I I I I I I I I

Final Rcport

_AsA

e_
20

PROJECT GEM INI EXTRAVEHICULAR LIFE SUPPORT SYSTEM (E LSS)
NASA (:ONTRA(iT NAS-9-2il2

66-1.ig Ecbruarv 1967

I I I I I I I I I

Prcparcd THE NASA MANNED HOUSTON,

tbr SPACECRAFT TEXAS CENTER

,..I.

"N

,I

j

/:_..)

v <,,

,= _"

\W. J. OREILLY Progranl M:magcr

AIRESEARCH

MANUFACTURING
Los Angeles, California

DIVISION

I I
CONTENTS

I I I I I I

Section INTRODUCTION General Events 2 SUMMARY Introduction Selection Required Addition Major 3 PROGRAM of Semi-Open-Loop in Program Ground Equipment System and Information

Page
I-I I-I I-I 2-1 2-1 2-1 2-2 2-2 2-2 3-1 3-1 Introduction Major Events System Study3 Definition and Packaging .3-2 .3-2 .3-10 of Aerospace Ground Equipment (AGE) 3-10 .3-11 .3-12 4-1 4-1 Design Requirements Specifications 4-2 4-2 4-2 4-2 4-9

Changes

of Aerospace

Milestones

HISTORY

I I I I I I I I I
AIRESEARCH

Mounting Addition Major Funding DESIGN AND DEVELOPMENT

Milestones

Introduction General

Environmental Reliability Quality Summary Series of

Assurance Suit Pressurization-Ventilation Test

Introduction Summary and Conclusions

66MANUFACTURING DIVISION Los Angeles, California

1483 i

Page

I I
CONTENTS (Continued)

I
Sect on Test Test Chestpack Facility Procedure Assembly and ECS 4-13 4-18 4-23 4-23 4-24 4-24 4-40 4-47 4-76 4-76 (Heat Valve Exchanger) 800278 and 800312 167880 4-76 4-105 4-111

I I I I I

General Purpose Description Performance Development Chestpack Components

General Evaporator-Condensor Suit Pressure Relief 800310

Oxygen Tank3 (plain) Oxygen 800284 Duct Valve Fill Suit

(baffled)

Pressure

Regulator

and

Relief

Valve

4-115 4-126 4-133

I I I I I I I I
California

(Ejector) Group and Loop

and 800282

Heater

Assembly

138969

Shutoff Check Gauge

Valve Valve 800300

800286 850040

4-142 4-146 4-152 4-154 4-156

Pressure Housing Electrical H202 Umbil ical

Assemblies Components Gauge 800526 800386

Quantity Assembly

4-160 4-1 83 4-183 4-1 83

General Purpose Description Performance Development (See Figure 4-97)

4-1 83 4-1 83 4-1 86

66-1483 Page ii

AIRESEARCH ANUFACTURING M DIVISION
Los Angeles,

I

I I I
Section

CONTENTS

(Continued)

I I I I I
f

Umbilical

Assembly

4-199 4-199

General Oxygen Oxygen Tether Tether Tether Electrical Purpose Description Performance Development Multiple Connector 800566 Supply Hose Line Hook3 Line Jumper 138642 and Tether Hook 3 138642 Hose Quick 138441 Disconnects

4-199 4-201 4-204 4-207 4-211 4-214 4-214 4-214 4-214 4-214 4-218 4-218 4-218 4-218 4-220

Cable

800372

Purpose

I I I I I I I I I
_I
6

Description Performance Development QUALIFICATION TEST PROGRAM

5-1 5-1 Test Plan 5-2 5-3 5-3 5-3 and Results 5-3 6-1 6-1

Introduction General Qualification Tests

Qualification

Introduction Test Test DOCUMENTATION Introduction Requirements Procedures

66AIRESEARCH ANUFACTURING M DIVISION
Los Angeles, Cahform_

1483 i i i

Page

I
CONTENTS (Continued)

Sect 7

i on QUALITY CONTROL 7-1 7-1 7-1 Log Change Control 7-1 7-I 7-1 - Phase - Phase I II III IV 7-2 7-2 7-2 7-2 7-2 8-1 8-2 of Program System 8-2 8-2 8-3 EQUIPMENT 9-I 9-1 I0-1 I0-1 Selections I0-1 I0-1 Materials Selected 10-7 10-8 I1-1 I1-1 II-I I1-1

I I I I I I I

Introduction Data File

Equipment

Configuration General

Accountability Investigation Program Repair Delivery 8 RELIABILITY Introduction Flexibility Data

Planning and

- Phase

Upgrading V

- Phase

- Phase

Processing

Conclusions 9 AEROSPACE GROUND

Introduction IO MATERIALS Introduction Nonmetallic General Candidate Material II FLIGHT HISTORY GT-8 GT-9 GT-IO (Launch (Launch (Launch Date)s 3-16-66

I I I I I I ! I I

Date) 3 6-3-66 Date)s 7-18-66

66Page

14.8.3 i v I_J AIRESEARCH ANUFACTURING M DIVISION
LOS Angeles CaJifornta

I I I
Section

CONTENTS

(Continued)

I I I I I

GT-I I (Launch GT-12 12 OPERATING (Launch

Date_ Date)

9-12-66) II-11-66)

II-2 I I-2 12-1 12-1 13-I 13-I 13-11

INSTRUCTIONS

Introduction 13 PARTS LIST Introduction Vendor 14 INSPECTION Codes AND REPAIR AS NECESSARY (IRAN)

14-I 14-I 14-I

Introduction Summary Operation Design Actual and History

14-I 14-I and Refurbishment 14-4 A-I

Modifications Modification

I I I I I I I I I

APPENDIX

A

AIRESEARCH RELIABILITY PHILOSOPHY ORGANIZATION3 AND DATA SYSTEM SECTION 5: TROUBLE REPORTING SYSTEM AIRESEARCH REPORT NO. RC-S6-R PROCEDURES FOR QUALIFYING NONMETALLIC IN OXYGEN BREATHING SYSTEMS AIRESEARCH SS-2108-MR DATA ACQUISITION PROCEDURE 210-A7 MATERIALS FOR USE REPORT NO.

APPENDIX

B

B-I

APPENDIX

C

C-I

66-1483
l_l AIRESEARCH MANUFACTURING DIVISION Los Angeles. California

Page

v

I I
I LLUSTRATI ON S

I
Figure 3-I 3-2 3-3 3-4 3-5 4-I 4-2 4-3 Zero Zero Zero Zero Gravity Gravity Gravity Gravity and Tank Tank Tank Tank Heating Heating Heating Heating

Page
3-.3 3-4 3-5 3-6 3-14 Spectral Spectral Density Density Cabin 4-5 4-6 4-7

I I I I

Funding Random Random Acoustic of

Expenditures Power

Vibration Vibration.

Power

Environment Module Load AP

Spectrum

in Pressurized

Reentry Limit Flow

4-4 4-5 4-6

Design Mass

Factors Gemini

Area

II

(Main

Cabin

Section) Suit

4-8 4-12 4-14

vs

for

Astronaut Altitude

Extravehicular Chamber

Sectioned Showing

View

of AiResearch Locations

Facility

Thermocouple

4-7

Schematic Diagram - AiResearch Altitude Chamber Environmental Control System and Instrumentation Schematic and Diagram Showing Location of the Suit Parameter

4-15

4-8

4-16

Gas Analysis

Instrumentation of Test Subject of Helmet C02 4-20 4-21

4-9 4-10

Preflight Closeup Analyzer Test

Preparation

I I I I I I I I I

of Subject Showing Location in Front of Subject's Head During Exercise and Period Left

4-11 4-12

Subject

on Side

Treadmill as Viewed by an

4-22 4-25

Chestpack Observer Chestpack Observer Chestpack

Assembly--Front

4-13

Assembly--Front

and

Right

Side

as

Viewed

by

an

4-26

4-14 4-15

Assembly--Back_

as

Viewed

by

an

Observer as Viewed by

4-27 4-28

Chestpack Assembly--Top an Observer Pneumatic Electrical Ejector Inlet System System Inlet and Rate

(Control

Panels)

4-16 4-17 4-18

4-31 4-36 Pressure Average Variation as a Function of Umbilical 4-54

Primary Pressure Flow

Temperature with Umbilical Inlet Pres4-55

4-19

Umbilical sure and

Temperature Primary Pressure Flow and Rate as a Temperature Function of Ejector 4-56

4-20

Ejector Primary

66- 1483 Page vi

I_l

AIRESEARCH

MANUFACTURING DIVISION Los Angeles. California

I I I I I I I I

ILLUSTRATIONS

(Continued)

Fiflure 4-21 Total Cooling Pressure and Suit Inlet Effect Variation Temperature Partial Pressure Pressure and with Umbilical Inlet 4-57

4-22

C02 Inlet Rate

Variation

with and Subject

4-58

Umbilical Metabolic 4-23 Ejector Pressure Ejector Supply

Temperature

Inlet

Pressure

Variation

with

MMU

Oxygen

Supply

4-59

4-24

Primary Pressure

Flow Rate Variation and Temperature of MMU

with

MMU

Oxygen

4-60

4-25

Cooling Effect as a Function sure and Temperature Suit Inlet C02 Partial Oxygen Supply Pressure Cooling Supply Setting Effect Pressure

Oxygen

Supply

Pres-

4-61

4-26

Pressure Variation and Temperature

with

MMU

4-62

4-27

as a Function of Emergency - Selector Valve Low-Flow

Oxygen Rate

4-63

4-28

Suit Inlet C02 Partial Pressure Variation with Emergency Oxygen Supply Pressure and Subject Metabolic Rate Selector Valve Low-Flow Rate Setting ELSS Ejector Altitude Performance as as Test Setup of of Primary Umbilical Flow

4-64

I I I I I I I I I
_

4-29 4-30 4-31

4-69 4-70 4-71

Umbilical Umbilical Flow Umbilical Umbilical Umbilical EVLSS

Outlet Outlet

Pressure Pressure

a Function a Function

4-32 4-33 4-34 4-35 4-36 4-37 4-38 4-39 4-40 4-41

Outlet Outlet Outlet

Pressure Pressure Pressure Test

as as as

a Function a Function a Function

of of of

Total Total Total

Flow Flow Flow

4-72 4-73 4-74 4-75 4-77 4-78 4-79 4-80 4-81

Vibration

Evaporator-Condenser Evaporator-Condenser Evaporator-Condenser Evaporator-Condenser Schematic of Evaporator-Condenser Test Module PA 48696 the Condensing Wick) Test Core-Module (Sintered

Evaporator-Condenser Porous Metal Used Evaporator-Condenser

4-85

as

4-42 4-43

PA 48696 (Felt Metal

4-86 4-87

Evaporator-Condenser Test Vaporizing Wick_ Separate

Module PA 60215 Air Trap)

66AIRESEARCH MANUFACTURING DIVISION Los Angeles California

1485 vii

Page

I
ILLUSTRATIONS Fi .qure 4-44 4-45 Evaporator-Condenser Evaporator-Condenser Test Date September Evaporator-Condenser Test Date September Evaporator-Condenser (Boiler Inverted) Test Unit Setup Equipped Test Module PA 60215 Module PA 60215 4-88 4-93 (Continued)

I i I I I I I

Test Resu]ts16, 1964 Test Results 18, 1964 Test Test -

4-46

Module

PA 60215

4-94

4-47

-

Results - Module PA 60215 Date September 21, 1964 Test Back Module Pressure PA 60215 Valve -

4-95

4-48

Evaporator-Condenser with Steam Duct Dry

4-96

and

4-49

Evaporator-Condenser Drop Test Suit Pressure of Relief Suit Valve Outflow Outflow Oxygen of the

Isothermal

Oxygen

Pressure

4-98

4-50 4-51 4-52 4-55 4-54 4-55 4-56 4-57 4-58 4-59 4-60

Valve Pressure Pressure Valve Valve Relief Drop (8002781 (800278) Icing Icing Test Test Setup Setup Valve

4-104 4-105 4-107 4-108 4-109 4-112 Tank, and and Burst Relief Relief Regulator Pressure Valve Va]ve and Relief 800284-1 Valve Test 4-115 4-116 4-117 4-118 4-120

Schematic Suit ELSS ELSS Relief Suit Suit

Emergency Results Oxygen Oxygen Schematic

Tank P/N 800310

Pressure Pressure of

Regulator Regulator Oxygen Pressure

"t
I I I I I I I I

Oxygen Pressure Regulator and Discharge Pressure Performance Emergency Emergency Emergency Emergency Duct Oxygen Oxygen Oxygen Oxygen Pressure Pressure Pressure Pressure Without Duct

Relief Valve Envelope Test Test Test Test

4-61 4-62 4-63 4-64 4-65 4-66 4-67 4-68 4-69 4-70 4-71 4-72

Regulator Regulator Regulator Regulator Heater Assembly and Regulator

Data Data Data Data

4-122 444425 24 25 27 28 29 51 52 54 35 36

(Ejector) of

Schematic Emergency Ejector Ejector Schematic Valve Valve Group Group

(Ejector) Pressure Test Test Group

Heater Test

Assembly Data

4444444-

Oxygen Performance Performance of Valve

66-1483 Page viii
AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

I I
Figure

ILLUSTRATIONS

(Continued)

I I I I I I

4-75 4-74 4-75 4-76 4-77 4-78 4-79 4-80

Valve Valve Fill

Group Group and Altitude Valve and Shutoff (Upstream (Down Valve Side) Side) Test Configuration

4-141 4-141 4-143 4-144 4-147 4-148 4-149 After Humidity Test: Middle - P/N 850040-2 Left and Incorporating 4-151

Shutoff of Fill

Schematic Suit Suit Suit Loop Loop Loop

Check Check Check

Valve Valve Valve

Stream

Suit Loop Check Valve Right - P/N 850040-I; New Flapper Material Pressure Chestpack Chestpack Schematic H202 Gauge Lower Lower of Case Case

4-81 4-82 4-83 4-84 4-85 4-86 4-87 4-88

4-153 Mold for Plaster Plug for Plug Fiberglass Lay-up 4-155 4-155 4-157 4-161 4-165 Temperature Heater and Oscillator Module Sensor 4-165 4-166 444Cycling Linearity Test Setup Configuration 444468 69 72 73 74 76 77 81 84 85 88 89

Plaster System

Electrical Gauge Sensor and Oxygen Control

Quantity

Temperature Oxygen Heater of

Schematic Temperature Electrical Pressure Pressure Pressure Battery Battery Osci Umbi Umbi Umbi Umbi Umbi lator ical ical ical ical ical

I I I I I I I I I

4-89 4-90 4-91 4-92 4-93 4-94 4-95 4-96 4-97 4-98 4-99 4-I00 4-101 4-102 4-103

System Transducer Transducer Transducer

Test

Control Assembly Assembly Oxygen Oxygen Oxygen

and

Voltage

Regulator

Module

44-

Pressure Outlet Outlet Outlet

Drop

444-

Temperature Temperature Temperature Mockup Failure

4-190 4- 192 4-195

Original Umbilical Evaluation

Umbilical System IX-Ray

Assembly

Insulation Resistance Showing Kinked Wires)

_1

AIRESEARCH ANUFACTURING M DIVISION
Los Angeles, California

66- 1483 Page 1;x

ILLUSTRATIONS Figures 4-104 Umbilical Evaluation Umbilical Evaluation Umbilical Evaluation Current Umbilical Umbilical Umbilical Tether Tether Instron 14 Ultimate Tether 16 Tether Production Electrical 19 2O Electrical Multiple Chestpack Line Line System [Kink System tKink System [Wire Umbilical Insulation in Teflon Insulation in Shield Insulation Showing Assembly Test Drop Drop Samples Samples Test

(Continued)

Resistance Failure Covering Over Shields) Resistance Over a Fair Failure of Wires)

4-196

4-105

4-197

I I I I
0 2 5 5 6 9

4-106

Resistance Failure Through Ruptured Insulation)

4-198

4-107 4444-11 4-12 4-13 44-15 44-17 4-18 4455-2 5-3 08 09 I0

4-200 Results (Figure Straight 6 9 8 position) 4-202 4-205 4-205 4-206 4-206 4-206 Temperature Views of View Test 4-209 4-2 4-2 4-2 4-2 4-2 4-2 of Humidity Setup Showing Chestpack in Test 5-9 5-11 5-15

Pressure-Drop Pressure Pressure Test Test

Test-Coiled Test I 7 -

Position

through through

Tensile Tether

Machine vs and After

Strength

Hook-Assembled Test Specimen Tether Jumper Jumper Connector at Completion

Disassembled Conclusion

Hook-Disassembled Cable Cable

I I I I I I I I
LOS Angeles. California

Pressure-Temperature Temperature Cycle Pressure Chamber Explosive on Third Explosive Test

Test

Setup

5-4

Decompression Test Location Side of Chestpack Assembly Decompression Serial Setup Sequence No. 65-102

of Dial 800308

Indicator

5-15

5-16 in Explosive 5-17

Battery 800670-2-2, Decompression Test 5-7 Emergency Assembly Pressure Suit Burst Top: Lower Lower

Oxygen Tank With Burst Test Setup Regulator System Results Tank with Fill Oxygen Pressure Pressure Burst Burst

Fill

and

Shutoff

Valve

5-20

5-8 5-9 5-10

Test Test

Setup Results (Closeup)

5-21 5-22 5-25

Circuit Test Oxygen Left: Right:

and Shutoff Gauge

Valve

Regulator

66Page

1485 x

_1

AIRESEARCH ANUFACTURING M DIVISION

I

I I I I I I I I
ILLUSTRATIONS Fi9ure 5-11 Burst Test 800526-I-I_ Setups for Umbilical Serial No. 45-I06 System Assembly 5-25 (Continued)

5-12

Test Setup for Broadband Radiated EMI Test with Chestpack Assembly Bonded to Groundplane (Chestpack Only)3 Frequency Range 0.15 to 25 mc Chestpack Random Random Fixture Random Vibration Test Test Test

5-26

5-13 5-14 5-15

5-28 5-30

Vibration Vibration Removed

Setups Setup with Top Cover of Test

5-31

5-16

View of Split Teflon Insulation Conductor Cable (Stranded Wire) Chamber Chestpack Chestpack Salt Spray Umbilical Assembly Test Shock Random

Cover

Surrounding

a

5-32

5-17 5-18 5-19 5-20 5-21 5-22

Vibration

Test

Setups

5-35 5-35

Acceleration Mounted Test to Setup

Simulator_ Relief

30g

Test

5-36 5-38 5-41

for Suit

Valve

Multiple

Connector Test Serial

Tests Setup No. Valve for Umbilical 45-106 Components After System Assembly

Tether Pull 800326-I-I_ Fill I00

5-42

5-23

and Shutoff Cycles Bench

Pressure

Cycling

5-44

I I I I I I I I I

9-1 9-2 9-3 9-4 9-5 9-6 12-1 13-1

Low-Pressure High-Pressure ELSS ELSS

9-5 9-6 Adapter_ Adapter_ or Inlet Adapter_ Connectors, Support P/N P/N Interface P/N 649204 649205-X Adapter 649213-X Controls System and Indicators Part No. 9-7 9-8 9-9 9-10 12-5 15-2

Bench

PDA Pneumatic PDA Electrical Outlet Valve Operating Life

Pneumatic Suit Outflow

Chestpack

Extravehicular 800308-8-2

Chestpack_

13-2

Chestpack Assembly (Less Housing Panel Assembly) (Sheet I of 3) Chestpack Assembly (Less Housing Panel Assembly) (Sheet 2 of 3) Chestpack Assembly (Less Housing Panel Assembly) (Sheet 3 of 3)

Assembly

and

Control

13-6

13-2

Assembly

and

Control

13-9

13-2

Assembly

and

Control

13-I0"

66I_l AIRESEARCH MANUFACTURING LOS
AnReles,DIVISION Caldornia

1483 xi

Page

TA BL E S

I
Page

Table 3-1 4-1 4-2 4-3 4-4 4-5 4-6 4-7 4-8 4-9 4-I0 4-11 4-12 4-15 4-14 4-15
5-1 5-2 6-1 6-2 6-3 6-4 6-5 6-6 9-1 I0-1 12-1

I I I I I

ELSS General

Program

Events Conditions Conditions

3-13 4-3 4-4 4-19 4-42 4-43 Under Valve Normal Umbilical in HIGH Position) Flow 02 Flow 4-44

Environmental Mission Subject Conditions Data

Extravehicular Basic Test

Operating Suit

Conditions Analysis (Selector

Performance Conditions Performance (Selector

Analysis Under AMU 02 Valve in MED Position)

Conditions

4-45

Performance Analysis Under Emergency (Selector Valve in HIGH Position) Gemini ELSS Performance Verification Conditions Test Data Analysis Tests

02

Flow

Conditions

4-46

4-53 4-67 4-83 4-90 4-99

Preliminary Operating

Evaporator-Condenser Test Data3 (Development

Evaporator-Condenser Unit No. 2) Capacity DataHeat Rejection Tether with Strap 02 Leakage

Representative Tensile Pattern Test

4-102 4-208

Umbilical

Stitching

Qualification Administrative ELSS

Tests Data

Performed

5-4 5-5 Reports 6-2 6-5

Preliminary Reports

Organization

Progress ELSS ELSS ELSS ELSS

Component Component Component Reliability

Acceptance Qualification Qualification and

Test

Procedures Procedures Reports Reports

6-8 6-10 6-11 6-14 9-2

Test Test

Miscellaneous

Aerospace Nonmetallic Operating

Ground

Equipment Used in the ELSS Indicators

Materials Connectors_

10-2 12-1

Controls_

and

66-1485 Page xii
AIRESEARCH MANUFACTURING DIVISION LOS Angeles, California

I I I I I I I I

SECTION 1 INTRODUCTION

I i I I I 'I I I I

I I
SECTION I

I
GENERAL

INTRODUCTION

I
This document System is the (ELSS). of The final The report program of the was Project conducted Gemini Extravehicular

I I I

Life

Support

by AiResearch California_

Manufacturing under EVENTS NASA AND Events

Division Contract_ INFORMATION are covered of

Garrett

Corporation_

Los Angeles_

NAS9-2412.

from the

the

inception (March purposej

of 31_

the 1967).

program In

(January addition_

30j other

196/4) useful of

I

through

completion is and

program such as

information components

included_ the

descriptionj

and

performar, ce

complete

system.

I I I I !I I I
I

I I_IA MANUFACTURNG RESEARCH O VSON
Los Angeles, California

66- 1483 Page I- I

I I I I I I I I I
i

SECTION SUMMARY

2

I I I I I I I I

I I
SECTION 2

I i i
INTRODUCTION The was Gemini by Extravehicular NASA The on an Manned ELSS Life awarded

SUMMARY

Support Centerj for

System

(ELSS)_

Contract

NAS

9-2412j in Project design-

Spacecraft was

Houston_ use

Texas_ during ELSS

to AiResearch the was Gemini to be

January

1964. based

concept Mercury to

short-term and data.

I I I
I

and ed lar

was to

Project astronaut The

hardware simple

The

permit

perform system It

part-tasks an of

making

up extravehicuconfiguration pressure oxygen life

activities. off-the-shelf fitted

original parts.

specified the use

open-loop GFE

using

involved

!oxygen

vessels) quantity for a

with

AiResearch and

regulators_ hoses.

suit The

pressure system

controllers_ was to support

controllers_

connecting with

20 minutes suit OF

operation leak. SEMI-OPEN-LOOP

5 minutes

additional

operation

while

sustaining

IO-cfm

I I I I I I I
I I

SELECTION

SYSTEM

Early metabolic

in the heat

program

IFebruary capability during

1964)_ of the

concern open-loop operations the

was

expressed

regarding

the

rejection suit tests were to were of an

system. indicated concept

Prototype metabolic design Apollo to

Apollo rates

extravehicular of was and study 2000 Btu per to

treadmill whereas hr.

hr 500

possible_ Btu per

open-loop

limited ELSS the

700 not

Accordingly_ NASA type of

although directed systems: system for

the

test

activity concept and the

directly

related_ with three

AiResearch open-loop_ were

umbilical

closed-loop_ in March 1964

semi-open-loop• semi-open-loop

The merits system was

each

analyzed_ development.

and

s_lected

further

66- 1483 _ AIRESEARCH ANUFACTURING M DIVISION
LOS Angeles, California

Page

2- I

I
REQUIRED The and CHANGES IN PROGRAM system involved using design_ spacecraft development_ oxygen for qualification_ make-up via

I I I I I I I
resulted heat in a system utilizing and use of a three pneumatic malfunction system Because ELSS life_ to 14.

semi-open-loop of flight

production

hardware

an

umbilical. an

This

concept

loops_ detector on of one the

evaporating-condensing system. Original with to

exchanger_ for

complete the

planning units

called to be

open-loop

flight

only

eight

supplied system_ Unit of 8_

over

II months. of the

change-over Air Force use on

the

semi=open-loop Maneuvering the on the

integration extended was

with and They

the

Astronaut six to

,(AMU)_ systems 9_ IO_

mission

intended were

flights_ be used

number GT-6_

increased

scheduled

II_ and

12 missions.

ADDITION

OF

AEROSPACE of the that

GROUND increased

EQUIPMENT number and complexity (AGE) test of the have system_ to be it was utilized late

Because determined to in ensure 1964_

Aerospace test to

Ground results the

Equipment from all

would

consistent AGE was

locations.

Therefore_

added

contract.

MAJOR

MILESTONES The first major milestone version fabrication a special This ELSS that used Gemini was due until of was the the ELSS on=time delivery 1965. were made in February for to NASA of the

first

qualification Accelerated

in January

and

qualification design the

efforts and

through use on

May the

1965 on GT-4

umbilical interrupted initially to time the

multiple

connectors of the

mission. The

normal

delivery for the pilot

chestpack however_ the ELSS

program. NASA would

scheduled

GT-6

mission_

decided not used be on

limitations mission. II_ and

and The 12.

training_ was

GT-8 9_ IO_

chestpack

subsequently

flights

66Page

1483 2=2 AIRESEARCH ANUFACTURING California M DIVISION Los Angeles,

I I I I I I I I I I I I I I I I I
i

Wrist The hardware

thrusters was

(AIMS)

were and and

added

to

the

program

in June

of

1965. due were to

designed this

partially various

fabricated tasks in the

when_ basic

in August contract

funding curtailed. Due the

limitations_

to

the

increasing a field As a

field

support contract

required was three added test

to to

support the

the in assembly at

chestpacks_ 1965. and

support as

program one

October

result_ engineer

many

as

technicians_ support

technician_ one time.

one

were

engaged

in field

activities

Early subassembly done

in

1966_ GT-8

NASA

authorized

heaters

to 15_

be

added the

to

the

ELSS was

ejector

for

(scheduled Corp. and

for March Since field

1966); flights was of to

work

to be

by McDonnell 1966_

Aircraft ELSS and repair permit

Gemini support

were

scheduled to support Inspection in February placed for GT-9 Maintenance made on an in

throughout flight and

required program. program were

activities as

orderly was

control then added of

the the

repair

necessary repair_ to the

(IRAN) and all

1966.

Rework_ hands GT-12;

modification of

ELSS and

then

AiResearch through of

achieve program

uniformity was extended

repair

testing 51_

through

March

1967.

schedule

was critical_ basis. Gemini The 12. 3

and

changes ELSS

in the

system

were

frequently with the

expedited flight of All throughout page of

Gemini

program

was

concluded

successful

qualification the program

interface_ such that

and

pre-flight

checkouts never though

were

completed slipduration

the ELSS This was

operations true_ even

necessitated mission

the

spacecraft almost

schedule. from

requirements

doubled

the first

qualification

levels.

I_I

66-1483 AIRESEARCH ANUFACTURING California M DIVISION Los Angeles, Page 2-5

°3

i] "l
SECTION PROGRAM 3 HISTORY

J

i]

J

d
i

I I I I I I I I
INTRODUCTION Studies a were conducted by self-contained As a extravehicular result of these and

SECTION PROGRAM

3

HISTORY

NASA-CSD life studies_

throughout system

most for

of use

1963

on

the

design

of

support system flow

during such stated. conforming as

Project weight_ AiResearch to these

Gemini. volume_ submitted

requirements_ rate could be

mission

]ength_ for

ventilating

a proposal and of
I ,

a self-contained_open-loop a contract components: in January

system 964.

requirements consisted

was

awarded

The

system

the

following

Oxygen Pressure Oxygen Oxygen Pressure Pressure

reservoir regulators fill valve valve (2)

2. ,5. 4 5

shutoff gauge switch

I I I I I I I I I

6 7 8 9 I0. II.

