s hypergolic i g n i t i o n ,
combustion, and t h e generation of t h r u s t .

As shown on Figures 2 and 3 , p a r t of t h e OhNS i s designed on a

modular basis, with t h e modules consisting o f s e v e r a l components conveniently
and compactly arranged t o reduce weight, eliminate l e a k s , and f a c i l i t a t e i n -
s t a l l a t i o n , t e s t i n g and s e r v i c i n g of the system. There are s i x such modules:
component packages "At1, IIB1' J I1C" 9 I'D", and W', and t h e TCA's. I n addition,
,
t h e r e a r e the pressurant storage tank(s) pressure r e g u l a t o r , p r o p e l l a n t tanks,
p r o p e l l a n t supply on-off valves, and propellant l i n e g u i l l o t i n e s .

The Components are divided i n t o t h r e e main groups: a pressuriza-

t i o n group, oxidizer and f u e l groups, and 'I'CA group. The p r e s s u r i z a t i o n group
c o n s i s t s of a pressurant s t o r a g e tank(s), component packages "A" and rlB1l, and a
pressure r e g u l a t i o n group ( a pressure regulator/component, package "E" cmbina-
t i o n ) . The o x i d i z e r and f u e l groups are s i m i l a r , c o n s i s t i n g of p r o p e l l a n t tanks,
component packages ltC1l and l'B1l,and p r o p e l l a n t supply on-off valves. Each ICA
i n t h e TCA group contains p r o p e l l a n t valves, i n j e c t o r s , and t h r u s t chambers.- A
d e t a i l e d d e s c r i p t i o n of the components c o w r i s i n g t h e s e groups i s contained i n - '
t h e following paragraphs.
b' ' The pressurant storage tank i s an all-welded, s p h e r i c a l tank.
Helium gas i s s t o r e d i n t h e tank a t a nominal storage pressure of 3000 psig.
E i t h e r one o r two tanks areprovided depending on t h e mission t o be performed.
When two tanks are used, they a r e i d e n t i c a l i n s i z e . Each tank i s 15.20 inches
i n o u t s i d e diameter and has a n i n t e r n a l volume of 1696.0 cubic inches.
Component package llA1l, Figure 5 , c o n s i s t s of a pressure transducer,
a normally closed cartridge-actuated valve, and two manual valves. The pressure
transducer i s used t o monitor t h e pressure of t h e s t o r e d high p r e s s u r e gas. The
c a r t r i d g e valve i s used t o i s o l a t e t h e pressurant from t h e remainder o f t h e
system p r i o r t o system a c t i v a t i o n . 'The manual valve upstream of the c a r t r i d g e
valve i s used f o r f i l l i n g , draining, and purging of t h e p r e s s u r a n t W i l e t h e
manual valve downstream from t h e c a r t r i d g e valve i s used during ground checkout
of t h e pressure r e g u l a t i o n group.
DATE
20 February 1962 9
ST. LOUIS, MISSOURI PAGE
18 July 1962 q.2
UL ‘4
REVISED REPOFT

REVISED 1 MODEL GEaX

COMPONENT PACKAGE “A” SCHEMATIC

PRESSURE TRANSDUCER

CARTRIDGE-ACTUATED V A L V E
(NORMALLY CLOSED)

AL
VE

N
E
W

GROUND TEST
CONNECTION INLET

Fiaure 5
MAC 73lC (RTV I AUG 611
DATE 3 bphp1l=(ry 1967 ST, LOUIS, MISSOURI PAGE 10
REVISED -.
7 9 &d4?_7.?h7 REPORT 86b2
REVISED MODEL Gemini

3 03 DESCRIPTION ARD OPERATION.- (Continued)

I'
-
The pressure r e g u l a t i o n group i s shown s c h e n a t i c a l l y i n Figure 6.
lhe r e g u l a t o r , Figure 7, provides the primary inode of pressure r e g u l a t i o n OS the
p r e s s u r a n t gas, the nominal pressure s e t t i n g f o r r e g u l a t i o n being 280 psig. I t
i s of t h e single-stage, conventional mechanical-pneumatic type. A 2-micron
i n l e t f i l t e r i s used t o reduce t h e contaminants i n t h e . g a s t o an a c c e p t a b l e ,
. l e v e l , thereby i n c r e a s i n g t h e r e l i a b i l i t y o f . t h e r e g u l a t o r .
r 2-\ r
+.
Component package rlE1l, Figure 8, provides t h e secondary mode of
pressure r e g u l a t i o n of t h e pressurant gas. It c o n s i s t s o f a normally open
cartridge-actuated valve, a normally closed solenoid by-pass valve, a normally
closed cartridge-actuated valve, a pressure switch, and a manual valve. I n the
normal mode of operation gas flows through t h e normally open c a r t r i d g e valve
and t h e regulator. I n t h e event of f a i l u r e of t h e r e g u l a t o r , such t h a t the N
output pressure r i s e s towards a l e v e l which would cause t h e system overpressure E
r e l i e f components t o function, t h e pressure switch i n t e r v e n e s and causes t h e W
normally open c a r t r i d g e valve upstream of t h e r e g u l a t o r t o be closed. Pressure
then may be c o n t r o l l e d by t h e crew's manual switch, with c o n t r o l information
obtained f r o x t h e pressure transducer i n component package lrBtl and an instrument
panel i n d i c a t o r . Tnus, a d d r t i o n a l pressure i n c r e a s e i s prevented and a manual
electro-mechanical mode of r e g u l a t i o n i s i n i t i a t e d . I n t h i s mode t h e opened
valve permits gas flow and r i s e of pressure. This cycle i s repeated manually
as r e q u i r e d t o maintain system pressure f o r the p r o p e l l a n t a t a s a t i s f a c t o r y
l e v e l . I f s u f f i c i e n t pressurant flow cannot be achieved through t h e f a i l e d
r e g u l a t o r , a by-pass l i n e may be opened by a c t u a t i n g a switch which opens t h e
normally closed c a r t r i d g e valve. Provision i s made i n t h e c i r c u i t r y t o insure
t h a t both c a r t r i d g e valves a r e f i r e d i f t h e by-pass i s opened. This prevents
i n a d v e r t e n t by-pass of both t h e r e g u l a t o r and t h e solenoid valve. Fuses are
provided i n t h e c a r t r i d g e valve c i r c u i t s t o prevent excessive e l e c t r i c a l power
d r a i n i n t h e event t h a t a c a r t r i d g e bridge wire element s h o u l d . f i r e t o give a
s h o r t c i r c u i t . The manual valve and t h e solenoid valve are provided f o r ground
checkout of t h e components.

& Component package I I B I I , Figure 9, c o n s i s t s of a pressure transducer,

r e l i e f valves, burst, diaphragms, check valves, manual valves, and ground t e s t
connections. The. pressure transducer i s used t o monitor t h e regulated gas
pressure. 'The b u r s t diaphragms and pressure r e l i e f vent valves provide over-
pressure p r o t s c t i o n i n t h e event of % a i l u r e of t h e pressure r e g u l a t i o n group o r
excessive temperature cycling. The b u r s t diaphragms a r e used t o provide assured
zero leakage ( m t i l a c t i v a t e d ) pressure r e l i e f devices. If t h i s here t h e s o l e R
p r o t e c t i v e element, a s i n g l e a c t a a t i o n would r e s u l t i n venting of t h e t o t a l E
supply of pressure. Xowever, t h e a d d i t i o n o f t h e pressure r e l i e f valves avoids v
t h i s and r e s t r i c t s t h e venting t o t h a t required t o c o r r e c t conditions of a
t r a n s i e n t type and keep t h e system pressure a t a s a f e l e v e l (i.e., i f t h e reg-
u l a t i o n f a i l u r e i s momentary i n nature, the r e l i e f valves r e s e a t and permit
n m n a l system operation t h e r e a f t e r ) . Such a s i t u a t i o n can occur i n the event of
an abno-mal t h e n a l cycle coupled with a low r a t e of p r o p e l l a n t consumption.
 20 February 1962 D 11
DATE ST. LOUIS, MISSOURI PAGE

REVISED 18 J u l y 1962 REPORT 8642

REVISED :GEMINI MODEL
.

ORBIT ATTITUDE AND MANEUVER S Y S T E M

PRESSURE REGULATION GROUP .

PRESSURANT
STORAGE TANK

r-
I ' COMPONENT
PACKAGE "A" COMPONENT PACKAGE "E"

1
I I
I I
I CARTRIDGE- MANUAL SPST I
I ACTUATED SWITCH (CREW) I
I + I
I SOLENOID I
BY-PASS
I VALVE I
I (NORMALLY 1
I
r'
CLOSED) 1 E
w
I I
I I
I I
I I
I VALVE I
I I
I
I
I
REGULATOR FLOW I
- LIMITING I
ORIFICE
I
I

CARTRIDGE
ACTUATED I
VALVE I
PRESSURE - (NORMALLY
CLOSED)
----II
i
*

-
INDICATOR
P RE SSURE ( T H E PRESSURE TRANSDUCER
TRANSDUCER I S T H E ONLY COMPONENT
BEING SHOWN I N PACKAGE B )

COMPONENT
PACKAGE "B"
Figure 6
AC 231C ( R E V I AUG 6 1 1
 20 February 1962 LL
DATE
ST. LOUIS, MISSOURI PAGE
12
REVISED
18 July 1962 REPORT 86L2
REVISED MODEL
rJ%Th?

PRESSURE REGULATOR

VENT 7

SURE

H
E

INLE
ET

Figure 7
~~

MAC 231C (REV I AUG 6 1 )

____- --
 20 February 1962 13
DATE ST. LOUIS. MISSOURI PAGE

REVISED
18 July 1962 REPORT
06L2
REVISED 1 MODEL GEPZKI

C O M P O N E N T PACKAGE rrE’’ SCHEMATIC

‘D

.LY

CONNECTION

OUTLET
T O PRESSURE
-
REGULATOR)

N L E T (FROM
PRESSURE +
? E G U L A T O R)

OUTLET
( T O COMPONENT PACKAGE “6”)
Figure 8
 D
DATE
20 February 1962 ST. LOUIS, MISSOURI P A G ~ __ Ilr
REVISED
18 July 1962 R I r'oiiT ____--_ 8642
__
17 E V I SE D MDI t L __ll____.__l-
GEMINI

COMPONENT PACKAGE"B" SCHEMATIC

P R E S S U R E TRANSDUCER

IONS

Fiaure 9
DATE 20 February 1962 ST. LOUIS, MISSOURI PAGE ,A
REVISED 18 J u l y 1962 REPORT 86L2
REVISED MODEL GemirL

3 03 DESCRIPTION AND OPEW\TION.- (Continued)

A check valve i s provided upstream of t h e f u e l propellant tank t o prevent back-

flow of f u e l i n t o the gas system, should t h e expulsion bladder f a i l , Check
valves are provided upstream of t h e oxidizer propellznt tank t o prevent backzlok-
of o x i d i z e r vapor i n t o the gas system. Two are used f o r double p r o t e c t i o n agains
oxidizer vapor which w i l l permeate t h e t e f l o n expulsion bladder. The ground
t e s t connections a r e used f o r component checkout and t h e manual valves are used
f o r ground checkout and servicing.

The propellant tanks a r e spherical. They a r e of t h e p o s i t i v e

expulsion type, with expulsion bladders which a r e compatible with t h e pro-
p e l l a n t s t o be contained. The bladders i n the f u e l and oxidizer tanks a r e Fade
of t e f l o n and can r e q u i r e replacement a s they have a limited expulsion or
c o l l a p s i n g cycle service l i f e (not time limited). A flow p a t h i s provided
through t h e propellant p o r t i o n of t h e tanks f o r bleeding, purging, and drying.
T h i s p o r t i s designed such t h a t each flow path t o t h e atmosphere i s sealed
twice t o i n c r e a s e t h e r e l i a b i l i t y of t h e tanks; The oxidizer tank i s 22.00
inches i n o u t s i d e diameter and t h e f u e l tank i s 20.13 inches i n outside dianeter.
The f l u i d volume capacity i s 5355.0 cubic inches f o r the oxidizer tank and
4130.0 cubic inches f o r t h e f u e l tank. The charged f l u i d volume capacity a t
16O?E' f o r t h e design propellant weight i s 5100.0 cubic inches f o r the oxidizer
tank and 3900.0 cubic inches f o r the f u e l tank.
E
Component packages llC1l and trDtl, Figure 10, contain e s s e n t i a l l y t h e h

same compc/ne%ts: A normally closed cartridge-actuated valve, two manual valves,

and a f i l t e r . The c a r t r i d g e valves a r e used t o i s o l a t e t h e p r o p e l l a n t s f r G T t h e
remainder of the system p r i o r t o system a c t i v a t i o n . The manual valves upstrean
of t h e c a r t r i d g e valves are used f o r f i l l i n g , draining, and purging of t h e pro-
p e l l a n t s while t h e manual valves downstream from t h e c a r t r i d g e valves a r e used
f o r ground checkout of downstream component function. The f i l t e r s a r e m e d t o : '
reduce t h e particle contamination of t h e p r o p e l l a n t s t o a l e v e l acceptable to '.
t h e TcA1s.
i.
f r Downstream from component packages and "D" a r e the propellant
llCtl
supply on-off valves. These motor operated valves are i n a c t i v e during n o r m 1 -
system operation. Only i n case, of f a i l u r e (open) of a TCA p r o p e l l a n t valve (or .'
valves) o r other s e r i o u s l e a k downstream would t h e s e valves be closed t o reduce :
p r o p e l l a n t l o s s . They would then be opened only t o allow f i r i n g of the TCli's fcr . I

a t t i t u d e changes and maneuvers and reclosed u n t i l t h r u s t i s again required. c\

A l l T u ' s are i n s t a l l e d submerged beneath t h e s p a c e c r a f t moldline.

Each one c o n s i s t s of two t h r u s t chamber propellant valves, two c a l i b r a t i o n
o r i f i c e s , a f u e l and oxidizer i n j e c t i o n system, a combustion chamber, and an
expansion nozzle. A t y p i c a l 21; pound 'i'@ is shown i n Figure 11, The propellant
v a l v e s a r e quick acting, nornally closed solenoid valves which open upon a p p l i -
c a t i o n of an appropriate e l e c t r i c a l s i g n a l t o permit flow of oxidizer or f u e l to
 20 February 1962 ELL
DATE ST. LOUIS, MISSOURI PAGE
16
REVISED I 18 July 1962 REPOFT 66L2
REVISED MOD EL GEI.IINI

C O M P O N E N T PACKAGES “C” AND “D” SCHEMATIC

e .
MANUALVALVE
OPERATING H A N D L E (2)
7
M A N U A L V A L V E I N L E T (2) INLET

e
ART R IDG E- ACT UA T E D
VALVE t
(NORMALLY CLOSED) OUTLET
 OAT F

REVISED
20 February 1962
18 J u l y 1962
MWINNELLQ *c!*&
ST. LOUIS. MISSOURI
P A G F

REPORT
17
86h2
--
REVISED-- MODEL-
GEMINI

W
0
Z
4
.J
u.
0
f
I-
.
Z

0 0
7
I

n
v)

z
a
0

w
Lu
m
z
a
I
V

0
U
a

Figure 11
DATE 20 February 1962 ST. LOUIS. MISSOURI
PAGE 15
REVISED 19h3 REPORT
86,!,2
REVISED MOD EL

3 03 DESCRIPTION AND OPERATION. - (Continued)

the i n j e c t o r t o which they are f i t t e d . 'The i n j e c t o r u t i l i z e s p s e c i s e j e t s which
impinge t h e f u e l and o x i d i z e r on one another f o r c o n t r o l l e d mixing and good
combustion e f f i c i e n c y . The c a l i b r a t i o n o r i f i c e s a r e t r i m devices used i n con-
junction with t h e propellant valves and t h e i n j e c t o r s t o a d j u s t t h e flows t o t h e
design f l a w l e v e l s . The t r i m orifices a r e adjusted and f i x e d during E A
acceptance t e s t i n g . The combustion chamber i s t h e enclosed a r e a between t h e
i n j e c t o r f a c e and t h e t h r o a t of the nozzle, The expansion nozzle i s bell-shaped
and contoured t o terminate flush with t h e moldline of t h e spacecraft. The
combustion chamber and t h e nozzles a r e l i n e d with a b l a t i o n m a t e r i a l and i n -
s u l a t i o n t o c o n t r o l e x t e r n a l w a l l temperature. S e a l s a r e provided between t h e
nozzle and t h e spacecraft s k i n t o prevent t h e backflow of exhaust gas i n t o t h e
spacecraft, A p r o t e c t i v e cover o r plug i s provided t o protecz t h e t h r u s t
chamber from e n t r y of f o r e i g n matter when t h e 'ICA i s not i n use, The cover o r
plug i s manually removed p r i o r t o launch and/or j e t t i s o n e d i n f l i g h t by the
first s t a r t .
For t h e two day c o n f i g u r a t i o n a p o r t i o n of t h e OYS(six 'JEAts) is
l o c a t e d i n t h e adapter retrograde s e c t i o n while t h e remainder (?s-!located i n t h e
adapter eqcipment s e c t i o n . Because t h e s e s e c t i o n s are j e t t i s o n s d i n two stages
p r i o r t o re-entry ( t h e equipment s e c t i o n approximately t h i r t y secopds p r i o r t o
ackual F t r o g r a d e f i r i n g and t h e retrograde s e c t i o n approximately s i x t y seconds
l a t e r ) , g u i l l o t i n e s are provided t o sever the f u e l and oxidizer l i n e s t o pennit
s e p a r a t i o n of the p o r t i o n of t h e OAMS l o c a t e d i n t h e equipment s e c t i o n f r o n t h e
six ' E A ' S i n the retrograde section. The g u i l l o t i n e s , Figure 12,are c a r t r i d g e -
a c t u a t e d devices which c u t and s e a l p o s i t i v e l y t h e &el and o x i d i z e r tubing
l e a d i n g t o t h e TCAts i n t h e retrograde equipment section. Redundant g u i l l o t i n e s
are u t i l i z e d t o assure separation. When the f o u r t e e n day arrangement i s used,
t h e t o t a l OAMS system i s j e t t i s o n e d p r i o r t o retrograde s i n c e it i s e n t i r e l y
l o c a t e d i n t h e adapter equipment s e c t i o n ,
DATE 20 February 1962
18 July 1962
MIDONNEIAL & &&Z&??Z PAGE----- 19
8642
REVISED ST. LOUIS. MISSOURI REPORT
REVISED MODEL----.--- GEMINI
-

PROPELLANT LINE GUILLOTINE

FUEL

' - OXIDIZER
LINE

Figure 12
DATE -20a-1962 ST. LOUIS, MISSOURI PAGE A
REVISED
, - - REPORT 86L2
REVISED m v MODEL Gemini

I
3.3 DESCRIPTION AND 0PERATIQN.- (Continued)

A temperature and pressure i n d i c a t o r and a manual switching device,

Figure 13, are located on t h e crew's instrument panel to provide i n d i v i d u a l
readouts of s p e c i f i c temperatures and pressures sensed a t various l o c a t i o n s i n
t h e OAMS. These readouts a r e manually s e l e c t e d by m a n s of t h e switching device
\and are displayed on t h e indicator. The temperature and pressure of t h e s t o r e d
high pressure gas and the regulated gas can be used to:

A. Provide a n i n d i c a t i o n of t h e p r e s s u r i z a t i o n c a p a b i l i t y
a v a i l a b l e f o r t h e remainder of t h e mission.