Electrical Manned Demand Suit flow

heaters control

(3) valve

regulator outflow valve

Battery

The a period

system of were

was

to

be

capable

of providing reserve 6 test

a ventilating at this flow to be on

flow rate.

of A

S cfm total over

for of an

25 minutes ordered (2

with

a 20-minute units was and

8 units II-month

flight system

units) used

delivered one

period.

This

scheduled

to be

only

flight.

66-1483 _] AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles, Page 3-1

I
MAJOR EVENTS (See Table 3-I at the end of this section.)

I I
testing the system. rates of of low the Apollo

--System Study t Definition Because extravehicular heat rejection of high suit_ (500

and

Packaqinq loads experienced became of during

metabolic NASA Btu/hr) of At the about

engineers

concerned the

about

metabolic During

I I
the

capabilities suit test

proposed

treadmill had been

operation observed. of

program

3 metabolic

2000 to

Btu/hr NASA

this on

same the gas

time_AiResearch effects storage for of

presented

I I

results on heat

an analysis

prepared pressure

zero-gravity To perform

environment this of the analysis_ required the heat due the to

transfer

in high

tanks. rapid

AiResearch equations. transfer heat

developed The through and model the

a computer used vessel_ flow.

program program then

assimilation in essencej the mass on

in the and

does 3

calculate redistribution transfer expansion

calculates was

transfer

fluid mass

This

model to

based

heat fluid

by

conductive removal. Using model in the

mode

and

transfer

due

accompanying

and

I
this program_ to a series the 4-1b of computer runs oxygen were made using tank rates the a tank high-pressure Several oxygen to storage used and applica-

corresponding Project heat this the

I I
the For

Mercury input type

program. rates to were the shown

withdrawal determine

programmed bility results The state this of of

investigated extravehicular in Figures

tank

application. 3-I through 3-4. are

Typical

program shown the on

are the

lines of

pressure-enthalpy volume into on

diagrams as a

the

locus of or

of

points program The

tank was

control divided

elements five the

function spheres is a

time. control of

the

tank

concentric several which

volumes. state

line of

identified

as (I) control

curves is

locus with

the tank

points

the outermost

volume3

in contact

the

66- 1483 Page 3-2

[_1

AIRESEARCH ANUFACTURING M DIVISION
L0S Angeles, California

I il I I I I I I I
AIRESEARCH ANUFACTURING M DIVISION
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fNIIIAiPY

{ tilU/tll)

A-

_.471G

-A

Figure

3-1.

Zero

Gravity

Tank

Heating

66Page

1483 3-3

Figure

3-2.

Zero

Gravity

Tank

Heating

I I I
L

66Page

1483 3-4

AIRESEARCH

MANUFACTURING

DIVISION
California

LOS Angeles

I

I I
I 10,000 8,000

I

6,000

TANK HEATING = 50 Btu/hr OXYGEN FLOW = 1.0 lb/hr TANK IS SIDE TAPPED

I

4.000

I
I 2,000

BOO

\0

CONTROL 600 .! CONTROL

VOL.

riO. 2

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VOL.

NO.

CONTROL VOL. NO. 5 CONTROL VOL. NO. 4 _._ CONTROL

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,oo

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ENTROPY DENSIrY

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80 70 .90 I10 1 _'_") I_0 110

I I I I I
_

ENTHALPY

(BTU/LB) A-,_?. 14 .

Figure

3-3.

Zero

Gravity

Tank

Heating

AIRESEARCH ANUFACTURING M DIVISION
Los Angeles. California

I
|o000

6,000

TANK HEATXNG - 6 Btu/hr OXYGEN FLOW - O. I l b/hr TANK XS SXDE TAPPED

I I I I I

I

I ,000

L

_00

CONTROL VOL. NO.

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CONTROL VOL, NO, 2 I CONTROL VOL. NO. ,5 "1_ ,. CONTROL VOL. NO. 4 -i II

I I I

OUTLET

"

I I

Figure

3-4.

Zero

Gravity

Tank

Heating

66- 1483 Page 3-6

[_I

AIRESEARCH

MANUFACTURING

11

DIVISION

LOS Angeles, California

I I

I I I I I I I I I I I I I I I I I I

wall. points tank

Correspondingly, of heat the innermost rates noted are

the

line

identified volume. The runs

as

five

is the

locus

of rates

state and

control for that each all

oxygen

withdrawal shown on the

input be

of

the

is also have

figures. higher than an

It will O.I Ib per

runs which by

oxygen

flow which

rates

hour

characterized This tank heat

tank

behavior though process

is essentially

isentropic of heat an

blowdown is being isentropic As shown

process. to if the the the

is true to make could the

even the be

a sufficient deviate to the the

quar_tity

added path by

substantially entire tank almost to any

from

supplied added very to

contents. entirely of the

figures, control

heat

tank

resides

in the inner

outermost

volume_with

little

penetrating

control

volumes. holds are true regardless as to of shown heat the by the by was point (control volume) 3-I from and 3-2.

This which Thus, gas the the

phenomenon tank be

contents seen

withdrawn, attempt

comparing contents the to be mere of

Figures

it can storage tank

that

the

high-pressure of the heating pro-

tanks

under

zero-gravity the very

conditions effect that

expedient i.e;

walls of

produces

avoided_

duction As Mercury It will locus that be of the

nonhomogeneous of

tank

contents. interest_ the oxygen The flow results rates are used shown is in Project in Figure 3-4. the

a matter were be also

incidental on even

programmed here that of

the

computer. some

noted

though

nonhomogeneousness sphere are no longer

indicated, and

state tank

points contents too_ of

innermost remain that

control in the In the

isotropic It

would course,

single-phase is based Project

condition. on the most

should

remembered of by the

program the

rigorous minor

approach movements provide all

absolute the very

zero-gravity. capsule

actual

Mercury the

programj like would contents

astronaut_ modest

attitude to

corrections_and ensure homogeneous

mixing

required

tank

at

times.

AIRESEARCH ANUFACTURING M DIVISION
Los Angeles, California

66-1483 Page 3-7

I
As a result of this analysis and the Apollo suit AiResearch to study the use of an umbilical loop_ semi-closed-loop_and closed-loop. The ensuing investigation technical February
I.

tests_ NASAdirected

with three types of systems: open-

was based upon rules which resulted from a

I I I I I I
hr.

coordination meeting held between NASA and AiResearch personnel in 1964, The rules
An and umbilical electrical metabolic hr. Peak line established will supply are as follows: and high flow energy oxygen

normal

power, load for normal loads under mission of 2000 (up Btu to per one hr hour) may is occur, Btu per 1400

2.

Average Btu per

metabolic load of

3.

The a. b.

design The The (375

metabolic condition system Btu may per

emergency will so not that

conditions exceed body

is 2000

I I I

emergency

20 min. heat storage

be designed is permitted. was held at

hr)

Another in March because system tion of was in the of

technical 1964.

meeting this

Houston open flow for

between loop

NASA

and

AiResearch

During

meeting_the oxygen too

concept

was

eliminated closed-loop qualificaas the disit

its

prohibitive because

spacecraft it was The both

requirement. development was then At items

The and

rejected II-month

complex

schedule. features of

semi-closed-loop the other One of the systems. major

selected timej under

combined system cussion The and

desirable was was not the

this still

completely size of

defined. the emergency 1964

I I I

oxygen June

tank. 1964 was spent in system definition

time

between

March

and

packaging. Among I. 2. the items that and were added or defined in this time period were:

Chestpack Multiple

umbilical added

storage

envelope

I I I

connectors

66- 1483 Page 3-8 _ AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles.

I I

I I I I I I I I I I I I I I I I I I
_r

3. 4.

Second Data a. b. c. d. e. f.

umbilical monitoring Emergency Demand

connection requirements oxygen supply

for

use

with

the

AMU

added

flow and

warning audio

light signal

and

audio

signal

flow

warning

light

Emergency Suit Suit Audio inlet outlet

oxygen

pressure

gauge and and transmission

temperature pressure generator the emergency

sensing sensing to

transmission manual size was shutoff switch

signal 1964_

incorporate oxygen was the tank

Early During given program this

in June same

determined. AiResearch eight, was and the

month_ The was

the number

revised of

program in

negotiated program was

and

a go-ahead. duration

systems

still

still NASA

II months. directed AiResearch to modify the the chestpack for so which it was

In August that it could

1964_ be

stowed To area by

in the

spacecraft thisj

90 o from the area.

position

originally from pack a

designed.

accomplish to

chestpack The total

cross-section volume The of

changed the chest-

rectangular also

a trapezoidal

was

reduced after volume

approximately being made more

500

cubic by

inches. the the

already

tight cross-

packaging section displays. of to the after the

problem and the The

severe

nonrectangular addition of the

reduction

was

compounded was for of required other the AMU

by

AMU

chestpack volume flight. to be used To

repackaging space

to achieve used

better

utilization required to allow missions was

stowage the

to allow The

items

in experiments was the required scheduled of

support

addition the AMU

displays to all the

chestpack Gemini

with

in addition missions_

VII,

support of 14.

these

added

number

systems

increased

to a

total

66-1485 I_l AIRESEARCH ANUFACTURING M DIVISION
LOS Angeles, California

Page

5-9

I
Mounting As method the of design progressed mounting to previous by to the and the packaging in the became firm_ the AiResearch mounting) preferred the was to

I
rigidly . the Due chestpack the which the spacecraft (edge

I I I I I I I I I I I I I I I I

challenged hardmount Guide pins

success_ using pins to ensure

spacecraft would

contractor into

chestpack have

protrude to the engage pins would

chestpack. on the in

would to

be added pack the of the to edge the

chestpack of

rails the

spacecraft the more

index

the

mating

with

holes require

chestpack. volume and was

Because because

mounting

technique success of

probably

previous

hardmounting_ accordingly.

the

hardmounting

technique After the

selected; method

chestpack selected NASAj 3 a and

was

modified of

this

was

series AiResearch

technical took place

interchanges to resolve tooling The

between the would chestpack

spacecraft

contractor_ As a

interface be was required then

problems. to ensure to

result_ proper

it was mating the

determined of the

that

master points.

the

hardmount

changed of

incorporate Ground was

master IAGE)

tooling

concept.

Addition

Aerospace testing benches

Equipment planned

Acceptance low pressure

to be with the

performed laboratory

using

the

Gemini Because

high of

and the

in conjunction of the the many system_

adapters. of the

increased planned special had the

complexity by NASA AGE most and and

magnitude test built sites 3 for

acceptance apparent The benches

testing that which special

different have to be

it became ELSS.

equipment appeal modules

would was to

the

approach with

complement specially 1965. added to To

the

existing the

Gemini AGE

adapters to the

designed

for support

ELSS.

was_therefore_added test schedule_a

contract set of

in January spares was

the

expanded

complete

the

program

in November

1964.

66-1483 Page 3-10

l__

AIRESEARCH ANUFACTURING California M DIVISION Los Angetes,

I I I I I I I I I I I I I I I I I I

Major

Milestones The first major milestone of the program ELSS to NASA was the on-time delivery The fact monLhs indicative the program.

of

the

first

production could

prototype be designed with the

in January shipped were

1965. only

that after of

this the

system contract

3 manufactured_and many changes that and

seven is

start efforts of

necessary

the

cooperative the middle

exhibited 1965 program

by NASA until on the

AiResearch of May_

throughout an and

From fabrication nectors

March

middle

accelerated multiple As the conELSS

and

qualification

special

umbil icals the GT-4 effort to be

was

conducted program tests.

by AiResearch was While to in progress maximum the ELSS

to support 3 this

flight. resulted made of

qualification some cation tests of the by were The test meet to

added

in postponing qualifisome

use was umbilical

attempted and

similarity repeated.

multiple

connector_

AiResearch be conducted

qualification was humidity; test.

test

program

began

in April of the

1965.

The failed of

first to

three

components serious

chestpack was the that

performance As and for a on the to

after result a very

this of

The most

failure cancelled

the

battery. battery in time

this

failure_ basis

AiResearch produced the

vendor-produced had it qual ified

expeditious of the

a new

design

and test

completion AiResearch required

rest of

qualification program_ and

program. arose with

Subsequent the test battery

the

qualification several design

test changes

problems

which

another

qualification

program. To support NASA of the the acceptance AiResearch bench. testing to being performed a test to the at the different for NASA Iocause also in

tions_ place

directed low

fabricate In addition

bench test

suitable bench_

pressure

l_

AIRESEARCH ANUFACTURING M DIVISION
LOS Angeles, California

66Page

1485 3- I I

I I
added field support and then to the contract. another This test effort started one with assembly two test technicians added technician_ technician_

I I I I I I

and

one

engineer. this to and same time period_ AiResearch to fabricate This submitted and system test was NASA a proposal a wrist proceeding was required and received (AIMS)

During an addition

the

ELSS

contract

thruster on

translation expeditious the were rest of

stabilization due

system.

a highly to limit of effort

basis when_ the ELSS the

to funding

l imitationsj in August the

program. program.

Therefore_ Some of

1965_ several were:

areas

deleted I. 2. 3. 4. 5. 6. 7. In

from

reductions

AIMS

cancelled or test of and the last of two the chestpacks umbilicals

No assembly Omit final

assembly

test

Reduced Delete All

program some AGE

documentation items

I I I I
the program the pace increased. By were systems cost and reduction test of efforts all flight

overtime reduced

eliminated

Spares July_ of

another first

important two and flight

milestone systems. of 196_

of

the

program

was

met

with

the

delivery

the

During necessity3 reinstated_ Work however_ This on

October many of

November items

the as

cancelled spares continued performed IRAN

during and on

I I I I I
California

such the

increased program work in was the

assembly an even the

ELSS

faster IRAN

pace

during of

19663 the contract.

most

of the is covered

under

provisions this

effort

section

(Section

14) of

report.

Fundin 9 A funding and expenditure curve is included on Page 3-14 of this report.

66-1483 Page 3-12

AIRESEARCH ANUFACTURING M DIVISION
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66AIRESEARCH MANUFACTURING
LOS Angeles,

148.5 3 = 14

DIVISION
California

Page

,t

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SECTION

4

]
DESIGN
.... i

AND DEVELOPMENT

i.l

! I I I I I I I
• INTRODUCTION This • • section General A summary contains design of the following information: SECTION DESIGN AND 4 DEVELOPMENT

requirements. Suit Pressurization-Ventilization SS-3135. the design_ changes operation_ of the major complete development chestpack Test Series_

AiResearch • A description

Report of

testing_ assembly.

and

resulting

A description development

of

the

design_ and

operation

or

function_ of the

major chestpack

testing_

resulting

changes

I I I I I I I I I I

" •

components. A description and of the design_ changes function_ of the major development system and

testing_ electrical • A

resulting cable. the of

umbilical

jumper of

description

design_

function_

major

testing_

and

resulting

changes

the multiple

connections.

66-1485 _ AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles, Page 4-1

I
GENERAL DESIGN REQUIREMENTS Specifications shall be required the to operate prelaunch, 4-4), following launch, and The modes_ must and remain shall exposure orbital intact be to the Environmental The system

I I
phases during to freethrough

environments (Table the 4-I

outlined and Figures

under 4-I

re-entry

and

post-landing normal and

phases. emergency outlined

system during

required to the

I I I I
I

operate, space

in both

exposure

environmental

conditions

in Table

4-2.

Reliability Reliability Quality Assurance assurance shall be in accordance with NPC 200-2. shall be assured by the implementation of NPC 250-I.

Quality

I I I I I 1 I I I I

66-1483 Page 4-2
AIRESEARCH MANUFACTURING DIVISION
California Los Angeles,

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66= 1485
_ AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

Page 4-5

I
TABLE EXTRAVEHICULAR 4-2 CONDITIONS MISSION

I I I I I I I I I I I I I I I I I

ENVI RONMENT

EXTRAVEHICULAR

Arabient

Pressure

6 x

10 -12

psia

6°K Ambient Temperature O°F -50

(Deep

space

sink) to spacecraft

(Earth)o to +250 F (Range from adapter re-entry module, respectively)

Acceleration

0 to 0.68 1.64

0.25G _without AMU) Ft/secZo(Translation, rad/sec _ (Rotational

with AMU) with AMU)

I,

M ic rometeoro

id

Solar

Radiation

Approximates

6000°K

Black

Body

(thermal)

J_ o,

Use

MSC

engineering

standards

and

criteria

bulletin

EC-]

and

Addenda.

66- 1483 Page 4-4
I_J

AIRESEARCH

MANUFACTURING DIVISION LOS Angeles_ Cahfornla

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1000

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Figure 4-

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66-1485 Page 4-5

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DIVISION MANUFACTURING Los Angeles, California

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,Ill|Ill,

,,i,|li,,

140

150

120

I 0

I00

90

SOUND PRESSURE Figure 4-5. Acoustic Cabin of

LEVEL - DB RE: 0.0002 Environment Spectrum Reentry Module

DYNES/CM z
A- 24400

in

Pressurized

_1

AIRESEARCH

DIVISION MANUFACTURING LosAngeles, California

66- 1485 Page 4-7

_22o

,

d

/ /
AFT /

/ / /

Z 160.00,

/ / / /
/ 3¢

\ \ \ \ \

220 A-ill03

Figure

4-4.

Design (Main

Limit Cabin

Load Section)

Factors

Area

II

I I I I

66Page

1483 4-8 _1 AIRESEARCHMANUFACTURING DIVISION Los Angeles, California

I I I I I I I I I I I I I I I I I I
I_

SUMMARY

OF

SUIT

PRESSURIZATION-VENTILATION

TEST

SERIES

Introduction

The

tests

described life-support

herein

were

conducted

as

a

part

of The

the

Gemini

extravehicular of the tests (2) drop tests test

system (1) flow of

development the oxygen

program. flow for This

purposes for (3) C02 the of space

were the

to

determine

requirements cooling_ and

washout, pressure manned suit suit lating for

ventilating

requirements the suit. and were

characteristics in the AiResearch Two test

involved

a series laboratory

research subjects

development used_ both

facility. and rate design. cfm; to

with rate the over

extensive and ventineeded of subject mph was a

testing flo_

military were

flying

experience.

Metabolic to provide were those varied obtained subject used

varied

parametrically flow ranged rates from

data a

system 35

Ventilating rates per hr

range the 2.2

IO to was

metabolic 1750 Btu suit on

while walking

resting

(obtained

by The

the suit Suit

in a pressurized David ditions of 3.7 Clark

a treadmill). G2C Gemini were a

in the

tests test

Company

Model

Space

Assembly.

The

con-

constantly psig_ and

maintained pressure

suit-to-ambient altitude inlet of suit

differential of 34_000 ft gas

pressure (3.5 of psia)_ 45°F

a chamber wall and

equivalent of 95°F_ suit

ambient

temperatures IO0 percent during rectal

ventilating water exit vapor). dry-bulb

(saturated_ quantities point

oxygen the

(exclusive include

The and dew-

measured

tests

temperatures_ rate_ area and suit at

temperature_ drop, outlet. and

electrocardiograph the C02 partial

(ECG)_ pressure

rein the

spiration oronasal Summary I.

pressure the suit

and

Conclusions

Summary Under the open cycle of breathing accumulation gas of conditions C02 in the used in the test, there

was

little

indication

oronasal

area.

AIRESEARCH

MANUFACTURING DIVISION LOS Angeles, California

66-1483 Page 4-9

I I
The ventilating flow in the helmet was adequate to sweep the C02away from inhalation of the respiratory the oronasal area so that there was negligible products Application

I I
a

of the open-cycle test data to a semiopencycle lifepressure would be
rate of 15.0 cfm at

support system indicated that the inspired C02 partial approximately
metabolic The volumetric The of outlet 86°F The ing gas rate suit 5.70 of mm 1320 Hg for a design hr. temperature rate is essentially has only ventilating flow

Btu

per

outlet rate.

dry-bulb The

a function

of

I I I I

flow

metabolic

a secondary with flow flow

influence. from a maximum

dry-bulb at

temperature 10 cfm (the

decreases minimum

linearly ventilating is a a

obtained suit flow

rate). of both ventilatupper dew-point of I0 cfm effect and the

outlet rate and

dew-point metabolic

temperature rate_ with of

function well

fairly storage.

defined

limit

obtained of

only ?9°F rate hr. effect

under was of The

conditions at a per

heat

A maximum flow rate

temperature and of

obtained 1370 suit Btu

ventilating hr3 providing

gas

I I I I I I I
gas_

a metabolic 960 Btu per

a total

cooling decreases rate. and heat

outlet with

dew-point increasing energy the

temperature ventilating produation of

total

cooling The heat

increases between stream flows was a work noted from

balances gas

metabolic indicate and

removal in the state.

in the body

ventilating all of

occurrence rates

heat the

storage resting

for

ventilating heat storage of

metabolic by or the This suit a an

above

Incidence After several than fact and back the that energy the

verified period in which suit. in the during

increase

in rectal in the

temperatures. rate_ was by lower the

conclusion

reduction calculated observation was dried

exercise rate

instances heat

were

metabolic

removed

the

is explained out by was the

unevaporated stored gas

moisture body

ventilating

I I I

in the stream.

the

exercise

period

transferred

to the

66- 1483 Page 4- IO _ AIRESEARCH ANUFACTURING M DIVISION
LOS Ailgeles, Califorma

I I
The test data as reported that for hr high for the in AiResearch Report cooling Latent high flow. drop the parameter apparent case agrees for well NASA with Subject to is cooling SS-31583 188 Btu is corrected per hr Btu for per to low hr for ELSS

I I I

design flow low

conditions and flow As 206 and shown received the suit Btu 1015 in

indicate per Btu Figure from was and hr per 4-5, the

sensible flow. the suit

980

pressure As was for the

the

data 13

NASA-MSC. large suit

I I I

No. lower 2.

slightly lower

two drop.

AiResearch

subjects3

leading

resistance Conclusions

pressure

Achievement rates Btu per The (up hr. design hr the can to 25

of cfm)

a

heat is

balance

in below

the total

Gemini heat

G2C Suit loads of

as

moderate

gas

flow 1230

possible

approximately

metabolic be

and

external at the

heat design

loads suit

of flows

1650

Btu

per by

hr storage

and of

2250

I
Btu heat per in The accommodated only

I I I I

astronaut. maximum of 15.0 washout metabolic drop heat and is removal 18.7 cfm capability is 1168 for and the of the Gemini Btu per G2C at hr the

estimated flows dioxide and

design

suit Carbon

1271 presently

respectively. ventilating

sufficient

anticipated

gas

flow The

rates suit

rates. characteristics are valid as specified in AiResearch

pressure

Report

SS-3135.

I I I I
66483 4-11

I

I_l

AIRESEARCH MANUFACTURINGDIVISION Los Angeles, California

Page

I I I I
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I I I I I I

66- 1485 Page 4-12
_lllluln,_.. IRESEARCHMANUFACTURING DIVISION A I. ..%,. "l
L _ _ _ Los Angeles, California

I I
Test Facility The research and ECS suit ventilation laboratory This chamber of tests were conducted in the with AiResearch an internal and with Com-

I I
volume

pressure and

development cu ft.

in an altitude is equipped test subjects each with to test an with at

chamber a

of

750

250-cu-ft

lock

I I I

windows

for

visual were

observation maintained is also The is a

simulated of

altitude. an and intercom masks

munications system. unsuited the test The

throughout equipped

by means supply

chamber

oxygen

for loads on

personnel. subjects were radiant suit

mechanism

used

induce

various

metabolic treadmill. in the

variable-speed_ on the skin

variable-inclination of the chamber Figure for and

I

Thermocouples to measure The designed

located and

interior

air

ambient

temperatures system flow

(see used rates_

4-6). tests was specifically and

environmental the Figure

control proper 4-7 suit

these

to maintain humidity. C02

temperature of the

3 pressure_ suit ECS.

I
relative is a schematic and diagram

I
were

The

concentrations with No. Beckman I was head

in the helmet IRIS-A infrared the

suit-outlet (see chamber C02

ventilating Figure 3 about 4-8).

gases

analyzed IR Cell

analyzers altitude the up

I
from

located and was

within used

18 in.

the

subject's helmet. cell of

to analyze was picked and then

volume

percentage

I
level through duct in the the The gas sample in the helmet 3 passed to the suit outlet

I l I

where the sample

it was point was at

analyzed_ which the

returned sample

upstream suit-outlet pump was

suit-outlet a

was

extracted. line by a

The

pumped No. 2_

through located returned

I/4-in.-OD of the

polyflow altitude

diaphragm The sample the

to

IR Cell

outside to the

chamber. upstream

analyzed

and

then

suit

outflow

line

I i

of

Volo

Flowmeter.

66-1485

I

[_i
,

AIRESEARCH

MANUFACTURING

DIVISION
California

LOS Angeles,

Page

4-13

I I

Q: I-

66Page

1483 4- 14 i_ AIRESEARCHMANUFACTURING DIVISION LOS Angeles, Califorma

L

0

E

*m m

C

u

u'_

m

0
i L. 4,4

E m oi o u
°_

c 0

c

m o

u

I:

I I I I I I
I' I_1

f
i

t,

!

AIRESEARCHMANUFACTURING DIVISION Los An.e,es, Ca,ifomia

60-1483 4 - I 5 Page

V

66= 1483 Page 4= 16
AIRESEARCH MANUFACTURING
LOS Angeles,

DIVISION
Cahfarnia

Calibration parameters. the the gas same The samples flow gases on once accurate the

checks specially and rates were to and

were

made designed

on

the console

analyzers allowed

without the gases used

disturbance operator to the an IR to shut

of

test off at Cali-

introduce cell

the pressures into the

calibration as were

analyzers

during

analysis. thus were had

bration effect least for

exhausted

laboratory systems. were of

atmosphere Calibration connected sample to

and checks a Type

no at

closed-loop hour.

splrometry The IR of analyzers the

made

every

S Dynograph

determination

stability

concentrations.

Extremely as well as were

reliable physiological measured All with

instrumentation parameters. laboratory

was Suit test were

used and

for

measuring and

ECS parameters_ differential or water Honeywelltemperatures recorder. and aircraft rate 3 and pres-

ECS total and on radiant mercury

sures

gauges recorded

manometers.

ECS temperatures recorder, Altitude and

a multichannel and ambient

I I I I I I I I I I

Brown were Altitude altimeters C02

temperature recorded on

chamber multichannel by

a Leeds pressures chamber were

Northrup

temperature manometers respiration

chamber at the

were control recorded

measured console. on and an

mercury

ECG3 pulse3

concentrations The were was one

Offne_Type and

_eight-channel_solid-state Northrup of full of temperature scale, full sca|e3 and The millivoit Offner a sensi-

dynograph. recorders dynograph tivity of

Honeywell-Brown held held to an accuracy

Leeds of one

percent percent

to an

accuracy chart

of three division.

with

mlcrovolt

per

66-1483 I_1 AIRESEARCH ANUFACTURINGCalifornia M DIVISION LOS Angeles, Page 4-17

Upon arrival

at the test facility_

each subject was examined in order to to perform adequately the
the experiment of the an are eyes_ subject analytical shown in performed nose_ at throat_ rest. The having pre-

I I I I I I I I

determine his physiological
experimental f]ight ears_ stripped an accuracy medica] and ]ungsj weight of program. The

state and his ability
physician that the was test monitoring inc]uded pulse

examinations and of ±1 measuring

inspection rate with on data

each gram.

subject Basic

determined subject

ba]ance Table 4-3.

TABLE BASIC TEST

4-3 SUBJECT DATA

Subject No. No. l 2

Age_ 32 29

yr

We ight_ 78.8 76.2

kgm

Height_ 178.5 176.5

cm

Test

Procedure After completion for a full was of this of ECG_ suit then of the and preflight rectal and and medical ear examination_ canal and the entered temperatures. the continuity the test The of suit. subject test the subbioUpon

I I I I I I
to

was ject

instrumented donned

underwear checked the ]oop before test

socks_ donning

instrumentation completion and was

full-pressure the altitude of ft_ I00

procedure_ to the tests_ test in suit

subject

chamber the the percent ascent approxiattaining calibrated. test test

connected In as prior altitude 30 min altitude for these

and involved

instrumentation altitudes was required the held IR C02 at over to

sensors 25_000 breathe blood. 19_000 ft

facility. subject_ oxygen a test mately the test

which

well to

as the takeoff of 34_000

observer_ order ft_ the of ft_ to

denitrogenate was

During for After was

chamber the the helmet suit-outlet

calibration of 34_000

C02

analyzer, IR analyzer

66-1485 Page 4-18

_

AIRESEARCH

MANUFACTURING DIVISION LOS Angeles. California

I I I I

I I
The subjects's exercise treadmill altitude_al] suit period was then commenced. pressurized 0ifferent of to 3.7 psi above rates chamber were 0uring pressures, monitored. sat down pressure_

I I

and

the

metabolic walking period.

achieved the entire temperaFollowing

by varying period at

speed

and duration

important

physiological were the

parameters, continuously test subject

I I I I

tures, the

flowrates, completion of

and gas compositions the was exercise returned period, to subject were of to run psia the test

and the examination

altitude was then

chamber conducted

sea level.