B. Evaluate regulator operation.

R
C. Provide a secondary means of determining propellant q u a n t i t y E
i n t h e tanks. v
The pressure s i d e o f t h e i n d i c a t o r i s scaled t o read from 0 t o 500 psig. This i s
compatible with t h e expected pressure reading t o be obtained from t h e regulated
pressure. However, i t must be mentally m u l t i p l i e d by 10 f o r t h e pressure read-
ing of t h e storedogas. The temperature s i d e of t h e i n d i c a t o r i s s c a l e d t o read
from -100 t o e200 F and i s compatible with t h e expected temperature reading t o
be obtained from t h e s t o r e d gas and t h e regulated gas.

A propellant q u a n t i t y guaging system i s provided t o i n d i c a t e t h e N

amount of oxidizer and f u e l r e m i n i n g i n . t h e OANS p r o p e l l a n t tanks. Individual E
readouts of t h e oxidizer and f u e l are displayed on t h e crew's instrument panel W
as shown i n Figure lk.
@ A TE 20 February 1962
ST. LOUIS, MISSOURI

9EVlSED
18 J u l y 1362

PROPELLANT TEMPERATURE A N D PRESSURE INDICATOR

AND SELECTOR SWITCH

S EL EC TO R
SWITCH ’

T P

Ei
E
w

-200
- 100
-0
I
PROPELLANT

TEMPERATURE AND PRESSURE

INDICATOR
DATE
20 February 1962 ST. LOUIS, MISSObRI PAGE
22
REVISED
18 July 1962 REPORT
8642
REVISED MO!) t L
GEKCNI

PROPELLANT DISPLAY
.

N
E
w

- Figure 14
DATE 20 Febl"uam 1962 ST. LOUIS. MISSOURI PAGE - 23
REVISED . u u ! REPORT A
REVISED I r " 0 D E L Gemini

3 .b DESICrj CRI'TFBIA,- A propulsion system, capable o f performing t h e

CIA% mission, was evolved from t h e design c r i t e r i a l i s t e d below:

....S t o r a b l e propellants having an advanced development background.

... h e -couples f o r r o l l control.
..,.A
weight .
nozzle expansion r a t i o optimized f o r minimum o v e r - a l l system

....Pressurant storage pressure optimized f o r minimum o v e r - a l l

system weight.

....Helium used f o r pressurant f o r minimum o v e r - a l l system weight.

r
... .Compatible m a t e r i a l s (and no dissimilar metals) f o r a l l
conponent p a r t s except t h e s t a t i c s e z l s i n t h e high pressure
. manual valves and various non-exposed p a r t s . I n a d d i t i o n , no
p l a t i n g or surface treatment i s allowed t o make any s u r f a c e
compatible.

.... Corrosion r e s i s t a n t s t e e l l i n e s , f i t t i n g s and components, and

titanium tanks and b o t t l e s .
N
E
... .A k t y l rubber bladder f o r t h e f u e l tanks.
W

.... t e f l o n
A f o r t h e o x i d i z e r tanks.
bladder

....Packaging of s e v e r a l components t o reduce weight, E iminate

testing.
l e a k s , save space,and f a c i l i t a t e i n s t a l l a t i o n , s e r v i c i n g and

....Ccmponents interchangeable. between t h e OAMS and tiie Re-entry

Control System t o reduce d e v e l o p e n t and c o s t and increase

.
r e l i a b i l i t y information; i.e., t h e pressure r e g u l a t o r and
component packages tlAtf and rrL3'1

.... A r e g u l a t o r back-up t o provide p r o t e c t i o n f o r any mode of

primary r e g u l a t o r failure. .

..,,Motor-operated p r o p e l l a n t s h u t o f f valves t o conserve p r o p e l l a n t

i n t h e event o f a downstream leak.

. .A system t a i l o r e d t o M.A .C./Rocketdyne philosophy f o r s e r v i c i n g

and checkout. However, adequate connections and t e s t p o i n t s
are incorporated so t h a t any o t h e r s e l e c t e d procedure is n o t
excluded, Design of t h e system such t h a t f u n c t i o n a l checks 6f
a l l components can be made using gas, s u b s t i t u t e t e s t f l u i d s ,

.
o r p r o p e l l a n t s , d t h by-passes f o r component packages rtA", "C"
and ItD1'
DATE 20 February 1962 S f . LOUIS, MISSOURI PAGE 2b
QlI.2
VU-
REVISED REPORT

REVISED MODEL
-. ...
LA11

3.4 DESIGN CRITERIA.- (Continued)

....A diaphragm-relief valve s e r i e s arrangement t o provide assured

zero leakage p r i o r t o a c t i v a t i o n of t h e pressure r e l i e f . oper-
a t i o n and then t h e l i m i t i n g o f the pressure venting t o t h a t
required t o p r o t e c t t h e System,

. . . . A l l dash-numbered p a r t s and packages i n s t a l l e d with threaded

fittings,

....No e x t e r n a l leak paths through dynamic s e a l s ,

.... Double and t r i p l e s e a l manual valves f o r service connections

i n s t e a d of t h e use of disconnects,

.,..Cartridge valve s e a l s placed on t h e pressurant and t h e pro-

p e l l a n t t a n k s f o r r e l i a b l e actuation, with a p o s i t i v e s o l i d
metal seal.

..., Replaceable cartridge-actuated valves i n component packages

ItCti and I'Dt1 so t h a t t h e component does not have t o be removed
from the system t o replace a f i r e d unit.

... .Main f i l t e r s located dowstream from t h e c a r t r i d g e valves and

t h e ground t e s t connections f o r p r o t e c t i o n of downstream
components,

.... Supplemental f i l t e r s provided a t each solenoid valve, a t each

f i l l point, and i n each c a r t r i d g e valve f o r a d d i t i o n a l pro-
tection.

. ....Non-replaceable
leaKage .
f i l t e r s f o r reduced weight and t o prevent

.,.. Check valves t o provide p r o t e c t i o n a g a i n s t a c c i d e n t a l propellant

mixing i n t h e regulated gas elements.

...,Purg e connections on t h e p r o p e l l a n t tanks f o r servicing.

.... .
M ~ l t i - e x p u l s i o n bladders t o allow s e v e r a l expulsions f o r systen
checkout

....Individual, non-redundant i n - l i n e solenoid valves f o r TCA

p r o p e l l a n t valves t o take advantage of accunulated develop-
ment experience.
DATE 20 February 1962 ST. LOUIS, MISSOURI PAGE 25
REVISED.-. REPORT
8642
REVISED MODEL Gemini

3.4 DESIGN CRITEXU. - (Continued)

.... I d e n t i c a l valves and i n j e c t o r s f o r all 85 and 100 pound TCA's.

....I d e n t i c a l envelopes f o r t h e 100 pound l a t e r a l and aft f i r i n g
TCA's.
N
. ... . I d e n t i c a l
valves and i n j e c t o r s f o r a l l 25 pound TCA's i n t h e E
OAMS and t h e Re-Entry Control System. Also, y-DAm-.thrust
chambers are i d e n t i c a l . __----' "1.p,
....!!%e duty l i f e of the TCA's t o include contingencies f o r a l l
p r e d i c t e d uses.

. .

I
 1
3a 5 DESIGN WUIREMENTS
3.501 INPUTS AND FLUIDS

A. Pressurant.- The cold gas pressurant i s helium, Federal Stock

NO 6030-283-9842

0 B, Propellants.- The bipropellant is:

- Nitrogen
Oxidizer
MqL-P-26539A . t e t r o x i d e (N204) conforming t o S p e c i f i c a t i o n

Fuel - MMH - Monomethyl hydrazine (N2HjCHj) conforming t o

=if i c a t i o n MIL-P-27403

3.5.2 PERFQRI4fiNCE.- The OAMS e x h i b i t s t h e following vacuum performance

c h a r a c t e r i st i c s :
I
A t titude Maneuver R
A. Sys tem Performance Control 'I'CA's 'I'CA S ' E
V
Design t h r u s t level per T C A . 25 lbs. 100 l b s . *
300 1b.-sec. 300 1b.-sec.
Minimum steady s t a t e lb.
s p e c i f i c impulse lb

M i n i m impulse b i t .25 1b.-sec.

required

Minimum s p e c i f i c impulse 260 1b.-sec.

f o r minimum impulse b i t Ib.

Pulse frequency range 0-6 pulses

sec.
.Minimum 'impulse b i t
sec
.25 sec. t o
.
0-2 p u l s e s

Pulse width range

width t o continuous continuous

Maximum TCA response time - 25 milliseconds 50 m i l l i -

seconds
time from a p p l i c a t i o n of
e l e c t r i c a l s i g n a l t o 90% of
maximum chamber pressure

Maximum Tck shutdown time- 7 milliseconds 50 m i l l i -

time .from removal of elec- seconds
t r i c a l s i g n a l t o 2% of max-
imum chamber pressure

I * The TCA's used f o r t r a n s l a t i o n aft are d e r a t e d t o 85 l b s . t h r u s t . I

 DATE 20 F e b w 1962 ST. LOUIS. MISSOURI PAGE 27
REVISED. - REPORT 8652
REVISED MODEL Gelxini

+-a
, c
<a;,< ,
PERE'ORNANCE .- ( Continued )
A t ti tude
I I

GJ ihneuve?
B. Other Sjqstem Parameters. Control TCA Is TCA'S

0 Oxidizer
Fuel
-
Flow r a t e a t mixture r a t i o
(O/F) of 2.0
.OsSs lbs/sec.
.0278 lbs/sec.
i' .222 lbs/sec
,111 lbs/sec
Mixture r a t i o - r a t i o of pounds 2.0 + 1% -
of o x i d i z e r t o pounds of f u e l
i n j e c t e d i n t o each TCA

Regulated pressure 280 p s i g

TCA chamber pressure 150 psiz

Burst diaphragm rupture 420-500 psig
pressure range

Relief valve operating . 3804~30p s i g

pressure range

kE1CHi'S.- Target weights f o r the Orbit A t t i t u d e and Pbneuver System

are as follows a t I S O F :

Fission
2 Day 14 b y '
A. System Dry Weight 303.3 lbs. 181.0 lbs.
0 Components
Lines
(204.0)
( 16.6)
(100.2)
( 13.4)
S t r u c t u r e and ( 82.7) ( 67.4)
Electrical . -
-8 9 :, *

13. Propellznt Keight (Loaded) 724.0 241.0

I
: ',
C. Propellant height (Usable) 692.0 :" 226.0

Lf. Propellant Leight 32 e 0 15.0

(Trapped & Residual)

E. Pressurant !pieight 4.6

F. System Let \:eight 1031.9 424.3
 (6
DATE 20 February 1962 ST. LOUIS, MISSOURI PAGE
28
REVISED l8 1962 REPORT 86b2
REVISED MODEL Gellinj.

3.5.4 MATERIAIS OF CCINSTRUCTI0N.- Except f o r t h e a b l a t i o n m a t e r i a l i n the

'EAts, all i n t e r n a l wetted surfaces are f u l l y compatible with th
f l u i d s contained t h e r e i n . The pressurant and propellant storage tanks are
'
f a b r i c a t e d of t i t a n i u m alloy and corrosion r e s i s t a n t s t e e l l i n e s are used
throughout the system. Components are f a b r i c a t e d o f corrosion r e s i s t a n t s t e e l
except i n c e r t a i n l o c a t i o n s (e.g., springs, valve s e a t s , bladders and solenoid
c o i l s ) where functional requirements d i c t a t e t h e use af o t h e r more d e s i r a b l e
materials of c o m p a t i b i l i t y appropriate t o t h e i r environment.

3.5.5 ASSEMBLY.- "he Components o f t h e system are assembled i n t o groups

as shown i n Figures 2 and 3.

3.5.4
-
INTERXANGEABILITY. System components which perform i d e n t i c a l
functions are d i r e c t l y and completely interchangeable with one
another.

3.5.7 CCMPONICNT LIFE.- A l l components are designed f o r a minimum of

--.
f i f t e e n missions with an operating; l i f e comparable t o a t l e a s t one (
mission,with t h e following exceptions:

A. Cartridge-actuated valves have a one-shot l i f e with a

p r o b a b i l i t y of s a t i s f a c t o r y operation of a t least 0.9999.

B. Fxpulsion tank bladders have a minimum l i f e of six complete

expulsions under service conditions.

C. Thrust Chamber Assembly l i f e c o n s i s t s o f operation, e i t h e r con-

tinuous o r i,n pulsing m d e , wherein pulse frequency and
duration i s randomly d i s t r i b u t e d between 0 and 6 p u l s e s p e r
second and 0.010 and 3.75 seconds p e r pulse, respectively, f o r
the attitude control TCA's, and 0 t o 1 pulse F e r second and
0.25 and 200 seconds p e r p u l s e f o r the maneuver ' E A ' S .
Individual l i f e r a t i n g s are:

25 pound Thrust Chamber Assemblies ..................270 seconds \

85 pound Thrust Chamber Assemblies.. ...............,270 seconds

I

100 pound Thrust Chamber Assemblies .................S 40 seconds

i
3 .!Le GROUND CHECKOUT.- Ground checkout c o n s i s t s of leakage measurements
and f u n c t i o n a l checks of a l l components using helium and nitrogen
gases a t s u i t a b l e pressures. Component gas flow rate c a l i b r a t i o n s a r e performed
and comparisons made with a c c e p t a b i l i t y standards. The manual valves and t h e
gmund t e s t connections are used for component checkout. A complete f u n c t i o n a l
checkout of every component can be performed i f necessary, including t h e f i r i n g
of the 'EA'S with propellant.
DATE 20 Februarv 1 96? ST. LOUIS, MISSOURI PACE

REVISED lfi k J y 1?67 REPORT A

R E V l SED MOD E L

3.6 F;NVIRONMBlTAL CONDITIONS.- The OANS f u n c t i o n s i n accordance with

t h i s s p e c i f i c a t i o n when subjected t o any n a t u r a l combination of
t h e environments shown i n Tables I and 11.

3.7 STRUCTURAL REQUlXlW3I?TS.- A l l components of the OAMS a r e designed

for t h e p r e s s u r e s defined i n S e c t i o n s 3.7.1 and 3.7.2. The com-
ponents a l s o withstand', without permanent deformation, t h e l i m i t a c c e l e r a t i o n
and shock l o a d s from Tables I and 11, t h e maximum r a t e d t h r u s t of t h e TCA units,
and any l o a d s which may r e s u l t froin t h e operation of the system. Ultimate design
loads a t which s t r u c t u r a l f a i l u r e s h a l l n o t occur a r e 1.36 times l i m i t loads"
An a d d i t i o n a l 1 . 5 f a c t o r i s used on any c a s t i n g s i n t h e components. When
c r i t i c a l , the ultimate s t r e n g t h provides f o r a minimum o f 1.36 times l i m i t l o a d s
combined with the design p r e s s u r e s of Sections 3.7.1 and 3.7.2. The components
a r e considered f u l l (pressurant and p r o p e l l a n t ) . L i m i t temperatures are shown
i n Tables I and 11, and operating temperatures w i l l be determined by t e s t s .
Ultimate heating e f f e c t s a r e considered by i n c r e a s i n g limit temperatures t o 2W°F
under c e r t a i n s p e c i f i e d conditions. Ultimate design conditions a r e e i t h e r R
ultimate l o a d s o r proper' combinations thereof with limit temperatures o r ultimate E
h e a t i n g e f f e c t s combined with limit loads. v
3.7.1 PRESSURES AND TEMPERATURES

A. Normal Operating Pressures.- The noma1 operating p r e s s u r e s f o r

components l o c a t e d upstream of t h e p r e s s u r e r e g u l a t o r
(including the r e g u l a t o r i n l e t ) are 3000 p s i g and regulated
.
.
pressure (280 p s i g ) f o r components l o c a t e d dmnstream from t h e
pressure r e g u l a t o r (and including the r e g u l a t o r o u t l e t ) .