A postflight

medical

and the seven

was reweighed. required full-pressure altitude, for instrumentation suit, gathering prebreathing of test data, of the for and descending test

Approximately subject, donning

hours

and doffing ascending .T_sts were

denitrogenation, to sea level. Inlet Rate, Dry

under_the

following 7.6

conditions:

I I I I I

Suit Flow Inlet Inlet The of having

Pressure, cfm Bulb

lO, 13, 16, 20, 25 Temperature, Temperature, OF OF 45 45 to 34_000 ft was the desirability Also_

Dew Point

reason for limiting an unpressurized safety

the test altitude

observer factor

in the chamber

with the subject.

this was an added Figures

in case of an ECS failure. are photographs chamber of the test subject facility. and

4-9_ 4-I0_

and 4-11

I I I I I

observer

inside the AiResearch

altitude

_]

AIRESEARCH

MANUFACTURING

LOS Anseles, California

DIVISION

66- 1483 Page 4-19

1

I . I 1 I I I I I

I ,
I 1 I I I I I I I
i
I
4

1

P

J

F i g u r e 4-9.

P r e f l i g h t P r e p a r a t i o n o f Test Subject

I

AIRESEARCH MANUFACTURING DIVISION
Los Angeles California

66- I483 Page 4-20

I .

'0

3 I I I
I 1
F i g u r e 4-10. Closeup o f S u b j e c t Showin L o c a t i o n o f Helmet C O z Analyzer i n F r o n t o f u b j e c t ' s Head

9

I
AIRESEARCH MANUFACTURING DIVISION
Los Angeles
California

66- 1483 Page 4-21

I I I I I I I I I I I I I I I I I I
66-1485 L_l AIRESEARCH ANUFACTURINGCalifornia M DIVISION LOS Angeles, Page 6-23 CHESTPACK General ASSEMBLY

Many on January a

significant 30_ 1964. open-]oop

events The

have

occurred

since was

the the

inception

of of

this the

program

most

significant

evaluation semi-open-loop and and the

design to of an

from

simple better

arrangement under life

to a complete

system

provide umbilical

conditions for the

emergency support_ Other

operation_ tethering_ major changes position to

addition

assembly from to

main

electrical

network the box

connections chestpack (keystone) and the displays AMU

spacecraft. stowing making it the

include in the

redesigning center the food

permit and

in a specific required the

area

additions to be

accommodate

controls with

required

to aI]ow

chestpack

used

in conjunction

backpack. programs the were written for the AiResearch chestpack was also IBM 7074 digital computer

FORTRAN to analyze The the high

chestpack case surface In

performance temperature temperatures addition_ a

and

the

case

temperature. to the determine extraand

chestpack and low

ana|ysis to be

performed during was

encountered chestpack

vehicu|ar subjected

mission. to

deve|opment tests. the purposej

assembled

preliminary paragraphs and describe

verification outline the

Subsequent the chestpack

description_ and

and

operation tests

of

analyses

performed

verification

conducted.

I I
Purpose The system, provides spacecraft, Description I. General The lightweight source for chestpack is a portable_ control suit self-contained_ system utilizing (See of central component of a chestpack When used is the central component with to an of an extravehicular GT4 suit and life support system

I I I I I I eI I I I I I I I I I

in conjunction environment

a Gemini astronaut

helme_ outside

this his

a controlled

functioning

environmental breathing of the and

a high-pressure Figures three 4-12

oxygen 4-15.) sources: from con-

circulation. utilization through (AMU)

through oxygen oxygen umbilical within

Provisions oxygen an from

chestpack

allow

different

a spacecraft maneuvering oxygen The from

system unit an

an umbilical through supply are

connector_ a second container as

astronaut and

backpack oxygen

nector_ chestpack.

emergency weight and

the

chestpack Ib

dimensions 40.0 2.5 0.7 45.2 6 x

follows:

Dry

weight_

Expendable Water_ Total Ib

oxygen_

Ib

weight_ in.

Ib

Envelope_

I0 x

18

66- 1483 Page 4-24
_ AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

I

I .

Figure 4-12.

Chestpack Assembly--Front a s Viewed by an Observer

and L e f t Side

AIRESEARCH MANUFACTURING DIVISION
Los Angeles. California

66- 1483 Page 4 - 2 5

Figure 4-13.

Chestpack Assembly--Fron t and Right Side a s Viewed by an Observer

I

AIRESEARCH MANUFACTURING DIVISION
Los Angcles. C a l h ~ n ~ a

66- I483 Page 4-26

F i g u r e 4-14.

Chestpack Assembly--Back, by an Observer

a s Viewed

I

AIRESEARCH MANUFACTURING DlVlSlON
LO%

66- I483

~ngelesCalifornia

Page 4-27

1

I I 1
1

I I

F i g u r e 4-15.

Chestpack Assembly--Top (Control Panels) a s Viewed by t h e Wearer (Astronaut)

66- I483 Page 4 - 2 8

I !
The entire extravehicular cable_ an end. the the chestpack thighs to to is positioned below the the user. on the on the and astronaut's the control is held ends affixed is made suit via chest panels (occupying are on two life support pneumatic system consists and of the chestpack_ umbilical a tether

I I I I I I I I i I I I I I I I

an

electrical containing at each

dual-line

connectors_

a 25-ft and

cord hook

electrical

connector_

a pneumatic

connector_

When an area

in use_ above

from

chin)_ The suit.

readily the user

visible by

and

accessible web

chestpack The belt

in place laid the

a self-adhering of the same

belt

are to

across of the

strips

self-adhering_ connection the

web-belt to the

material chestpack or the

back the

chestpack. jumper cord or

Electrical cable the to

through the 25-ft suit is same

electrical umbilical a short

either

spacecraft Unit

Astronaut The from

Maneuvering oxygen the

(AMU

backpack)

and

via

umbilical

cord.

external either

supply

to the or AMU

chestpack through oxygen the

pneumatically umbilical between cord the

connected used for

spacecraft

electrical suit the

connection. the two by

Controlled dual-line the

is routed connectors. of four

chestpack devices switches_

and on

through chestpack six

pneumatic

Operating valves_ three

used

astronaut and

consist

two

meters_

warning

lamps_

five

connectors.

_1

MANUFACTURING AIRESEARCH DIVISION LOS Angeles, California

66-1483 Page 4-29

I
I
2.
Pneumatic The ventilation oxygen oxygen and input source. System (See Figure of the 4-16) chestpack emergency umbilical couplings on t_ consists oxygen connection for of supply to a pressurizationsubsystem_ a spacecraft to two the and is the and and spacecraft dual-line and the suit_ an AMU pneumatic portion

I

subsystem_ subsystem

a 7500-psig allowing

I I I I
I

Quick-disconnect are to provided

connection The between valves_ chestpack

AMU umbilical used with

chestpack.

identical chestpack permit in place

connectors_ are to provided the

make

pneumatic

connection check the

internal ECS suit

probe-to-open circuit while

attachment on the

spacecraft chest.

astronaut's The humidity_ mentation regulator

pressurization-ventilation and gas consumption are monitor provided of in the

subsystem recirulating subsystem suit

controls suit which total

the circuit

temperature_ oxygen. suit and

pressure_ Instrupressure control

sensors flow_

this

monitor pressure_

recirculating vent gas supply a

loop

I

recirculating The a fill

circuit

temperature. subsystem shutoff consists an 02 of an oxygen supply to tank_ indicate

emergency with

oxygen check

port oxygen

valve_

valve_

pressure relief valve_ oxygen

gauge valve_ and an

I I I I
I I I

stored and flow

quantity_

a pressure sensor_

reducer_

a pressure check stored

a heater emergency

controlling sensor the to

temperature provide

an emergency if the

warning check to the

indications to the

is flowing subsystem. for emergency and

through This

emergency

valve store stored of the

pressurization-ventilation high-pressure during the oxygen

subsystem to

functions regulate

sufficient oxygen oxygen

operation_ to maintain 45°F during

supply from

emergency tank at

operation_ a nominal

the

temperature

supply

emergency

operation.

66Page

1483 4-30
__.[ AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

I I

oo _-_ -¢I I _0 m ,o _-

! O_

uO
!

E
4._

>.,.
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ill

N m

m

m

m

m

m

Ill

mm

m

m

111 mm

mm

111

I I
The which the chestpack pneumatic vent gas system is dumped partial a portion heat operates overboard pressure of the on a semiopen-loop recirculation the loadj in and the 91 allowable the principle in

I I
I

sufficient inspired

during below heat

to maintain maximum. heat loop. to This load Durthe

carbon also by the

dioxide removes

overboard being ing

flow

remaining

removed normal

evaporative oxygen

exchanger at 70°F

recirculating psig the is supplied oxygen supply. where suit

operation3

nominally

i
I I I I

chestpack system is

pressurization-ventilation 02 CONNECTOR) in the from gas

subsystem the duct the

through

input This its loop.

suboxygen energy The

(UMBILICAL to an

spacecraft and vent heater gas

oxygen

supplied

ejector

assembly around the

is converted heater

into work icing

in circulating in the ejector. flow rate

prevents Ejector

primary and

oxygen

selection and

is made is dependent primary

by

manual on the

control level flow of

(02

FLOW

SELECTOR

BYPASS/NORMAL of the

valves)_ The

physical the suit

activity can the valve suit be 02 to

astronaut. to

ejector for

oxygen

rate by

to

increased FLOW the

compensate valve to or

excessive HIGH

heat

conditions pressing of the

rotating NORMAL maximum

SELECTOR BYPASS

the

position_ the

BYPASS/ when

I
I

position_ is desired.

changing

setting

both

valves

ventilation vent the

Recirculating is combined the with carbon

gas

from flow

the heat from the

exchanger ejector oxygen

passes jet_ and

through enters ezhaled 85

the the by

ejector_ suit the and to suit passes heat

oxygen

1 I
i

remove at

dioxide

and of

moisture-laden and relative

being of

a nominal the

temperature suit A return of

BS°F

humidity

percent_ valve

through exchanger. vent gas gas

connector the

to the

suit-pressure and and

outflow

and

I I i

portion

carbon-dioxide overboard_ to be

moisture-laden the and remaining cooled. gas

recirculating recirculating This is accomplished As the gas

is automatically enters the heat heat to

dumped exchanger copper

vent by

dried

transferring

fins

located

in the

stream.

II

AIRESEARCH MANUFACTURING DIVISION
Los Angeles, California

66 83
Page 4-32

l I I I I I I I I I I I I I I I I I
66-1483
_ AIRESEARCH MANUFACTURING
LOS Angeles,

stream picked

cools_ up

its

temperature suit

drops

below

the

dew

point

and

the

water

vapor of the of

in the

is condensed It

on a wick through

in the this

condenser wick to

section the steam the

evaporator-condenser. the heat exchanger where

is conducted it is used be stored. valve of

side

as a coolant_ Cooling maintains the liquid.

thereby

reducing by

initial

amount this turn;

of water water. controls as

which

must

is accomplished a small The back

vaporizing which_ in valve

A pressure the a

control point of

pressure

boiling function a constant From the the suit

back

pressure

control

is regulated thereby inlet the

the outlet

evaporator-condenser temperature and dew

outlet point

temperature_ with variable gas enters

providing conditions.

evaporator-condenser_ loop. such as a tear the

the

ventilation

ejector_ In the

completing event of

failu_e_

or

rip

in the

fabric_ regulator the lamp the valve flow on

the valve. through the helmet

chestpack If the suit

will failure

maintain should

suit occur_

pressure the valve_

through flow the audio

suit-pressure will sense

demand light an

sensor SUIT

suit-pressure control

regulator panel The 3 and

PRESS

warning tone to

chestpack of the

initiate closed loop

warning

suit

astronaut. in the

normally

suit-pressure of the

regulator suit loop to

senses valve_ and

pressure

recirculating and The suit.

upstream when this valve

check 3.3

automatically above add suit oxygen

opens ambient. to the

regulates

pressure allows

falls the

±0. I psi to manually

BYPASS/NORMAL

astronaut

DIVISION

California

Page

4-33

If the input oxygen source (spacecraft or AMU)pressure falls
67 psig,
As the the input chestpack oxygen regu]ated to line the the emergency source oxygen recirculating the astronaut pressure from the oxygen drops, chestPack The he the is supp]y the will be automatica]]y check oxygen Flow sensor supply panel supply valve

to a nominal
initiated. opens, tank the for

I I I I I I I I I I I I I I I I I I

emergency emergency

admitting application supply lighting an audio

supp]y in

loop. when ]amp suit on

emergency on his

emergency by initiating

warns

emergency control the emergency oxygen admitting and

oxygen and

EMERG 0 2 warning tone to the

chestpack Since remaining before line the heater emergency

warning

helmet. as the the

oxygen a the lower recirsensor_ at a nominal

temperature pressure, cu]ating automatically 45 degrees it

continually is necessary This control F. is

decreases to heat

expands it

to to

oxygen by of a

loop.

accomp]ished temperature

a temperature oxygen

the

supply

66-1483 Page 4-34
i_

AIRESEARCH

MANUFACTURING DIVISION LOS Angeles, California

I I
5. Electrical a. foreseeable Purpose System The ELSS electrical and the for system signallin 9 provides the a means for detecting to the

I I I
nine

emergency astronaut Description

modes and _see

emergency

modes

extravehicular b.

command 4-17) -

astronaut. The electrical are 28 system modularized v d-c wet-cell physiological The system functions consists control of and

Figure

electrical circuit_

subassembles. sensing cable

These circuits_ serves as

subassembles and a link to test_ the a nominal for

I I I

monitoring An data in electrical from three •

battery.

jumper the modes Normal electrical

transmitting spacecraft.

extravehicular of operation: Mode With to

astronaut n ormal_ the the on-off display

and in

emergency. suit is the and the suit by is pressurized_ the astronaut backbe is

astronaut electrical switch, panel battery astronaut

the system When

power of lamps by

applied power

I I I I I I I I I I

by

means

a power on the by the the

applied_ the power system

ground supplied determined

illuminate. or the in

Whether spacecraft

chestpack command

power

the

spacecraft.

When

spacecraft to

power

is

applied_ ground. on the

the When

relay

also

switches power

ELSS

ground used_ The

reference a spacecraft display of the

spacecraft power lamp

spacecraft panel which by the will

is being

display unit viewed of

illuminate. on

panel chestpack

is a multimessage and the is easily

is panel-mounted the astronaut panel_ ejector

top suit. is

in the power

Simultaneous applied to

with the

il]umination

display to the

suet

pressure

transducer

and

heater.

66I(_l AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

1483 4-35

page

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The suit pressure to astronaut any With ice the suit transducer pressure. in the provides This spacecraft. in the in its d-c a linear output An ejector norma] should system or ejector throat, mode check is of to operation_ be certain Norma]ly_ switch a TESTthe switch before the d-c is output received heater is which by the is

I I I I I I I I I I I I I I !
t

ana]oguous command to Test leaving emergency this c]oses system (see prevent Mode

provided

formation chestpack the display when mode). depressed is This closed results

the

spacecraft

astronaut and the audio demand To to to in to to power the check the

warning operates

operable. sensor system_ With and to

emergency the warning position. demand

emergency switch a circuit is

DIM-BRIGHT depressed_ sensor

TEST

bypass power emit

the being an

emergency Gates A and

switches. the 28 v audio dc

applied signa].

B causing neously_ SUIT

oscillator is applied

audib]e

SimultaEMERG 02_

background lights which

lights_ resu]t

PRESS_

and

spacecraft

in

their

illumination.

The

audible

warning exists. and the

signal This command of

provides genera] alarm

a general is The heard

alarm by the

if

an

emergency

condition astronaut has the the

extravehicular astronaut by means of

astronaut. the the

extravehicular visua]ly

capability message Mode An

analyzing unit on

em.=rgency panel. operation or when

lighted

display mode of

Emer,cjency chestpack /_IU.

emergency to the

could it is

occur connected

with to

the the

connected

spacecraft

66-1485
[_1
i

AIRESEARCH

MANUFACTURING

DIVISION

LOS Angeles, California

Page

4-57

I I
When drops_ flow This connected which demand allows to could causes a 14-vdc switch the spacecraft as demand input is (or in the a and result sensor 28 vdc_ DIM or if of to the a pressure tear_ the an in the suit in switch. the to the suit occur the increase demand on whether

I I I I
to

close depending BRIGHT

TEST-DIM-BRIGHT logic,

position)

The the lamp

logic audio

provides warning_ display

inputs when panel will

to the

the demand

audio

warning

system. the

In SUIT

addition PRESS the the suit

switch

closes_

I I I I I I I I

on the

will

illuminate. suit pressure

Simultaneously_ readouts may from stop

command pressure warning switch the

astronaut transducer. signal ($2) by

receive If

desired_ the to

the reset

astronaut switch.

the

audioreset

depressing apply the Gate 28 vdc

Depressing the threshold one of

the

will to

a threshold; This

passes C's

signal

reset

flip-flop. C no longer

removes an

Gate

inputs;

therefore_

provides

output.

If

the

maximum the

obtainable required

umbilical

flow

is not

great

enough oxygen the

to supply emergency same

maintain system sensor manner with is

supply

pressure_

the

emergency causes logic

is automatically switch as when the closing to close_ demand the

activated. providing sensor emergency the

This inputs switch switch

action to the closes. sensor_ sensor The from

in the

the of

Simultaneously_ the EMERG also Oz lamp

illuminated. to the (A4)_ tank

Closing temperature

emergency

switch module the

provides the high the

inputs heater pressure

control

module. gas

controls

I

which at

maintains a comfortable

expanded

emergency Because

I

temperature

level.

66- 1483 Page 4-38

,,

A

_, AIRESEARCH

MANUFACTURING
LOS Angeles,

DIVISION
California

I i

I I
emergency sensor emergency temperature may stop the is in the emergency supply is oxygen being is slgnal loop, used. employed. by it This If is is only the desired, the actuated only the reset

I I I I I I I I I I I I I I I

when time

the the

oxygen control

circuitry

astronaut switch.

audlo-warnlng

depressing

When one

connected of four and

to

the

AMU

and

if an emergency AMU light causes on the

exists the

in the

_MU,

any to

warning

devices

in the warning

audio

warning panel to same are

start

the

appropriate Then, the to

display

illuminate. as when

audio-warning spacecraft. devices.

system The

operates AMU message

in the units

manner

connected by AMU

the

illuminated

warning

AIRESEARCH MANUFACTURING DIVISION
LOS Angeles, California

66-1483 Page 4-39

I
Performance I. Normal The from the Operation mode of operation through From of the is for the 25-ft primary umbilical the to oxygen to supply to the be supplied disdiverted pushes

I I
the umbilical is This for normal Gemini in the the

spacecraft chestpack. position gas

I I I I I I I I I I I I I I

connect through the

this

disconnect_ valve

oxygen

high

selector the

the to

ejector. Table 4-4

;:otal ventilating conditions.

through

suit.

Refer

normal

operation

66-1483 Page 4-40

i_

AIRESEARCH MANO_CTOR_NO DIVISION
LOS Ansele s California

I

I I
TABLE /_-4

I
OPERATING CONDITIONS

I
02 FLOW SELECTOR Valve in HIGH Position

I
Parameter Units

Normal Flow Through the Umbilical System

Emergency Flow from 02 Tank

I
Total Heat Rejection Rate Rate Btu per hr Btu per hr psig lb per hr oF psig

2150 211 91.0 approx 7.8 70 92.5

I I

1550 152

Sensible Oxygen Oxygen Oxygen

Heat Rejection

(Primary) (Primary) (Primary)

Pressure Flow Rate Temperature

67 5.6 45
m--

UMBILICAL 02 or AMU 02 Connector Inlet Pressure

I I I I I I I I I I

Suit Circuit Suit Circuit Secondary Total Flow

(Secondary) (Secondary)

Flow Rate Pressure Rise

Ib per hr psig in. H20 lb per hr mm Hg

18.8 3.7

Flow Pressure Rate Pressure Temperature Temperature Relative

9
26.6 7.8 max 90 max 80 max 15 max 90 max 80 max

CO2 Partial Sui_ Return Suit Return Suit Return Suit Suit

(Dry Bulb) (Dew Point)

oF oF % max oF percent lb per hr

Humidity

70
52.5

7O 45 65 5.6

Supply Temperature Supply Relative Valve Humidity

53 7.8

Suit Outflow

Flow Rate

L_t

AIRESEARCH

DIVISION MANUFACTURING Los Angeles, California

I I
With conditions shown in the as Table chestpack indicated 4-5. operating in Table normally 4-4_ the and the suit return the and oxygen chestpack provided conditions

I I I

TABLE SUIT

4-5

CONDITIONS

Suit Suit inlet conditions

Return Total

Pressure flow (with (dry (dew 9 in. H20 AP)

3.7 25.6 44 34 to

±0.2

psig hr

I I I
AMU

Ib per 55°F

Temperature Temperature

bulb) point)

to 42°F

Refer design_ and

to

Tables

4-6_

4-7_

and design

4-8

for

parameters

under

normal

design_

emergency

oxygen

conditions.

I I I I I I I I I
66Page 1483 4-42
I_[ AIRESEARCH MANUFACTURING
LOS Angeles,

DIVISION
California

I

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66-1483
I_l AIRESEARCH MANUFACTURING DIVISION LOs Angeles, Califorma

Page

4-43

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66Page

483 4-44 [_] AIRESEARCHMANUFACTURINGDIVISION LOS Angeles, California

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DIVISION AIRESEARCH MANUFACTURING California LOS Angeles,

66-1483 Page 4-45

I I
2.
,Emerqency Operation following: • Case 02 hr • Case I. supply of 02 2. If loss will at 45 If suit MED of be umbilical automatically to the 0 to the the 0 and the to or AMU 02 supply and occurs_ will the emergency 5.7 Ib per Operation of the chestpack under emergency conditions will result in the

I I I I I I I I I I I I I I I

actuated for

supply

±5°F

ejector 13.5

23 min. hr with the selector at 3.3 56 valve psia_ the

leaks

Ib per

in the

position will

and

primary suit 15.5

oxygen

pressure at the

chestpack • Case in 3. the

maintain leaks

return Ib per

pressure hr with at at

±O.I

psig. valve chest-

If suit HIGH

selector the

position

the

primary return

oxygen pressure

67 psia_ 3.3 ±O.I

pack

will

maintain

suit

psig.

66-1483 Page 4-46
[_ AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

!

I I
Development

I I I I I I

I.

System

Performance program chestpack change in

Analysis was written for the This system AiResearch program IBM allows 7074 the due were data to used for the digital rapid varying in writing individual and the computer determiinput

A FORTRAN to analyze of system program the the

performance. the estimated

nation and the

performance techniques

ambient in order

conditions. that became as

Generalized experimental it can

performance be easily

system new

components performance suit

available

incorporated

system The

calculated. (total in program. suit using a cooling separate This effect subroutine subroutine and pressure returns the in drop characteristic) the cooling the pertinent effect-

performance determined

is

completely to of the

which determines data

variables iveness series

the

main

I I I I I I I I I I
_

Gemini by

experimental

obtained

suit-test

performed The ejector changed at by the by

AiResearch. map is entered become the be in which experimentally. which oxygen primary inlet flow are flow varied rate_ conditions, rate, in analyzing the and are system temperature. inputs of the as input available data for and can, therefore, under

performance as the experimental

be

easily

data Also, this

the

ejector

development is drop described across

present data,

time. and

evaporator-condenser changed as required. lines constants

performance Pressure between which them have are been

input various

can and

components of correlations and the program primary of ejector

connecting use input

described determined The performance Corresponding the and estimated carbon

a series

both main are to

analytically inputs the to

ejector set

pressure, there

every

evaporator-condenser dioxide partial pressure.

temperature_

vapor

pressure_

66-1485
AIRESEARCH MANUFACTURING DIVISION LoS Angeles, California

Page

4-47

I
Other system parameters which are used as inputs and which, therefore, can be varied to determine their effect on system performance are the pressure and temperature,

I I I I I I I el I I I I I I I I I I

evaporator-condenser inlet pressure, steam-side outlet and the spacecraft ambient temperature. Briefly,

the operation of the program is as fo]lows:

At the evaporator-

condenser inlet,

the values of the mass flow rate, temperature, vapor pressure, pressure are set equal to the estimated va]ues being investigated. Using

and carbon dioxide partial

corresponding to the ejector primary conditions

these values as well as the specified evaporator-condenser inlet pressure and outlet temperature, the pressure drop across the evaporator-condenser is ca]From this pressure drop, the new outlet conditions can be calcu]ated.

culated.

Next, the evaporator-condenser-out]et-to-ejector-inlet ca]culated. Using the calcu]ated ejector

pressure drop is

secondary inlet pressure and flow

rate and the given primary oxygen pressure and flow rate, the ejector outlet conditions are ca]cu]ated from the ejector performance mapwhich is in the computer memory. Progressing around the suit ventilation are calcuiated next. the inlet humidity. loop, the suit inlet conditions

Data which are transferred

to the suit subroutine includes

gas constitutent

flow rates, pressures, temperature, and specific

With this information as wel] as the suit experimental data, the pressure drop, and outlet conin

subroutine calcu]ates the suit cooling effect, ditions.

The subject's metabolic rate is set equal to this cooling effect

order that the amountof oxygen consumedand carbon dioxide produced may be determined. The amountof water (perspiration) describing the suit's
subroutine

produced is determined in the in latent heat

empirical correlation removal.
The suit

effectiveness
uses a

performance

successive-approximation

66-1483 Page 4-48

_

AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles.

I I
scheme in a computation all the computations to the values If the loop to arrive at the suit outlet conditions. the computed Each variables

I I I I I I I I I I I I I I I I

time are cycle given If on of

in the of the

loop have same

been

completed_ calculated in these is returned factors_ occur giving

compared of the

variables differences control

in the values to the the new

previous are main less than

loop.

percentage (input

convergence differences loop are

factors are

date)_

program. used

the the

larger If

than

the convergence does not

values

repeated. input old data)_ and

convergence a message values are of then

within the

a given of

number cycles

cycles

(also and

is printed the used The and

number final

completed was and in

the

new

variables for two the loop the

when suit

the

cycle

completed. control this way

The returns are the

new to

values the main

outlet which humidity.

conditions are tested

program. pressure computation outlet

parameters specific to be it

suit

outlet the suit

Experience

with

this Having

program

has

shown the

rapidly is then

convergent. possible the to suit out-

determined the

conditions_ pressure Since the

calculate flow valve

suit-outlet-to-outflow-valve rate is determined. inlet tested are

drop. valve the

Also_

flow

outflow

inlet

and and suit

evaporator-condenser temperature performance then set the to new are

in the same given input

location_ convergence are

new

pressures as those

against If of the

factors than and

in the

subroutine. estimates just the to and

differences vapor

greater

specified_ dioxide rate are is a pressure. was the

temperature_ The

pressure_

carbon flow given

those by

calculated. of the

evaporator-condenser inlet rate was pressure

inlet to the

adjusted This too flow tends low_ rate

ratio

calculated flow drop value the

inlet drop

increase decrease to

the it

inlet

if the

suit-loop It has

pressure been the new found

if the

too

large. even

that

converges

a stead'/ from

very

fast_ value.

when the

initial flow

estimate

is considerably

different

actual

With

rate_

66-1485 _ AIRESEARCH ANUFACTURING California M DIVISION Los Angeles, Page 4-49

temperature_ Once all the is

and

pressure_ have telling not

the

entire

suit-ventilating within cycles a given and using the of the given loop of

loop

is

retraversed. factors_ If data)_ a

I I I I I I I I el I I I I I I I I I I

parameters printed do printed

converged how many

convergence were cycles of required. (input the of

a message the

parameters is

converge the

within specified

number present

message factors. parameters. In engineering molecular

giving then

values

convergence the system

Computation

continues

the

present

values

the

system gas weight the

analysis_

an constant point in and the

existing pressure in the

subroutine specific

is

used

to

calculate and

the

constant_ at each

heat

capacity_

system. loop have been fixed_ are _ the evaporatorThe

Once condenser final buildup exceeds heat of

conditions effect of the body cooling inlet for

suit

cooling

water

storage involve

requirement the when section dioxide suit analysis the subject's of the partial flow

calculated. the carbon-dioxide rate ates

computations and the storage metabolic of Printed the astronaut total and rate

program heat effect.

storage This carbon approximate

metabolic program pressure calcul, as in the

body

and the

outlet same

a function main

rate

used

section

program. output and at of the Gemini ELSS flow of Performance rates all and major and Analysis pressures_ components. cooling the effect_ suit rate dioxide Computer Program

includes and are

total

constituent the inlet and

mass outlet

temperatures_ Also the latent and its included ejector and

humidities the

evaporator-condenser primary cooling body pressure_ effect_ heat and and storage

water

requirement pressure listing and

w_ight_ sensible

secondary a tabular _ inlet_

ratios_ of metabolic carbon

corresponding pressures.

outlet

partial

66-

1483 4-50 _ AIRESEARCH ANUFACTURING M DIVISION
Los Angeles. California

Page

I I II I I I ! I I I II I II I II I I I
66-1483
_ AIRESEARCH MANUFACTURING
Los Angeles. California

Results results emergency inlet (flow are

of for

the the

above high

described and low flow

program settings

are

shown at both

in

Table

4-9. spacecraft

The and

Gemini at

oxygen selector

supply

pressures valve outlet).

and

temperatures

expected

the

ejector

Subsequently_ contractor be expected would the normal regarding at the use

new the

specifications range of inlet. flow

were oxygen In selector

received pressures

from and it

the

spacecraft that that the

prime could ELSS

temperatures decided the the high

umbilical only of one the

addition_ valve will

was

mission Only MED

position; use

position. valve

mode

AMU-ELSS

mission

flow-selector

position.

As the ELSS

the

new

flow

conditions Analysis

differ Computer positions.

slightly Program The

from _as new

those to

used

previously_ the new from 7.8 and Ib

Performance at

used

calculate

system

performance Aircraft the and pressure between

the

new

specification oxygen flow

received rate of 81

McDonnell per hr_

Company and

stated temperature IO0°F_ 92.5

that at can

a nominal vary

independently Selecting gives an

between the

I04 psia umbilical inlet

40 o and of

respectively. psia and 70.O°F

average secondary

inlet

conditions of 90.0 psia.

ejector

pressure

DIVISION

Page

4-51

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66- 1483 Page 4-52 __I AIRESEARCH MANUFACTURING DIVISION LOS AnEeles. alifornia C

I

I I I
hr Using fixes range ejector the of nozzle design nozzle pressures was calculated system Temperature program by all an heat object transfer conditions cross-sectional and at temperatures off-design at of 90.0 area. at the psias Then 70°Fs using and 7.8 lb area the through per and theoretical possible this inlets 4--!8

I I I I I I I I I I 1 I I I I

the

umbilical Figure conditions.

system 4-28 2.

performance show Case A the

conditions. off-design

calculated

performance Analysis was written to or

Operating

digital

computer achieved so that

to

determine

the

steady-state The of program the

temperature was written

exposed to

a space from the

environment. outer surface

object is may by be In chestpacks to which

is

by

radiation alones

onlys and

the the

heat heat or high

transfer transfer convection. and low

across to the

the interior

wall

of oP

the the

object device

conduction by radiation to the the model

s conductions determine and will for the the

order

temperature environmental a normal of a

limits sink mission 1/16-in.-thick Because of

achieved

by

the

maximum chestpack used

minimum be

effective during consisted sink or

temperatures were determined. fiberglass the interior transfer pack occ_s was an

exposed

The case

chestpack heat it can It was

surrounding of two the

a black-body chestpacks bodies. at an fact sink boiled.

source. that the

geometry between isothermal assumption temperature amount large craft of

be assumed assumed

radiation interior The

heat of

black body

that of

the

average that between Also_ and at or

temperature the

65°F.

justification operate by as

for

this

is the heat water

evaporator-condenser extremes oxygen beginning of tank of 45°F and the

will and its

a constant the a

the the the

85°F

adjusting represent be at

contents will

thermal ambient

capacity

mission

space-

temperatures

approximately

70°F.

66-1483
AIRESEARCH MANUFACTURING Los DIVISION Angeles, California

Page

4-53

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100

UMBILICAL INLET PRESSURE, PSIA
A-7916

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Figure

4-18.

Ejector Primary Umbilical Inlet

Inlet Pressure as a Function of Pressure and Average Temperature

66-

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66- 1483
AIRESEARCH

Page

4-64

MANUFACTURING DIVISION L0s Angeles, California

I i I I I I i I
The a paint absorptivity The the thermal consisting of maximum this and coating of for aluminum coating minimum are the outer powder given surface in as sink silicone. 0.25 and of the case was assumed and _ by to be The 0.24_ emissivity respectively. to and be

effective to

temperatures (152.2°F) the

encountered (-459.7°F)_ surface the hot

chestpack

were Using

calculated these were (35.4°F) will

be 612.2°R

O°R

respectively. state ment of

temperature

limits_ 546.7°R

case

outer for is

steadyenvironthis range

temperatures and 495.1°R

determined for cause the

to be cold

(87.0°F) It

environment.

felt

that

peak

temperatures

no particular

problems.

i.
I I I I I I I I I I
_

Neel_ Carr B._ for Spacecraft,"

"Research on NASA_ Ames

the Stability of Research Center_

Thermal-Control Moffett Field_

Coatings California.

66-1483
AIRESEARCH MANUFACTURING Angeles, California DIVISION Los

Page

4-65

I
3. Verification An assembled tests Tests development shown chestpack 4-I0. was subjected to the preliminary
i

i
in Table

verification

I I I
I

I oI I I I I I I I i I
66-1483 Page 4-66 ___.I AIRESEARCH ANUFACTURING M DIVISION
LoS Angeles, California

I

I II i I l l I I
Suit TABLE PRELIMINARY 4- I0 TESTS

VERIFICATION

Test loop leakage Leakage was

Results

and

Comments due to a poor No this not inlet finish on

excessive

the inlet tubes made to correct development The after Medium Leakage Proof pressurization of high-pressure system Satisfactory pressure Within finish test of

of the ejector. the problem at results gas of would ejector

attempt was time as be compromised. was improved

the

completion

verification

tests.

specification.

==
I I I I I I I I I
I_

Ejector at sea altitude

performance level and

The test setup schematic is shown in Figure 4-29; Figures 4-30 through 4-34 show the results of these tests. The results of these tests are discussed in the testing. to damp cps. below lO0 cps. out,

Panel lighting and electrical tests Vibration performance (See Figure 4-35) and

section In most rather There There

covering cases, than was were

component the test

development tended

unit

amplify or

inputs no

above

lO00

little no

amplification failures.

structural

Post-vibration

performance circuit

testing was

indicated

the

entire electrical vibration program. Post-vibration pressure increase

undamaged

by the

leakage

tests

of

the

medium no

and suit circuit in leakage. leakage gauge.

leakage

indicated

Post-vibration system the indicated pressure

tests in The

of

the

high

pressure at mounting excessive Production

no change

leakage gauge causing gauge. that

except

pressure

was found vibration units have

to be unsatisfactory, inputs to the pressure an improved mounting

is designed

DIVISION
I AIRESEARCH MANUFACTURING Los Anseles, Ca_iforma

I I
TABLE 4-I0 (Continued) Test Vibration performance (See Figure and 4-35) Results and Comments

to eliminate this problem. Previous gauge vibration tests indicate that satisfactory if properly mounted.

pressure the unit

is

(Cont)
Nitrogen gas proof pressure of 12,400 psig Pressure was applied through the fill port. The high pressure shutoff valve was open, permitting the proof pressure to be sensed on the upstream side of the high was monitored at pressure was regulator pressure regulator. the downstream side at the test. test port. Pressure of the The assembly

I I I
I I I eI I

unaffected

by the

I
I I I I I I I
66- 1483 Page 4-68 ,,_A,_,_...,,- AIRESEARCH ANUFACTURING M DIVISION
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t/3 i,q © 3.... t'l

q)

0

L_ °_ °_ ..Q E

.j
I -,.3"

o_ i,

66Page

148.3 4-74
AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

! I I I

u
E
I
1 1
b

I

F i g u r e 4-35.

ELSS V i b r a t i o n T e s t

AIRESEARCH MANUFACTURING DIVISION
LOS

Angeles Calllorma

66- 1483 Page 4-75

I I I I I I I I I I ! I I I I I I I
CHESTPACK General The of and the following paragraphs of the cover the purpose_ and the major description_ phases of and their operation design COMPONENTS

components

chestpack

development. IHeat Exchanger) 167880

Evaporator-Condenser I. Purpose The and

evaporator-condenser the unit suit inlet

removes and

heat

and

moisture

from with valve

the

suit

loop heat ejector.

regulates The

dew point the

temperatures loop check

variable and the

loads. 2.

is located (See Figures

between 4-36 metal

suit

Description This unit

through wick-type

4-401 heat exchanger heat fins wicks of gas load IFigure of 1500 gas it is 4-40). Btu stream reof by the the the gas per

is a sintered of removing stream. an air

It hr

is capable from the

a total Water trap

latent-sensible on into copper metal

gas

condensed material The heat water

in the where

is wicked evaporated water latent s t ream. Gas back

through and

exhausted by the

to space. sensible of the

latent loss of

heat the being

evaporation stream and from

is provided heat of

condensation

vapor

removed

output

temperature control gas valve. stream which on

is maintained This in a unit

at uses

45 a

±5°F fusable The its

by

use wax

of

a vernatherm which change is in

pressure

element_

submerged volume actuates gas back of

in the this

finned

casing. of of

differential

element_ valve is above This

is a function boiler the side

change heat

in temperature_ When the more the

a poppet

the

the

exchanger. lowering

temperature pressure.

45°F_ the

poppet

valve point of

opens_ the

steam water

lowers

boiling

water_

and

1_1

AIRESEARCH MANUFACTURING DIVISION
Los Angeles. Cahforn,a

66-1485 Page 4-76

1 I

C
I I I

I
I I h P I 1 i I I I

Figure 4-36.

Evapora tor-Condenser

AIRESEARCH MANUFACTURING DIVISION
LOS

Angeler. California

66- 1483 Page 4-77

I 1 I I 1 1 I

Figure 4-37.

Evaporator-Condenser

1

66- 1483 Page 4-78

Figure 4 - 3 8 .

Evaporator-Condenser

ARESEARCH MANUFACTURING DIVISION
Los Angele~ California

66- 1483

Page 4-79

F i gu r e 4 - 3 9 .

Evapo r a t o r-Conden se r

66- 1483
Page 4-80

i I

I
I

1

7,I;3 E

cO C_ I L O L O Q.. > i,i u+. 0 U o-

E OJ +-

I I I I I I I

I

_J L

I

oi,

66[_ AIRESEARCH MANUFACTURING DIVISION Los Angeles. California

148.3 4-8 I

Page

I I
is boiled temperature the water to space_ comes boiling outlet thus within rate. conditions carrying the In away more thermal the energy. poppet As closes_ the gas controlled this with method_ variable range_ the inlet reducing maintains evaporator-condenser conditions.

constant 3.

Performance a. Pressure (a) (b) (c) b. Water Max requirements: operating pressure pressure 3.9 7.8 15.6 psig psig psig

I I I I I

Proof Burst holdup: The

unit drop:

shall

hold

0.65

Ib

of

water

minimum.

c.

Pressure 1.0 02 with :

in. inlet

water

maximum 5.9

pressure psia

drop and

at

a

flow

of

178

lb

per

hr

I I I I I I I I I I I

conditions

85°F.

d.

Leakage (I) (2)

External-evaporant Gas gas breakthrough breakthrough per hr -

port with

blocked a gas the

side

0

cc

per

hr of

at

4.0 5.7

psig psig 2 the be

pressure control

through maximum. the The inlet outlet

evaporant

valve

shall

12 cc e. Temperature to 45 +5°F_

control with in two

gas

temperature as as stated in

shall in Table

be

controlled 4-II_ for while a

conditions runs

operating total of

uninterrupted

shown

Table

4-11

90 min.

66-

1483 4-82

Page

I_l

AIRESEARCH ANUFACTURING California M DIVISION Los Angeles,

I

I I
TABLE

i i I I I I
I I I
Pa ramet Minimum Duration_ er min

4- II CONDITIONS

OPERATING

Run Condition I0 A

No.

I Condition 65 (minus Condition B time A) Run 25 No. 2

Oxygen Oxygen Inlet Inlet

Inlet Flow_ Dry Dew

Pressure_ Ib per OF OF hr

psia

5.75 18.2 85.8

±0.05 ±0.4 -+2.0

3.75 18.2 85.8 71. 5.0

+-0.05 +-0.4 -+2.0 I -+I.0

5.75 15.2 87.4 74.0 5.0

-+0.05 -+0.4 -+2.0 -+1.0

Bulb_ Point_ Outlet max

8 1.5 -+ 1.0 5.0

Evaporant mm Hg abs

Pressure_

I
I I I I I
m

I

66l_ 1 AIRESEARCH MANUFACTURING LOS DIVISION Angeles, California

1483 4-83

Page

I
4.
Development a. concerned port air Evaporator-Condenser with block the development configuration_ conceptual section_ full-sized was a low to of Test this three design. and_ heat demonstrate boiler for of 48695 each as Module--Since unit test Each such_ revolved modules test could matrix. operation depends of its the around were primary the problem water transto of as a gas an

I I I I
and HzO constructed consisted considered The of primary

demonstrate and an

module be

evaporating of the

increment of these

transfer the

function

modules in during

water upon

removal

I I I
a

utilization generated A brief •

pressure

which

metabolic

operation

a portion module

evaporant.

description Module porous (direct PA

follows: type where open to HzO to is condensed on

- sublimation has one from

plate H20

which

surface

evaporating

pressure surface). type

I I I I I I I I I I

transport (Figures

condensing and as 4-42) the water through and 4-44)

sublimation bootstrap

Module utilizing out

PA 48696 sintered

4-41 metal (indirect surface 4-43 vaporizing

porous air trap

condensing transport a wick and

wick from manifold). type air

witha con-

a separate to

densing • Module utilizing

evaporating (Figures metal

PA 60215 felt

bootstrap separate

wick

trap.

66-1483 Page 4-84

[__

AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles,

I

F i g u r e 4-41.

Evaporator-Condenser T e s t Module PA 48696 ( S i n t e r e d Porous Metal Used as t h e Condensing Wick)

AIRESEARCH MANUFACTURING DIVISION
LOS

~ n g e i e scaltfornia

66- I483 Page 4-85

8
I I

F i g u r e 4-42.

Evaporator-Condenser T e s t Core-Module PA 48696

AIRESEARCH MANUFACTURING DIVtSION
LOS

66- I 4 8 3 Page 4-86

Angeles Callloma

Figure 4-43.

Evaporator-Condenser T e s t Module PA 60215 ( F e l t Metal V a p o r i z i n g Wick, Separate A i r Trap)

66- I483 Page 4 - 8 7

t 1

F i g u r e 4-44.

Evaporator-Condenser Test Modu e PA-60215

66- I483 Page 4-88

I I I I I I I I I I I I I I I I I
sented from The which

Module in It the reasons form will

PA 48695 Table be 4-12. noted

was

tested;

data

obtained

from

these

tests

are

pre-

that

the in

test both are the

conditions operating as follows:

contained pressure the boi]er_ an air trap and

in

the

data

vary humidity.

design for the This above

conditions these tube

relative metal I_

variations plates is of not

sintered are at of

plates_

sublimation suitable tests as

nominal difambient air so trap. that air

porosity. ferentials pressure The the trap method used as inlet additional would of

material 3 psi. with was

pressure an the ]eve] the

Thereforej the

were

conducted

with of

commensurate humidity water be adding reduced_ the gas_ water of water

operating at for test

characteristics a higher and did Since per water pound to the than for not air of design maintaining contain rather gas inlet the inlet

maintained

required as this

cooling setup water.

a satisfactory than was of high. the (with unit. respect 02 was All

supplemental the amount added required surfaces. on as of

a test

water solid to wet

supplemental An to excess air flow) A detail showed Module wick The that

was was

cornp]etely

sublimation test the

performed transport the the data

sintered capability

metal of sintered water this

of this

the

I_

nominal was

size low.

water utilized transfer test

material metal as

PA 48696 which would

concept condensed showed

of

a condensing action. not function

through module

capillary would

sintered

metal

that

satisfactorily.

66-1483
_ AIRESEARCH MANUFACTURING LOs AnGeles, California DIVISION

Page

4-89

i _
c c

N

N

N

I I I I I I I I I I I I I I I I I I

_ _
c c c c c -_

s _ _o _ _ _ _ _
,g

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s

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--

.--_

--

_

_

__

o _

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_

_

_

:

:

:

:

:

[

A

A

A

A

A

A

A

A

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m ILl v

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_IZ09 t'd :l'lNOOW .l.S_.L

66- 1483 Page 4-90
_1 AIRESEARCH MANUFACTURING DIVISION LOS Angeles California

I
Consequently_ a of third boot as of the the ambient gas to the module strap was constructed This wick with to componentj a separate on of the the air unit. in exceed Table the 4-12. air Again break demonstrate identified air trap trap. would the feasibility as PA 00215 presdraw I

I I

of

a

second

type

concept.

utilizes sure the

feltmetal differential

condensing to space

The then

exerted side is

I I I

water Test

from data side

evaporating this was module limited

obtained absolute of unit

from pressure the sintered

also so as

included not to

the

gas

through With 90 minutes

pressure the were

plate. waterj air trap of several dried transferring test out. runs At the with the water a duration same time_ this on over

charged before quite

with the

I

made appeared

configuration the air side

capable side. on of flow and the

condensed

to the

the test following indicated was of

evaporation run shown a charge by air

During

data 75 cc through of

sheetj water, the of shows

the

unit The

operated end of

a period

I
of 90 minutes was of water satisfactory Approximately was re-evaporated, type trap while the is

I I

operation 0.64 Ib

porous the

metal,

condensed two

0,45

lb

condensation that the

Comparison boiler requires remote air

the

configurations water-feed does Since is or state not the not

sublimation the air water sintered hot on spots the

a secondary trap concept charge, material little the of in

system require wick capable is art

to any

maintain additional of the

I
the initial limitedj beyond plate (such adjacent is areas_ it was

I I I I I

evaporator the air sintered inlet) In

capacity of

sustaining condensed metal

as fin such such

the area.

where addition3

no water of is the very

being in

porous over For these air

fabrication surface reasons_

that as

maintenance the to tube plate

porosity this

difficult

large two

configuration. work on the

decided

concentrate

further

remote

trap

configuration,

66-1485

I

_J

AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles

Page

4-91

I
Module PA 60215
and The same the pan discharge air was was was for modified then to connected over the incorporate to a steam a sleeve-type power unit. s]eeve within the the air The valve the discharge contro] element output so that of of pan_ valve. the this with chamber pressure inhigh

discharging type proposed

ducted use in

a wax-filled completed the pressure temperatures to maintain thermostat.

I I I I I I I I I I I I I I I I I

thermostatic air discharge and

element

directly the air

operated back

temperatures with low the operating test module the

steam steam

decreases creases. ature withfn Since ditions 65°F. observe Figure setup. 94°F charge and air These temperature side of g. ment

discharge effect range discharge is of

Therefore_ the the

discharge

temper-

the

temperature selected heat sink was

under controlled the

design

point 55

conand to in test to dis-

was This the 4-45 As the

60°F_ provided control through indicated_

thermostat a sufficient

between heat

within test shows was

exchanger are shown

function, Figure inlet 4-47. air

The

test Figure

module 4-48

resu]ts the

experimental from 71°F be seen_ point. discharge on the

temperature was

varied As

discharge temperature tests by

temperature was maintained that boiling it

monitored. at the feasible sink) selected to

may

control control

demonstrate varying the

is (heat

air

pressure

evaporative

the

evaporator-condenser. Evaporator-Condenser 167880 167880--A was layout of and a prototype detail parts developwere

Evaporator-Condenser for fabrication. of the unique the joint

completed

released

Because condenser-boiler junction is

design exact

concept configuration

of

this at caused

unit_ the some

that

of

continuous

feed_ new. This

condenser-boiler manufacturing problems

configuration

66Page

1483 4-92
I_l AIRESEARCH MANUFACTURING DIVISION LOS Arl_{e{es, Califorrlia

I
-o 6H WW 'SS3_d

I

.

T

.

T

r

?

?

_

T

o8_

0 o,

|

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0 -0 0 0 @" 0 cO 0 r_ 0 wO

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3 o_

, ,
I I I
_1
AIRESEARCH 30 'dW31 MANUFACTURING DIVISION Los A.geles, California

o

o o i,'h

' 66- 1483 Page 4- 95

3o

'dW31

66-1485 Page 4-94

IIG, _ETT)I
_ _k

AIRESEARCH

MANUFACTURING

DIVISION

Los Angeles, Catifornia

o,

o o,

w 0 ¢) ",I" '0

0.. o

--

tM

E

o ,o m _

z o 1¢3 w _r p-

4.J m o I.--

4.J m o I.--

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O_ _ O

_z
o ¢M !

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o_

o o

I

30

' dW].L

I I

I_1 A,_A_CH _A_U_CTU_,NO D,V,_,O_
LOS Angeles,Califorma

66-

1485 4-95

Page

1

F i g u r e 4-48.

Test Setup Evaporator-Condenser T e s t Module PA 60215 U n i t Equipped w i t h Steam Duct and Back P r e s s u r e V a l v e

-

-

AIRESEARCH MANUFACTURING DIVISION
Los Angeles. Cal8Iornia

66- I483 Page 4-96

I
which resulted The could prior the be second in scrapping assembly the the the first core assembly so that fabricated. the The 7.4 development unit was tests weighed views 4-39.) of

I I I
:|

core at of

was

completed possible

performed

earliest valve; assembly the

moment. was

to assembly

dry weight shown in was

lb. 4-36

(Various through

evaporator-condenser When the

are

Figures

evaporatOr-condenser
t

assembly conducted.

completed_ results

a dry of the

oxygen test are

isothermal shown

pressure

drop

test

was

The

I I I I I I I I I I I I

in Figure Development

4-49. tests were continued toward the runs for on the completed development stored unit. water These and

tests water A

were

directed

primari]y within

optimizing geometry design

internally of the

delivery number the such the

methods of

fixed at the

outline. were The cooling absorb made design must the to requirebe water action cellusponge

performance material the water

conditions area. heat

determine ments stored and at are in the

optimum that unit. time

the water for

storage sensible

required must

A material this

be provided be fairly

which

will by

same wicks.

material fiberglass,

must

dryable

capillary felt_

evaporator lose

Etched combination

sintered were and Of

stainless The be

steel pure dried

sponge_and had the

materials absorptivity_

tested. it could the

cellulose by the this

material wicks most with

highest

evaporator was the unit

with

reasonable Table

effectiveness. 4-13 shows sponge and

materials of

teste_ No.

satisfactory. the pure

the performance

2 development

cellulose of filling an of

in the evaporant emptying the

storage. was operation dry-out evaluated. and of increases the

A method The the unit. results

evaporator-condenser speeds up the

are

improved a complete

technique fill and

which a

reliability

subsequent

complete

66-1485 _1 AIRESEARCH ANUFACTURING_liforn_ M DIVISION Los AnIie_, Page 4-97

I •

.8

0
N

"I-

_Y

I I I I I I I I
BAROMETRIC 29.96 IN. PRESS. HGA INLET PRESS• IN. HGA 6.66

0

¢/}

Q.

INLET TEMP. 70°F

i

I I I
50 40
A-8425

2

3

4

5

6

78

910

20

OXYGEN

FLOW

RATE,

LB PER

HR

Figure

4-49.

Evaporator-Condenser Oxygen Pressure Drop

Dry Isothermal Test

I I I I I I

66Page

1483 4-98
_ AIRESEARCH MANUFACTURING Angeles, California DIVISION LOS

I

I
TABLE 4- 13

I I
Parameter

TEST

DATA, EVAPORATOR-CONDENSER (DEVELOPMENT UNIT NO. 2)

Run Cond Total run heat heat time_ min Btu Btu Btu/hr IO73.5 141.5 16.8 OF 85.25 506 OF 47.0 47.8 1

No.

1 2 Cond

Run 1

No.

2
J.,,J...,,..t_

I I I I
Air inlet temperature, gr/Ib temperature, point, OF

Cond I00 1632

Cond

2

130 1946 II15.5 161.5 15.6 87.4 440 41.2 46.0 986.0 152.8 18.0 85.8 441 47.2 45.1 955.2 145.2 16.5 87.4 430 .;-_,,'-"M'. 47.4 45.5

Total Latent

rejection, rejection,

Sensible Airflow

heat

rejection, OF

temperature,

Ie I I I I

Humidi ty, Air Air

discharge out dew

*65 mi n _t_'_25 min _w_"_55 m in _'Y,_,_,',Low Temperature Operation Thermostat 154382-I

I
I I I I I

66- 1483
I_ 1 AIRESEARCH MANUFACTURING Los Angeles. DIVISION California

Page

4-99

Air in as

traps

used

in

the gas

evaporator-condenser breakthrough. The

were problem

not

completely reviewed

effective and solved

I
air

preventing outlined The

premature below.

was

function the steam Oz flow.

of

the

air This

trap

is

to

transfer of water

condensed is to the be

water

from

the while

side

to

side, The with the freely used for

transfer trap

accomplished condensing

restricting evaporating while pores wet to The sintered microns.

air

material wettable action restricting

divides and within gas a powder a nominal minutely the flow.

from so the

the that minute

I I I I I I I I I I I I I I

sections with pass water water

a very capillary while air

porous material

surface causes

material 516L

traps plate

is with

metallurgy porosity

material rating of

of 0.5

stainless

steel

66-1483 Page 4-100 _ AIRESEARCH ANUFACTURINGCalifornia M DIVISION LOS Angeles,

I I

I
The sponge material used as water development Of reservoir program packing which tested_ was also the selected considered cellulose capacity portion by in water is but of

I I I

after felt sponge coupled that

a

relatively and

extensive fiberglass.

material

the materials superior readily The

demonstrated with to the the

a substantially ability to transfer wicks.

water-holding a substantial as

water

evaporating with

sponge_ which the

purchased

I I I

AiResearch_ not cut soluble to size to the

is treated in alcohol. and then

a preservative receipt The of

is soluble the

Upon

sponge_ procedure the be

material

cleaned.

cleaning with

is specifically (DuPont) or the

designed treats

remove sponge. will

the The then

preservative cleaning contaminate and analysis problem. consequences leakage

which must

manufacturer adhered Tests before to have

procedure the of air the

preservative that effective

traps. sponges

verified

cleaning

assembly

I I

eliminates When review the

the

contamination the of has two gas

considering quantity

of

air

trap

leakage_ has

we

should and

that

AiResearch of the

experienced

I I I

how Table at

this

quantity is for the second

affected

performance

evaporator-condenser. the at of gas both leakage 3.75 per and min at

4-14

evaporator-condensers heat two rejection units had

and

shows

5 psi

and The

capacity of

capabilities a leakage

5 psi.

these of

I03 cc unit

a pressure required steam

differential amount begins of heat.

S psi. Gas the can

Nevertheless_ added valve_ from the to

this the

rejected amount of in

the

I I I I

leakage control be seen this

maximum an

flow

to choke As

causing attached

increase data sheet_

evaporative neither of

pressure. these units

reached

condition.

66-1483

I

I_

AIRESEARCH MANUFACTURING DIVISION
LOS Angeles, California

Page

4-101

._1__

0 m

o

I I I I I I

"1 O O

_.--

b.

°

O. E

_ U_ 0

0 0

_0

k_

0

o_
0

hi V I.LI ml
.;..;

0 I'-r._ o __ C
i

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cO

oO

oO

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I

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A

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"2-

u'_

I I I
AIRESEARCH MANUFACTURING DIVISION
California LoS Angeles,

66- 148,5 Page 4- 102

I

I I I I I

Suit I.

Pressure Purpose The suit

Relief

Valve

800278

pressure (See relief

relief Figures valve

valve 4-50

controls and 4-51)

the

suit

loop

pressure.

2.

Description The suit As the

is an acting

unbalanced against stop in _he of free the

poppet,

spring-loaded-closed the the unit is affectspring

valve. load, flow

suit poppet event

pressure, opens; the

poppe t overcomes to limit The

a fail-open valve fails

is provided open water position. to be

in the to

I I

designed ing 3. the

allow

small

amounts

dumped

without

valve's

performance.

Performance Normal flow shall be of 13.S 80°F. open position, of 80°F. exceed 0.0081 of 70°F. Ib per min at an inlet pressure flow will be a maximum of 17 Ib Ib per hr with an inlet pressure of 3.9

psia

at If

a temperature valve at an fails inlet

I
per

in the

hr

temperature should inlet not

I
of

Total 3.5 psia

leakage and an

temperature

I
4. Development The pression unit spring design was with was only one guide on the poppet stem and a standard unit met comthe

I I I

subjected however, and an

to development it had a very guide

testing. severe was

The sticking to

required Testing

flow;

problem. poppet stem. its

stopped, a special along

additional was

added

the

In addition,

spring

fabricated. of the spring

This

spring a the

maintains few degrees. met

I I I

force

vector With the

the

centerline of the

within

addition

two changes

mentioned,

valve

the

performance

requirements.