B. Normal Operating Temperature

i s 70°F.
.- The normal operating temperature
*
--_
*, , C. Design Pressures.- The design pressure f o r components l o c a t e d
,I upstream o f the pressure r e g u l a t o r i s 3000 psig. The design
i pressure f o r cox@onents l o c a t e d downstream from t h e r e g u l a t o r
!
i s 300 psig.
'A- ~

D. Design Temperature.- The design temperature spans the range of

+1SOFto +160?F.

E. Proof Pressures.- Component proof p r e s s u r e a t 70°F i s 150% of

I
>-' t h e design pressure, except t h a t f o r t h e pressurant s t o r a g e and
$,.3-)r9-( t h e p r o p e l l a n t tanks it i s 167% of t h e design pressure.

F, Burst Pressures.- Component b u r s t pressure a t 70°F i s 250% of

t h e design pressure, except t h a t f o r t h e pressurant storage and
t h e p r o p e l l a n t tanks it i s 222% of t h e design pressure.
 E&&
DATE 20 February 1962 ST. LOUIS, MISSOURI PAGE ?n
REVISED REPORT 86/07
RW I S E D MOD E L Genini

00
urn
cvcu

e
r

Cd:
koP
F4P

rld

p:
pc 88
mt-3
m

00 00
8% 043
cucu

a m
DATE LaJo 2 PAGE
C E&gt
REVISED ST. LOUIS, M I S S O U R I REPORT

REVISED MODEL

Transportation and Prelaunch

(Operating and Nonoperetdng)

+ W F to 1600F (Serulced) & -6WF to 160% ( ! h e r . *

s.5 t o 1.4 p s i &
N.A. (1)
15% t o 100%
HIL-E5272C, Procedure I1
MIGE;.5272C, Procedure I
MIL-E-S272C, Procsdwcr I
HIt.E-s272C, Procedure I
N.A. (Prelaunch) and Protected per H.A.C.
&port 8757 (Transportation)
Acceleration (4) ( 5 ) N.A. (Prelaunch) and Protected per M.A.C.
Report 8757 (Transportation)

Vibration
Category A (Figure 15) (7)
Category B (Figure 16) (8)
H.A. (Prelaunch) and Protected per M.A.C.
Report 8751 (Wansportation)
N.A. (Prelaunch) and Protected per H.A.C.
Report 8757 (Raneportation) '

Acoustic Noise N.A. (Prelaunch) and Protected per M.A.C

Report 8757 (Transportation}
Radio Interference MIL-1-26600
Explosive AtaDosphem Hydrogen Atdumphere (9)

5. A l l ahock and accalerati

are limit loads. Satis:
propellant tank and distribution syatea. The r e q u i r e d during and/or a-
combustion chamber I s designed f o r a maximum external cation, whichaver IS P A T .
temperature of SOOOP, a h a l l tear l o o a s frai it,
3. Applicable to untested and untreated materials only. shall be contained under
4. Lateral Spacecraft Axes refers to both t h e p i t c h and lo&. Ultimate load is
yaw axes aa defined for specclcraPt control, 6. Longitudinal and Lateral
--

TABU I
ITUDE AND WAIJEUVER SYSTM 4 J H " T d TXE ADAPTER
IBCATED E

+1PFt o 160°F
10-12 psia
1600F a t 15.5 t o 10-12 p a i a ~ W F a t 10-12 psia
15%t o 100% Ned.
N.A. N .A.
N.A. N.A.
N. A. N.A.
N.A. N.A.

N.A.
E
E
Longitudinal Spacecraft Axis: B
1.g to 7,25gts linearly with time over
326 sec. L a t e r a l Spacecraft k e a :
b,Ogts i n any d i r e c t i o n for 1 aec. ( 6 )

Curve I Curve II

Curve I Curve I1

155 db Over-all , N.A.

Sse Figure 17
MIL-1-26600 MIL-1.26600
N. A, N e A e

i loada i n this table
:tory performance i s
a r Wt load appU-
ipriate. No equipment
mount and i n t e r n a l p a r t s
lpplication o f ultimate
'-36 times u t load.
i o not act simultaneously.
-5
7. Ekpipment items which are mounted t o spacecraft primary
s t r u c t u r e direct* o r through intervening s t r u c t u r e and/
o r are of s u f f i c i e n t l y small maas t h a t the mechanical
impedance of the spacecraft s t r u c t u r e rn seen by tbe equip-
ment i n s t a l l a t i o n a t t a c h p i n t a can be conaidered
effectively infinite,
8. Equipment items o r canplete syatam i n s t a l l a t i o n s of sufii-
c i e n t l y large size and mass that the mechanical Impedenm
of the a t t a c h p o i n t s cannot be takan os Infinit., and tbr
feeding back mechanism has been given coneld3ration.
9. Equipment v i 1 1 be tested for exploaion proofing wing a
standard conmerclal butane and & mixtwo.
 Transportation and
b e h u n c h (Operating
and Nonoperating )

Anbient Temperature rn to 1 6 W
b b i e n t Pressure 15.5 t o 13-12
rature- Pres sure 16ooF at 15.5
OWdity 15%'to 100%. 15% to-le@
MIL-E-5272C, Procedure II N.A.

Salt Sea Atnoephere MIL-&S272C, Procedure I NJ

SandandDuat N.A .
MIL=E05272C, Procedure I N.A.

02 a t 15.5 p s i a
N.A. (Prelaunch) and Pro-
tected per M . A . C . Report
8757 (Transportation)
N.A. (Prelaunch) and Pro- Longitudinal _"
t e c t e d per M.A.S. Report 1. g t o 7.2'
8757 (Transportation) tfme over i
Spacecraft ::
any d i r e c t i r

N.A. (Prelaunch) and Pro- curve I

t e c t e d per M.A.C. Report

Equipment Category B (Figure 16) ( 8 ) N.A .

8757 (Transportation)
(Prelaunch) and Pro-
tected per M.A.C. Report
Curve I

0
Acoustic Noise
8757 (Transportation)
N.A. (Prelaunch) and Pro- 135 db Over-a1
t e c t e d p e r M.A.C. Report
8757 (Transportation)
Radio I n t e r f e r e n c e MI IF1.26600 M I L-1.26600
Explosive Atmosphere N.A . NoAo

NOTES:
m . A . -
Not applicable.
2. Applicable to untested and untreated materials only.
5. Longitudinal and L a t e r a l do n o t
6. Longitudinal and L a t s r a l a c t sire
2

3. L a t e r a l Spacecraft axes r e f e r s to both the p i t c h and 7. Equipment items which a r e mountel

yaw axes as defined f o r s p a c e c r a f t control.
b. A l l shock and a c c e l e r a t i o n loads I n this t a b l e a r e
limit loads. S a t i s f a c t o r y performance is required
during and/or after l i r r l t load application, whichever
i s appropriate. No equipment shall tear loose from
I t s rcount and internal p a r t s s h a l l be contained under
q 2 p l i c a t i o n o f ultimate loads. Ultimate load l a 1.36
tlmes limit load.
primary s t r u c t u r e d i r e c t l y o r t?.r
s t r u c t u r e and/or a r e of sufi'icier.
t h a t the mechanical impedanco c?
s t r u c t u r e as seen by the eqi:i?r.?:.
a t t a c h p o i n t s can be conaidered E
infinite.
I1
CONTROL SYST31 EQUIIXENT LOSATED IN THE RE-E;!n.*y )KIDUT,S IN T I E PRESSURIZED CABIN

PosCLanding
(Nonoperating 1

OOF to 1609F
6.0 to 10-12 psia
16OOF a t 6.0 to 10-12
psi8
5@ to 8a 155 to 100%
N.A. MIL-E=S2 72C,
Procedure I1
NeAo M IL I E 4 2 72C ,
A.ocedurQ I
Nd. MIL-E-5272C,
Procedure I
N.A. MI LE-52 72C,
Procedurs I
6.0 psia 1m O2 a, 6.0 psla lm 02 a, 6.0 paia N.A.
N.A. See Figure 19(Area 11) l5g's i n m y
direction,11
nd 1336 e cond
duration R
sl Spacecraft Axis: longitudinal Spacecraft 3.e E
7.25 g l i n e a r l y with Axis: l5g(s,3O aec. V
r 326 sec. L a t e r a l duration. I a t e r a l
f t Axes: b.0g's i n Spacecraft Axes: b.5j3r8j
ction f o r 1 sec. (5) 30 sec. duration ( 6 )
Curve I1 Curve I11 N.A .
Curve I1 Curve 111 N.A.

r-al@See Figure 18 N*A. Same as f o r Launch NeA.

M I L-1-2 6600 MIL1-2 6600 MI L-1-2 6600

N.A. N.A. N.A.

iimultane ous1y
itad t o spacecraft
.
)t a c t simultaneously 8, Equipment items or complete
c i e n t l y l a r g e s i z e and mass
of t h e a t t a c h points cannot
system i n s t a l l a t i o n s of f3uffi-
t h a t t h e mechanical impedance
be taken a s infinite, and the
through ir,tervening feedback mechanism has been given consideration.
: i e n t i y small mass
of the s p a c e c r a f t
inen t i n s t a l l a t i o n
!d e f f e c t i v e l y
 ELL 33
DATE 18 July 1962 S T . L O U I S , MISSOURI PACE

REVISED REPOFT 864 2

REVISED MOD E L
GF3U NI

GEMINI SPACECRAFT VIBRATfON SPECTRA

EQUIPMENT CATEGORY A

l.t

TO 5 CPS

.10

CURVE I
-- -CURVE I1
--- CURVE I I I

\
;
v)

.01
V
-z
Y

W
n
3
-
I-
J
(L
I '
a
W
J
rn
0" .001
n

I \ \*
.0001

\
\
\

.oooo
10 so 100 500 10 1 SO00
F R E Q U E qCY (CPS)

Figure 15
 ~ U b U W l W S W ~ L L
OAT E
18 July 1962 S T . LOUIS, MISSOURI PAGE
34
REVISED REPOFT 8642
GEMIiJI
REVISED MOVEL

GEMINI SPACECRAFT VIBRATLQN SPECTRA

EQU IP M ENT CATEGORY B

TO 5 CPS

.1

CURVE I
-----
---
C U R V E I1
C U R V E Ill

f 2g

N
.O E
W

.00

* 000

* 0006 1
, 0 7 5 0
FREQUENCY (CPS)

Figure 16
 18 July 1962
DATC
- ST. L O U I S , M I S S O U R I PAGE 35
REVISED REPOFT w.42
RFVISFD
MODEL
GWJSI

a
e

0
v)
I--
-
0
m 0
cy
c
 16 J u l y 1962
DATE
S T . L O U I S , MISSOURI PAGE 36
REVISFO
REPOFT 8642
REVISED
MODEL
GEMI t i I

Figure 18
 bhL
DATE __ 18 July 1962 ST. LOUIS, MISSOURI PAGE
37
REVISED REPORT
8642
REVISED MOD E L GEMINI

\
\
\ I-
LL
\ ' E
\
\
\
\

/
/
/ n
/
/

Fiaure 19
DATE 18 Ju l v 1962 ST. LOUIS, MISSOURI PAGE 38
REVISED REPORT B5L2
R E V lS E D MODEL
Ge n i n i

4. RETHOGRADE ROCKET SYS'I'EM

4.1 GENERAL.- The retrograde rocket system c o n s i s t s of f o u r s o l i d -

propellant rocket motors mounted i n the retrograde s e c t i o n of t h e
adapter, symmetrically located about t h e l o n g i t u d i n a l a x i s of t h e s p a c e c r a f t a s
shown i n Figure 20.

A d e s c r i p t i o n of two d i f f e r e n t retrograde r o c k e t systems i s con-

t a i n e d i n t h i s report. 'The system described i n t h i s s e c t i o n will be used i n a l l
s p a c e c r a f t providing t h a t the delivery schedule i s compatible with v e h i c l e
launch. An a l t e r n a t e rocket motor, which i s a modified version of t h e Thiokol
TE-345 rocket, may be required f o r the e a r l i e r spacecraft i n t h e event t h a t
t h e s e u n i t s a r e not available. A d e s c r i p t i o n of t h e a l t e r n a t e rocket motor i s
contained i n Addendum A.

4.2 FUNCTION.- I n t h e normal mission mode of operation, t h e retrograde

rockets a r e used t o i m p a r t an impulse t o t h e re-entry module. The
r e s u l t i n g v e l o c i t y decrement permits re-entry i n t o t h e e a r t h ' s atmosphere. The
retrograde r o c k e t s a l s o provide t h e required spacecraft v e l o c i t y and separation
d i s t a n c e from t h e launch vehicle i n t h e event of a mission a b o r t r h i t h t h e s y s k
described i n this s e c t i o n , an a b o r t can he accomp1.ished a t a l t i t u d e s varying f r c n
approximately,80,000 t o 300,000 f e e t . h i t h t h e system described i n Addendun A ,
an a b o r t can be accomplished a t a l t i t u d e s varying from 110,Oc)O t o 3OO,OOO f e e t .
Escape i s manually i n i t i a t e d a t t h e d i s c r e t i o n of t h e crew upon i n d i c a t i o n of
booster o r spacecraft malfuncbion.

4.3 OPERATION.- Retrograde rocket operation permission i s established

by mancally ar;ning t h e retrograde squib f i r i n g c i r c u i t s , a f t e r
which t h e f i r i n g sequence i s controlled e i t h e r automatically through t h e t i n e
reference system or manually by t h e crew. 'l'hirty seconds p r i o r t o a c t u a l r e t r o -
grade f i r i n g ('lR-30), t h e e l e c t r o n i c timer i l l u m i n a t e s t h e RE'TRO AFUI i n d i c a t o r /
push button on the a s t r o n a u t s ' instrument panel. The automatic f i r i n g c i r c u i t
i s then manually armed. A t TR-0 the e l e c t r o n i c timer i n i t i a t e s t h e r e t r o - f i r e
-
sequence. The rockets a r e then f i r e d a t 5 3 second i n t e r v a l s . Rocket nurnber
1 i s t h e first t o be f i r e d , followed t h e r e a f t e r by number 2, 3 and L rockets,
r e s p e c t i v e l y (see Figure 20). The rockets me f i r e d i n salvo f o r a mission abort

4.4 DESIGN REU'JIREMENTS /

L.14.1 RETROGRADE ROCKET.- The f o u r retrograde rocket motors employed i n
t h i s system a r e i d e n t i c a l i n design and performance, containing a
case-bonded,polysulf ide/ammonium perchlorate propellant and dual pyrogen
i g n i t e r s i n each u n i t , as shown i n Figure 21.
 18 July 1962 M&'DUFii#
DATE ST. L O U I S . MISSOURI PAGE 39
REVISED REPOPT 86L2
REVISED MODEL GEKKI

RETROGRADE
R O C K E ARRANGEMENT
~

.
ADAPTER
RETROGRADE S ECTl ON

N
E
w

NOTE:
POSITIVE SENSE OF AXES AND ANGLES INDICATED B Y ARROWS
CAT€ 18 July 1962 S T . LOUIS, MISSOURI PAGE 40
Q E \ !SED REPOFT 8642
9EVISED MODEL
GEMINI
--
RETROGRADE ROCKET ASSEMBLY
ANT

'LATION

PRESSURE CAR T
IN1 T

BORON
INITIATOR AND PELLETS
PYROGEN IGNITER .-
ELECTRICAL SCHEMATIC OF
FIRING, CIRCUIT
SEPARATE
POWER SUPPLY

PYROGEN
INITIATOR
SECTION A-A ( T Y P I C A L TWO
PROPELLANT CAVITY
r 'AsE

BU

.LANT

N O 2. Z L E

-
DATE 18 July 1962 hl
ST. LOUIS, MISSOURI PAGE

REVISED REPORT
e5L2
REVISED MODEL Gsnini

4.4.1 RETROGRADE ROCKET..- (Continued)

The retrograde rocket i s a 12.80 i n c h diameter s p h e r i c a l motor

Kith a titanium a l l o y case, a partially-submerged contoured nozzle with a 40:l
expansion r a t i o , and aft-end-mounted pyrogen i g n i t e r s with removable pressure
c a r t r i d g e i n i t i a t o r s . It i s approximately 23.0 inches i n over-all length.

Each rocket d e l i v e r s a t o t a l impulse of 13,800 pound-seconds a t an

average t h r u s t of 2&O pounds over a burning time of 5.44 seconds. 'lhese per-
formance r a t i n g s a r e based on a propellant bulk temperature of +60% and vacuurn
operation. Rocket performance, weight, and other p e r t i n e n t design parameters
are shown i n Figure 22.