66-1483

I

_

AIRESEARCH

MANUFACTURING DIVISION Los Angeles. Califorma

Page

4-103

1

I
I 1

Figure 4-50.

Suit Pressure Re1 i e f Valve

AlRESEARCH MANUFACTURING DIVISION
LOI Angeles California

66- I483 Page 4 - I O 4

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66Page

148.3 4- 105

•I
After to correct manned to be the unit was placed in productionj during several unmanned design and manned that changes tests. the the unit were made performance tests had malfunctions been performedj After would of in stop; design and 3

I I I I I I I eI I I I I I I I I I

many have a

it was The to

determined

substantially Cover to over one

redesigned. the poppet

redesign

included damage; of

addition

protective material

prevent and by by test.

handling

a change the and upper the

seat

that of

was the

stronger poppet

harder;

removal the

increasing changing to be

the the

strength

changing the

material of

poppet

guide after

material_and each manned

addition

a cleaning

procedure

incorporated Results of the

flow-versus-pressure-drop performed with wide to verify of that gas

tests the

are suit

shown outflow

in Figure valve (see

4-52. not 4-5.3

Altitude be and subject 4-54 No of test

testing to for icing time. from was system per

was

would Figures

icing the or

ranges

flow

and

humidity

test

setup). was observed was throughout varied per from lb of the 90°F dry 3 hours and 15 minutes The flow water through

malfunction inlet

The

temperature Ib of to 13.8 of

to 56°F. air. The

added the for of

was valve the

0.00?6 varied are

to 0.1652 from 7.5

water lb per oxygen

hour. flow

(Normal with

high-flow

conditions 0.085 Ib

7.8

Ib per oxygen.)

hour

approximately

water

Ib of dry

66Page

1483 4- 106 _ AIRESEARCH ANUFACTURINGCalifornia M DIVISION LOS Angeles,

I

i I I I I I
7.8 / / 8.0

7.9
..,..--

/ /
/

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7.7

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,

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POINT

/

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7._

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7.3

.-'-- RESEAT 7.2

3.5

SCCM

CABIN 7.1

PRESSURE

= 0.5

PSIA

I I

7.0 0 I 2 5 4 5 6 FLOW 7 RATE, 8 LBS/HR
A-8804

9

I0

II

12

13

I_

Figure

4-52.

Suit Drop

Relief

Valve

Pressure

I I I I

66-

1485 4- 107

I

AtRESEARCH

MANUFACTURING

DIVISION
California

los Angeles.

Page

l I
I--

66Page

148.3 4108

AIRESEARCHMANUFACTURING DIVISION
LOS Angeles,California

I .
II I

I

HEATER

7
~

~~

/INLET

TEMPERATURE

u
1

-.__

I

E
1

P L A S T I C DUCT

/

F-2066

VACUUM SOURCE

F i g u r e 4-54.

ELSS S u i t O u t f l o w Valve (800278) I c i n g Test Setup

I

AIRESEARCH MANUFACTURING DIVISION
Los Angeler Calilornia

66- I483 Page 4- IO9

I I

An The

outflow of of

valve the test

icing was

test to

was

performed

on

the was

chestpack any change

assembly. in percords per-

object

determine to

if there on

formance located formance

the

test valve

unit

due

ice buildup results

nylon

supporting that

I
I I i I
1o

in the was

exhaust. by

Test

indicate buildup

chestpack from hr at

not

affected to the

ice or frost valve_ was as

resulting IO Ib per three

satura which

ated

gas

flows_ of the

outflow The test

high

as at

temperature simulate were and 4.7

90°F.

conducted of

primary

flows

probable hr

operating the AMU_

conditions 7.4 Ib per oxygen

this from

valve. the

These umbilical

flows system_

Ib per hr

from

hr

10 Ib per

from

the

emergency

supply.

I I I I I I I I

1
I
[_l
DIVISION AIRESEARCH MANUFACTURING
Los Angeles, Cahfomla

66- 1483 Page 4-1 I0

I I I I I I I I I I I I I I I I I I
_l

Oxygen I.

Tank 2 800510 Purpose The emergency operation (See

(baffled)

and

800512

(plain)

oxygen in the Figure

tank event

contains of loss

enough of

oxygen

for oxygen,

25

minutes

of

chestpack 2,

primary

Description The emergency of psig the from the [nconel and

4-55) tank is of of cylindrical this tank to the to geometry is 2.48 inner prevent during lb wall the a and of of is conat tank of blow-

oxygen 718. Internal area

structed 7500 provide the down 5. tank of

Capacity fins for heat

oxygen the

70°F.

brazed transfer liquid-gas

necessary entering tank.

contents rapid

a two-phase

state

Performance Capacity: Pressure 2.48 Rating: 7500 12_400 16_600 psig psig psig at at at 70°F 70°F 70°F Ib minimum oxygen at 7500 psig and 70°F.

Operating Proof Burst
.

Development Eight tanks All test of (three have plain been psig. and The three minimum of the baffled tanks is to were subjected psig. and five baffled) to at were least used one during the

program. pressure Two to The

tanks of

subjected

hydrostatic-proof

12_400 plain

the

tanks test.

a burst tanks

pressure burst at

burst from

requirement psig

16_600

pressures

ranging

17_900

19_550

psig.

All the

tanks results

ruptured of the

in the last

heat-affected tanks

zone

of to

the the

weld. burst

Figure pressure

4-56

shows

three

subjected

test.

AIRESEARCH MANUFACTURING DIVISION
LOS Angeles, California

66-1485 Page 4-111

I
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I I I I I

66- 1483
Page 4- I 12

AIRESEARCH

MANUFACTURING DIVISION Los Angeles, California

c
0

55338

F i g u r e 4-56.

Results o f t h e P/N 800310, Tank, B u r s t Pressure T e s t

66- I 4 8 3 Page 4-113

I I I i I I I I I I I I I I I I I

One to

of

the

plain cycle

tanks test and

and from the

one

of

the

baffled psig.

tanks The

were

subjected ruptured 16_723rd

a hydrostatic the 7450th

0 to 9800 baffled

plain during

tank the

during cycle.

cycle_

tank

ruptured

One oxygen. for

of

the

baffled this

tanks age The

was

subjected the of the

to

164 hours was tank cut was

at

9800 small

psig

with

After

oxygen

test_ interior met in the

tank the

into

sections con-

material the

evaluation. mechanical indicated

in excellent the

dition; evaluation there effect

properties no change that

requirements; joints oxygen or

microscopic tank had and any

brazed pressure

in the exposure

was on

no the

indication tank.

the

high

_I

AIRESEARCH ANUFACTURING M DIVISION
LOS Angeles, California

66-1485 Page 4-114

I I I I I I I I I I I I I I I I I I

Oxygen I.

Pressure Purpose The pressure

Re_lulator

and

Relief

Valve

800284

regulator oxygen the

section to a

of this pressure when the

unit below the

regulates the

the

oxygen supply

supplied pressure. is

by

the

emergency provides

bottle shutoff and loss

umbilical supply

This within

unit its

feature regulates of loop and

umbilical

pressure with valve is

required demands "medium" the

limits upon

emergency supply.

supply The

pressure relief The

variable protects downstream 2.

flow the

the umbilical against shutoff through a

portion located

pressure oxygen fill

pressure valve. 4-59) normally Tank and

surges.

unit

from

Description a.

(See

Figures unit

4-57

Regulator balanced reducer the

- The poppet through

contains

open_

metal

diaphragm-operated_ enters +IO force the by or

metering a

valve. filter

delivery is

pressure to 67 of

lO-micron

reduced result

psig

metering on

valve. this

Regulated metering

pressure For

is a a given

balance the inlet up and

unbalance flows causes valve past the to

valve. until

flow

demand_

the metal

metering

valve to

downstream thus

pressure the

builds

diaphragm the in flow. inlet

stroke_ This

aIlowsing valve affect by a

attached a balance

metering area pres-

throttle variations

metering do not

employs the

so that sure. actuator sion b. Relief

pressure setting

regulated the

The

pressure

balance with

is attained spring plus

preloading calibration

diaphragm

a belleville

compres-

spring. Valve - The relief poppet valve is a normally valve. the area and closed As force the metal diaphragmpressure

operated_ increases by the

unbalanced past the

metering point_ poppet valve_

regulated

calibration on the relief

imbalance the

produced calibration overboard.

pressure This

acting opens the

overcomes the gas

spring.

is dumped

AIRESEARCH ANUFACTURING M DIVISION
LOS Angeles, California

66-1483 Page 4-115

F i g u r e 4-57. .Oxygen P r e s s u r e R e g u l a t o r and R e l i e f Valve

I

AIRESEARCH MANUFACTURING DIVISION
Los Angeler California

66- I483 Page 4-116

Figure 4-58.

Oxygen Pressure R e g u l a t o r and Re 1 ie f Va 1 ve

AlRESEARCH MANUFACTURING DIVISION
Los Angeles California

66- I 4 8 3 Page 4-1 17

I I I I I I I I I I I I I I I I
AIRESEARCH ANUFACTURINGCalifornia M DIVISION LOS Angeles 66-1485 Page 4-118 METALLIC SEAT_ FILTER J
i i i i

MOUNTING

SENSE PORT

IBRATION SPRING

METALLIC DIAPHRAGM_

EVILLE

SPRING

UTLET PORT INLET PORT

fA

/A "_

RELIEF VALVE

PORT

BALANCE

SEAL

A-2186-B

FILTER

Figure

4-59.

Schematic

of

Oxygen

Pressure

and

Relief

Valve

I I I I I I I I I I I I I I I I I

3.

Performance

Pressure Max

Rating: operating 7500 12_400 16_600 67 of 350 +I0 0 to to psig 0.225 7500 outlet Ib psig per and psig psig psig at 70°F at at 70°F 70°F a flow pressures Figure to inlet 4-60 be 90 capacity of ). psig max. of psig.

P roof Burst Regular ion:

pressure rain 70°F at

with inlet (see

No flow Internal leakage: 7500 External leakage: of Downstream relief: 6 x psig 5.25 7500

condition_ I0 -6 and x psig The I0 at integral pressure The Ib 70°F -7 Ib per

lockup min and per

pressure max outlet min with

pressure of inlet 85

pressure max with

pressure

70°F. relief to relief 215 valve psig will max will limit with reseat the at the regulator. 95 psig min.

downstream failed open.

valve

66_ AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

1483 4- 119

Page

I I I
7500 _NOMINAL OUTLET PRESSURE 67 PSIG WITH TOLERANCES SHOWN FOR TEMPERATURE RANGES SHOWN IS

I I I I I I I

C9 u_

U_ _J

,,i Z l-.,i

_:13 PSI

35O 0 +160

+80

-20 OF

-130

INLET TEMPERATURE,

I I I I I I I:

Figure

4-60

Oxygen Pressure Regulator and Relief Valve Discharge Pressure Performance Envelope

800284-1

A-_4614

66- 1483 Page 4- 120

I_l

AIRESEARCH

MANUFACTURING Angeles, California DIVISION Los

I
4. Development Flow per min at are schedules inlet shown were performed of 4-61 The This are on -60°F_ through lockup this unit from +66°F_ The lockup and unit to 0.5 Ib The

:1 I I I I I
Io

temperatures in Figures cases.

-20°F_ 4-64.

+I60°F. operated the as

results

satisfactorily limit time at -20°F

in all and

pressure

exceeded

required only the unit testing

-60°F.

is considered is during

no problem_ tank blowdown

the and to

these

temperatures to lock were

reached

is not the

required limits

up after changed

this from 65

occurrence. to 85 psig

Subsequent to 57 to

this

design

77 psig.

I I I I I I I I I I
66-1485 _1 AIRESEARCH ANUFACTURINGCaliforma M DIVISION Los Angeles, Page 4-121

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AIRESEARCH

MANUFACTURING

DIVISION
California

66-1483 Page 4-125

LOS Angeles,

Duct I.

(Eiector) Purpose To maintain

and

Heater

Assembly

138969

I I
in the ELSS. a converging energy. This ventilating a diffusing pressure through using the nozzle high gas where velocity flowing coaxially increasing across of oxygen 25.6 of 14 rate, lb in. the supply per of hr 3 the the its

the (See

venti]ating Fi,qures is 4-65

gas

circulation and 4-66) to

2.

Description High pressure energy the nozz]e. of

oxygen is converted

supplied to kinetic ]ow

internal gas with static ejector ventilation a primary through water. 3. entrains the

]ow The

pressure3 combined ventilating

velocityj enters This flow

stream gas, for fluid

section_ differential the remainder

pressure provides loop. f]ow the This Performance Primary

the the

I I I I I eI I I I I I I I

potential normal per and hr will

During 7.8 suit the ]b

operation; wi]] circu]ate a

spacecraft flow of rise flow

of

a total tota] for pressure the

Gemini matches

provide pressure

system

drop

same

oxygen and flow an in]et shall

flow

sha]] temperature

be

7.8 of per

+0.4 70°F, hr of 45°F; in. 3.15

]b

per

hr

at

an

inlet

pressure

of

92.5

psia Total

be

25. b

lb

02

with the

a primary gas ejector

f]ow shall

of

7.8

Ib a

per

hr

of

02

at

a

secondary rise leakage

temperature equivalent shall not to

of 14

cause

minimum

pressure

H20. x 10 -4 Ib per hr 02 at 4.0 psi AP.

Externa] 4. Development Extensive configuration pressure. gas ejector

exceed

testing of Figure under the

was venturi shows

done

on

gas for

ejectors pumping

to

determine at the

the design

optimum system of the

section the

gas

4-67

experimentally

determined

performance

development.

66-1483 Page 4- 126

_[

AIRESEARCH

DIVISION MANUFACTURING Los Angeles, California

I I I

I
D

F i g u r e 4-65.

Duct ( E j e c t o r ) Without Heater Assembly

E ]

AIRESEARCH MANUFACTURING DIVISION
10s Angeles California

66- 1483 Page 4 - 1 2 7

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66' AIRESEARCH ANUFACTURING California M DIVISION LOS Angeles Page

1483 4- 129

I
Results and 4-69. 4-68 for two of The additional curves show data nozzle for to performance how for this one tests unit conducted are to shown in Figures location. contains 3 the design 4-68 is sensitive position of of and these the nozzle

I I I I I I I I I I I I I I I

Figure data was This

contains other

nozzle

Figure

4-69

positions. angular be and set the

Because

variations in Later the

changed allows

to allow each unit

positioning to its optimum valve

nozzle

ejector. pro-

location. outlet of this

in the

gram 3 a This

heater

was

added

bypass IRAN

location report.

was

changed.

effort

is described

in the

section

66Page

1483 4- I,:30 _ AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles,

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66Page

1483 4-131

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66- 1483 Page 4- 152

AIRESEARCH

MANUFACTURING DIVISION Los Angeles,California

I I I I I I I I I I I I I I I I I
_
I

Valve I.

Group General The

800282 (see Fiqures is 4-70 comprised one housing. and and weight joints. through of 4-72) three check valves_ and of one two f]ow flow control was ]eakage sensors_ va]ve selected paths by

valve pressure into

group

one

suit

regulator_ common size tubes (3) check

bypass This and to

va]ve_ method reduce

combined to reduce

one

fabrication possib]e

package many Valves

e]iminating 2. Check a.

Purpose--One loss is of lost. in fitting. and primary This the

valve_ in occur_ position other

the the if or two

emergency event the as are and open. check and element_ on the a the

02

check

valve_ 02 relief broken

prevents pressure valve line of Oz or the if

oxygen could open The

emergency Oz of a

emergency result

failed loose umbilical either b. Description flapper main with poppet c.

immediately prevent ]oss

downstream of primary

AMU disconnects fails FiQure whi]e

disconnect (See type_ valve an

4-70)--The

valves are or

are

of

the into is the meta]lic The

spring-loaded-c]osed_ The bonded to ensure flapper to it

threaded poppet_ portion. during

housing.

e]astomer is guided

sealing seating have at

effective shall oxygen 90 psia

repeated pressure 13.2 ]b of I0 -5 lb per

use.

Performance--Each drop hr at of an 0.5 inlet allowable psi

check whi]e pressure interna]

valve flowing of

a maximum a rate at of

and shall

a temperature be 3.15 x

90°F. per hr.

Maximum

]eakage

AIRESEARCH ANUFACTURING M DIVISION
LOS Angeles California

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66-1485
GARREI"T

Page

4-

1:54

AIRESEARCHMANUFACTURING DIVISION
Los AngePes Cah_:r,; <_

I

-- -.

J .

Figure 4-71.

Valve Group

AIRESEARCH MANUFACTURING DIVISION
Los Angeks. California

66- I483 Page 4-135

1 ' I I I 1 I I 1

I I I 1 I I I I I I

I ,

F i g u r e 4-72.

Valve Group

AIRESEARCH MANUFACTURING DIVISION
Los Angelel
California

66- 1483 Page 4-136

I

I
I I I I I I I I I I I I I I I

.

Flow a.

Sensors

(2) emergency from the 02 flow emergency and regulator suit This O_ (See flow Figure valve of the the pressure action sensor. 4-70)--Each and a flow pressure type drop flow rate moves drop sensor switch. containing to be is off high 0.2 its with a to seat flow an orifice. to Ib per This actuate hr. the of 13.2 lb With consists of a springvisual flow sensor 02 closes a circuit This of closes occurs_ similar the operation flow, whenever loss devices as whenever gives

Purpose--The flow the The flow of the occurs astronaut suit

supply.

audio

indications sensor regulator indicates

pressure the

a circuit indicating warning

through suit

pressure.

emergency

b.

Description loaded-closed The check

check valve allows switch in flow3 The is

poppet

arrangement the an pressure increase

pressure the

enough 1.5

when the

poppet pressure

reducing rate

restriction, per The hr is 2

maximum

psi. switch contains a pressure-activated sealed closes of of micro its 1.5 0.2 the and switch. circuit hr per flow at a and hr. rate is 13.2 of opens when when diaphragm which

pressure against

presses c,

a hermetically flow increases decreases pressure drop sensor to

Performance--Each oxygen the The lb flow flow rate

applicable lb per lb

a maximum to a minimum is 2.0 of psi

maximum per hr at

when psia

an

inlet

pressure

55

temperature

50°F.

66-1483 L_ 1 AIRESEARCH MANUFACTURINGCalifornia DIVISION L0s Angeles, Page 4-137

o

Suit a.

Pressure Purpose--The at 5.5

Regulator suit pressure in flow. (See Figure 4-70)--The I00 psi of the oxygen valve suit to pressure the suit regulator at 5.5 rubber uses the regulator event of a maintains suit leak the greater suit than pressure the

±0. I psig primary

normal
b.

Description a tilt The valve

to meter surface

±0. I psia. and which on the below the as is

sealing

tilt

is silicone

I I I I I
have

essentially has suit

leak-proof. pressure on the one tilt

A pressure-sensitive side valve. and a As reference suit

diaphragm_ pressure

other_ the

actuates

pressure

decreases against is closed

calibration and

point_ opens the

the

reference valve. above the

pressure The tilt

pushes valve

diaphragm the suit

tilt

pressure using a

increases reference with the

calibration is to the reduce control

point. the

The control pressure must

reason spread a large

for

pressure Since by

associated stroke_ than a that fixed to

springs.

diaphragm be much

oI I I I I I I I I

spread

produced The scc

a spring pressure through

would

larger metering flow or
C.

allowed. flow (IO0 The bleed

reference per min) has

is maintained a calibrated for

by out-

valve

ambient. this suit when shuts psig the off

housing flow.

provisions

isolating

shutting

off

Performance--The the 5.2 suit psig loop and of

pressure suit the

regulator pressure when

allows drops

oxygen to

to

flow of a The of 67

to

loop supply

a minimum rises 90 psia. to

the of an flow x

pressure 67 to

maximum maximum psia valve an at

5.4

with is 9.8 of does

inlet lb per 70°F. not psia 5.15

pressures hr with

flow

rate

inlet

pressure the

a temperature orifice of

Oxygen

through IO-_ of hr.

pilot min with

bleed

exceed at x

2.95

Ib per 70°F.

inlet

pressure does not

90

a temperature IO-5 Ib per

Internal

leakage 66-1483 Page 4-138

exceed

I
MANUFACTURING AIRESEARCH DIVISION Los Angeles, California

[_

I I I I I I I I I I I I I I I I I
_i

.

Bypass a.

Valve Purpose 7.4 - The bypass valve gas allows to the of the astronaut in the to add of an additional

Ib per

hr of failure (see by

oxygen or

suit

event

a heat

exchanger b. Description the

clogging 4-?0)

the

ejector. bypass of an to valve actuating close device, gas the is manually lever valve. actuated the by

Figure pushing on

- The end

astronaut and by

on one the other

to open Attached

valve to

pushing

end

this

actuating or it seals

lever the

is a piston-like inlet port. The

incorporating by

seals,

that

opens as

is metered

a calibrated

orifice c.

leaves

this

valve. valve allows an a flow inlet of 7.4 ±0.20 of 67 Ib per psia at hr a

Performance of oxygen

- The into of The the

bypass suit

loop with force leakage to

pressure the exceed bypass

temperature 2 to 8 hr. Flow a. Control Purpose valve are b. lb.

70°F.

The

actuate not

valve x IO"5

is from Ib per

internal

does

3.15

.

Valve - The which flow control the valve flow to (selector the ejector valve) is a 3-position The positions

controls and

nozzle.

OFF,

MED,

HIGH. Fiqure 4-70) the - This to valve one of is manually three fixed to to the the so actuated stops. OFF MED position, the gas and by The the

Description astronaut handle by

(see

rotating be

handle before

must

depressed the valve

it can from

be moved the OFF

position. a passage will into to flow

As

is rotated device

in the through

piston-like a

is positioned the

that

restrictor, to

through

piston-like When the

device valve

a duct HIGH

leading position,

the ejector

nozzle.

is rotated

the

66- 1483
AIRESEARCH MANUFACTURING
Los Angeles,

DIVISION
California

Page

4- 139

the same

gas

enters as

through in the are MED

an

unrestricted The

port flow

and

leaves

through and

the the

duct

position. in a common

control This

valve housing

I I I I I I I I I

bypass mounted

valve to

located valve the

housing.

is flange-

the main - With

group

housing. nozzle downstreamj oxygen flows

C.

Performance as fol lows: •

ejector

MED of

position; 97 psia and

4.75 at 8.0 an a

to 5. 15 Ib temperature Ib per hr

per

hr

at

an

inlet

pressure

of O5°F. at a maximum of 92 psia pressure and a drop of

HIGH 0.5 of

position; psi with

inlet

pressure

temperature

70°F. leakage does not exceed 3.15 x lO-5 Ib per hr.

Internal
.

Development This unit flow check successfully sensor valve valve an completed and nozzle constant and a a proof pressure flow pressurization drop tests, high bypass tests, test, and and demand low and

emergency leakage, sure torque altitude

actuation leakage, leakage,

pressure pres-

seal

leakage, flowrate

suit

regulator tests, test

bleed flow 4-73

and sensor and

actuating check. The

altitude

check,

calibration 4-74.

setup

is shown

in Figures

I I I I I I I

66Page

1483 4- 140 _1 AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles,

I I

Figure 4-73.

Valve Group

F- I806

Figure 4-74.

Valve Group Altitude Test Configuration

66- I483
AIRESEARCH MANUFACTURING DIVISION
Las Angeles. California

Page 4-141

I I I I I I I I I I I I I I I I I

FIll I.

and

Shutoff

Valve

800286

Purpose This valve to is used use. for filling and isolating the stored high-pressure

oxygen

prior

2.

Description The manifold oxygen two

(see of tank

Figures the and oxygen has

4-75

and

4-76) shutoff (BAR as X) valve seal mounts at for the directly interface. the to the The pressure

fill

and

emergency unit gauge. The

a metallic as

contains

separate

valves_

well

a port

connecting

shutoff

valve poppet

contains seating.

an O-ring-sealed_ To open the valve

manually-operated fully_ one to poppet and it

valve

with to turns.

metal-to-metal rotate the

is necessary quarters

handle rotation

counterclockwise of to the handle

approximately causes the poppet The

three

Clockwise torque assuring The seals on

seat.

A maximum

40

in.-Ib thus

of

is required effective fill valve

provide

zero

leakage. repeated ball the

is antirotational_

sealing utilizes seat

even

after

use. for the sealing The a poppet. ball The ball

a metallic machined seating. to ensure

a sharp-edged to ensure at

into

housing.

is springsealing

loaded-closed super-pressure 3. Performance Leakage:

rapid its

The

valve

contains

redundant

cap

inlet

zero

leakage

capability.

Internal: External:

6 x 5.25 psig

I0-8 x

lb per

min (max)

at

inlet at

pressure inlet

of

7500 of

psig 7500

10-7

Ib per

rain (max)

pressure

_

AIRESEARCH

MANUFACTURING DIVISION Los Angeles. California

66-1485 Page 4-142

I
I 1

Figure 4 - 7 5 .

F i l l and Shutoff Valve

8 I

66- I 4 8 3

Page 4- 143

I I I I I I I
*,_g)
CLOSE I MANUALLY OPERATED HANDLE

SHUTOFF-VALVE

FILL PORT (PLUGGED) FOR EMERGENCY TANK Oa

Io
_Fl_

/p

/#* ,,r/

I I
I TO SUIT LOOP

I I I I I I
Figure 4-76. AIRESEARCHMANUFACTURINGDIVISION
Los Angeles, Cahforma

/f //

Lz

FROM EMERGENCY 02 TANK

TO EMERGENCY Oz TANK
A-26589

Schematic

of

Fill

and

Shutoff

Valve

66- 1483 Page 4144

I
Pressure rating: 7_500 12_400 16_600 psig psig psig

I I I I I I I I I I I ii I I I I

Operating P roof Burst Operation:

Torque

required

40

in.-Ib(max)

4.

Development Tests performed on torque over]oad through torque check completed. valve this tests_ prior and unit include proof pressurization torque test_ of fill R&E va]ve. to tests_ test to A]] 12_400 cycling check tests were psig_

cycling-actuating test ]eakage successfully with

temperature-actuating to beginning of test

functional

66-1485
I_ AIRESEARCH MANUFACTURING DIVISION
California LOS Angeles.

Page

4-145

Suit I.

Loop

Check

Valve

850040

I I
prevents regulator throuclh rubber The are flow sheet backed direction gas direction_ flow to reverse is 4-79) sheet is up retained in by the the valve to disc. flow actuated. in the event the manual

Purpose The suit loop or the (see consists outer check suit valve pressure 4-77

bypass 2.

valve Description The valve at four its

I I I I I I I I
center metal are the are forced perforation. forced

Fi.cjures of

a circular

housing form When away If

periphery. 3 which in disc in the the

cross-cut by 3 the pass the

hinged is

flappers applied

a perforated flappers through flappers the

pressure from the is

perforated applied

3 allowing reverse preventing

pressure the

against

perforated

disc_

through

perforations.

.

Pe rformance Leakage: External Internal 3.15 a) x 0.5 I0 -s lb lb per per hr hr max 0 2 at max at 3.9 3.5 psig psig check

oxygen

I I I I I

pressure b) 1.0 per pressure Pressure Rating: 3.9 7.8 15.6 Drop: H20 max an of at 16. I lb per pressure of hr 3.47 psia _ and an inlet AIRESEARCH MANUFACTURINGDIVISION
LOS Angeles, California

hr

oxygen

max

at

I0 in. H20

check

Operating Proof Burst Pressure

psig psig psig

I
inlet 45°F

I. I0 in. Oxygen 66Page 1483 4-146 temperature

with

,

I
1 1

I I I I

Figure 4-77.

S u i t Loop Check V a l v e

(Upstream Side)

AIRESEARCH MANUFACTURING DIVISION
LOS

66- I483

nngeler California

Page 4- 147

F i g u r e 4-78.

S u i t Loop Check Va ve (Down Stream Side)

I

AIRESEARCH MANUFACTURING DIVISION
tor Angeler Caltfornn

66- I483 Page 4- 48

I I
I'-

I ! I I I
U GJ 0 0 IJ

o_

!

°_ L_.

I

I I
66- 1485
[_ AIRESEARCHMANUFACTURING DIVISION
LOS Angeles, Cahfornia

Page 41 149

I
4. Development Initial leakage _ proof Excessive suit of then Results (EPR), tested. and_ Figure component loop chestpack_ made check development and burst tests of this and of item flow. the during AiResearch which EMS 364_ several the flappers conditions S/N and elastomer the flapper qualification and material humidity Materia]s the in the test Laboratory condition. rubber and test units. consisted of external and internal pressure_ and were curling encountered S/N 102.

swelling valve P/N

I I I I I I eI

800308, of

Process might

a study that solve was

potentia] AiResearch

materials, material and

e]iminate propylene

showed could It therefore_ 4-80

ethylene were

the

problem, that

constructed of the humidity

found it was the

EPR withstands into of both

incorporated condition

chestpack the origina]

102 and new

subsequent after

shows humidity

material

testing.