The rockets are beam-mounted i n t h e retrograde s e c t i o n of t h e

adapter a s shown i n Figure 23 and are i n d i v i d u a l l y aligned i n t h e adapter p r i o r
t o adapter/re-entry module mating s o as t o minimize t h e e c c e n t r i c i t y between
t h e t h r u s t vector and the retrograde weight center-of-gravity.

h.4.1,1 N O Z m ASSEMBLY AfjD CASE.- The rocket motor case i s a high-strengtl

titanium a l l o y sphere 12.80 inches i n diameter. The case i s
formed from two hemispherical halves joined together a t the equator with a
"uniweld" a f t e r heat treatment t o 190,000 p s i ultimate and a m i n i m u m y i e l d of
170,000 p s i , Each half i s formed by forging, then final-machined t o t h e mininu?n !i
wall thickness a s determined by using a f a c t o r of 1.h times the maximum expected E
p r e s s u r e a t +180?l?.

The aft hemisphere incorporates a d r i l l e d and tapped flange which

mates ~ t h t h nozzle e assembly. The nozzle assembly c o n s i s t s of three com-
ponents: a n expansion cone, a t h r o a t i n s e r t , and a nozzle bulkhead. Each
of t h e s e v e r a l concepts and materials embodied i n the nozzle assembly design
have been s u c c e s s f u l l y proven i n a number of d i f f e r e n t solid-propellant rocket
motors. The expansion cone i s constructed from a v i t r e o u s silica-phenolic r e s i n
t h a t i s compression molded. This lightweight m a t e r i a l w i l l a b l a t e s l i g h t l y i n
t h e supersonic region, a s evidenced from a c t u a l s t a t i c tests. However, when
used with a non-eroding throat, t h e a b l a t i o n i s q u i t e uniform and m a l l . It
has an expansion r a t i o of 40 t o 1.

The throat i n s e r t i s machined from a high density graphite and i s

bonded i n t o t h e expansion cone. The i n s e r t i s separated from t h e titanium nozzle
supporting s t r u c t u r e of t h e a f t bulkhead by t h e p l a s t i c of t h e e x i t cone and t h e
case i n s u l a t i o n . This construction reduces t h e h e a t t r a n s f e r t o t h e s t r u c t w e
supporting t h e nozzle, thereby preventing loss of s t r u c t u r a l i n t e g r i t y . The
t h r o a t K i l l be recessed t o permit a reduced length.
DATE

REVISED

FEVISED
18 July 1962

- ST. LOUIS. MISSOURI

RETROGRADE ROCKET P E R F 0 RMANCE

b''E;GHT, A N D DESIGN PARAMETERS
' PAGE

REPOFT

MODEL
GEMINI
42
8642

PERFORMANCE AT 6OoF A N D VACUUM OPERATION

AVERAGE PRESSURE OVER BURNING TIME (PSIA) 846
AVERAGE THRUST OVER BURNING TIME (LB.) 2,490
'

. T O T A L IMPULSE OVER ACTION TIME (LB.-SEC.)

IGNITION TIME; T l E M TO 75% P M A X (MILLISECONDS)
BURNING T I M E (SECONDS)
13,800
100 (MAX.)
5.44
ACTION T I M E (SECONDS) 5.80
SPECIFIC IMPULSE(LB.-SEC./LB.) 254

WEIGHTS (LB.)
65.0 (NOM.)
66.0 (MAX.)

N O Z Z L E DESIGN
EXPANSION RATIO 40: 1
E X I T AREA (IN.2) 85.2
THROAT AREA (IN.2) 2.13
N
E
w
32 00

2400

d
J
I
-
2
1600
-
I
3
3
J
U
>

800

0
0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0
TIME - SECONDS
Figure 22
.
 r -- .--
-- ._ __- 1

RETROS?ADE ROCKET S Y S T E M I.NSTALLATION

ADAPTER RETROGRADE SECTION

0 RETROGRADE

N
E
W

I MOUNTING POINTS

INITIATOR WIRING

MOUNTING LUG

N O Z Z L E ASSEMBLY
NOZZLECLOSU

L Figure 23
 ELL
DATE 18 July 1962 ST. LOUIS, MISSOURI PAGE 44
REVISED REPORT 86L2
REVISED 7- MODEL Genini

4.4.1.1 NOZZLE ASSEMBLX AND CASE.- (Continued)

A nozzle c l o s u r e i s sandwiched between the i n s e r t and t h e

expansion cone i n t e r f a c e . "his closuye has a shear groove t h a t permits t h e
c l o s u r e t o be e j e c t e d a t a predetermined pressure l e v e l . The closure contains
a f i t t i n g t o permit pressure checking of the motor 3s required.

The a f t bulkhead i s machined fran a forging of t h e same t i t a n i u m

a l l o y a s t h e case. It provides a threaded i n t e r f a c e i n t o which t h e expansion
cone i s f i t t e d . The bulkhead i s bolted t o t h e motor case and a n O-ring i s used
t o e f f e c t proper s e a l i n g of t h e chamber during motor operation. A l u g i s pro-
vided f o r t h e p p p o s e of motor i n s t a l l a t i o n and alignment. I n s u l a t i o n m a t e r i a l
i s applied t o t h e case i n t e r i o r by a bag-molding technique.

4.4.1,2 SOLID PROPELLANT.- The propellant used i n t h e rocket motor i s a

f u l l y developed polysulfide-ammonium perchlorate system. The
p r o p e l l a n t formulation used provides a propellant g r a i n which i s extremely r e l i -
a b l e over t h e required temperature range. The' g r a i n i s c a s t and cured i n t h e
motor chamher and has a n i n t e r n a l burning eight-pointed star configuration.

4.4.1.3 I G N I T I O N SYSTEM.- Two independent and redundant pyrogen type

i g n i t e r s a r e used i n each motor, mounted on t h e a f t end of the i
motor. Each pyrogen i s e s s e n t i a l l y a small, i n t e r n a l burning, solid-propellant E
r o c k e t motor with i t s own i n i t i a t o r and i g n i t e r p e l l e t s . 'the motor i s pre- I
pared f o r f i r i n g by i n s e r t i n g a pressure c a r t r i d g e i n i t i a t o r i n t o each pyrogen
i g n i t e r . The i n i t i a t o r i g n i t e s t h e pyrogen p r o p e l l a n t which discharges i t s
exhaust gases i n t o t h e motor cavity, providing t h e pressure and thermal energy
t o i g n i t e t h e surface of t h e motor propellant g r a i n i n a smooth, reproducible
manner. The pyrogen provides a sustained discharge f o r approximately 200 milli-
seconds t o provide a l a r g e factor of safety and t o assure a high l e v e l of con-
fidence i n r e l i a b l e vacuum i g n i t i o n .

The case and cap are machined from a titanium a l l o y . The case is
threaded a t one end t o permit attachment of t h e pyrogen head caps. It i s 1,4
i n c h e s i n diameter and has an over-all length of 1.6 inches and a throat dianeter
of 0.19 inches. An i n s u l a t i o n sleeve made from a s i l i c a f a b r i c , reinforced
with a phenolic material, p r o t e c t s t h e pyrogen assembly during motor operation.
It i s bonded i n place t o t h e e x t e r i o r of t h e case. 'The p r o p e l l a n t i s c a s t
i n t o a paper phenolic tube and, a f t e r i t i s cured, i s i n s e r t e d i n t o the i n t e r i o r
of t h e case.

The pyrogen employs a booster charge c o n s i s t i n g of boron/potassiun

n
n i t r a t e p e l l e t s . lhese p e l l e t s a r e constrained i n a container assembly conposed
of a s t a i n l e s s s t e e l body, type 303, and a perforated n i c k e l diaphragm t o pre-
vent i g n i t i o n d e b r i s from blocking t h e nozzle.
 DATE 18 J u l y 1962 ST. LOUIS, MISSOURI PAGE 4s
REVISED REPORT 86U
REVISED MODEL Gemini

4.4.1.3 I G K I T I O N SYSTEM. - (Continued)

The propellant used i n t h e pyrogen i s a f u l l y developed, poly-
sulfidq/amnonium perchlorate system designated TP-L-8035, which has been widely
employed a s a pyrogen propellant i n a number of solid-propellant rockets.

The i n i t i a t o r i s a small pressure c a r t r i d g e t d a t i s threaded

0 ' i n t o t h e pyrogen bulkhead assembly a t time of.arming of t h e motor. Each i n i t i a -
t o r contains a bridgewire system capable of k i t h s t a n d h g a one amp, one watt
current/pouer i n p u t f o r f i v e minutes without f i r i n g and i s capable of f i r i n g
with t h e c u r r e n t l i m i t e d t o four amperes, A f i r i n g lead cable i s connected t o
a Bendix PT type r e c e p t a c l e incorporated i n each i n i t i a t o r , The design i s such
t h a t i f t h e e l e c t r i c a l power t o one i n i t i a t o r i s i n t e r r u p t e d , the other i s
adequate t o i g n i t e t h e motor.

4.5 ENVIRONMENTAL AND LOAD REXJUIRENENTS N

E
4.5.1 ENVIRONPlENTkL CONDITIONS.- The rocket motor and packaged i n i t i a t o r W
(handling and storage) or i n s t a l l e d i n i t i a t o r (prelaunch and launch
do n o t suffer any detrimental e f f e c t s during and a f t e r exposure t o extreme
temperature, r a i n , s a l t spray, sand and dust, and hwnidity a s defined by Table
111. Only nonnutrient m a t e r i a l s a r e used i n t h e construction of the rocket
motor and the components thereof.

Materials used i n the construction of t h e u n i t t h a t a r e s u b j e c t t o

d e t e r i o r a t i o n when exposed t o climatic and environmental conditions l i k e l y t o
occur under t h e ccnditions specified i n Table I11 a r e protected a g a i n s t d e t e r -
i o r a t i o n i n a manner t h a t will i n no way prevent ccmpliance with required motor
performance. P r o t e c t i v e coatings t h a t w i l l crack, chip, o r s c a l e k i t h age o r
extremes of climate and environmental conditions are not used.

The unit is designed f o r storage and operation a t r e l a t i v e humidi-

t i e s up t o 100 per cent, including condensation due t o temperature change.
-I.-
y..l) -- = PAGE It0
REVlSED
ST. LOUIS. MISSOURI REPORT 8611a

9
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REVISED REPORT EOL?
I

REVISED _-
-4XFRFIDXNTIA L MODEL

4.5.1.1 OPERATING RM;IEES

4.s.1.1.1 ALTITUDES AND TEXPERATU!ES.- The rocket motor i g n i t e s and operates

s a t i s f a c t o r i l y throughout t h e ambient pressure range of 15.5 t o 0
p s i a and as follows:

A. S t a t i c Exposure - The rocket motor performs s a t i s f a c t o r i l y

a f t e r s t a t i c exposure t o a minimum ambient temperature environ-
ment of + 1 8 0 O ~f o r a period long enough t o condition t h e e n t i r e
mass of t h e engine t o +180°F and a f t e r exposure t o a m a x i n u n
temperature environment of -20°F f o r a periodolong enough t o
condition t h e e n t i r e mass o f t h e motor t o -20 F,

B. F l i g h t Operation - The rocket motor i g n i t e s and p e r f o m

s a t i s f a c t o r i l y , exhausting t o vacuum conditions.

C. Temperature Gradients - The rocket motor p e r f o m s s a f e l y and

c o n s i s t e n t l y w i t h the thermal. condition of t h e g r a i n a f t e r
exposure t o a minimum ambient temperature of + 1 8 0 O ~f o r a
p e r i o d long enough t o condition t h e e n t i r e mass of t h e motor t o
+180°F and f i r e d a f t e r exposure t o a maximum ambient tem-
p e r a t u r e of -20°F u n t i l t h e maximum temperature gradient e x i s t s
w i t h i n t h e propellant grain. It a l s o performs s g t i s f a c t o r i l y
when conditioned t o a maximum temperature of -20 F and then
f i r e d after exposure t o a m i n i m u m ambient temperature o f + l 8 @ F i
u n t i l the maximum temperature gradient exists i n t h e p r o p e l l a n t
grain.

4.5.1.2 STORAGE TDPE%I!RJRE RANGE AND ATTITUDE.- The rocket motor and
packaged i g n i t e r under f i e l d storage conditions do n o t suffer any
detrimental effects when exposed t o t h e prelaunch temperature range as pre-
sented i n Table I I I and when s t o r e d i n any a t t i t u d e . The t o t a l accumulated
storage time above +a09w i l l not exceed two weeks.

4.5.1. 3LIMI'ITNG EXPOSURE TIME.- The rocket motor operates w i t h i n spegifi-

c a t i o n l i m i t s afterecposure t o a temperature varying from -20 F t o
+180°F and a vacuum environment f o r a period not less than fourteen days.

L5.1.4 VIBRATION.- The rocket motor, with i n s t a l l e d i g n i t e r s , i s capable of

withstanding without d e l e t e r i o u s e f f e c t s t h e v i b r a t i o n s a s pre-
s e n t e d i n Table 111.

4.5.1.5 DROP.- The packaged rocket motor with i n s t a l l e d i g n i t e r s and

packaged i g n i t e r i n i t i a t o r s will perform s a t i s f a c t o r i l y after being
subjected- t o a f o u r f o o t drop onto s o l i d r e i n f o r c e d concrete.
DATE 10 July1962 ST. LOUIS, MISSOURI PAGE 48
REVISED REPORT 86112
REVISED ~ MODEL Gemini

4.5.1.6 ACOUSTIC NOISE.- The rocket motor and i n s t a l l e d i g n i t e r are capable

.
of withstanding acoustic noise as s p e c i f i e d i n Table I11 without
d e l e t e rious e f f e c t s

4.6 STRUCTURAL REQU1REMENTs.- The rocket motor and i t s supports are

capable o f withstanding without permanent deformation t h e f o r c e s
r e s u l t i n g f r o m t h e l o a d s s p e c i f i e d i n Table I11 and Figure 24. For design
.purposes,the ultimate strength provides f o r a minimum of 1.36 tines t h e f o r c e s
r e s u l t i n g from the loads s p e c i f i e d i n Table 111 and Figure 24. The proof and
b u r s t pressure limits of t h e t h r u s t chamber exceed the m a x i m u m pressure based on
e i t h e r t h e m a x i m u m i g n i t i o n pressure o r t h e maximum chamber pressure a t +180°F,
whichever is l a r g e r , by f a c t o r s of 1.1 and 1.4, respectively. Temperature
effects shall! be considered. As an a d d i t i o n a l condition on a l l i n e r t hardware,

.
these temperatures s h a l l be increased 100°F and combined with limit loads
(ultimate temperature with limit l o a d condition)
DAT€ 18 J u l y 1962
ST. LOUIS, MISSOURI PAGF - ------ L9
REVISED
Rk PORT 8642
REVISEC Mf>ilkL . GEMINI

L I M I T L O A D S FOR R E T R O G R A D E ROCKET

4 P (THRUST)

14O43' Z
4 2
I-
d
LIY
O W

-n>-
-VIt-
0
Q

ORIENTATION OF RETROGRADE
ROCKET TO E OF ADAPTER

N
E
W

I *

/ 'Ei %
: \J S:

9 14'43'

8
1) U L T I M A T E LOADS A R E 1.36
TIMES LIMIT LOADS
2) LOADS ARE I N POUNDS AND ARC
. BASED ON A WEIGHT OF 65 LBS
(NOM.) AND 66 LBS. (MAX.)
7.39 R
3) 6 = + 3 O FOR MISALIGNMENT
4) I N T E R N A L PRESSURES S H A L L 8F
I-

CONSIDERED WITH THE A P P L I C A B' L E

THRUST CONDITION.
/

CONDITION P 0 S Rl&R2 R3
R4 R5 R6 R7
MAX. THRUST 3740 0 0 1560 1450 927 927 0 0
LAUNCH 7.25 9's
0 478 0 -1 93 -180 -30 -30 0 0
ABORT 4.0
, g'r 0 0 264
0 0 - 62 62 125 -125
 0
DATE 18 July 1962 ST, LOUIS, MISSOURI PACE
so
REVISED REPORT
8gI2
REVISED - ! ) MODEL GeziIii

5. RE-ENTRY COETROL SYSTFSil

5.1 GE1iERAL.- The Re-entry Control System (RCS) i s a l i q u i d bipro-

p e l l a n t rocket engine propulsion system. The re-entry module
c a r r i e s two of these systems, each one c o n s i s t i n g of e i g h t fixed-mount Tcfr’s
operating on s t o r a b l e hypergolic propellants supplied by a cold gas p r e s s u r i z e a
p o s i t i v e expulsion feed system. Complete redundancy i s achieved by simultaneous
operation of t h e s e two completely separate systems. The s i x t e e n T U ’ S are
arranged i n t h e re-entry module as shown i n Figure 1.

5.2 FUNCTION.- The two systems, i n conjunction with t h e A t t i t u d e Con-

t r o l and Maneuver E l e c t r o n i c s (ACME), various sensing devices and
t h e a t t i t u d e hand c o n t r o l l e r and f o o t pedals, a r e normally used t o provide a t t i -
tude c o n t r o l of t h e re-entry module from r e t r o g r a d e t o deployment of t h e drogue
chute o r paraglider, subsequent t o the j e t t i s o n i n g of t h e OAMS.