I I I I I I I I

66Page

1485
_ AtRESEARCH

4- 150

MANUFACTURING DIVISION Los Angeles, California

P
I I I
I 1 1 1

I 8
I

0
03

u

I

z

.LL

3

(31

I 8

P
I

I

AIRESEARCH MANUFACTURING DIVISION
Los Angeles. California

66- I 4 8 3 Page 4-151

I I I I I I I I

Pressure I.

Gauge

800300

Purpose The pressure both gauge before (see is used and Ficjure to monitor the oxygen pressure in the emergency

oxygen 2.

tank

during 4-81) to the only which

extravehicular

activity.

Description The gauge valve.

is connected The gauge

system one

by

a port part:

on

the

oxygen

fill wound_

and

shutoff

has tube_

moving

a helically to the

beryllium-copper source. pointer_
.

bourdon

is directly tube dial cause face.

connected it to unwind_

pressure the

Internal at the

pressures free end_

in this across the

sweeping

Performance

Leakage: External 3.15 7500 Pressure Rating: 7_500 12_400 16_600 ±5 Range percent of Dial: psig psig psig scale IO_O00 psig x I0"5 Ib per hr max with inlet pressure of

psig

I I I I I I I I I
4.

Operating Proof Burst Accuracy: Pressure Development Pressure subsequently in the A second was of high Gauge P/N 800300 A

of full 0 to

was leak the

proof-pressurized of 9 cc was per min of

to

12s400

psig air

and was for A after discovered repair. resoabout area_

leak-checked. pressure ports was

standard to the

and

part to

returned

vendor test.

pressure found dwell at at

gauge about this

subjected and The

a sinuoidal in the was not

vibration case in

nance 3 min

1350 cps frequency.

a crack crack

developed high

the

pressure

and

a

remedy

was

not

difficult

to

find.

66-1483 Page 4-152

_AIRESEARCH

MANUFACTURING DIVISION Los Angeles California

I I I I I I I I I I I I I I
i
' A-2&$O8

Figure

4-81.

Pressure

Gauge

I

[_l

AIRESEARCH

MANUFACTURING DIVISION LOS Angeles, California

I
Housing Assemblies During close housing had tolerance assemblies in March 1965_ fiberglass of wall from and from Figures mold. a development construction Chestpack thickness the same were S/N and mold. improved with 4-83 the show I01 hole program extended the The in S/N is also the 102 state upper original incorporated the 104 same and of and the lower mold and an mold_ subseused art in

I I I I I I I I I I I I I I I

techniques. was formed

variations technique process units S/N 103. are

sizes. S/N still techniques two steps 103

improved but quent for the the

from S/N

methods new 4-82

further. and in

mo]ds_ and

machining process

methods of making

the

fiberglass

66-1485
_I AIRESEARCH

Page

4-154

MANUFACTURING DIVISION Los Angeles, California

I

1

Figure 4-82.

Chestpack Lower Case

Mold f o r P l a s t e r Plug

Figure 4-83.

Chestpack Lower Case Plaster Plug f o r F i b e r g l a s s Lay-Up

AIRESEARCH MANUFACTURING DIVISION
Lo$ Angeles California

66- I 4 8 3 Page 4 - 1 5 5

i I I i I I I I I I I I I I I I I
_

Electrical I. Harness a. A2 through b, (where module

Components (AI)

(see

Figure

4-84)

138723 To provide all electrical connections between subassemblies

Purpose A9. Description needed) or

-

The

harness

is to

comprised connectors

of

insulated mate

and with

shielded appropriate

conductors device.

attached

which

electrical

c. harness d. an excessive

Performance restrains Development delivery was

-

In

addition

to

providing to of of this

electrical acceptable Wiring availability While resulting the assembly of

connections_ limits. Harness_ 138527_ the

the

electromagnetic The original

interference switch Because redesignated was and

the

had

lead-time. modified the system and

problem_ the in the modification fewer

wiring was which_ easier.

harness taking in place_ turn_

138723.

wiring

simplified made

wires_

improved

reliability

system

2.

Indicatin a.

9 Purpose

Panels To

(Control provide

Pane] visual

Assembly_ indications

A2 / of

138594 chestpack

and

138793 and AMU backpack

emergency b. warning lamps maximum each panels astronaut. application.

conditions. Description lights and panel circuits. of and on panel circuitry_ elimination top of the The indicating in This panels a unified offers are designed of to acrylic lighting lighting section. by the include with all the

lighting

panel

imbedded

and

electric

appoach the of possibility a

buried of dual

elements_ elements The for

protection area_ mounted Each

message are

loose

wiring easily

harness viewed

chestpack_ background the

extravehicular power valve

contains 138594

light name and

to

indicate of

chestpack the bypass

Panel

indicates

position

66-1483
AIRESEARCH MANUFACTURING
Los

DIVISION
California

Angeles.

Page

4-156

i

l i I I
i TO/FROM SUIT

-

I I I I I I I I I I I I I

L
I

( .-

I
33 ,JUMPER i7 14 I 36 35 20 37 18 28 29 30 15 16 11 25 24 23 22 21 I0 3t 32 27 t3 L

,"_.?ii'

c_

c_

dd
Z Z

0

oo_
0 0

0

z_
'Z Z

w

o

_o __

4
w

R

'ii!
36 35 3433 UMBILICAL ,4+ "117

20

37

'_B

28

29

30

1S

S

16

10 24

23

11

25

B

7

"

+

+

-

-

+ TO/FROM" SPACECRAFT

,9/_- 15")

A3 TEMPERATURE SENSOR r

A,
HEATER 1

1
J

A5

TEMPERATURE

CONTROL

& OSCILLATOR J

j

A6
TRANSDUCER

OSCILLATOR

]

T
TRIG TRIG 2 3 I 6 7 8 5 2 1

I
E L P2
---

P2

J3

'AUDIO

WARNING

r_!

I

AUDIO BATTERY

WARNING RETURN i _ 1_

SUET

PRESSURE

t'_

HARNESS ASSEMBLY

.202 AGE G
H202 GAGE MMU H20 TEST +28 2 (+14-28 VDC VDC)

[tl
i & ! i' LI I I _!

0 2 .FUEL RCS

PRESSURE PRESS (+14-28

(+14-28 (+14-28 VDC)

VDC)-,_ VDC)_ J 'H -J-

RESET _

_T.__

_

__. _

-91_ _

__ALARM CASE

TR,GGE GRD

R

'm _ I,L_

tl C

26

9

12

3

7

2

6

4 •

f

4

÷

÷

-

4 t

MMU

"ONLY

2

5 OUTPUT

11

19

15

16

6

7

17

18

1

3

J
[

J DSI "S/C POWER"

TRIG

TRIG

TRIG

28V

14V

+

RESET

VOLTAGE REG

J
DEMA FLIP-FLOP AND

OR'

GATE

OSCILLATOR NOT USED ELECTRICAL SPARES VOLTAGE

A8 CONTROL REGULATOR

31 27

26

19

9

13

12 22

21

6

3

2"_

P2 --CHEST PACK

I

V--

e_

A7 BATTERY

]

• o-,,_ _a_4 ,
I

J

.°___
---_'
.20 WATT I

I
J
$1 --

{_,4

J

-..__,

.__
J

iF'•)

[
'.a
II, ,._,t i I I

,,Lp

,-, M,\ / 11: '""._o,_
p -......._-,,

_
, i

_,

"TEST",--'_-----_

C>
_
DS9 DS10

c _' I
i

<_,
_ _-_
)SI, )$2

_

_.--

I
I

_DSll,

DS12

ptES_S,

DSS, DS6

C' C_
I i

°°
J1 P1

'"I -I
"SUIT PRESS" f 1

A2A

I

D.. :'_"EMERG 0 DS8 Lr_J 02 -:
LEFT-HAND BACKGROUND DS13-DS17 DS3, PANEL LIGHTS

L.,-_.)
"._
m

B ClP4

+ ¢ASqj1

A

A9 FLOW ID SENSORS

J
EMERGENCY

I
BACKGROUND I A2 CONTROL PANEL ASSEMBLY DSI-DS5 LIGHTS

I
AZ_2 J

I_

B- 12530 Figure 4-8z_. Schematic of Electrical System

I I I I I I I I I I I I I I I I I

and ated power ing rent

the in

oxygen Pane] light

flow 138793. four

selector These

valve; include

all

other

displays oxygen_ diodes lights. the and

and suit are

controls pressure_ provided The diodes lights are When

are

incorporspace craft testcur-

emergency lights. the The background when diodes_

3 and

AMU warning PRESS_ the test and

to

permit prevent are

the

EMERG Oz3

SUIT

flow-back The

through six

circuitry lights_ panel the

background conductors switch.

illuminated

normally. in the

emergency on

encapsulated this and when switch turns is off

panel. 28

Mounted vdc

this to

is a button flip-flop

depressed_ the power gauge

is applied tone. as the A

in Module to

800374 indicate

audio-warning is employed is included meter_ AMU

28-vdc

lamp

is provided source. is a the

spacecraft quantity scale

chestpack panel. leads will

power This

A hydrogen

peroxide full

in the with

gauge to

1,0 milliampere

deflection Each directs A TEST

both light

going

AMU, the proper AMU warning device

warning ground.

illuminate

when

it to

three-position provides the the

(TEST_ 28 vdc

DIM_ to

BRIGHT) the EMERG

switch 02

is mounted the to _he

on

the PRESS of

panel, light_ module

The both

position

light_ and on

SUIT logic

background 8700374 The positions c. following

lights_ (bypassing DIM

spacecraft demand provides vdc. - The lights

power and

light_ turning of

switch an

the

audio

oscillator). the BRIGHT

position 28

input

14 vdc

to the

chestpack;

provides Performance operating The The The SUIT EMERG

on

the

indicator

panel

illuminate

under

the

conditions: PRESS 02 light light pawer illuminates illuminates light when when the the demand switch switch closes. closes. power is

emergency when

spacecraft used,

illuminates

spacecraft

being

66-1485
l_I AIRESEARCH MANUFACTURING DIVISION Los Angeles California

Page

4-158

I I I I I I I
• d. 138595. Indicator tests • are

The

AMU

warning from -

lights the AMU.

and

the

H202

_JANTITY

gauge

receive

their

inputs Development Because Panel outlined All that • A lamps of

Indicator

Panel which

138793 took

was

initially during

designated

modifications was

place

development, of the development

138595

redesignated following when

138793.

The

results

in the

paragraphs. their lamps design and circuits diodes, with were tests are were energized, indicating

operated

circuits, was on

including found to be

correct. within prevent with a shield the

shield

in contact precautions electrical

a conductor taken were to made

potting

Panel

138595;

recurrence. isolated Relative character

Subsequent electrically brightness was of

this

from

other on

conductors. Panel than 138594 the less was was very On than by good; one no area on the one of

lights

preceptibly the lighting

brighter was a

others. intense

I I I' I I I I I

Panel balance lamps. • The

138595 of

little

that

the

panel.

This

condition

remedied

relocating

thermal

distortion lights panels monitored temperature and

test

consisted

of

applying lights bell jar.

28

v

to

the for

background 95 min while were

two adjacent in an know_

warning

simultaneously Surface

were at

evacuated hot spots by

tempera-

tures The

by means Panel

of

thermocouples. was 220°F area The of 130°F. at a warning The

maximum

experienced by

138594 was the

maximum location lights, for this

temperature immediately Panel panel 138595 has

experienced over

Panel light.

138595 In

a warning

the

showed

temperature to Lexan,

distortion. made by

material Electric

been

changed

General

66-1483 [_J AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles, Page 4-159

Company. Subsequent testing was
Lexan the 4 hr. Hz02 Quantity mode] panels of in a Pane] 230°F distortion 138595° hot air of The oven the

performed test with panels

on

Panel of

138594

and

a

consisted all lights

heat-soaking operating for

I I I I I I I eI I I I I I

No heat Gauge 800386

occurred.

!.

Pu rpo.s.e The HzOz quantity gauge liquid Figure is numbers a 0 are to indicates propellant 4-85) of background the Weston_ is moving-coil type. black. The bulk quantity in (in the percent AHU. of full tank)

of 2.

hydrogen

perioxide

remaining

Description/see This unit and

I milliammeter white. The

pointer 3.

nonreflecting

Performance The gauge the is calibrated meter Between and these to I00 read percent zero percent the when flow of there is the vs no current is varies

flow 0.001

through ampere.

when the

through percent

gauge current

points_

reading

1 inearly. The levels accuracy of 0 and this 0.001 gauge ampere. is 500 +-5 ohms at a temperature of 70°F. is +5 percent of full scale for all current

between Electrical

resistance

4.

Development The development types was of phase gauges of this until to verify component one was consisted found that primarily was acceptable. of vibration After

of that_

different testing

performed

accuracy.

I I I I I,

66Page

1485 4- 160 __1 AIRESEARCH ANUFACTURING California M DIVISION Los Angeles,

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MANUFACTURING DIVISION Los Angeles, California

66-. 1483 Page 4-161

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Figure 4-86) of heater oxygen outlet_ control from and chestpack controls in

Temperature a. Purpose

Sensor - This

IA3) unit

800294 senses

(see

temperature at the

I I I I

emergency operation module b. equals 920

oxygen of

supply (A4)

tank

heater

through

temperature

circuit

(A5). - The at element is a of thermistor. 45 ° ±O.I°F. The sensor resistance

Description ±92 ohms

a temperature

c. bridge d. conjunction

Performance in the

- The

sensor

constitutes module. was

one

leg of

a

_eatstone

I I
in

temperature -

control The (A4).

Development with heater

sensor

subjected

to

development

tests

I I I I I I I I I
66-1483 P_ge 4-162 I_ IAIRESEARCHMANUFACTURINGDIVISION Los AnKeles, California

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MANUFACTURING

DIVISION
California

Los Angeles,

66- 148.3 Page 4- 16,3

I
4. OxyRen a. cooled emergency b. heater stream the (see and by Heater Purpose the {A4) The 800290 heater and is throttling used to heat the as oxygen it is which delivered has been from the expansion tank. 4-87 inside gas The and heating 4-88). the delivery is element The is element tube sensed by by by a a a Cal-Rod is the electrical in fins sensor control the resistance gas to process

oxygen Description Figures

I I I I I I

submersed heating

supported The the

brazed (A3) and

element. at

temperature outlet and

temperature temperature

located oscillator c.

heater (A5).

controlled

module Performance Gas

-

Performance range:

characteristics Inlet_ when +80 o inlet to is

are -IlO°F; less

shown outlet_

below. +40 to +50°F

temperature

than

40°F

Heat

input: drop:

160 w ,nin at I psi 57 max

24-v at

dc flow with inlet conditions of

I

Pressure

rated -llO°F

psia 13.2 3.2

and

Rated Element

flow

1.0 to

lb per

hr oxygen at 70°F

resistance:

±0. I ohms

d. electrically time time The and of was tests a flow

Development powered heater

- A oxygen might

preliminary heater. too large.

test The

was

performed concern found, was

on

a design the that

for

the

! I I
I I I I I I
DIVISION

main It was

that

response the response

the

be

however_

small were rate

enough

to maintain using Ib of per

allowable with

outlet an

temperatures temperature

adequately. of was -llO°F One control of per sec.

performed of 13.2 watts

nitrogen hr.

inlet

Outlet

control

temperature applied at

45°F.

hundred

and

sixty and

power at with

were

alternately control to time

l°F below The to be

temperature change of

switched

off

l°F above respect

temperature. was found

rate

outlet

temperature

O.8°F

66-1483 Page 4-164

I_IAIRESEARCH
_

MANUFACTURING

L_An_eles,_lifornia

L

F i g u r e 4-87.

Oxygen Heater and Temperature Sensor

66- I483 Page 4-165

..tJ QJ "-r r" Q.,I 03 >:< C_

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I I I 1_1 A'RESEARCH MANOFACTOR,NO O,V,S,ON
LOS Angeles, Cahfornla

66- 1485 Page 4- 166

P
I I I I I I I I I I I I I I I I I
_

5.

Temperature a. b. Purpose

Control - To

and control

Oscillator heater 4-89)

Module (A4) and

(A5)

800518 audio warning tone.

provide a

Description and an

(see

Figure circuit.

- Contains

temperature circuit (AS). spacecraft (A8). an Gate

control turns on and

circuit turns circuit by logic c. C output input output

oscillator (A4)_ audio as

Temperature by temperature to suit voltage in module to the

control sensor and

off

heater

dictated tone and

Oscillator when triggered

provides

warning control - When (A8) by

helmet regulator (A8) the 1700

in oscillator Performance from module received C

module

logic

discerns of

emergency_ D.

Gate

is circuited Gate D from a

input Hz

A continuous the Hz the

is also of Gate

oscillator; passage of

therefore_ the 1700

is effectively input results of the

trigger

to enable The output

oscillator I_Hz at

to one

modulator.

modulator's of a 1700-Hz

other tone

input_

oscillator_ the the

in a modulated tone. control

modulating

I Hz, When

audio-warning temperature output voltage and

circuitry and

is

idle_the to the The output type

continuously hold: off output bias

operating circuitry. thus is the

1700-Hz The hold

oscillator off bias leakage into

is amplified applies thermal

directed bias to

reverse runaway This is a

amplifier_ output to drive

eliminating directed temperature sensor (AS)

problems. amplifier

oscillator is used the

another

amplifier. The bridge

bridge. and is an

Wheatstone constituting and When is used the

with

temperature The bridge drops bridge Figure the a variable when below output 4-90.) sensor the

a variable external equals

resistance adjustment 45 ±l°F.

two to

legs. the

resistance sensor this

null

temperature value_its

sensor

temperature The _See When but

delta fed

resistance into a

causes

a bridge

imbalance. (SD). output. also

is ampl if led and The SD samples

synchronous with its

demodulator amplified is

the

bridge 45

input ±I°F_

temperature

is above

the

bridge

imbalanced

180 ° phase

66AIRESEARCH MANUFACTURING Los Angeles DIVISION Californla

1483 4- 167

Page

1 I

I
1 1 I

I

Figure 4 - 8 9 .

Temperature Control and O s c i 1 l a t o r Module

AIRESEARCH MANUFACTURING DIVISION
10s Angeles California

66- I483

Page 4 - 168

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occurs The SD

when

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sensor that

temperature phase which from

passes represents the

through

the

45

±I°F

temperature above the

rejects result

a temperature demodulator to

point when an

±I°F.

The

is an is below

output 45

synchronous output the base

sensor signal (PWM). the

temperature circuit A which

±I°F. an input

This to

is directed of to a pulse the PWM

error modulator As its PWM output which

provides ramp

width

sawtooth signal

generator greater_ width of of

output the the PWM

is applied output wave

emitter. increases The PWM

error

becomes (the

(square becomes

wave)

average output

power

output

square

wider). The

is ultimately to a

capable The

attaining output heater when

a"full drives (A4_ the the

on"d-c the

level. darlington 4-84). switch oxygen which

is applied is PWM in series and the the

driver. the

driver 02

amplifier that the

with driver

emergency power sensor

Figure emergency

Note

obtain flow

only

is closed. loop_ it is only only

Because

emergency the

is in supply

emergency

I I I I I I I I I I

actuated time the d. during

when

emergency control - All at the

oxygen

is being

used_

is the

temperature Development

circuitry the required

is employed. performance parameters and were tested levels.

development

required

temperature

extremes

overvoltage

66-1485
_j AIRESEARCH MANUFACTURING DIVISION Los Angeles California

Page

4-170

I I I I I I I I I I I I I I I I I
_[

6.

Pressure I.

Transducer To

(A6) provide for (see between

800298 an indication purposes. 4-917 coils. The These pressure-sensitive-transducer coils circuit. leg moving in an air of it a are energized Matched four-leg-balanced closer gap of to one coil by an 8-kc of recirculating suit loop total

Purpose to

pressure b. diaphragm sinusoidal and circuit. away produce an inch from

spacecraft

monitoring Figure two

Description is mounted

carrier

generated each winding

in the serves the minute reluctance in total the

solid-state as one

electrically bridge and circuit of

magneticallys Pressure the wide produce in The other.

displaces Since in

diaphragm_ changes

a magnetic of

variations variations turn bridge for zero and absolute

s diaphragm reluctance of and_ means

displacement up to ±7.5 the

thousandths These of the

percent. amplitude

variationss carrier. compensation after theoretical c. • • d. temperature burst-pressure tests linearity were rectifying

s control circuit drift filtering accuracy -

inductance ready

thereby_ for

provides and sensitivity

introducing Resultant within

temperature signal I percent levelss of

changes. linear EC output system. are

s provide for the

overall

Performance Linear Pressure Development checks_ and successfully test setups. d-c

Performance 2.5 psig to

characteristics 5.0 v dc

described

below.

outputs 0 to 5.0 Tests

conducted

on checkss

this

unit

include

linearityand ]inearity check. the cycling All and tests

cycling-linearity linearity tests completed. and

proof-pressure resistance and 4-93 show

an

insulation 4-92

Figures

66-1485
AIRESEARCH MANUFACTURING DIVISION Los Angeles. Califorma

Page

4-171

585 I 1-3

Figure 4-91.

Pressure Transducer

AI RESEARCH MANUFACTURING DIVISION
Los Angeler. California

66- I 4 8 3 Page 4-172

I I

I
I I I I I I I I
F i g u r e 4-92.

Pressure Transducer Cycl i n g T e s t Setup

I I
66- I 4 8 3
AI RESEARCH MANUFACTURING DlVlSlON
LOS

Angeles California

Page 4-173

i I I I I I I I I e 1 I I I I I I

I
I

Figure 4-93.

Pressure Transducer L i n e a r i t y Test C o n f i g u r a t i o n

8

AIRESEARCH MANUFACTURING DIVISION
Lo6 Angelel. Cal8lornla

66- 1483 Page 4-174

I I I I I I I I I I I I I I I I I I
_]
.

Battery a.

(A7) Purpose

800670 The battery #rovides all primary power required for the

chestpack. b. peroxide-alkaline in into a nickel-plated_ a The connected and_in of the turn, five for self-sealing battery in series. are series connecting cells each. watt-hours. are The is Description (see secondary aluminum cover. comprised Two banks in are 24 Figures storage case. The of wires 24 of 4-94 and 4-95) The This battery output in cells. connected 14 cells. strip. the are the an unit cells is is a zinc-silver_ are contained wires potted

battery. The electrical

through

terminate individual

electrical Fourteen in The

connector. cells are paralleled

five with to in

cells_ the

series_are inner This

connected cells all

series brought cells in

connections provides cycle. 1.5 a The

a terminal during case and of

means individual capacity 38.8

series

charging rated at

housed minimum

a plastic

amp-hour is

energy

requirement

completed

battery

When plate in a and single

in a

the silver layer

charged peroxide of cloth The The cyclic

condition_ negative material electrolyte chemical is: + 2Z n discharge charge

the

cells

have The then

a metallic positive plate in percent the

zinc is

positive wrapped layers of

plate. and is reaction is an

enclosed 40 describes

four

cellulosic hydroxide

material. solution.

aqueous which

potassium reversible

discharge-charge Agz

Oz +

H20

2Ag

+

Z n

0 +

Z n

(OH)2

The

silver and

oxides

are

soluble the silver

in

the ions

electrolyte. from reaching

The the

cellulose zinc plate_

acts

as

a

barrier preventing

prevents short

thus

circuiting.

AIRESEARCH MANUFACTURING DIVISION
los Angeles. Cahfornla

66-1485 Page 4-175

D ’

I I
I I
F i g u r e 4-94. Battery

I

I

AIRESEARCH MANUFACTURING DIVISION
tas ~ngeiesCalifornia

66- 1483 Page 4-176

I I I I I
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66- 148.3
_i AIRESEARCH MANUFACTURING
Los Angeles,

DIVISION California

Page 4- 177

I
After undergoes requirements will return c. • assembly two if to 3 the

cells

I
are activated A cell power during with is electrolyte. judged these to meet It the then specified and cycles. rated

discharge-charge it full will supply

I I I I I

discharge

cycles

charge, Performance characteristics are shown below.

Performance Leakage External

:

5.15

x

I0 "6

lb/hr

Oz

(max)

at

20

psig

Relief

pressure Crack: Ful 1 flow: Reseat: 30 50 20 psig psig, psig (max) (max) (min) AP to flow I000 sccm 02

I I

Power

output 38.8 watt-hr between 24 and 32 v dc

Life Dry charge: Wet Output charge: 36 20 months days or 6 charge-discharge cycles

I I I I I I I I

voltage Open Closed circuit: circuit: 58 At v the (max) end circuit of a 38.8 is 24 watt-hr v (min) discharge the

closed

66-1483 Page 4-178
I_l AIRESEARCH MANUFACTURING DIVISION LOS Angeles, California

I

I I I I I I I I I I I I I I I I I I
I

d. initial

Development--Considerable version of the battery. low

development This testing

testing covered

was such

performed areas after as

on high

the

temperature discharge short After tion did

discharge_ in vacuum_ test of This

temperature after test.

discharge_ inverted

discharge

standby_ vibration marginal. qualificatests s

discharge and burst

standby

acceleration_ was adequate_but to

circuit completion testing. not. This_

The

performance was

development_ test brought with the the the

the battery out

subjected that the

humidity

deficiencies poor Because design_

development rate_

coupled

vendorTs

production of the

necessitated schedule testing of unit. The (Section and the the

AiResearch experience new battery

to manufacture gained was with started was

battery. battery

critical

first

qualification of the

without limited

development to testing

testing cells in the and

completed of cells. section

Development qualification 5) of this

testing testing report.

groups

performed

is covered

qualification

66-1485 _1 AIRESEARCH ANUFACTURING M DIVISION
LOS Angeles. California

Page

4-179

I I
8. Oscillator a. and provides b. input circuit and The Purpose output .Description Control This and Voltage Regulator logic Module that (A8) discerns 800374 emergency modes module provides to Figures circuit_ to when output of harness their provided and The C, Gates trigger input to either (AI), A and B provide Each stop the from gate an output an when input The a fast to signal in rising a threshold, from turn_ and D of the Gates provides also prod-c warning 4-90 and triggering (see oscillator. and 4-96) The module contains circuit, in temperature are an flow two Flip-flop control three-

OR gates_ generates oscillator ac OR gate through _MU back

a flip-flop a voltage module supplies the (A5) an switch

a voltage

regulator circuit

oscillator signal the the from

both circuit or

OR gates if

received. is (A9)

I I I I I I I I I I I I I I

flip-flop demand

input sensor

received or from c, level The is

emergency

through

Performance applied are threshold Gate to and of ($2) reset not C. to

inputs. to sets

provides signals. the

thresholds the to

nongenuine flip-flop; Gate

A passes an vides ture input an control

flip-flop_ the to an is threshold Gate audio provided. the input to

signal Gate

B passes is directed causing tone

input

Gate oscillator

C output finally

temperaoutput. the the

module_ off apply the 28 audio v dc

oscillator Pressing passes C_

A means reset signal Gate switch to

turning will the

warning to a

threshold; one

threshold Gate

flip-flop. an - A

This

removes

therefore_

C will d.

provide

output. complete development test program was conducted on

Development without

this

unit

problems.

66-1483 Page 4-180

[_

AIRESEARCH

MANUFACTURING

Los Angeles,

DIVISION
California

I I

W

8 8 8 8 8 8 8 I la 8
-

*

8 8

I
1

I 8

~ - , g u r e4-96.

O s c i l l a t o r Control and V o l t a g e R e g u l a t o r Module

AIRESEARCH MANUFACTURING DIVISION
Los Angeles California

6 6 - I483 Page 4-181

I

I
I

9.

Flow a.

Sensors Purpose

(A9) - The suit, the demand The flow sensor flow supply sensor is provided sensor tank. and an emergency flow sensor are to monitor flow of flow

oxygen

through from

emergency oxygen flow

is provided

to monitor

I
I I I I

of

oxygen b.

emergency - A

Description

demand

provided. type flow with a

Both

flow

sensors

are

of the

pressure-differential_ Contacts and close oxygen

diaphragm-switch in the flow demand is

single-pole_ if suit

double-throw drops to

contact. 3.3

sensor_

pressure

±0. I psig_ valve. flow sensor

initiated c. input to

through

suit-pressure - Closing in module an

regulator of demand

Performance the OR gate to of

contacts the suit

provide

an

(A8)_ audio

thereby warning the

causing tone SUIT to

oscillator helmet and lamp

circuit spacein

in module craft.

(A5) Closing panel

initiate contacts to

also

causes

PRESS

warning

I I
I I I I I I I

indicator

(A2) close tank

light. flow sensor_ if oxygen check contacts oscillator helmet in chestpack to the an emergency recirculating input to the (A5) of

Contacts oxygen suit OR to supply loop.

in emergency flows of (A8)_ through

the emergency flow causing to the lamp sensor the

valve

Closing

emergency thereby

provide circuit and

gate

in module an

in module

initiate

audio the

warning EMERG Oz

tone

suit in

spacecraft. panel (A2) to

Closing light.

contacts

causes

warning

indicating

I

66_] AIRESEARCH MANUFACTURING Los
Angeles,

1483 4- 182

DIVISION California

Page

I I I I I I I I I I I I I I
I
I

UMBILICAL General For and

ASSEMBLY

800326

many

months_

the

umbilical most

problem of the The

statement eased

was the

continually severity outline of the to

refined the purpose_ thermal

redefined.

Fortunately_

changes

thermal

protection and

requirements. operation of the as

following

paragraphs

description_ analyses which

umbilical well as

assembly_ other phases_

in addition of the

the and

were

conducted_

design

development. Purpose The Gemini status umbilical assembly to and the provides for flow of primary oxygen from and the the

spacecraft readouts, (See

chestpack_

communications_ of the

biomedical astronaut to

system spacecraft.

mechanical 4-97)

tethering

Desc_[ription The a tether

Fiqure

umbilical strap_ and

assembly a sheath. of the the

is comprised The

of

an

oxygen conductors

hose_ are

electrical wrapped carries

conductors_ spirally all

electrical The

around tension The

the

outside on

oxygen

hose. and

nylon over

tether the

strap

loads

umbilical is then

is placed with

electrical of aluminized

conductors. mylar. This

entire

assembly

covered nylon

multilayers

is then

placed

in a protective

sheath.

Performance Leakage Ib per assembly the from hr at shall (with an or without pressure that socket mating of gas connector) Pressure 4-98. 15 lb. exceed 5 shall drop Force Force lb. not of to to exceed the 3.15 x IO-s

inlet not

120 psia. in Figure exceed not

completed 649257 649257 with

exceed

shown did

engage release

umbilical the

pneumatic

not did

I I
I

umbilical

pneumatic

socket

66-1485
I_1 AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

Page

4-183

I I I I I I I I
E QJ u
o_ o_

E

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I

I11 L. 3 °_

eI I I I I I I I I I

i,

66Page

1483 4184
_ AIRESEARCH MANUFACTURING DIVISION LOS Angeles, California

I

I I i I I I I I
I,---4 --J

I00 9O
i _

tlt

P_

8O 7O 60 5O
11:

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50 25 20
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f

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22_

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;.:

2_i

21!

i!_i

;!+

2.5 2

_¢s

th
It+ [i;

X:
_:-..

5 FLOW, LB/HR OXYGEN
A-26212

Figure

4- 98.

Umbilical

Assembly

Pressure

Drop

MANUFACTURING
LoS Angeles,

DIVISION
California

66Page

1485 4- 185

I I
Maximum static
load load was was 12 percent 16 percent load operating maximum. (max). was I000 lb (min). between connecting pins was 0.70 ohms (max). load Static shall design be 373 load lb; is elongation 600 lb; at elongation operating at design

I I I I

Breaking The Development I. Thermal

electrical

resistance

Analyses analysis The of the purpose and at its this then one conditions of the to to which the umbilical was hose it would to would was from it was reasoned the concluded would a more decision requirements that a which_ was lead hose) be

A steady-state subjected the reach the at that to worst was

I I I I I I I I I I I

performed.

steady-staR design as In

analysis though the

define

operating

conditions operation

steady-state umbilical would

point. (of minimal

this heat

manner_ transfer

meet

objectives after not

all

operating a steady-state

points. analysis solution to

However_ would the

a thorough produce It was

analysis_ guide to

a design decided

which

a practical and so

problem.

conduct This to of the actual the

difficult not of hose in based the

time-consuming much on the analysis would require

transient-performance difficulty as be it of was building on the an

analysis. umbilical

steady-state thus constructed case3 order would to

recognition for

fact

grossly

overdesigned of

the

problem_

this In

a high

degree

sophistication. results_ using it was necessary to

obtain

sufficiently numerical allows

accurate

write

a comprehensive The

computer arbitrary

program initial

finite-difference and arbitrary

procedures.

program

conditions

66-1485 Page 4-186 _ AIRESEARCH ANUFACTURING Calif0rma M DIVISION L0s Angeles,

I

I I I I I I I I I I I I I I I I I I

variation many as

of

both

fluid-inlet layers; giving two

and

sink be

temperatures. divided

The

hose into

may

have as

as 40

12 different elements the to be

it may

lengthwise different

as many

different For assumed For the thick metal between increases transient Upon concluded effect hr flow to on the

a total hose

of 480

possible used. an

elements. the hose of hose O.I for was O.L and in. the assumed steel its in.

analysis_ 0.5

models

were with

Initially_

in. overall only Later_ two the

diameter were

insulation the basic an To layer

thickness rubber assumed account of

analysis_

layers overall was

assumed:

insulation. layer wire the of wrap basic

diameter to basic

(including 0.625 hose_ in. a

insulation) used to

increased the the

strengthen hose and

steel of

was the

rubber

insulation. hose and

The

addition

the

thermal

capacitance

of the

thereby

slightly

delays

response. completion that the due to of the transient-performance oxygen mass flow thermal rates per analysis_ and the it was the 5.11b consequent per

the

low

invo]ved hr OR at

capacity the minor

rate

(approximately change of the

I Btu oxygen

rate) even

temperature variations

in the

umbilical

is sensi-

tive

in the environmental (conduction_ of the umbilical rise mass_

conditions. specific also the have heat) an and

Variations spectral effect on The by the

in the

mechanical

(emittance) the oxygen

properties temperature of the

can

appreciable

drop or

through temperature

umbilical. is further aggravated this be con-

fluctuation

umbilical

outlet

stated be

variation into

in the an

spacecraft

supply

temperature_ change through

although could 4-101.

could trolled

converted or scheduled_

advantage for example_

if the

temperature 4-99

as_

in Figures

_

AIRESEARCH ANUFACTURING M DIVISION
LOS Angeles, California

66-1483 Page 4-187

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66Page

148.3 4188 _ AIRESEARCHMANUFACTURING DIVISION Los Angeles, California

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66AIRESEARCHMANUFACTURING DIVISION LoS Angeles, California Page

1483 4189

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66-1483 Page 4-190

[__

AIRESEARCH ANUFACTURING California M DIVISION LOS Angeles,

I I I I I I I I I I ! I I I I I I I
Steady-state in the generation and_ from an analysis of an does overdesign use not sufficiently requirement standpoint_ define dictating impractical the the problem_ use of resulting sophistiand

cated reflective

intended

insulating

materials. umbilical hr ft°R in design and with conductivities in satisfactory is contolled at during the range solution the umbilical this time in of the 0.5 to range to the 0.2 of 0.05 properly to 0.112 combined provided least during at

An Btu will that Case 75 2. to per

emissivities

result oxygen

a practical_

problem at be

temperature The

inlet_ should

I operation. 90°F. Complete The

temperature

maintained

Umbilical

Assembly assembly a sheath. by consists During of the oxygen hose_ of at due like hose electrical development_ 6-in. to the the

complete tether were a

umbilical strap_ and

cable_

a

the

early

stages spaced mockup

components These

placed replaced of

together the the

polyurethane retainers The

retainers used on were the free the

intervals. poor

retainers

teflon

retaining bands trical

qualities

teflon. then nylon the

retainers to rope of the the

stretched oxygen to slide

rubbe# electhe

during cable and

fabrication together. was secured shows

and The at

released tether middle of

clamp was

and

through

retainers Figure external of all would the

umbilical. mockup. Then an overall snagging defeated

4-I02

a photograph around

umbilical to

sheath various for

was parts the

placed of triad the

the umbilical system. The a coaxial

prevent The

accidental however_ the was

three-member

sheath_ of

reasons be

configuration. Therefore_

flexibility

umbilical investigated_

reduced

greatly.

configuration

_l

66-1483 AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles, Page 4-191

F i g u r e 4-102.

O r i g n i a l Umbilical Assembly Mockup

AIRESEARCH MANUFACTURING DIVISION
Los Angeler. Cal!tornla

66-I 4 83
Page 4-192

I
with the oxygen around oxygen by hose the hose serving outside. as outer and in normal sheath. underneath was umbilical coaxial overall finally system. umbilical umbilical system flexibility was shown was to almost NASA. as It good was as the as a core and electrical conductors coaxial tether nylon strap sheath to be conductors would but not wrapped be molded be of merely the required and

I I I I I I I
I

spirally to the

The

electrical

combination A nylon the

hosess placed would the

wou]d on top the flexible

encased electrical lo_d. compact

a nylon conductors

carry most

This design

configuration for of that by this the itself. assembly in basic the

determi_d

A model pointed oxygen out hose The These to

umbilical

subsequently two steps from

underwant 800326-I-I the

a major to various

configuration and

change. finally

changes

occurred The

800326-4-I

800326-5-I. is most

differences in the following was and (covering) AiResearch resistance resistance was performed a first process step of

between

configurations

fabricated The outer

summarized significant of the

paragraphs. removal substitution of the umbilical several of this of the which of the of a gold plating (HT on nylon) This was the braid the

change umbilical sleeve

the

surface the of During nylon

the

Nomex

I
I

for result

outer to

assembly. umbilical tests the cause would was a few to it wires of

a test the was An

which

subjected portion between to determine

assemblies. was determined their low recurrence visually indicated The

insulation insufficient

I
I I I I

that shields.

there

some

and this

evaluation to

resistance of the this

and condition. of problem

determine The

technique the

prevent examine which

evaluation There was were

exterior

the

umbilical Nexts

assembly. the assembly

bumps with

possible

areas.

photographed

X-rays.

I

I_

AIRESEARCH

MANUFACTURING
LOS Angeles,

66-1485
DIVISION California

Page

4-195

I I
arrow coated wound teflon pair and of in Figure covering teflon 4-103 of the points out the was kinks removed_ as under one of the bumps. in the The gold assembly over removed_ the exposing illustrated kink Nexts a kink doubleThe the

I I I I I I I
It

covering was as

shielding the

in Figure

4-I04. over was

covering wires

exposing in Figure the wires

same

in the the

shielding

illustrated that one of

4-I05. was the

shielding its

removeds as

it was

seen

protruding wire to

through

insulation to the

illustrated It was cycle at of the

in Figure concluded umbilical and of

4-I06s that

causing the kinking gold

short during

directly the

shield.

was

caused The

temperature-curing was performed cord

assembly

coating. of the the

curing

cycle of the The

about as

320°F spacers

caused

shrinking around had not

short

sections assembly.

nylon

used was

the wires the the nylon wires

umbilical

shrinking As the

caused

because occurred_ compression

been

pretemperature to in compress the and

stabilized. in a few pair on of

shrinking cases The was the

were caused the type

caused a kink

isolated wires. wires.

forces caused the

shielded

kinking_ also

in turn3

rupture of or

of

the noted

insulation would

the be

I I I I I I I I

concluded

that

failure

always tests. of

ascertained

during

the

insulation NASA outer

resistance suggested Nomex tests of

dielectric several provide

strength layers the

Subsequently_ placed under the

that to

aluminized thermal

mylar

be

sheath

required simulation

protection. at NASA

Umbilical verified

system the

thermal

conducted aluminized

in a solar mylar

chamber

acceptability

insulation.

66-1483 Page 4-194
__[ AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

i

F-2309

Figure 4-103.

Umbilical System Insulation Resistance F a i lure Evaluation (X-Ray Showing Kinked Wi res 1

AIRESEARCH MANUFACTURING DIVISION
Lo5 Aogeles. California

66- I483 Page 4-195

w

c

8 1 I i

B
I t
1

1 .
1

I
T 4

E
1

8
1

Figure 4-104.

Umbilical System Insulation Resistance Failure Evaluation (Kink in Teflon Covering Over Shields)

I

AIRESEARCH MANUFACTURING DIVISION
LOS

66-I 4 8 3
Page 4- I96

Angeles. Calilornia

1

I I i

E

E

1 t

8 8 8

F i g u r e 4-105.

U m b i l i c a l System I n s u l a t i o n Resistance F a i l u r e E v a l u a t i o n (Kink i n S h i e l d Over a F a i r o f W i r e s )

AIRESEARCH MANUFACTURING DIVISION
Los Angeles. California

66- 1483 Page 4-197

I

E0

Figure 4-106.

Umbilical System Insulation Resistance Failure Evaluation (Wire Showing Through Ruptured Insulation)

AIRESEARCH MANUFACTURING DlVlSlON
LOS

Angeles. Calltornla

66- I483 Page 4- I98

I I
The oxygen hose and electrical oxygen place. is longer (PVC) a nylon to cable hose_ On the than breakouts the were changed and considerably. the tether lead line comes

I I I I I I I I I I I I I I I I

On all out

the

spacecraft out at

end_ the angle

the

electrical end_

cable_ the

break at

same and

chestpack the

electrical

a 20

deg

previous sheath

configuration. was replaced was The not by a light for

The weight use in

polyvinyl sheath

chloride with

protective zipper.

dacron a vacuum an

The

PVC

sheath

suitable sheath vacuum

chamber

due

its outgassing cover for the view

properties. umbilical of the system

dacron

provides chamber UMBILICAL General

odorless See

flexible Figure

during umbilical

tests.

4-I07

for a

current

assembly.

ASSEMBLY

COMPONENTS

The development Oxyqen

following of the Hose

paragraphs components 158441 hose an

cover of the

the

major

phases

of

the

design

and

umbilical

assembly.

Supply The oxygen

supply hose_

is a composite layer_ The

of

a basic an

modified low on with at

military emittance_ Specification modification lower to

breathing

oxygen

insulation sheath. Pressure

and

outer_ is based Hose_ operate

micrometeroite MIL-H-22489_ reduce weight

protection Type and I_ Low size_

basic

hose Oxygen and

Breathing flexibility_

increase

temperatures.

I_1

66AIRESEARCH MANUFACTURING DIVISION LOS Angeles, California

1483 4- 199

Page

w

I

1 I I I I I I I 0 I I I

I

I
1 I I I I 1

Figure 4-107.

Current Umbi 1 ical Assembly

AIRESEARCH MANUFACTURING DIVISION
Los Angcles Callfornla

66- I483 Page 4-200

I I I I I I I I I I I I' I I I I I I
(less 4-I09 then

The a.

major

modifications resistant

of

the

Mil

Spec

hose

are wire by

as

follows: is decreased test to meet

Corrosion

spiral in.,

reinforcing as determined

size actual

to approximately 150-1b b. static

0.35 load.

Substitution of -lO0°F

of as may of

a

low be

temperature

silicone in the to AMU

to meet mission the

a

low

temperature no flow. caused

anticipated end fitting

with

c.

Modification by the hose

the

decrease

pressure

drop

inserts. hoses were to subjected the was to development hose_ to the the tests. except for The the hose, is end

Two first

prototype

oxygen was

prototype The one

hose second end

identical

production identical whereas

fittings. except made of that

prototype fitting was

hose

production

aluminum

production

fitting

stainless drop

steel. tests were conducted in a this on the first prototype position in Figure as oxygen and 4-108. The a hose

Pressure the quick The

disconnects) results the of hose

straight are

extended

a coiled Figure hose was

position.

test

presented position

illustrates coiled

in the

straight as shown

tested. 4-110 for

in a figure measurement.

8 position

in Figure

second

pressure Oxyqen

drop Hose

Quick

Disconnects hose quick disconnect is a trigger-operated The and operation (2) of coupling the designed is

The for as

oxygen

operation follows: to

with (I) a

the

pressurized push to

glove. connect

connector of the push

simple

a depressing

trigger

disconnect.

66-1485 I__ AIRESEARCH ANUFACTURING M DIVISION
LOS Angeles California

Page

4-201

40.0

30.

I I I I I I I
STRAIGHT

I
e,J nr_ ...J ! 0.,

<3 t_

eI I
I.¢ PROTOTYPE LENGTH o p o = = L Po STD AIR AT AND 70°F 14,7 PSIA 158441-1 IN. R&E NO. I = 524

I I I I I I I I I

0.1 5 FLOW 4 - LB/HR 6 AIR A-8088 7 8 9 I0 15 20

Figure

4-

108.

Umbilical

Pressure-Drop

Test

Results

66Page

1483 4-202 I_l AIRESEARCHMANUFACTURING DIVIS)ON
Los Angeles, California

1 I

I
1 1 1 1 I 1
F i g u r e 4-1

F i g u r e 4-109.

Umbi 1 i c a l
Pressure Drop Test-Coi l e d (Figure 8 ) Position

I .
IO.
U m b i l i c a l Pressure Drop Test Straight Position

-

F-1541

I

66- 1483 Page 4-203

I I
The connector providing The system minimum flush allows the bulk that prevent of the could connector interfere to be recessed the which into

I I I I I I
I I I I I I I I I I

the

pack

protrusion will

with

astronaut could

operations. cause

trigger

accidental

swagging

unintentional The oxygen

disconnect. disconnect development the basic from from was tests design changed early in the program. the This

supply from Also,

change of each

resulted unit. was was

conducted was taken and

to compare into

performance (1) The (2) the

consideration: 0.37 weighed Ib_ whereas 0.17 lb.

first final

unit unit Each

constructed constructed was The

aluminum stainless

weighed and

steel

disconnect

submitted unit

to a cycle failed at

test 435

under

pressure with The

until

a

failure spring slightly evident test. Tether

occurred. and an

first

cycles force.

a broken final unit

lever leaked no cycle

excessive 6300

connect as

and

disconnect of

after increase

cycles

a result or

an O-ring force

failure. the

There final

was unit

in coupling

uncoupling

during

Line The tether each line consists rope of has a 3/16-in.-diameter an IIO0-1b assembled breaking to the nylon strength umbilical_ rope with a safety

hook

at

end. The

The tether

with

a 20-percent than

elongation.

line_

when

is shorter

66-1485 _ AIRESEARCH ANUFACTURING M DIVISION
LOS Angeles, California

Page

4-204

I I I I i I I ! I I I I I I I I I I
the electrical eye cable splice of for the this and oxygen to hose secure and to allow the marine for the hooks elongation to the under rope. no acceptable must be easily" prevent to load.

A common

is used

safety

A survey safety hook

commercial particular by

hardware The

revealed safety hook

application. the pressurized

connected accidental the

and

disconnected and/or of

gloved and must

astronaut_ withstand

must the

connection strength point

disconnection_ rope. of the tether most

load

breaking A single

the

attachment to be

at

the

upper

left

chest

to the The grip with

parachute astronaut on the

harness could

appears easily

the

feasible

attachment if he cause of

location. lost his

reach

the

rope

in this points to the with

position would

spacecraft. umbilical required of

Multiple connections

attachment and_ due

interference the multiple only

other lines angles

short main be line

length tether attained. when the of

to prevent

visor

contact the in the is now

fitting_

small

alternation change The change

bracketing was made line

CG would tether a strap more

A major was adopted. This line

coaxial

configuration

tether

instead compact

a 3/16-in.-diameter umbilical system. The

rope. tether

resulted

in a slimmer_ from natural webbing loopad

is fabricated MIL-W-5625 IO00 lb. The to

nylon is over

webbing I/2

procured and hooks

per has a breaking stitched in

Specification strength place of

D. ends

The are

in. wide tether 301.

the Type

and

according Tests were

Specification to

FED-STD-751_ the

conducted

determine

strongest test

stitching were 4-III the

pattern fabricated and loops

for

the using

tether several Samples an

hook

connection. sewing 6 were in.

A series patterns

of tensile and are

samples

possible I through of 6

shown

in Figures long between

4-I12. and had

approximately 7

14 in. also

overlap

Samples

to 9 ware

approximately

14 in.

long_

66- 1483
AIRESEARCH MANUFACTURING DIVISION LOS Angeles, California

Page

4-205

F i g u r e 4-111.

T e t h e r L i n e Test Samples I through 6

Figure 4-112.

Tether L i n e Test Samples 7 through 9

F i g u r e 4-1 13.

I n s t r o n T e n s i l e Test Mach i ne

AIRESEARCH MANUFACTURING DIVISION
Los Angeles. California

66- 1483 Page 4-206

I i
except that the on on test by an stitching Instron left side Each overlap tensile of end the of pin_ was only test 3 in. on each end. Each sample

I I I I I I I I I I' I I I I I I

was The

tested graph

the the

machine

pictured the

in Figure elongation secured

4-I13. vs to load the of the

machine the

records straps to the

tensile heads sample break webbing vs was was the not

sample.

sample

was pin

crossEach design

0.25-in.-diameter loaded of the until failure

similar

in the was

tether

hook. the of

was load and

which_ sample

in each failed Table at the

test_ in the 4-15

greater

than

webbing.

Each

center lists the

section the stitch

the pattern

not

in the load point the

stitching the the

pattern.

breaking the weak for

and of

elongation junction_ stitching on 24

break. simplest

Since

stitch (sample

pattern No. 8)

patt3rn

selected A tensile

production was conducted

pattern. tether samples The the to determine the

test at

ultimate causes a

strength definite at

elevated

temperatures. but as

increase required

in temperature strength level 4-I14. is The

decrease

in strength_ below 300OF k-IS. sewn the

maintained test data The had a a

temperatures

illustrated

in Figure

is presented test sample of 6 per

in Table ends were

identically stitching. tensile

to The test

the

umbilical were

tether pulled

and at

distance of

in. between min on an

samples machine.

rate

IO in.

Instron

Tether

Hook t Figure

138642 4-115 shows the R and E hook assembled and disassembled.

66-

1483 4-207

_I

AIRESEARCH

MANUFACTURING

DIVISION
California

Page

LOS Angeles,

I I
° _......_---'_L-"'_Z. ---_..........J .4° _'_ __ _.4 I
r- ............ -i I

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r ............
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66Page 1483 4-208

i
I

!_

I

AIRESEARCHMANUFACTURING DIVISION Los Angeles, California

I I I
1400

I I I I I I I I I I I I I I I
_____

1300

1200

I-Z w I--

IlOO

w I--

I-.J

I000

)

900

8OO

®

7OO 0 I00 2OO TEMPERATURE, OF
A-13798

500

400

Figure

4-114.

Ultimate Temperature

Tether

Strength

MS

66AIRESEARCH MANUFACTURING DIVISION Los Angeles.California

1485 4-209

Page

Figure 4-115.

Tether Hook-Assemb ed and Disassembled Views

AIRESEARCH MANUFACTURING DIVISION
Los AngeCs. California

66- I483 Page 4-2 0

I I
Tether Line and Tether tests the of the breaking nylon 4-116 view of tether after the Hook m 138642 were conducted strength strap the of using the the tether hook restraint. lb. The Figure 138642. test and tether The line breakis

I I I I I I I I I I I I I I I I
to ing shown a

Development determine load in

combination at of 1340 the hook

occurred conclusion tether

specimen 4-117 shows

Figure

test. P/N

disassembled

production

66_1 AIRESEARCH ANUFACTURING M DIVISION
Los Angeles Cahf0rnia

1483 4-2 II

Page

F i g u r e 4-116.

Tether Test Specimen A f t e r Conclusion o f T e s t

J

I

I I I I I

II
C

F i g u r e 4-117.

P r o d u c t i o n T e t h e r HookDisassembled View

I

66- 1483 Page 4-2 I 3

I I
ELECTRICAL JUMPER CABLE 800372

I I I I

Purpose The cal ity system between electrical to the jumper AMU cable allows system a transfer from the umbilical electrical electricontinu-

electrical and

with

uninterrupted

astronaut (See

chestpack. 4-I18 and jumper 4-I19) cable consists twisted wound to of six twisted pairs of

Description The shielded electrical ble cable or on the

Figures

umbilical conductors

electrical 3 one triple The not kink One case

I
I I I

conductor are

shielded spirally

cable 3 and to permit shape a

their flexi-

connectors. that will

conductors and will

return plugs

its original the the

after one is con-

flexing mounted nector;

being the

coiled. chestpack

connector and

into

chestpack; umbilical or

receives

either to the

AMU

remaining

connector

is attached

suit.

Performance The connecting cable pins was was wired as shown in Figure The 4-84. key The resistance a pull of between 150 lb. two

0. I0 ohms

(max).

withstood

I I
I

Deve Iopme n t Teflon-insulated ET_ was obtain changed initially the greatest used wire in accordance with Specification weight MIL-W-I6878_ and wire E. size has and been Type to

in order of

to maintain

minimum The

degree

flexibility. ET3

electrical Type

from the

MIL-W-168780_ two types is

Type

to MIL-W-16878D_

The

difference

I
I

between

I
1 I
66_____ AIRESEARCH ANUFACTURING M DIVISION
Los Angeles. California

1483 4-214

Page

J

F i g u r e 4-1 1 . 8

Electrical Jumper Cable

AIRESEARCH MANUFACTURING DIVISION

1

LOS

~ n g e l e sCalifornia

66- I483 Page 4-215

I I I i I I I I I I I I' I I I I I I
66- 148.5
I_ AIRESEARCH MANUFACTURING
Los Angeles, 0 _J Z z

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DIVISION
California

Page

4-216

I I I I I I I I I I I I I I I I I I
_l
66- 1483 AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles, Page 4-217 that the the E wire ET wire has has a wall a nominal thickness to insulation of mate 0.010 with were connectors addition_ the the to the wall in. the thickness The existing terminal of 0.006 connectors and from the in. whereas were spacesuit con-

Deutsch plugs, nectors of the I. 2. 3.

Company The to latest

components

spacecraft changed to match changes in the

electrical the Microdot space in suit,

connectors Marc 53 In of to changed

subsequently in order following slot was

Deutsch configuration

were

incorporated:

Change The The the key

location

key-hole jumper allow

chestpack.

attachment was

strengthened. power to be utilized by

wiring chestpack.

spacecraft

I
MULTIPLE Purpose The spacecraft at to the the same multiple life time. connector support The permits or to connection the ELSS_ allow cabin. of or a space to both suit life either support from the to the CONNECTOR 800566

I I I I
type A check of a T configuration located in each nipple equally locked system systems ELSS

prime a

purpose

is to

a change-over

spacecraft (See

ECS with Figure

decompressed

Description The which of is the has

4-120) is a quick-disconnect two the female open ports. position locked the of on female an outer nipple

multiple one male

connector port moves and to

I I I I I ! I I I I I I

valve a

female

ports The the

whenever in place port. race. that

connecting by The six balls

inserted. around closed closed

nipple internal by

is automatically diameter the of

spaced in the in the lock

balls race

are

position position

location

This is

is located To and un-

by a shoulder two independently

the

inserted. be pulled

the

connection_

operated

tabs

must

rotated. Pe rfo rma nce External inlet pressure Pressure Ib per hr with or of drop an internal 3.9 did inlet psig. not exceed 2.0 of in. of water psia and an at an oxygen flow of of 25.6 leakage did not exceed 3.15 x I0-s Ib per hr at an

pressure

3.7

inlet

temperature

70°F. Release tab depression force did not exceed 8 lb.

66Page

1483 4-218 j__ AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles,

I

I I
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661483 4-219

I

_[

AIRESEARCH

MANUFACTURING DIVISION Los Angeles, California Page

I
Development The test similar successfully. mation.) initial prototype without on ali prior Gemini to units were subjected tests A11 V, tests to because in the a complete of prior qualification experience were detailed completed inforof

I I I I I I I I I I I I I I I I
development suits.

program units

program 3 for

(Refer

Section

Qualification

Tests

66-1483 Page 4-220
I_l AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

I

..... t

SECTION QUALIFICATION
o ii

5 PROGRAM

TEST

! J

l

i

_J

I I I I I I I I I I I I I I I I I I
INTRODUCTION This the units section contains

SECTION QUALIFICATION

5 PROGRAM

TEST

a summary

of

the

qualification subjected. included. Office

tests The

to which quantity of

chestpack tested All

assembly and the

and results

its components of by the tests

were are

tests

were

directed

the ELSS

Program

of AiResearch

Manufacturing

Company.

_1

66AIRESEARCHMANUFACTURING DIVISION
LOS Angeles, California

1485 5- I

Page

I I
GENERAL QUALIFICATION TEST PLAN defines test the plan 1963. scope of the the qualification requirement Plan was of test the AiResearch plans NASA to for the Document ELSS. of This SS-3207 general

I I I I I I I I I I I I I I I

satisfied The Program

Statement overall were

Work_dated of the to

19 June test define

Test

confined and test

the

scope

program. the

Detailed

test tests

instructions and test

procedures for specific The

prepared

applicable

parameters

items. test of at conditions the the were as of described Work_ with in Table minor II 3 General

environmental Conditions_ was

Environmental The testing

Statement Garrett at

exceptions. Manufacturing laboratories

performed

Corporation_ other

AiResearch

Division_ in the Los

Los Angeles, Angeles

California_and

Government-approved

area.