The two systems respond t o e l e c t r i c a l s i g n a l s from t h e A t t i t u d e

Control Electronics (ACE) which i s a p a r t of A C I G o r from t h e a t t i t u d e hand
c o n t r o l l e r 2nd f o o t pedals. I n response t o t h e e l e c t r i c a l s i g n a l s , t h e s y s t e m
produce rocket t h r u s t f o r c e s t o control t h e a t t i t u d e of t h e vehicle. I n the
event of f a i l u r e of one system, t h e remaining system h a s t h e impulse capacity
and t h r u s t t o guarantee a t t i t u d e c o n t r o l during retrograde and s t a b i l i z a t i o n i?
f o r safe re-entry, although touchdown c o n t r o l accuracy may be lessened. E
V
A t t i t u d e i s c o n t r o l l e d automatically by the ACHE o r manually by t h e
crew e i t h e r d i r e c t l y o r through t h e ACHE. Control by t h e crew i n p i t c h and
r o l l is accomplished with the a t t i t u d e hand c o n t r o l l e r a n d ’ i n yaw with t h e f o o t

.
pedals (a d e t a i l e d discussion of the guidance and c o n t r o l modes of operation i s
contained i n M.A.C. Report 8637)

P i t c h , r o l l , and yaw torques are obtained by s e l e c t i v e l y f i r i n g

p a i r s of TCA’s. Each TCA has a nominal t h r u s t output of 25 pounds.

5 03 DESCRIPTION AhD 0FGUTIOK.- The components i n each system are

arrayed as shown schematically i n Figure 25. Only one system i s
being sho.E;n s i n c e both are i d e n t i c a l . Both systems a r e i n s t a l l e d as shovn i n
F’igure 26. I n general, system operation may be described as follows. Cold gas
i s s t o r e d under pressure i n t h e pressurant storage tank and hela t h e r e i n by a
normally closed cartridge-actuated valve. hhen t h e system i s t o be a c t i v a t e d ,
t h e c a r t r i d g e valve i s opened and the p r e s s u r a n t flows t o the pressure regulator.
The gas pressure i s reduced a t t h e r e g u l a t o r t o a p r e s e t value and t h i s
r e g u l a t e d pressure i s imposed upon each of t h e p r o p e l l a n t tanks t o p r e s s u r i z e
t h e propellants. These tanks a r e of t h e f l e x i b l e c o l l a p s i n g bladder type f o r
p o s i t i v e expulsion of the propellants i n t h e gravity-free environment of
 L-
--.*

RE-ENTRY C O N T R O L SYSTEM S C H E M A T I C

PRESSURANT GROUP .

LEGEND:
TOOVERBOARDVENT

+
TCA THRUST CHAMBER ASSEMBLY

CONNECTED
.. I
i
rt I-
NOT CONNECTED

PA OR pg PRESSURE (TRANSMITTED TO INSTRUMENT

: +
TEMPER,
P A N E L INDICATOR) - TELEME‘
TA OR T g TEMPERATURE (TRANSMITTED TO :TO GROUP
INSTRUMENT P A N E L INDICATOR)

F l CHECK V A L V E .
8

RELIEFVALVE .
-@- MANUAL VALVE :
.. COMPO!

e CARTZIDGE-ACTUATED
(NORMALLY CLOSED)

FILTER
VALVE

NOTE: RING “A” I S SHOWN

f---l BURST DIAPHRAGM RING “B” IS. IDENTICAL

-2
a PRESSURE TRANSDUCER

GROUND TEST CONNECTION

I Figure 25
MAC 318U (RLV 2 5 AljG 61)
 OXIDIZER/FUEL GROUP TCA GROUP

I-
1 - I
I THRUST CHAMBER AND
INTEGRAL SOLENOID VALVES
(RELATIONSHIP O F SEQUENCE
AS VIEWED FfiOM SMALL END
LOOKING TOWARD H E A T SHIELD)

U
I
I
RING “6” E --.
I
I
I --- -

3UND ONLY F U E L TANK . R

PROPELLANT E
TANKS

RING “6” I /
1 I/

I
.
#.
I

I
METERED
O X I D I Z E R TANK
)UND ONLY

’ONENT PACKAGE “C”

.
 mG-D4LTmwELL
DATE 18 J u l y 1962 52
ST. LOUIS, MISSOURI PAGE

REVISED REPORT €542

REVISED MODEL
GEXIXI

n RE-ENTRY CONTROL SYSTEM COMPONENT

MSLIE!

-
RE-ENTRY CONTROL SYSTEM SECTION

Figure 26
 DATE 18 J U ~ S1962 ST. LOUIS. MISSOURI PAGE 53
REVISED .RE PORT 8642
REVlSEb ,-- MODEL Gemini

5 03 DESCRIPTION ALII OPERATION.- (Continued)

space. Simultaneously with t h e f i r i n g of t h e above mentioned valve, s i m i l a r

valves located downstream from t h e propellant tanks a r e opened. The systemj
with valves open and propellants pressurized, i s ready f o r a f i r i n g command.
The f i r i n g command i s received a t the t h r u s t chamber p r o p e l l a n t valves which
open i n response, permitting propellant flow t o the t h r u s t chamber. The
.simultaneous i n t r o d u c t i o n o f both propellants t o t h e t h r u s t chamber p r e c i p i t a t e s
hypergolic i g n i t i o n , combustion, and the generation of t h r u s t .

As shown on Figure 25, p a r t s of t h e two systems a r e designed on a

modular b a s i s , with t h e modules consisting of s e v e r a l components conveniently
and compactly arranged t o reduce weight, eliminate leaks, and f a c i l i t a t e t h e
i n s t a l l a t i o n , . t e s t i n g , and servicing of the system. 'There a r e f i v e such
modules: component packages ttktt,t t B f l , 'tC1l, and 'tI)lt,and the TCA's. I n addition,
t h e r e a r e t h e pressurant storage tank, pressure regulator, and propellant tanks.

The camponents a r e dividea i n t o t h r e e main gro'ups: a pressuriza-

t i o n group, oxidizer and f u e l groups, and E A group. 'The p r e s s u r i z a t i o n group
c o n s i s t s o f a pressurant storage tank, component packages tlA1l and ItBtl, and a
pressure regulator. The oxidizer and f u e l groups a r e s i m i l a r , consisting of
propellant tanks and component packages trC1l and IfDtt. Each TCA i n t h e T U group
contains p r o p e l l a n t valves, i n j e c t m s , and t h r u s t chambers.

The arrangement and function of t h e RCS components comprising

t h e s e groups are e s s e n t i a l l y the same as those f o r comparable components i n t h e
O&E, with the d i f f e r e n c e beinp that component package Wl, t h e propellant
supply on-off' valves, and t h e propellant l i n e g u i l l o t i n e s are not included i n
t h e RCS and pressure r e g u l a t i o n i s accomplished only by the regulator. Component
packages IIAtt and lrBfl and t h e regulator a r e the same p a r t s a s t h o s e i n t h e OAMS
while component packages "Ctl and 'lDt'a r e scaled down versions of t h e same p a r t s
i n t h e OAMS. A d e t a i l e d d e s c r i p t i o n of t h e s e components i s contained i n t h e
following paragraphs.

The pressurant storage tank i s a n all-welded, s p h e r i c a l tank.

Nitrogen gas i s stored i n t h e tank a t a nominal storage pressure of 3000 psig.
The tank i s 7.25 inches i n o u t s i d e diameter and has a n i n t e r n a l volume of 185.0
cubic inches.

Component package ItA" c o n s i s t s o f a pressure transducer, a norm-

a l l y closed cartridge-actuated valve, and two manual valves (Figure s).
The
pressure trtnsducer i s used t o monitor t h e pressure of t h e s t o r e d high pressure
gas. The c a r t r i d g e valve i s used t o i s o l a t e t h e pressurant from t h e remainder
of t h e system p r i o r t o system activation. The manual valve upstream of t h e
c a r t r i d g e valve i s used f o r f i l l i n g , draining, and purging of t h e pressurant
while t h e manual valve downstream from t h e c a r t r i d g e valve i s used during
0 ground checkout o f t h e pressure regulator.
 DATE 18 July 1962 ST. LOUIS. MISSOURI
PAGE 54
REVISED REPORT
8642
REVISED ~ F I D E N T I A L MODEL
Gemini

5.3 DESCRIPTION AND OPERATION. = (Continued

The pressure r e g u l a t o r j s of t h e single-stage, conventional mech-

anical-pneumatic type (Figure 7). A 2-micron i n l e t f i l t e r i s used t o reduce t h e
contaminants i n t h e gas t o an acceptable l e v e l , thereby i n c r e a s i n g t h e r e l i a b i l i t y
of t h e r e g u l a t o r . The nominal pressure s e t t i n g f o r r e g u l a t i o n i s 280 psig.
Component package "B" c o n s i s t s of a p r e s s u r e transducer, relief
valves, burst diaphragms, check valves, manual valves, and ground t e s t connections
(Figure 9). The pressure transducer i s used t o monitor t h e regulated gas pressure.
The relief valves and b u r s t diaphragms a r e used i n conjunction with t h e r e g u l a t o r
t o c o n t r o l t h e regulated gas pressure. The b u r s t diaphragns are used t o provide
assured zero leakage (until a c t i v a t e d ) p r e s s u r e r e l i e f devices. I n t h e event of
failure of t h e p r e s s u r e r e g u l a t o r t o reduce t h e supply pressure s u f f i c i e n t l y o r
excessive temperature cycling, t h e burst diaphragms w i l l rupture and permit jet-
t i s o n i n g of t h e p r e s s u r a n t - g a s through t h e p r e s s u r e r e l i e f vent valves, thereby
a f f o r d i n g overpressure p r o t e c t i o n f o r the o t h e r system components. If t h e b u r s t
diaphragm were.the s o l e p r o t e c t i v e element, a s i n g l e a c t u a t i o n would r e s u l t i n
venting of t h e t o t a l supply of pressure. However, t h e relief valves avoid t h i s
and r e s t r i c t t h e venting t o t h a t required t o c o r r e c t conditions of a t r a n s i e n t
type and keep t h e system p r e s s u r e a t a safe l e v e l ( i . e . , i f t h e r e g u l a t i o n
f a i l u r e i s momentary i n nature, t h e r e l i e f valves r e s e a t and permit normal
system operation t h e r e a f t e r ) . Such a s i t u a t i o n can occur i n t h e event of a n
abnormal thermal cycle coupled with a low r a t e of p r o p e l l a n t consumption. A
check v a l v e i s provided upstream of the f u e l p r o p e l l a n t tank t o prevent back-
flow of f u e l i n t o t h e gas system, should t h e expulsion bladder f a i l . Check
valves are provided upstream of t h e oxidizer p r o p e l l a n t tank t o prevent backflow
of o x i d i z e r vapor i n t o t h e gas system. Two are used f o r double p r o t e c t i o n
a g a i n s t o x i d i z e r vapor which w i l l permeate t h e t e f l o n expulsion bladder. The
ground t e s t connections a r e used f o r component checkout and t h e manual valves
are used f o r ground checkout and servicing.

The p r o p e l l a n t tanks a r e c y l i n d r i c a l . They a r e of t h e p o s i t i v e

0 expulsion type, trith expulsion bladders which are compatible with the p r o p e l l a n t s
t o be contained. The o x i d i z e r tank bladder i s made of t e f l o n and can r e q u i r e
replacement as it has a l i m i t e d expulsion o r c o l l a p s i n g cycle s e r v i c e l i f e ( n o t
t i m e l i m i t e d ) . The f u e l tank bladder is made of b u t y l rubber and does n o t
r e q u i r e replacement as it has an almost unlimited time and expulsion o r flex
cycle l i f e . A flow path i s provided through t h e p r o p e l l a n t p o r t i o n of t h e tanks
f o r bleeding, purging, and drying. T h i s p o r t is designed such that each flow
path t o t h e atmosphere i s s e a l e d twice t o increase t h e r e l i a b i l i t y of t h e tanks.
The f u e l and o x i d i z e r tanks a r e 5.10 inches i n o u t s i d e diameter. The f l u i d
volume capacity is 546.0 cubic inches f o r the o x i d i z e r tank and 439.0 cubic
inches f o r t h e f u e l tank. The charged f l u i d volume capacity at 1600~f o r t h e
design p r o p e l l a n t weight is 535.0 cubic inches for t h e oxidizer tank and 400.0
cubic inches f o r t h e f i e 1 tank.
DATE 18 July 1962 ST. LOUIS, MISSOURI PAGE

REVISED REPORT
EL7
4
REVISED MODEL Gemini

5.3 DESCRIPTION AND OPERATICIN .- (Continued)

Component packages W1 and oD1lcontain e s s e n t i a l l y t h e same coz-

ponents: a normally closed cartridge-actuated valve, two manual valves, and a
f i l t e r (Figure 10). The c a r t r i d g e valves are used t o i s o l a t e t h e p r o p e l l a n t s
from t h e remainder of t h e system p r i o r t o system a c t i v a t i o n . The manual valves
upstream of t h e c a r t r i d g e valves a r e used f o r f i l l i n g , draining, ana purging of
t h e p r o p e l l a n t s while t h e manual valves downstream f r o m t h e c a r t r i d g e valves a r e
used f o r ground checkout of downstream component function. The f i l t e r s a r e used
t o reduce t h e p a r t i c l e contamination of t h e p r o p e l l a n t s t o a l e v e l acceptable t o
t h e TCA's.

A l l TCA's are i n s t a l l e d submerged beneath t h e s p a c e c r a f t mol&Line.

Each one c o n s i s t s of two t h r u s t chamber p r o p e l l a n t valves, two c a l i b r a t i o n
o r i f i c e s , a f u e l and o x i d i z e r i n j e c t i o n system, a combustion chamber, and an ex-
a ,

pansion nozzle (Figure 11). lhe propellant valves are quick a c t i n g , normally
closed solenoid valves which open upon a p p l i c a t i o n of a n appropriate e l e c t r i c a l
s i g n a l t o permit flow of o x i d i z e r or f u e l t o the i n j e c t o r t o which they a r e
f i t t e d . The i n j e c t o r u t i l i z e 8 precise j e t s which impinge t h e f u e l and oxidizer
on one another f o r c o n t r o l l e d mixing and good combustion e f f i c i e n c y . The c a l i -
b r a t i o n o r i f i c e s are trim devices used i n conjunction with t h e p r o p e l l a n t valves
and t h e i n j e c t o r s t o a d j u s t t h e flows t o t h e design flow l e v e l s . The trim
o r i f i c e s are adjusted and f i x e d during TCA acceptance t e s t i n g . The combustion
chamber i s the enclosed a r e a between t h e i n j e c t o r face and t h e t h r o a t of t h e
nozzle. The expansion nozzle i s bell-shaped and contoured t o terminate f l u s h
with t h e moldline of t h e spacecraft. The combustion chamber and the nozzle are
l i n e d with a b l a t i o n material and i n s u l a t i o n t o c o n t r o l e x t e r n a l w a l l temperature.
Seals are provided between t h e nozzle and t h e s p a c e c r a f t s k i n t o prevent t h e
backflow o f exhaust gas i n t o the spacecraft. A p r o t e c t i v e cover o r plug i s Fro-
vided t o p r o t e c t t h e t h r u s t chamber from e n t r y of f o r e i g n matter when t h e TO\ i s
not i n use. The cover o r plug i s manually removed p r i o r t o launch and/or
j e t t i s o n e d i n f l i g h t by t h e f i r s t start.

Readouts of t h e temperature and pressure of t h e s t o r e d gas i n t h e

two system are a l s o provided on the temperature and pressure i n d i c a t o r on the
a s t r o n a u t s ' instrument panel (Figure 13). These readouts a r e a l s o s e l e c t e d by
means of t h e manual switching device. 'The temperature and pressure of t h e s t o r e d
gas can be used t o provide a n i n d i c a t i o n of t h e p r e s s u r i z a t i o n c a p a b i l i t y avaif-
a b l e f o r t h e remainder o f the mission. Regulated gas pressure and temperature
a r e not t r a n s m i t t e d t o t h e i n d i c a t o r , but are telemetered t o t h e ground s t a t i o n s
f o r subsequent system analysis.
DATE 18 July 1962 ST. LOUIS, MISSOURI PAGE 56
REVISED REPORT 8642
REVISED -v MODEL Gemini

5.3 DESCRIPTION AND OPERATION.- (Continued)

J e t t i s o n i n g of theremaining p r o p e l l a n t s i n t h e two systems may be

necessary a f t e r re-entry but p r i o r t o touchdown i n order t o a s s u r e crew safe.ty
during landing. Since r a t e damping i s required up t o deployment o f the para-
g l i d e r , j e t t i s o n i n g w i l l occur a f t e r p a r a g l i d e r deployment. The p r o p e l l a n t s will
be j e t t i s o n e d by operating a l l y a w chambers simultaneously. . Exhaust from t h e s e
TCA's presents t h e l e a s t danger t o the paraglider during e i t h e r f i r i n g o r dumping
'of p r o p e l l a n t because the burned and unburned exhaust.products will be c a r r i e d
away from t h e paraglider by t h e surrounding movement of a i r . If f o u r yaw TCAls
a r e f i r e d per system, t h e propellants w i l l be j e t t i s o n e d a t t h e r a t e of one-third
pound per second, .which f o r a f u l l load of p r o p e l l a n t s (35 l b s , ) woula take 105
seconds. A f u l l load of propellants may have t o be j e t t i s o n e d i n t h e event t h a t
an a b o r t becomes necessary.

5.4 DESIZN CRITERIA.- A propulsion system, capable of performing t h e

acS mission, was evolved from t h e design c r i t e r i a l i s t e d below:
... .Two completely redundant systems, s e a l e d u n t i l retrograde, each
of which can accomplish a nominal mission.

.... S t o r a b l e propellants having an advanced development background.

N
....Nitrogen
istics.
used f o r pressurant because of low leakage character- .E
W
.. ..Pure couples f o r r o l l control.

..,.No t r a n s heatshield p r o p e l l a n t o r pressurant l i n e s .

....A nozzle expansion r a t i o optimized f o r m i n i m u m over-all

sys tem weight.

.... .
Pressurant storage pressure optimized f o r minimum over-all
system weight
!
... .Compatible materials (and no d i s s i m i l a r metals) f o r a l l com-
ponent p a r t s except t h e s t a t i c s e a l s i n the high pressure
manual valves and various non-exposed p a r t s . I n addition,
no p l a t i n g or surface treatment a r e allowed t o make any sur-
face compatible.

.,..Corrosion r e s i s t a n t s t e e l l i n e s , f i t t i n g s and components, and

t i t a n i u m tanks and b o t t l e s .

..A b u t y l rubber bladder f o r t h e f u e l tanks.

....4 t e f l o n bladder f o r t h e oxidizer tanks.

DATE ST. LOUIS, MISSOURI PAGE 57
REVISED REPORT A
REVISED c MODEL Gemini

5.4 DESIGN CRITERIA .- (Continued)

.... Packaging of several components t o reduce weight, eliminate

.
leaks, save space, and f a c i l i t a t e i n s t a l l a t i o n , s e r v i c i n g and
testing

.... Components interchangeable between t h e RCS and t h e CAMS t o

reduce development and c o s t and i n c r e a s e r e l i a b i l i t y informa-

llA1l
and I1EP .
tion; i.e., t h e pressure r e g u l a t o r and component packages

... .A system t a i l o r e d t o M,A.C./Rocketdyne philosophy f o r s e r v i c i n g

and checkout. However, adequate connections and t e s t p o i n t s
a r e incorporated s o t h a t any other s e l e c t e d procedure i s not
excluded. Design o f t h e system i s such t h a t f u n c t i o n a l checks
of a l l components can be made using gas, s u b s t i t u t e t e s t f l u i d s
o r propellants, with by-passes f o r packages Wtl and tlDI1.

*..A diaphragm-relief valve series arrangement t o provide assured

zero leakage p r i o r t o a c t i v a t i o n of t h e pressure r e l i e f oper-
a t i o n and then t h e l i m i t i n g of t h e pressure venting t o t h a t
required t o p r o t e c t t h e system.
N
. . . . A l l dash numbered p a r t s and packages are i n s t a l l e d with E
threaded f i t t i n g s . W
....All non-threaded f i t t i n g connections are brazed o r welded.

... ,No e x t e r n a l l e a k paths through dynamic seals.

... .Double and t r i p l e s e a l manual valves f o r s e r v i c e connections

i n s t e a d of t h e use of disconnects.

...,Cartridge valve s e a l s placed on t h e pressurant and t h e pro-

p e l l a n t tanks f o r r e l i a b l e a c t u a t i o n , with a p o s i t i v e s o l i d
metal s e a l ,

... .Replaceable cartridge-actuated valves i n component packages

"CIt and llD1l s o that t h e component does not have t o be removed
from t h e system t o replace a - f i r e d u n i t .

..,.Main f i l t e r s located downstream from t h e c a r t r i d g e valves and

.
t h e ground t e s t connections f o r p r o t e c t i o n of downstream
components

.,..Supplemental f i l t e r s provided a t each solenoid valve, a t

each fill point, and i n each c a r t r i d g e valve f o r a d d i t i o n a l
protection.
 WCD
DATE 18 J u l y 1962 ST. LOUIS, MISSOURI PACE
58
REVISED REPORT 8542
R E V l SED F m . MODEL Gemini

DESIGN CRITERIA.- (Continued)

.... .
Non-replaceable f i l t e r s f o r reduced weight and t o prevent
leakage

.... Sheck valves t o provide p r o t e c t i o n a g a i n s t a c c i d e n t a l pro-

p e l l a n t mixing i n t h e regulated gas elements. N
E
..,.FIu.ss connections on t h e p r o p e l l a n t tanks f o r servicing. i.i

....Multi-expulsion
system checkout.
bladders t o allow s e v e r a l expulsions for I
....Individual, non-redundant i n - l i n e solenoid valves f o r 'EA

experience .
propellant valves t o take advantage of accumulated develosxent

....RCS
I d e n t i c a l valves and i n j e c t o r s f o r
and the O M S . Also, a l l HCS
all25 pound 'KA's i n t h e
t h r u s t chambers a r e i d e n t i c a l .

.,.,The duty l i f e o f the TCA's t o include contingencies f o r a l l

predicted uses.

DESIGN RE(J.JIREI%NTS
t
INPUTS AND FLUIDS

A, Pressurant.- The cold gas pressurant i s nitrogen, conforming

t o S p e c i f i c a t i o n MIL-N-6011.

B. -
Propellants.- The b i p r o p e l l a n t i s :
R
-
Oxidizer
.
Nitrogen t e t r o x i d e (N20h) conforming t o Specifica-
t i o n NIL-P-26539A
E
F
-
Fuel - 1WII - Monomethyl hydrazine (N2H3C5) conforming t o
S p e c i f i c a t i o n MIL-P-27403.

C. --
E l e c t r i c a l Inputs.- E l e c t r i c a l power f o r components o t h e r than
instruments i s taken from t h e common c o n t r o l bus a t 22.0 t o
30.0 v o l t s D . C . Instrument power i s taken from a regulated
source a t 5.0 volts D.C. + 0.5%. I
 18 July 1962 ST. LOUIS, MISSOURI PAGE 59
REVISED REPORT 86h2
REVISED MODEL Gemini

5.5.2 PERFORMANCE.- The two systems e x h i b i t t h e following vacuum per-

formance c h a r a c t e r i s t i c s :

A. Svstem Performance

Design t h r u s t l e v e l per 'TCA 25 pounds

. Minimum steady s t a t e s p e c i f i c
impulse
287
'ound-sec.
pound

M i n i m u m impulse b i t requlred .25 pound-sec.

Minimum s p e c i f i c impulse f o r 2h7 pound-s e c

pound
.
minimum impulse b i t

Pulse frequency range 0-6 pulses

sec.
Pulse width range Minimum impulse b i t kiidth
t o continuous

Maximum TCA response time - 25 milliseconds

time from application of
e l e c t r i c a l s i g n a l t o 90% of R
maximum chamber pressure E
V
Maximum TCA shutdown time - 7 milliseconds
time from removal of e l e c t r i c a l
s i g n a l t o 2% o f m a x i m u m chamber
pres sure

B. Other Svstem Parameters

Flow r a t e -
a t mixture r a t i o
(O/F) of 2.0
Oxidizer .Os55 lbs ./sec.
Fuel .!I278 lbs/sec.

Mixture r a t i o - r a t i o of pounds 2.0 2 I$

of o x i d i z e r t o pounds of f u e l
i n j e c t e d i n t o each ' E A

Regulated pressure 280 p s i g

T U chamber pressure 150 psia

Burst diaphragm rupture 420-500 p s i g
pressure range

Relief valve operating 380-430 psig

pressure range
 EL
DATE 18 J u l y 1962 ST. LOUIS, MISSOURI PAGE 60
REVISED
REPORT 8642
REVISED CON MODEL Gemini
c

5.5.3 hE1GHrS.- Target t o t a l weights f o r the two systems are a s follows

f o r both t h e two a d fourteen day mission at 15'?F:

A. Systen Ury height 109.2 lbs.

Components (81.0)
Lines ( 6.8)
S t r u c t u r e and E l e c t r i c a l (21.h)
71r*o -2 : I t !i
B. Propellant h e i g h t (Loaded)

c. Propellant height (Usable) 70 00

1). Propellant h e i g h t (Trapped 4.0
and Residual)

E. Pre ssGrant Weight 2.8

F. System Wet Weight 186.0
5.5.4 MATERLAIS OF COhSTRUCT1Q.N.- Except f o r t h e a b l a t i o n m a t e r i a l i n
t h e TCA's, a l l i n t e r n a l wetted surfaces a r e f u l l y compatible with
t h e f l u i d s contained therein. The pressurant and p r o p e l l a n t s t o r a g e tanks are
f a b r i c a t e d of titanium a l l o y and corrosion r e s i s t a n t s t e e l l i n e s a r e used
throughout t h e systems. Components a r e f a b r i c a t e d of corrosion r e s i s t a n t s t e e l
except i n c e r t a i n l o c a t i o n s (e.g., springs, valve seats, bladders and solenoid
c o i l s ) where f u n c t i o n a l requirements d i c t a t e the use of o t h e r more d e s i r a b l e
m a t e r i a l s of compatibility appropriate t o t h e i r environment.

5.5.5 ASSC"IBLY.- The components of t h e two systems a r e assembled i n t o

groups as shown i n Figure 25

505.6 INTERCHANGEABILI'iY .- System components which perform i d e n t i c a l

functions a r e d i r e c t l y and completely interchangeable w i t h one

.
another. S p e c i f i c a l l y , a l l t h r u s t chamber assemblies used i n t h e s e systems are
interchangeable with one another

5.5.7 COMPONENT LIFE.- A l l components a r e designed f o r a minimum of

f i f t e e n missions w i t h an operating l i f e comparable t o a t l e a s t
one mission, with t h e following exceptions:

A. Cartridge-actuated valves have a one-shot l i f e with a

p r o b a b i l i t y o f s a t i s f a c t o r y operation of a t least 0.9999.

B. Expulsion tank bladders have a minimum l i f e of six complete

expulsions under s e r v i c e conditions.
 DATE
ST. LOUIS, MiSSOURl PAGE 61
I I n
REPORT EO2
REVISED

REVISED
MODEL C-eFZni

5.5.7 COMPONENT LIFE. - (Continued)

C. Thrust Chamber Assembly l i f e c o n s i s t s of operation, e i t h e r
continuous o r i n pulsing mode, wherein pulse frequency and
duration i s randomly d i s t r i b u t e d between 0 and 6 p u l s e s per
second and 0.010 and 2.0 seconds p e r pulse, respectively,
Individual l i f e ratings are:
a A l l Thrust Chamber Assemblies.. ..... .........162 seconds

505.8 GROUND CHECKOUT.- Ground checkout c o n s i s t s of leakage measurexents

and f u n c t i o n a l checks of a l l components using nitrogen gas a t
s u i t a b l e pressures. Component gas flow r a t e c a l i b r a t i o n s are performed and.
comparisons made with a c c e p t a b i l i t y standards. The manual valves and t h e g x m d
t e s t connections a r e used f o r component checkout. A complete f u n c t i o n a l check-
out of every component can be performed i f necessary, including t h e f i r i n g o f
the TCA's with propellant.

5.6 ENVIRONMENTAL CONDITIONS.- The two systems function i n accordance

with t h i s s p e c i f i c a t i o n when subjected t o any n a t u r a l combination
of the environments shown i n Tables I1 and IV.

5. 7 STRUCTUFAL PcEQU1REMENTS.- A l l components of t h e two systems a r e

designed f o r t h e pressures defined i n Sections 5.7.1 and 5.7.2e
The components also withstand, without permanent deformation, t h e l i m i t acceler-
a t i o n and shock loads from Tables I1 and I V , t h e maximum r a t e d t h r u s t of 4he E A
u n i t s , and any loads which may result f r o m t h e operation of t h e systems. Ulti-
mate design loads of which s t r u c t u r a l f a i l u r e s h a l l not occur a r e 1.36 times
l i m i t loads. An a d d i t i o m l 1.5 f a c t o r i s used on any c a s t i n g s i n t h e components.
When critical, t h e ultimate s t r e n g t h provides f o r a minimum o f 1.36 times l i m i t
l o a d s combined with t h e design pressures of Sections 5.7.1 and 5.7.2, A l l com-
ponents are designed f o r t h e critical f l i g h t conditions with t h e proper pressur-
a n t and p r o p e l l a n t quantity, with an a d d i t i o n a l condition considered using t h e
a design landing c r i t e r i a with f u l l pressurized components. Limit temperatures
am shown i n Tables I1 and I V , and operating temperatures w i l l be determined by
tests. Ultimate heating e f f e c t s are considered by i n c r e a s i n g l i m i t temperatures
t o 2000F under c e r t a i n s p e c i f i e d conditions. Ultimate design conditions a r e
e i t h e r ultimate loads o r proper combinations thereof combined with l i m i t ten-
p e r a t u r e s o r ultimate heating e f f e c t s combined with l i m i t loads.

5.7a PRESSURES AND TERPERATURES

A. Normal Operating Pressures.- The normal operating pressures
f o r components located upstream o f t h e pressure regulator
(including the regulator i n l e t ) a r e 3000 psig and regulated
pressure (280 psig) f o r components l o c a t e d dnwnstream fron
t h e pressure regulator (and including t h e r e g u l a t o r o u t l e t ) .
DATE 1 8 July 1962 ST. LOUIS, MISSOURI
PAGE 62
REPORT
REVISED
MOOEL Gemini
REVISED

507.1 PTIESSURS AND TEIPERATURES. - (Continued)

B. Normal Operating Temperature.- The normal operating tempera-
t u r e i s 700F.

C. Design Pressures .-
The design pressure f o r components l o c a t e d
upstream of t h e pressure r e g u l a t o r is.3OOO.psig. The d e s i m
. pressure f o r components located downstream from t h e r e g u l a t o r
is 300 psig.
Do Design Temperature.
of +150F t o +160OT.
- The design temperature spans t h e range
E. Proof Pressures.- Component proof pressure a t 706F i s 150% o f
t h e design pressure, .except t h a t f o r t h e p r e s s u r a n t s t o r a g e
and t h e p r o p e l l a n t tanks it i s 167% of t h e design pressure.

F. Burst Pressures.- Component b u r s t pressure a t 70°F i s 250% of

t h e design pressure, except t h a t f o r t h e p r e s s u r a n t s t o r a g e
andthe p r o p e l l a n t tanks it i s 222% of t h e design pressure.
DATE 18 JULY 1962 ST. LOUIS, MISSOURI PAGE 63
REVISED REPORT 66/12
REVISED
MODEL ' Gemini

O N O N
mhl 'LnN
cuhl cucu

Q)

5
4-rm
o m
lE
N
00 E
m m
rlrl W

O8
8 m .
88
03-
CI
m

0
UJ
P
ri
u
DATE 18 1962 PAGE - 6 L
REVISED ST. LOUIS, M I S S O U R I REPORT 6642

TABLE: IV
DESION EXWIONf4ENTfi CONDITIONS Fa.
RE-ENTRY CONTROL SICSTM IPf4EIJT LG
Transportation and
Prelaunch
(Operating and Nonoperating)
Ambient Te;npsraturs (2) +20°F t o 160°P (Sorviced) and
' 4 O P t o l W F (UnservPcsd).
15.5 t o L 4 psia IS;*S

'"
i e n t Pressure t o 10"1*psia
erature-Pressure N.A. (1) 16WP a t 15.5 t o psia

Relative Humidity 15%t o 100% 15s t o 100%

S a l t Sea Rhosphere HIL-E-S272C, Procedure I1 N.A.
H 1 L E & 5 2 7 2 C , Procedure I N.A.
sand and Dust H I G % L ; 2 7 2 C , Procedure I NbAb
pungus (3) MIGhS272C, Procedure I N.A.
Shock (4) ( 5 ) ( 6 ) N.A, (Prelaunch) and Pro- N.A.
t e c t e d per H.A,C. Report
8757 (Transportation) ,

N.A. (Prelaunch) and Pro- Longitudinal Spacecraft Axis:

t e c t e d per M.A.C, €bort lg t o 7 . 2 5 g 1 8 , Linearly with
8757 (Transportation P t h e over 326 sec. Later&
Spacecraft Axes: 4.0g's in
any direction f o r 1 sec. (6)
Vibrat i o n
~ a t w o r yA (figure 15) (9) N.A, (Prslamch) and Pro- Curve I
t e c t e d per M.A.C. &port
8757 (Transportation)
Category B ( Pigure 16) (10) N.A. (Prelaunch) and Pro- curve I
t e c t e d per H.A.C. Report
8757 (IPrarrJportation)
Acouatic Noiee N.A. (Prelaunch) and Pro- 145 db Over-all, Sae figure
t e c t e d per M,A,C. deport 27

P dlo Interference
E&plosive Atmosphere
8757 (Transportation)
MIGI-26600
N ,A.
MIL-1-26600
N e A,
NOTES!
- Not applicable.
2, 'Rmm are t h e design extreme temperatures f o r the pro-
6 . Iangitudinal ard L a t e r a l do no:
7. h a I i s I n t h e Re-htry Modu;
p c l l a n t tank and cKstribution system. The combustion 160.00 and 192.00 (Upper Cabin
chmber l e deaigned f o r a maximum e x t e r n a l temperature Section). Area I1 is i n the Rfi
of mop. 2 S t a t i o n 8 103.u and 160.00
3. Applicable to untested and untreated materials only. 8. Longitudinal and Lateral a c t 3:.
4. L a b r a 1 Spacecraft Axes refers t o both t b p i t c h and yaw 9. Equipment i t e m s which are mom'
axes as dofined f o r s p a c e c r a f t control, structure d i r e c t l y o r through
5. A l l ahock and a c c e l e r a t i o n loads i n this t a b l e 81'8 l i m i t and/or a r e of s u f f i c i e n t l y ma"
loads. S a t i a f e c t o r y performance i s required during and/ mechanical impedance o f the SF
o r after U t load application, whichever is appropriate. aeen by the equipment i n s t a l l a
No equipment shall tear loose *om i t s mount and i n t e r n a l be considered e f f e c t i v e l y i n f i -
p a r t s shall be contained under application of ultimate
loads. Ultimate load IS 1.36 times limit load.
:V
LOCATED I N THE RE-EXRI MODULE MTERNAL TO 'RIE ppmURXZED CABIN
Orbit
(Operating or Poat -Landing
Nonoperating) (Nonop r a t i n g )
+isOP to 160OF +2WF to l&*P

10-12 t o 15.5 p s i a 15.5 pda

160°F at 10-12 t o 15.5 p i a over 10 N.A.

"a
N.k,
minutes
15% t o 100%
N .A.
15% t o 1005
pIXL-l+5272C, Procedure LI
N,A, N. A. HILE=5272C, Procedure I
N.A. N. A. H&b5272C, Procedure I
N.A.
NoAo
N.A.
- '

Area I jog's along Longitudinal

Spacecraft M e and 3 0 g 1 s along either
HIL-E5272C, Procedure
15g's in aAy dimctian,ll
DBB duration.
I

-
Lateral Spacecraft Axis, 11 m8 dura-
tion. (7) Area I1 See Figure 19 (?).
h n g i t u d i n a l Spacecraft ~ x i . 8 : lSg's,
30 SOC. duration, Lateral Spacecraft
Axes: b.Sg's, 30 sec. duration. (8)

curve I1 Curve 111

e w e 11 Curve I11 N e A.

N.P., Same an for Launch

MIL-1-26600 MILL26600 MIL-1-26600

N.A. N.A.

,ot act simultaneously. 10. E q u i p n t i t e m s or complete system i n s t a l l a t i o n of suffl-

u l e between Z S t a t i o n s - c i e n t l y large sizo and mass that the mechanical impedance
n Section and RCS of the attach points cannot be taken as infinite, and the
&-Entry Module between feedback mechanism has been given conaidarat ion,

simultaneously .
(Hain Cabin Section).

nted t o s p a c e c r a f t primary
intervening structure
all mass t h a t t h e
pacecraft structure as
ation a t t a c h p o i n t s can
Fnite,
 18 July 1962 ELL
D4TI
ST. L O U I S , M I S S O U R I PAGE P 65
RtVI\EO REPOFT 86b2
RFVISED - MODEL __ GEiQNI

Figure 27
 ClD
DATE 18 J u l y 1962 ST. LOUIS, MISSOURI PAGE
66
REVISED
REPORT 8642
REVISED e X D E I V 1i l i ~ MODEL
Gemini

6. QUALITY ASSUFANCE

6.1 GEIEFAL,- System components and m a t e r i a l s a r e subjected t o both

acceptance and design approval tests. Acceptance t e s t s include,
but are not l i m i t e d t o those t e s t s performed t o insure t h a t t h e m a t e r i a l s ,
workmanship, and performance of components are not substandard, and t h a t the
components have been manufactured t o approved drawings and s p e c i f i c a t i o n s ,
Design approval t e s t s a r e defined as those t e s t s conducted on pre-production
and/or production equipment t o determine t h a t t h e design of the equipment
complies with a l l requirements therefor. I n addition, production-line s u r v e i l -
lance i s maintained during fabrication, assembly, and i n s t a l l a t i o n of a l l com-
ponents and subassemblies t o assure t h a t a l l methods, procedures,and ambient
conditions are maintained i n accordance with e x i s t i n g s p e c i f i c a t i o n s and
e s t a b l i s h e d s p a c e c r a f t standards, Q u a l i t y assurance provisions a r e i n accordance
with E1.A.C. Report 8580-7, llQuality Assurance Provisions (Plan) f o r P r o j e c t
Gemini Space System,It

.FSLIABILI TY

701 GEhBi3AL.- An a c t i v e r e l i a b i l i t y program is e s t a b l i s h e d and con- R

ducted thmughout t h e design,&velopment, f a b r i c a t i o n , and in- E
s t a l l a t i o n of t h e P r o p l s i o n Systems , Adequate t e s t i n g , both i n - p l a n t and/or v
vendor/subcontractor-accomplished, i s performed t o i n s u r e a r e l i a b i l i t y f a c t o r
which does not d e t e r i o r a t e the over-all p r o b a b i l i t y of a s u c c e s s f u l mission.
Mission safety i s emphasized i n the design approach, back-up and redundant
systems are u t i l i z e d where necessary, and'every e f f o r t i s made t o minimize
system complexity. Reliability provisions are i n accordance w i t h M.A.C. Report
8580-3, "Project G e m i n i Reliability Plano1t
8. DATA REQUIREMENTS

8.1 -
GENERAL. Applicable design information and performance r e p o r t s are
submitted i n accordance w i t h the requirements s p e c i f i e d i n M.A.C.
,
Report 8580-8 IWodel 133P Gemini Program Documentation Plan.It
DATE 18 JULY 1962 ST. LOUIS, MISSOURI 'AGE 67
REVISED REPORT
8642
REVISED ~NFIDEN- MODEL Gemini

APPENDIX I

EQUIPMENT LIST

ORBIT ATTITUDE AND MANEWEX SYSTEM

. Quantity Nomenclature M.A.C. Par, No.

Two Day Fourteen Day
Mission Mission
1 1 Component Package "A" 52-52700-5

1 1 Pressure Regulator 52-52700-7

1 1 Component Package "B" 52-52700-9

1 1 Indicator-Temperature 52-52700-21
and Pressure

a a Thrust Chamber Assembly (25 l b . ) 52-52701-3 N

E
6 2 Thrust Chamber Assembly (100 l b . ) 52-52701-5 W
2 0 Thrust Chamber Assembly (85 lb.) 52-52701-7
2 1 Oxidizer Tank 52-52701-9
2 1 Fuel Tank 52-52701-11
2 1 Pressurant Storage Tank 52-52701-13
1 1 Propellant Quantity Gauging 52-52701-17
Systern

1 1 Cmponent Package "C" 52-52701-21

1 1- Component Package "D" 52-52701-23
2 2 Cartridge f o r -21 and -23 52-52701-25
2 2 Propellant Shutoff Valve 52-52701-31
1 1 Cartridge f o r -39 f o r N.O. Valve 52-52701-35
1 1 Component Package "E" 52-52701-39
1 1 Cartridge f o r -39 f o r N.C. Valve 52-52701-41

2 0 Propellant Line G u i l l o t i n e s 52-72708-1.

DATE 18 July 1962 ST. LOUIS, MISSOURI PAGE
68
REVISED REPORT 86h2
MODEL Gemini

APPENDIX I (Continued) *

EQUIPMEXT LIST

RE-ENTRY CONTROL SYSTEM

Nomenclature M.A.C. P a r t No.

Thrust Chamber Assembly (25 lb.)

Component Package ItAIf

Pressure Regulator

Component Package IfBtC

Component Package IIC"

Component Package I'Df' N

E
Oxidizer Tank W

h e 1 Tank

Pressurant Storage Tank

Indicator-Temperature and
Pressure

Cartridge f o r -5
Cartridge f o r -11 and -U 52-52700-25

RETROGRADE ROCKET SYSTEM

Quantity Nomenclature M.A.C. P a r t No.

Two Day Fourteen Day
Mission Mission

4 L Retrograde Rocket Motors 52-50703

 ...
m

I
DATE ST. LOUIS. MISSOURI
PAGE 69
REVISED
REPORT 8642
R €VISED MODEL
Gemini

APPrnM I1

LIST OF CHAWGES

Following i s an itemized l i s t of changes incorporated i n M.A.C.

Report t?&2 as a r e s u l t of successive revisions. I n instances where c o n f l i c t
o r confusion may r e s u l t , t h e a u t h o r i t y f o r these changes i s p a r e n t h e t i c a l l y
s p e c i f i e d ; where t h e reason f o r change i s self-explanatory (e.g., re-arrangement
of .format, a d d i t i o n of reference material, rewording f o r c l a r i t y o r a d d i t i o n a l
information, e t c . ) , no a u t h o r i z a t i o n is listed.

Section 1

Changes Incorporated i n 6 June 1962 Revision

Reference: A. P r o j e c t Gemini Abstract of Technical Negotiation Meeting on

Propulsion Systems, dated 1 May 1962

Paragraph Changes

T i t l e Page Added r e v i s i o n date, changed t h e t i t l e of

t h e r e p o r t , and d e l e t e d t h e downgrade note.

Approval Sheet Revised t o incorporate a d d i t i o n a l approvals.

Table of Contents Revised t o r e f l e c t changes made i n t h e

.
r e p o r t r e v i s ion

List of Figures and Tables Revised the numbers and t i t l e s of the

L i s t of E f f e c t i v e Pages
Index of Revisions
brigindl figures and t a b l e s , deleted origina:
Table IV, and added Figures 6 hhrough 27.
Added new pages incorporated i n t o t h e
revised report .
Added (as required).

1.1 Changed t h e t i t l e s of t h e r e p o r t and t h e

i n d i v i d u a l propulsion systems.

2.1 Changed "Subsystems" t o "Systemstt.

DATE 18 JUlY 1962 ST. LOUIS, MISSOURI
PAGE 70
REVISED REPORT 8642
REVISED
MODEL Gemini

APPENDIX I1

-- (Continued)
LIST W CHARGES

ParaKa&
I _
Changes

2.2-1 Deleted M.A.C. Repart 6433, added M.A.C.

Drawing 52-50702 and M.A.C. Heports 8611and
8637, and changed t i t l e s of M.A.C. Drawings
52-52700 and 52-52701.

3. Revised the e n t i r e s e c t i o n t o incorporate

a d d i t i o n a l information and f i g u r e s a s well
a s more current information ( p e r NASA r e -
q u e s t ) ; added a paragraph containing t h e
design c r i t e r i a f o r t h e OAHS (per NASA re-
q u e s t ) ; revised t h e a p p l i c a b l e paragraphs,
t a b l e s , and f i g w e s i n t h i s s e c t i o n (per
NASA comments i n Items 1 through 10 and 17
o f Reference A ) ; and incorporated component
operating pressures more current than those
shohn i n Item 11 of Reference A .

4. Revised t h e e n t i r e s e c t i o n t o incorporate
information, t a b l e s , and f i g u r e s on t h e
retrdgrade rocket system t h a t will be used N
i n a l l spacecraft providing t h a t t h e d e l i v e r y E
schedule i s compatible with v e h i c l e launch, W
including t h e conunents noted i n Items 12
through 16 of Reference A.

Revised the e n t i r e s e c t i o n t o incorporate

a d d i t i o n a l information and f i g u r e s as well
as'more c u r r e n t information (per IUsA re-
q u e s t ) ; added a paragraph containing t h e
design c r i t e r i a f o r t h e RCS (per NASA re-
q u e s t ) ; revised t h e a p p l i c a b l e paragraphs,
t a b l e s , and figures i n t h i s s e c t i o n ( p e r
NASA comments i n Items 4 through 8 and 10
of Reference A) ; and incorporated component
operating pressures more c u r r e n t t h a n t h o s e
shown i n Item 11 of Reference A.

Changed Y3ubsystemst' t o Wystems".

Appendix I Added a l i s t of equipment section.

 EL&
DATE 18 July 1962 ST. LOUIS, MISSOURI PAGE 71
REVISED REPORT 8642
MODEL
REVISED

LIST OF CHANGES (Continued)

Paragraph Changes

Appendix I1 Added a l i s t of changes section.

Addendum A Revised this e n t i r e s e c t i o n (which was pre-

viously Section 4) t o incorporate a d d i t i o n a l N
information and f i g u r e s as well as more cur- E
r e n t information on t h e a l t e r n a t e retrograde ou’
r o c k e t system t h a t may be required f o r t h e
e a r l i e r s p a c e c r a f t i n the event t h a t t h e sys-
tem described i n Section 4 i s not available;
. and incorporated t h e comments noted i n
Items 1 2 through 16 of Reference A .
DATE 18 July 1962 ST. LOUIS, MISSOURI PAGE
A1
REVISED
REPORT RhI!? - Add, A
REVISED
MODEL ' Genini

ADDENDUM A N
ALTERNATE RETROGRADE ROCKET SYSTEN
E
W
DATE 18 J u l y 1962 A2
.
Sf. LOUIS, MISSOURI PAGE
REVISED A
REPORT - H - n

REVISED
m b b MODEL Gemini

TABLE OF CONTENTS

TITLE PAGE
LIST OF FIGURES AND TABLES

A-1 . GENERAL
A-2. OPERATION
A-3. DESIGN RECJIRFKENTS
A-3.1 Retrograde Rocket

A-3.1-2
.
A -3 1 1 Nozzle Assembly and Case
Solid Propellant
1
E
A-3.1.3 I g n i t i o n System W

ENVIROhXENTAL AND LOAD REQUIREMENTS

Environmental Conditions
Operating Regimes
Storage Temperature Range and A t t i t u d e
Limiting Exposure Time
Vibration
Drop
Acoustic h'oise
A-5. S T R U C T L W REfJJIREMENTS

APPENDIX &
.
I EQUIPMENT LIST
DATE 18 July 1962 ST. LOUIS, MISSOURI PAGE A3
REVISED
REPORT 0642 - Add, A
REVISED & MODEL Gemini

LIST OF F1GU-m AND TABLES

F i g u r e No. Page

Alternate Retrograde Rocket Arrangement,

. A-1
A -2 A l t e r n a t e Retrograde Rocket Assembly .
AS

A6

A -3 Alternate Retrograde Rocket Performance, A7

'Weight,and Design Parameters

A -4 A l t e r n a t e Retrograde Rocket System I n s t a l l a t i o n A0

A-5 Gemini Spacecraft Vibration Spectra Equipment A12

Category A I
1

A -6 Gemini Spacecraft Acoustic Environment Spectrum A13 I

( I n t h e Adapter)

A-7 Limit Loads f o r A l t e r n a t e Retrograde Rocket A15

Table No. Page

A-I Design E n v i r o n i i n t a l Conditions for A l t e r n a t e All
Retrograde Rocket System Equipment Located
i n the Adapter
DATE

REVISED
18 J u l y 1962 S T . LOUIS, MISSOURI PAGE

REPORT
8GI:2 - Ldd ..!J:
1;

REVISED
-pd MODEL . (:eyini

A-1 . GEYE3JZ.- T h i s addendm d e s c r i b e s t h e a l t e r n z t e retrofrzcie rocket

spitm t h a t w i l l he used i n t h e e t i r l i e r s p a c e c r z f t i n t h e event
t h a t t h e rocket motors described i n Section 4 are not a v r i l a b l e f o r inst,alla'ticn.
These rocket motors are a l s o mounted i n t h e retrogrsde s e c t i o n of t h e &eptcr,
s j c m e t r i c a l l y located about t h e l o n g i t u d i m l axis of t h z spncecrLft as shown
i n F i g w e A-1.

A-2. OFEPYiTIU1.- RetroTade r o c k e t o p e - a t i o n permission i s estLblishcd

by manually armin? t h e r e t r o p d e squib f i r i n L c i r c x i t s , a f t c r
which t h e f i r i n & sequence i s controlled e i t h e r a u t o m t i c s l l j t h r o u c h t h e t i i e
reference systen o r manualljj by t h e crew. Thirty seconds prior t o a c t u a l
retrogrzde firin,.: (TR-30), t h e e l e c t r o n i c timer illuminates t h e PLTRO L L X
indicator/push button on t h e astronauts' instrument psncl. The automatic f i r i n g
c i r c u i t i s t h e n manually armed. A t TI?-0 t h e e l e c t r o n i c timer i n i t i a t e s t h e
r e t r o - f i r e sequence. The r o c k e t s are t h e n f i r e d a t five-seccrnd intervals,
Eocket numSer 1 i s t h e f i r s t t o be f i r e d , followed t h e r e a f t e r by nmlier 2 and 3
rockets, r e s p e c t i v e l y (See Figure A-1). Number 4 rocket i s n o t used during
t h e no&mal retrograde sequence and i s reserved as a back-up rocket i n t h e event
a m a l f m c t i o n occurs i n t h e f i r i n g o f one o f t h e o t h e r t h r e e rockcts. The
crex t r i l l z s c e r t a i n by t h e stesped a c c e l e r a t i e n i n p x t s t h a t a l l tLhrec r o c k e t s
have f i r e d successfully. The rockets are f i r e d i n srzlvo f o r c m5ssion zboz-t. R
E
v
k-3.1 -
PZTEOGFADE ROCKET. The f o1Jr retrcBgrg.de rocket motors employed
i n t h i s systen aye. i d e n t i c a l i n design and performtnce, containing
well-chzrscterized polyureth~ne/ammonim perclilorate p r o p e l l a n t zqd d u a l pyrogen
i g n i t e r s in.er.ch unit, as shown i n Figure -1;-2. k modified version of t h e
Thiokol TE-345 rocket, t h e retrograde rocket i s a 13.5 inch dimeter s p h e r i c a l
motor w % t h a 17-'/PII stainless s t e e l case, a partially-submerged nozzle with a
40: 1 expansion r a t i o , and internally-mounted pyrozen i g n i t e r s with removable
i n i t i a t o r s . It i s approximately 20.6 inches i n over-all len,rth.

Each rocket d e l i v e r s a t o t a l impulse of 18,400 pognd-seconds a t an

m e r a g e t h r u s t o f 860 pounds over a burning t h e of 20.6 seconds. These p e r -
fornance r a t i n g s are based on a p r o p e l l a n t bulk t e i n p r a t w e 0:' +600F and vacum
operation. Rocket performance, weight, and o t h e r p e r t i n e n t design ptrametcrs
are shown in Figure A-3.

The rockets are beam-mounted i n t h e r e t r o g r a d e s e c t i o n of t h e

adapter a s shotrn i n Figure 11-4 and a r e i n d i v i d u a l l y aligned i n tine adapter
p r i o r t o adapter/re-entry module mating, s o as t o minimize t h e e c c c z t r i c i t y
between t h e t h r u s t v e c t w and t h e r e t r o g r s d e weight center-of-eravity.
 ----- --------
ST. L O U I S , M I S S O I J R I PAGE AS
REPOFT 8642 -ADD, h

ALTERNATE RETROGRADE ROCKET ARRANGEMENT

RETROGRADE SECTION

‘b

N
E
W

8, = PITCH ANGLE
$b = YAW ANGLE
= R O L L ANGLE
$!j,

RETROGRADE
ROCKETS
‘b

NOTE:
POSITIVE SENSE OF AXES AND ANGLES I N D I C A T E D B Y ARROWS

Figure A-1
 A L T E R N A T E R E T R O G R A D E R O . C K E T ASSEMBLY

ELECTRICAL SCHEMATIC OF
FIRING CIRCUIT
SQUIBS
(TWO P E R I N I T I A T O R )
5 E PA R A T E
POWER S U P P L Y

PRIMARY
. POWER SUPPLY

I *-
PYROGEN
INITIATOR
J

(TYPICAL TWO

P R O P E L L A N T GRAIN

INSULATION

VIEW A-A
INITIATOR AND

-
PYROGEN IGNITER
SECTION B - B
PROPELLANT CAVITY
R
E
P Y R O G E N IGNITER V
( T Y P I C A L 2) 7

E X I T CONE-J LTEST
ADAPTER
Figure A-2
*Ic )'IC {RFV I AUG 611
c c VISED REPOFT 8642-AD~. A

ALTERNATE RETROGRADE ROCKET PERFORMANCE, I

WEIGHT, A N D DESIGN PARAMETERS

PERFORMANCE AT 60°F AND VACUUM OPERATION

AVERAGE PRESSURE OVER BURNING TIME (PSIA) 560

AVERAGE THRUST OVER BURNING TIME (LE.) 860
T O T A L IMPULSE OVER ACTION TIME (LB.-SEC.) 18,400
IGNITION TIME; TIME TO 75% PMAx (MILLISECONDS) 100 (MAX.)
BURNING TIME (SECONDS) 20.6
ACTION TIME (SECONDS) 21.6
SPECIFIC IMPULSE (LB.-SEC./LB.) ' 275

VI El GH TS (POUNDS)

PROPELLANT 65.60
LINER 0.45
INERT PARTS 14.11 ,

IGNITER (2)
TOTAL
-0.86
81-02 (NOM.)

. NOZZLE DESIGN

EXPANSION RATIO 40: 1

E X I T AREA 32.0
THROAT AREA (IN.2) - INITIAL 0.803 .R
- FINAL 0.935
E
V
120

100

d 801
-I
I

t;
3
I"
c
60(
s
3
3
U
<
> 40C

200

TIME - SECCNDS Figure A-3

- ~ _ _ _
 18 July 1962 S T . LOUIS, M I S S O U R I PAGE
A8
0ATt

REVISED REPORT
8642-ADD. k
REVISED -
-\ MC.DF1. GEiq Kl

ALTERNATE RETROGRADE ROCKET SYSTEM INSTALLATION

ADAPTER RETROGRADE SECTION 7

N
E
w

VIEW A -A
MOUNTING POINTS
INITIATOR HARNESS I1
INITIATOR -
INITIATOR WIRING 7

NOZZLE CLOSURE J NOZZLE ASSEMBLY

Figure A-:
 G A9
18 J u l v 1962 S f . LOUIS, MISSOURI PAGE

REVISED REPORT 86112 - hdd. h

REVISED -
& - MODEL Genini

A-3. 1 1. lJOZZL3 1iSLEa'3LY XIJD CASE.- The rocket motor has a 17-7PH s t a i n l e s s
s t e e l s p h e r i c a l (13.5 inch d i a n e t e r ) ccsc, which i s iblmed from two
hexispherical halvcs welded toge5'ner. Lach h a l f i s hydro formed t o a minimum
wall thickncss of 0.030 inches. The wall i s of constant t h i c k n e s s except f o r
a p a d u a l thickening t r a n s i t i o n s e c t i o n a t t h e nozzle attccliricnt boss.

The attachment f i t t i n g s are furnace-brazed t d t h e case during t h e

heat t r e a t o?eretion. The case assembly i s than annealed t o 1050°F and a i r
.cpenched.

The nozzle assembly i s mounted t o t h e motor case by twenty-four

1/1:inch cap screys. The nozzle design c o n s i s t s o f a XTJ g r a p h i t e t h r o a t and
a v i t r e o u s s i l i c a - p h e n o l i c e x i t cone providing a nozzle expansion r a t i o of 4O:l.
The nozzle t h r o a t i n s e r t i s recessed i n t h e motor climber t o decrease o v e r - a l l
motor length. The mfimum deviation i n t h r u s t alignment r e s u l t i n g from changes
-
i n nozzle synmetry during motor f i r i n g i s 10 minutes o f one de;--ree.

To p r o t e c t t h e csse w a l l s from t h e hi;h temperature combustion

products, a laminated v i 1 rcous s i l i c a - p h e n o l i c i n s u l a t i o n mat,erial i s bc.g molded
t o t h e case walls. The motor i s then l i n e d with a urethane type material com-
p a t i b l e w i t h t h e p r o p e l l a n t sysC em t o achieve a r e l i a b l e propellant-to-case bond.

A-3.1.2 S3LID PEcPLU.NT.- The p r o p e l l a n t used i n t h e rocket motor is corn-

p r i s e d of a polyurethane f u e l a n d amnonium p e r c h l o r a t e o x i d i z e r
which i s cast and cured i n t h e motor chzmber. The eight-pointed stLr design
used f o r t h e p m p e l l z n t p o r t r e s u l t s in a moderate "saddle" i n t h e thmst-time z
history, a s can >e seen i n Figure A-3. E
v
The p r o p e l l a n t can be s t o r e d f o r two years o r more w i t h i n t h e tem-
p e r a t u r e range of +loor" t o +1103E'without d e t e r i o r z t i n , t o t h e e x t e n t where t h e
rocket motor cannot meet t h e performance requirements of t h i s s p e c i f i c a t i o n . It
i s also extremely r e l i a b l e over t h e o p e r a t i n s temperature regime of +20°F t o
+13OoF. I t ' s a u t o i g n i t i o n temperature i s i n excess of 275Or' f o r one hour and
225'3' f o r e i g h t hours.

a-3.1.3 I G N I T I O N SYST-EM.- Two independent md redundant pyrogen type

i g n i t e r s ar'e used i n each motor. Mounted i n t e r n a l t o the motor,
each pyrogen i g n i t e r i s e s s e n t i a l l y a small, i n t e r n a l l m r n h g , solid-propcll,mt
rocket motor with i t s own i n i t i a t o r and i p i t c r p e l l e t s . The motor i s prepared
for f i r i n g by i n s e r t i n g the squib-actuated i n i t i a t o r s i n t o each pyrogen i g n i t e r .
The i n i t i a t o r i G i t e s t h e pyrogen pro?ellant which d i s c k t r g e s i t s exhaust gases
i n t o t h e motor cavity, providin;: the p r e s s u r e and t h e r n a l f n e r g y t o i g n i t e t h e
s u r f a c e of the motor propelldnt g r a i n in a m o o t h , reproducible manner. The
Pyrogen provides a s u s t a i n e d discharge f o r zppr oximatcly 200 milliseconds to
assure a high l e v e l of confidence i n r e l i a b l e vacuum i p i t i o n .
 A-3.1.3 I G N I T I O N SYSTEM.- (Continued)

The pyrogen case and cap a r e machined from 304 s t a i n l e s s s t e e l

and a r e i n s u l a t e d with a v i t r e o u s silica-phenolic m a t e r i a l t o prevent motor
burn-through i n the i g n i t e r a r e a a f t e r i g n i t i o n i s accomplished. 'I'he pyrogen
employs a booster charge consisting of boron/potassium n i t r a t e p e l l e t s and a
s u s t a i n e r charge of polysulfide/ammonium perchlorate propellant .
Each of t h e pp-ogen i n i t i a t o r s contains two e l e c t r i c a l l y - a c t u a t e d
squibs and i s capable of withstanding a one amp, one watt current/power i n p u t
f o r five minutes without f i r i n g and i s capable of f i r i n g with the c u r r e n t
l i m i t e d t o four amperes. A f i r i n g lead cable i s connected t o a Bendix Pi' type
receptacle incorporated i n each i n i t i a t o r . 'the design i s such t h a t i f t h e
e l e c t r i c a l power t o one i s interrupted, the other i s adequate t o i g n i t e t h e
motor with t h e sane r e l i a b i l i t y a s e x i s t s when both systems a r e operative.

A-4. ENVIRONP@NTAL AND LOAD RQUIREMENTS

A-4.1 . ENVIRONMENTAL CGUDITI0NS.- The rocket motor and packaged i g n i t e r

(handling and storage) o r i n s t a l l e d i g n i t e r (prelaunch and l a m c h )
do not s u f f e r any detrimental e f f e c t s during and a f t e r exposure t o extreme tem-
perature, r a i n , salt s p a y , sand and dust, and humidity a s defined by TaUe A-I.
Only nonnutrient m a t e r i a l s are used i n the construction of t h e rocket motor and
the components thereof.

Materials used i n the construction of t h e u n i t t h a t a r e s u b j e c t t o

d e t e r i o r a t i o n when exposed t o climatic and environmental conditions l i k e l y t o
occur under t h e conditions specified in'Table A-I a r e protected a g a i n s t d e t e r i o r -
a t i o n i n a manner t h a t w i l l i n no way prevent compliance with required motor per-
formance. P r o t e c t i v e coatings t h a t w i l l crack, chip, or s c a l e with age o r ex-
tremes of climate and environmental conditions a r e not used.

The u n i t i s designed f o r storage and operation a t r e l a t i v e humidi-

0 t i e s up t o 100 per cent, including condensation due t o temperature change.
OPERATING REGIMES

ALTITUDES AND TEMPERATURES.- The rocket motor i g n i t e s and operates

s a t i s f a c t o r i l y throughout t h e ambient pressure range of 15.5 t o 0
p s i a and as , d l o w s :

A. S t a t i c Exposure - The rocket motor performs s a t i s f a c t o r i l y

a f t e r s t z t i c exposure t o a minimum ambient temperature environ-
ment of +130% f o r a period long enough t o condition t h e e n t i r e
mass of the engine t o +13OoF and a f t e r exposure t o a maximum
temperature environment of +20°E' f o r a period long enough t o
0 condition t h e e n t i r e mass of the motor t o +2OOF.
DATE Ip PAGE All
REVISED ST. LOUIS, MISSOURI
REPORT 8642 - A d d . 1,
REVISED MODEL

a,
&

.
4
2
rz
F
;=
I-I

n
a
l
v

P a,
REVISED REPOFT 8642
REVISED MOD E L GEMINI

GEMINI SPACECRAFT VIBRATION SPECTRA

EQUIPMENT CATEGORY A

'.Or-----

-- CURVE I
-CURVE 11
---CURVE Ill

h
v)
w
N
E
w

\
\
 18 July 1962 PAGE A13
. t - I ST. LOUIS, MISSOURI

REPOFT
8642
UF: ISF 3
MOD E L ’ GEMINI

h
v)
a
V
Y

v)
n
Z
-x
m
W
>
2u
0
E
w

Figure A-6
 18 July 1962 ST. LOUIS, MISSOURI
PAGE A 14
@ATE

REVISED
REPORT 86112 - d. A

REV~SED MODEL

A-4.1.3. *I ALTITUCES AND TF.WF;RATURFS. - (Continued)

B. F l i g h t Operatior! - The r o c k e t motor i g n i t e s and p e r f o m s
s a t i s f a c t o r i l y , exhausting t o vacuum conditioris.

C. Temperature Gradients - 'The r o c k e t motor perfornis s a f e l y and

c o n s i s t e n t l y k i t h t h e t h e r n a l c o n d i t i o n of t h e g r a i n a f t e r ex-
posure t o a rrinirnum ambient temperature of +130 E f o r a period
-I)c l o n g enough t o c o n d i t i o n t h e e n t i r e mass of t h e mot@ort o
+130°E' and fired a f t e r exposure t o a maximum ambient tempera-

! ture of +20°F u n t i l t h e maxin:um temperal.ure g r a d i e n t exists

w i t h i n t h e p r o p e l l a n t g r a i n . I t a l s o performs s a t i s f a c t o r i l y
when conditioned t o a maximum temperature of +2O0F and t h e n
f i r e d a f t e r exposure t o a minimum ambient temperature of

.
tl3O F u n t i l t h e maximum t e n p e r a t w e g r a d i e n t exists i n t h e
p r ope lla r i t g r a i n

A-4.1 2 STORAGE TF2IPFJUTURE RkliGF; AND ATT1i'UDE.- 'The r o c k e t motor and

' packaged i g n i t e r under f i e l d s t o r a g e conditioris do n o t s u f f e r any
d e t r i m e n t a l e f f e c t s when exposed t o t h e prelaunch temperature r a n g e a s p r e s e n t e d
i n Table A - I ando kihen s t o r e d i n any a t t i t u d e . 'The t o t a l accumulated s t o r a g e
time above +l3O F h i l l n o t exceed two weeks.

A-L. 1.3 LIMITING EXPOSURE TIXE.- The r o c k e t motor o p e r a t e s w i t h i n s p e c i -

f i c a t i o n l i m i t s a f t e r exposure t o a temperature v a r y i n g from

.
+20°E' t o +130°E' and a vacuum environment for a p e r i o d not, l e s s t h a n f o u r t e e n
days

A-4 1.& V I W r 1 O N . - The r o c k e t niotor, w i t h i n s t a l l e d i g n i t e r s , i s capable

of w i t h s t a n d i n g without d e l e t e r i o u s e f f e c t s t h e v i b r a t i o n s as
p r e s e n t e d i n Table A - I .
\

A -4.1.5 DROP.- 'The packaged r o c k e t motor w i t h i n s t a l l e d i g n i t e r s and pack-

aged i g n i t e r i n i t i a t o r s w i l l perform s a t i s f a c t o r i l y a f t e r being
s u b j e c t e d t o a f o u r foot, d r o p onto s o l i d r e i n f o r c e d c o n c r e t e .

A-4.1. .6 ACOUSTIC NOISE.- 'the rocket, motor and i n s t a l l e d i g n i t e r a r e capable R

of withstanding a c o u s t i c n o i s e a s s p e c i f i e d i n Table A-1 without E
d e l e t e r i o u s effects. v
A-5. STRUCTURAL REkUIREJ4LhTS.- 'The r o c k e t motor and i t s s u p p o r t s a r e
c a p a b l e of withstanding I,< thout, pernanent deformation t h e f o r c e s
r e s u l t i n g from t h e l o a d s s p e c i f i e d i n h i p r e A-7 and Table A - I . kor d e s i g n
Purposes, t h e u l t i m a k s t r e n g t h provides :'or a minirnum of 1.36 times t h e f o r c e s
r e s u l t i n g from t h e l o a d s s p e c i f i e d i n k i g u c A - 7 and ? a b l e A - I . 'i'he proof and
burst p r e s s u r e l i m i t s of t h e thrust, chamber exceed t h e maximum p r e s s u r e based
0 on e i t h e r t h e maximw, i g n i t i o n p r e s s u r e or t h e maximum chamber p r e s s u r e a t
+130°h', whichever i s l a r g e r , by f a c t o r s of 1.1 and 1.11, r e s p e c t i v e l y .

L
LIMIT LOADS FOR ALTERNATE RETROGRADE ROCKET

2 P (THRUST)

R
E
V

CONDITION P P R1 R2 R3 R4 R5
MAX. THRUST 1290 . 0 6 10 610 576 404 404
LAUNCH 7.25G'S 0 595 -270 -270 -255 -6 3 -63
 APPElXIIDIX A - I

EQUIPPTEXT LIST

ALTEPJJA?'E RETX!M?.ADE ROCKET SYSTEM

Quantity Nomenclature M.A.C. P a r t KO.

&TwoDay Fourteen Day €1
Mi ss ion Fission
W
4 4. Retrograde Yocke t Motors 5 2 -507 00

' !
1