66Page

1483 5-2 I_l AIRESEARCH MANUFACTURINGDIVISION Los AngeJes. Cahfornia

I

I I I I I I I I
Io
QUALIFICATION Introduct The in Table ion tests 5-I performed are on the ELSS chestpack and its components Table and are 5-2 shown TESTS

and

discussed including

in subsequent test dates_

paragraphs. test agency_

presents document

administrative references. Test Requirements The Test were test

data_

report

requirements AiResearch necessary

for

most

of

the

tests

were

defined and

in Qualification change notices were

Procedure_ issued for as

Report for

No.

SS-3500. tests.

Revisions Separate test

certain

documents or

produced Test

specific and

test Results of

items

requiring

special

procedures

instructions.

Procedures A brief

description components were

the

test

procedures

for

each are

test general as of

performed

on

the

I I I I I I I I I I

chestpack detailed appropriate briefly I.

or

is given. varied for

The

descriptions

in nature; in are given

procedures documents the

specific 5-I.

applications The results

outlined tests

listed

in Table

the

after

procedures.

Hum id ity The • • specimens At the were start_ the exposed humidity 2-hr for was period_ was four 24-hr cycles of humidity was as 68 follows: to -0) lO0°F.

uncontrolled; humidity to was

temperature raised

During percent;

next

to 95

(+5_

temperature the next 6-hr

raised

120°F. was maintained at 95 (+5_ -0)

During percent_

period_ at

humidity 120°F.

and

temperature

66- 1483
L_______j AIRESEARCH MANUFACTURING LOS Angeles, DIVISION C_lifornia

Page

5-3

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66-1483
_1 AIRESEARCH MANUFACTURING Los
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66- 148,.3 Page 5-5

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66- 1483 Page 5-6

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AIRESEARCH

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AIRESEARCH

MANUFACTURING

DIVISION

66Page

1485 5-7

Los Angeles, California

v

I I
• Finally, percent, constitutes The record the After denced. All Small operation 2. first four chestpack prior chestpack 24-hr Figure during the next was 16-hr period, to with between humidity 68 and at 95 (+5, This -0) temperature one 24-hr decreased IO0°F. cycle. satisfied the test the the to rerun which rerun test test, setup. successfully on the electrical completed jumper the test. but the humidity required no requirement test. some detrimental of the performance arose rework.) were eviin

successfully to and humidity cycles 5-1 shows exposed were of after

test

(Problems redesign effects and

components of was

humidity observed

I I I I I I lI I I
the load.

spots

corrosion not impaired.

cable,

Pressure-Temperature The specimens profiles Phase the Phase which were (70 o , I was required 2 was is a subjected 160 o , preparatory conditions. 60-minute when period oxygen is at a pressure through 2150 of 2.5 the Btu mm Hg abs umbilical per hr heat (max) to and to -60°F) steps a pressure-temperature of to five put phases the each. into operation at test for three

mission

system

normal

supplied supplied

chestpack. C02 Phase a suit was added

A metabolic at a 0.44 lb

simulator per period The of hr.

I I I I I I I I

3 was leak

20-minute simulated. suit

under leak 3.3

Phase causes psig.

2 conditions, the regulator

except to

that operate

was the

to maintain

pressure

66-

1485 5-8
__l AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

Page

-1
PHOTOGRAPH ## 2 C H E S T PACK
I

1-

Report NO. Page No.. Date Revision

65 -47

10

June 14, 1965

AT COMPLETION OF HUMIDITY T E S T

F-2781

DYNAMICS TECHNOLOGY LABORATORlES
16304 South Main Street, Gardena, California

F i g u r e 5-1.

Chestpack a t Completion of Humidity Test

Form 120

AIRESEARCH MANUFACTURING DIVISION
Lo$ Angeles Calilornia

66- I 4 8 3 Page 5-9

I I I I
Phase the 4 was flow to a 15-minute umbilical period was under stopped in flow Phase and from 2 conditions, the the 1550 heat loads except and CO z the

supply system. load. Phase

were The C02 5 was of

changed metabolic added an

resulting

emergency Btu per hr

oxygen heat

simulator at 0.32

supplied hr. to

i
I I I I I I I I I I I I I
L_]

was of the

Ib per duration the

uncertain When

determine oxygen and

additional tank was

capadepleted,

bilities the Phase

ELSS.

emergency

2 conditions capacity and of

were_-established the evaporator-condenser of the chestpack a at

maintained was

until

the

reservoir The specimen A retest initial was

depleted. The were repaired. of the was setup.) missions. The

test

retest and

70°F and a

failed. valve

disassembled the

evaluated; time than and

regulator heat

indicated

operation less

rejection The

capabilities

evaporator-condenser refurbished_ final The tests retested, were dew

were and

required. (Figure for total pad, the

evaporator-condenser shows -60°_ the and was test 160°F

reassembled. performed but the

5-2 70°_

successfully was to high, the

outlet No

point

heat

rejection

acceptable. cable, and

deterioration connector 800326-I-I 80058Z-I-I.

restraint from

battery,

electrical tests. to chamber on

multiple System system which

resulted was

the pressure-temperature by means of similarity were

Umbilical umbilical the ELSS_of as a

qualified

Pressure-temperature was an integral of

tests

conducted was for not the test

800326-I-I

component. The

This

test

construed temperaturethat of

qualification pressure each were

requirement

8003c6-I-I. on the

criteria

test were contingent test on the

insulation

resistance The

followed tests

mission

chamber

umbilical.

requirements

these

satisfied.

66-1483
AIRESEARCH MANUFACTURING DIVISION LOS Angeles California

Page

5-10

I

--

I
1

I I
1

I
I

I

f

Figure 5-2. Pressure-Temperature Test Setup

-i

AIRESEARCH MANUFACTURING DIVISION
Los Angeles. California

66- I 4 8 3 Page 5-1 I

I I I I I I I I I I I I I I I I I I
_

3.

Temperature The specimen at was subjected atmospheric 5 +0.5 was psia. to a 9-day conditions. Each to 32°F soaks. and temperature The last test. two The days was 120°F of for first seven

days oxygen tion. hour at

were

ambient at

were a 4 for

in an IO-hr duraan days

atmosphere The specimen

temperature for The 4 hr and

cycle to

exposed between conditions

hr with seven oxygen

transition

period

cycling

was

continued

ambient

atmospheric at 5 +0.5

then An

temperature-cycled evaporator-condenser

in an

atmosphere test was The

psia

for the

two 9-day

days. test.

performance

performed initial

after chestpack

test the the

was

successful_

however_ did final

during not

the

subsequent the test required was

pressure-temperature heat load. (Figure on the

tests_ 5-3 shows

evaporator-condenser test setup.) The

reject

temperature 0.25 Ib of but due to

performed The rate

reworked

evaporator-condenser gas breakthrough because test of the

which was

lost

water. leakage

evaporator-condenser exceeded the required

performed_ water

the

limit

lost

insufficient

sponge

depth There

resulting were no

from

the signs

rework

of

the

evaporator-condenser. of a shear the restraint peel pad from the the

visible After

of deterioration test_

temperature

test.

the

temperature

and

test

proved

restraint nector_ passed 4.

pads

to

be

satisfactory. battery_

The and

electrical chamber

jumper

cable_ system

multiple

con-

umbilical the

system_

umbilical

satisfactorily

temperature

tests.

Explosive A

Decompression specimen explosive and amount was pressurized of to 6.6 6.6 psig. The within pressure 0.40 was sec was least

nonoperational reduced The for type The were

rapidly or less.

decompression of deformation tank was

psi (min) from to

resulting pressurized

decompression psig. At

determined. three sides

emergency measured

oxygen for

7500

deformation.

AIRESEARCH MANUFACTURING DIVISION Los Angeles, CaFifornla

66-1483 Page 5- I 2

F i g u r e 5-3.

Temperature C y c l e T e s t Setup Showing Chestpack i n P r e s s u r e Chamber

AIRESEARCH MANUFACTURING DIVISION
Los Angeles C a l h r n i a

66- 1483 Page 5-13

I I
Figure 5-4 the shows the setup. The Photographs film confirmed were the frames of taken dial of of a dial indicator that shown the in No

I I I I I I I I I I I I I I I I
_1

located case

on

chestpack. was

indications the film to the are

movement 5-5.

insignificant. were no visible for

Pertinent

Figure Trouble

There

indications explosive

damage

specimen.

Reports battery the

were was

issued exposed an energy

the

decompression with

test. no visible energy from damage. and the

The Following open

to explosive test was

decompression The

test_ voltage

performed. no

available change

circuit

after

recharge (A typical

showed setup

significant

initial No of the

servicing damage chamber System System or

values.

is seen the

in Figure

5-6.) decompression tests

deterioration system_ was

resulted

from

explosive cable_ of

umbilical 800326-I-I

electrical qualified

jumper by means

or multiple to

connector. chamber

Umbilical Umbilical

similarity

800582-I-I.

AIRESEARCH MANUFACTURING Los Angeles

DIVISION
Califorma

I -

1 I

I
1 1 1 I

I

R

10

I 1 I

I

i

P
I
t
r i y u r e 3-4.

txpiosive uecornpression l e s t L o c a t i o n O t u i a i l n d i c a t o r on T h i r d Side o f Chestpack Assembly 800308

I

I
I
A E E R H MANUFACTURING DVSO I SA C R III N
LM Angeks. Caltlornia

66- 1483 Page 5-15

v

1

I I I I I I I I I

b

I .

I I I I I I I

F-2855

Figure 5-5.

Explosive Decompression Sequence

I
I
AIRESEARCH MANUFACTURING DIVISION
Los Angeles California

66-I 4 8 3 Page 5-16

I I I I 1 1 I 1 I
I I I

I .
m
I I I I 1
F i g u r e 5-6. B a t t e r y 800670-1-1, S e r i a l No. 65-102 i n Explos i ve Decompress ion Test Setup

AI RESEARCH MANUFACTURING DIVISION
Los Angeles. California

66- I483 Page 5-17

I I I I I I I I I I I I I I I I I I

5.

Evaporator-Condenser Chestpack S/N 35-I03

Performance satisfactorily mission)_ passed after the evaporator-condenser acceleration test and

performance the shock

tests test.

(simulated

both

the

Chestpack for to the the the required water

S/N

124-I02 of 90

was

unable

to meet during the

the

heat

rejection

performance test_ test due

time

minutes previous

pressure-temperature test. A if was component as the rerun

lost

during

the

temperature

verified the

evaporator-condenser 0.5 Ib of water. was

would The

perform

satisfactorily_

it contained

required the cavity

evaporator-condenser as a separate parameters test) 24 and at was to 36 placed 24-hr test

reworked as

to correct in

size_ A

and

retested

described temperature

SS-3863. mission condenser The of

simulated the

mission

(same

ambient on the

pressure-temperature 124-I02 was loss to within refilled

performed hr after

evaporatortest. for

of

chestpack

the acceptance position The after test the

evaporator-condenser days; was The the water

in a vertical intervals. immediately test was

three

was

measured

specimen period. simulated after the

subjected water loss test

an acceleration to the

3-day A 12 hr a

due of

acceleration

determined. within

mission

the

evaporator-condenser Evaporator-condenser

was

performed S/N

acceleration of chestpack

test. S/N

167880-2, simulated

124-I04,

component ments of

124-I02, testing

failed of this

to meet unit was

mission

require-

SS-3500.

Further

discontinued.

Substitute requirements.

evaporator-condenser The results met of the tests an

S/N

75-I16 test for

was

used

to comply

with

testing the

acceptance

were

satisfactory_and mission. The

evaporator-condenser standby mission and test

requirements were

a simulated

3-day

acceleration after before

completed

satisfactorily. 3 min. above over 55°F.

In the the

simulated

acceleration, the outlet

the unit temperature

performed increased

140-minute

requirement

66I_i AIRESEARCH MANUFACTURING
LOS Angeles,

1483 5- 18

DIVISION
California

Page

Y

I I I I I I I I I I I I I I I I I I
66I_ AIRESEARCH MANUFACTURING
Los Angeles,

Interim

Report

66-0887 P/N

presented 167880 and

the

results

of

tests

conducted for for

on the

12 other configuratests

evaporator-condensers tion was to be used the in the

contained

recommendations The need

GT-12

extravehicular evidenced the when design coupled

mission. in Astronaut loads with

these GT-9

because

metabolic mission

loads

Gene

Cernan's for the

extravehicular These tax the load higher the

exceeded rates_

constructed over 2 hours

ELSS. lengths_ determine time-

metabolic of the

in mission to

capacity

evaporator-condenser. characteristics above. of the Based on of the

Tests

were

conducted

operating conditions the

limits

and

evaporator-condenser conclusions the exchanger. were

under reached

outlined extension

tests_ of

regarding 6. Burst The examined low at a

capabilities

specimen during

was

subjected

to The

several proof period

burst

pressure of 7.8 then

tests psig was

and

was

visually to the

disassembly. circuit) per at min

pressure of

applied was

pressure rate was of

(suit 2 psi

for (max)

a

IO min_

pressure The period until

increased pressure The specified a proof at

until

rupture of 240

occurred. psig min for a

medium of well

system pressure minimum pressure a rate

tested

a proof at a

pressure rate The of 50

IO min. above at

was

increased

psi

per

(max) was

rupture of of

pressure. psig per the for min

emergency of

oxygen IO min_ rupture

tank then

pressurized was

12_400 psi of

a period (max)

pressure

increased

IO00 results

until were

occurred. for above show all the systems 15.6 tested. psig parts psig and required_ that then was was

The The low

burst

test

satisfactory psig_ through was well 5-I0

pressure oxygen

system

ruptured

at 43.3 5-7 system of 480

in the were

outlet The

hose.

Figures

various to 240 no

tested.

medium

pressure value was

pressurized At 960

increased evidenced;

above

the

required the

psig.

psig_

rupture system

therefore_

test

discontinued.

The

high

pressure

1483 5- 19

DIVISION
California

Page

+ + I D E N T I F I C A T I O N AND W I T N E S S STAMPS AS APPEAR ON BACKSIDE O F PHOTOGRAPH

I
1

F-2844

I
1

F i g u r e 5-7.

Emergency Oxygen Tank w i t h F i l l and S h u t o f f V a l v e Assembly B u r s t T e s t Setup

AIRESEARCH MANUFACTURING DIVISION
Lo5 Angeles California

66- 1483
Page 5-20

I

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4 + I D E N T I F I C A T I O N AND WITNESS STAMPS AS APPEAR ON B A C K S I D E O F PHOTOGRAPH
F-2848

I I
I

Figure 5-8.

Pressure Regulator Burst Test Setup

AI RESEARCH MANUFACTURING DIVISION
LOS

~ n g d eCahfornia ~.

66-I 4 8 3 Page 5-21

Figure 5-9.

S u i t C i r c u i t System Burst Test Results (Closeup)

AIRESEARCH MANUFACTURING DIVISION
Lon Angelen California

66- I483
Page 5-22

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1 .

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1 1 1

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1

F i g u r e 5-10.

Burst Top : Lower Lower

T e s t Results Oxygen Tank w i t h F i l l and Shutoff Valve L e f t : Oxygen Pressure Gauge Right: Pressure Regulator

I
AIRESEARCH MANUFACTURING DIVISION
Los Angeles. California

66- I483
Page 5-23

I I I I I I I I
I I I

tested ruptured Regulator

independently at 17_800

in three psig_ S/N which 8_

parts. exceeded ruptured Tank psig

The

Pressure 16_600

Gauge psig

800300-I_ requirement. the

S/N

CA5648_ Pressure

the at

800284-I-I_ Emergency pressure burst of the

24_400

psig_ S/N

exceeding 45-I03_ The

16_600 after was

psig a

requirement. hydrostatic of as previous a result The a rate of of

Oxygen 18_800 on

800310-3-I_ had been tanks.

ruptured rupture reports

of

applied. No

typical initiated

tests burst

development

trouble

were

program. at A a pressure of the at of 58.8 3&.77 burst the been psig; was The pressure obtained multiple of was increased the at buss

battery 2 psi

ruptured per min. 24 7.8

voltage after and

volts test. burst

across

bars

the

battery at to psig) at

hours psig

connector psig. six The 330 There times

remained was no

intact damage (IO0

also

pressure

15.6

the

unit

after

it had

subjected

to pressures psig).

greater system are 7.

than

the

nominal which

burst was

pressure above

(15.6 the

umbilical Tests

ruptured

I I20 psig 5-II.

well

required

psig.

shown

in Figure

Elect romaqnet The test

ic Interference electrical No. ELSS_ SS-3500_ submitted July of 29_ system Rev. 2_ was subjected by on test test to the EMI EMI test Test and specified Plan and

specimen Report

in AiResearch Deviations for

amended

Proposed June plan 3_ was

the

to NASA/MCS/CSD 1965. The EMI The

1965_

approved with

I
I

by the

NASA

TWX

BG-63-1284_ IA requirements

in accordance electrical the

Class

MIL-I-26600. electrical

specimen cable_ and to and EMI

system

includes system comply EMI

the

chestpack The

assembly_ test

jumper

umbilical

I I I I I

assembly. with

instrumentation The chestpack specimen all EMI was

techniques subjected to_ and

measurements radiated the Report with

MIL-I-26600. with Test (A the

broadband

measurements

test of setup

bonded tests

isolated

from_

groundplane. No. SS-3797.

results

were

summarized 5-12.)

in AiResearch The chestpack

typical

is shown

in Figure

I_

AIRESEARCH ANUFACTURING M DIVISION
LOs Angeles, California

66Page

1483 5- 24

Figure 5-11.

800326-1-1,

Burst Test S e t u p s f o r Umbilical System Assembly Serial NO. 45-106

F-2817

AIRESEARCH MANUFACTURING DIVISION
Los Angeles. Calilornla

66- I 4 8 3 Page 5-25

I
1 1 1

F i g u r e 5-12.

Test Setup f o r Broadband Radiated EM1 Test w i t h Chestpack Assembly Bonded t o Groudplane (Chestpack) o n l y ) , Frequency Range 0.15 t o 25 rnc

AIRESEARCH MANUFACTURING DIVISION
Los Angeles. California

66- I483
Page 5-26

I I I I I I I I I I I I I I I I I I
electrical and jumper cable was subjected to broadband Conducted chestpack and and radiated_ radiated broadband conducted_ susceptibility were the EMI measurements. performed on with the susceptibility jumper umbilical EMI cable. system A

measurements specimen was The of

electrical cable and

chestpack

electrical and that

jumper broadband interference on any to

subjected recorded level not

to broadband EMI graphs

radiated indicated of

conducted did test. further not

measurements. the intermeasureEMI test

exceed

ference ments

requirements

MIL-I-26600 were

Current analysis

probe and

within and

specification were found was an to

subjected

measurements Battery the nent EMI of The and test. the

be

completely as the power the

satisfactory. supply battery. performance. was subjected up to 920 this to and the at radiated 5000 Each before any imposed and after for Chestpack The battery_ 800308 as during a compo-

800670-I-I This was

used added

test

for

chestpack_

displayed system

satisfactory EMI at specimen

chamber

umbilical

conducted

susceptibility There was no

tests change and of

frequencies

megacycles. signal the 8. EMI was

signals other that

throughout transmitted these

test.

evaluated There

with was

without

signals had

test.

no

indication

signals

cross-coupling.

Random

Vibration Document VTI the No. 132-EDJ was prepared test (and as for the use by an outside test). vibration of the test

AiResearch facility This test

in conducting further

random

vibration the

acceleration to The the

document as

amplified

requirements No.

applicable Rev. 2.

specified test

in AiResearch indicated the

Report chestpack except

SS-3500_ capable hydrogen the

results the

performance of and the its random

was the shows

of withstanding peroxide The the

forces meter

vibration light. the

test_

for 5-13 the

quantity

background corrected

(Figure with

setup.) and

revibration background light.

program

trouble

quantity

meter

AIRESEARCH ANUFACTURING M DIVISION
Los Angeles, California

Page 5-27 66- 1483

I m

F-2075

F i g u r e 5-13.

Chestpack Random V i b r a t i o n Test

I I I

AIRESEARCH MANUFACTURING DlVlSlON
LOS

66 1 4 8 3
Page 5-28

-

Angeles. California

I I
see

The Figure

suit 5-14

relief for

valve setup.

test

was

performed poppet

in accordance leakage A rerun was

with noted

requirements; the was

Excessive random of the

during test

I I I I I I I I I I I I I I I I

performance performed. (rerun) was

test

following

vibration. performance leakage performance

vibration

Acceptability authorized from the the a

test did

following not exceed after

random 0.005 the first

vibration Ib per min

if the leakage leakage of

poppet the

difference test. ments; The

test the but

vibration requireaccepted. shutoff test

However_ this was

did

return than

to within allowed_

original

leakage was and

change

greater were

this

condition on the each in the the The fill

random The no The

vibration internal

tests and There

conducted leakage damage to

successfully tests the

valve. showed test. test_ showed were the

external was no

following battery

vibration random random umbilical test

leakage. performance

vibration vibration unit results

test

(battery

discharge)_ above test. the

following 24 The v dc.

indicated no damage

65.54

watt-hours random

supplied vibration shows

in the

performance test test setup.) revealed P2 was

satisfactory. electrical

(Figure

5-15 and

vibration

However_ an found insulation to have

continuity The

insulation between the

resistance Connectors

resistance split allowed Figure teflon a

failure.

cable

PI and This

insulation resistance the

revealing path split to

bare

wire.

split

in the

insulation the cable. Failure

low

the metallic which

sheathing was analyzed

surrounding

5-16

shows

insulation No. random

in Reliability

Analysis_ The performance setup.) random

AiResearch chamber tests The

Report

RC-89-MR. vibration specimen showed no 5-17 damage. shows the The test the

umbilical were

completed jumper

satisfactorily. cable and multiple

(Figure connector

electrical test

also

passed

vibration

satisfactorily.

66_1 AIRESEARCH ANUFACTURING M DIVISION
LOS Angeles, Ca[iforma

1485 5-29

Page

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I I I 1 I 1 1 I I

F-3772

Figure 5-14.

Random V i b r a t i o n T e s t Setups

AIRESEARCH MANUFACTURING DIVISION
LOS

Angeles California

66- I483 Page 5-30

I 8

F i g u r e 5-15.

Random V i b r a t i o n Test Setup w i t h Top Cover o f Test F i x t u r e Removed

AIRESEARCH MANUFACTURING DIVISION
LO^ ~ ~ g e i e California s.

66- 1483 Page 5-31

F i g u r e 5-16.

View o f S p l i t T e f l o n I n s u l a t i o n Cover Surrounding a Conductor Cable (Stranded Wire)

AIRESEARCH MANUFACTURING DlVlSlON
LOS

66- I 4 8 3

~ngeler. California

Page 5-32

F i g u r e 5-17.

C,,amber UrrUk c a l rrsserr,, j Random V i b r a t i o n Test Setups
I

F-2770

AIRESEARCH MANUFACTURING DIVISION
Las Angeles California

66- I483 Page 5-33

I I
9. Accelerat ion

I I I I I I I I
(30 that

The AiResearch

acceleration Report the loads increase to forces of damage VTI

qual No.

ification 132-EDJ. tests. Figure from a manner (See

test This

requirements report The was

were furnished were Report 333

detailed to subjected No. the

in vendor to the Rev. 2.

performed

acceleration shown was in

specimens

acceleration The was load

18 of 1.0 to

AiResearch 7.3 g in

SS-3500, The lateral There

linear g in I g.

seconds. uniform setup.l tests

rotation

decreased

zero of or

which Figure forces.

would 5-18 for The

produce test

deceleration evidence

was

no

deterioration

performance

following

acceleration The battery, exhibited IO. Shock

were satisfactory. jumper cable, multiple connector, System, the and suit chamber relief valve system

electrical

evaporator-condenser, no damage or

umbilical from

umbilical

nonoperation

acceleration

test.

The g)

test two

specimens shocks No.

were

subjected

to

two Curve

shocks B (40

in accordance g) of Figure

with 19 of

Curve

A

and

in accordance SS-3500, duration shock of Rev.

with 2.

I I' I I I I I I

AiResearch of II +4

Report

The

shock as

profile sensed with

is a half-sine by the the

wave

milliseconds One the

in the direction each curve was

spacecraft rotated another longitudinal The and or chest-

during 22 was axis pack

landing. off

applied

specimen and

degrees applied in the

spacecraft specimen

longitudinal rotated The test 22

axis degrees

in one off was

direction

with other

the

the

spacecraft

direction. was 5-19 for

specimen the

nonoperational. was installed structural A

evaporator-condenser (See damage Figure was noted

filled test the

and

battery No

fully mech-

charged. anical

setup.) 40

external shock

after

30 g and

g

tests.

dimensional

66I_1 AIRESEARCH MANUFACTURING Los Angeles, DIVISION California

148.3 5-34

Page

1 8

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8
1 1 1
F-2973

F i g u r e 5-18.

Chestpack A c c e l e r a t i o n Test

I I 8

AIRESEARCH MANUFACTURING DIVISION
Los Angeles. Calilorn8a

66-I483 Page 5-35

F -2 806

Figure 5-19.

Chestpack Mounted t o Shock Simulator, 30 G Test

AIRESEARCH MANUFACTURING DIVISION
Los Angcks. Caltlornia

66-I483
Page 5-36

I
RD

I I I I I I I I
I

inspection shock 40 test.

was

performed original

on

the

case

to compare very

with

data with

after data

the after

40

g

The

data

compared

closely

the

g test.

The purposes. as

original The

battery

800292

was

included

in the

chestpack was

only

for to

weight test

Battery No

800670 to

(latest the

configuration) was noted and

subjected shock

the

a component.

damage was

battery to a the was

in the

test.

The The 24 vdc

post-shock specimen was 65.098

specimen

subjected completed Recharge volts

discharge test as the

recharge

cycle. above

satisfactorily watt-hours. of 35.32

energy as

supplied

satisfactory volts min

indicated The chamber

by an

open

circuit jumper system II.

voltage cable_

(35.0

required). and

electrical umbilical

multiple

connectors,

umbilical after the

system_ test.

performed

satisfactorily Tests test was

Shock

Additional A salt at A

spray sea

performed

on

the

suit

relief

valve. flow to

The

valve

was

operated flows.

level spray for the

ambient solution

conditions was of injected

under into

cyclic the

simulate flow

various of to

salt inlet during

nitrogen

upstream 3.5

I I I I I I I I

the 3.9 test

valve psig

a period salt

I0 hr. test.

The Figure

valve 5-20

was shows

regulated the test

within setup.

spray

The

results The

were

satisfactory. discharge rates during are battery 9 watts through was tests for a were the similar to expected 70 watts the

battery mission next is 24 to 24

maximum for the

requirements_ min_ and The then test

which

first

72 min_ until

discharge specimen

SO-ohm

resistor

voltage discharged the

v dc.

returned

to ambient test

conditions_ was performed in Report on

IO v dc_ Also the

then

recharged. was and

A gas

evolution to life

battery.

battery

subjected

tests

conducted

accordance

with

the

charging

discharging

procedures

in AiResearch

66- 1483
_ AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

Page

5-37

r
1

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R
1

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F i g u r e 5-20.

F-3773

Salt Spray Test Setup for Suit Relief Valve

I
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AIRESEARCH MANUFACTURING DIVISION
Lor Angeles California

66-I483 Page 5-38

I I
SS-3769. In addition_ test_ cc. cycle and 28 the The to volume gas 24 was v dc_ pressure of 90 gas relief after valve and leakage of tests battery were performed. was dis-

I I I I I I I I I I I I I I I I

In one IO std charge oxygen

the 96th and

minute

discharge After percent

percent total

oxygen

IO percent was of the 40 std

hydrogen. cc of test 72

the

gas evolved All

percent results output relief

hydrogen for above valve the 24

content.

life cycles

requirements the

were

satisfied. 38.8 the the test. current evolved The at per

All

discharge-recharge vdc discharge tests was

exceeded leakage After

required for

watt-hour pressure retest The

voltage. were

The

values

and

leakage battery

excessive.

cleaning_ short-circuit period of gas the

was

successful. fuse

The

subjected second

to a direct during The which amount

internal was

functioned

after

0.83 on

flow during

approximately period was was and

74 amperes not

this

test.

this

measurable. to a performance and tests flow were from flow. was was found test (flow of 5 vs AP) to 35 Ib

multiple

connector 18.4_ 8.2_

subjected 3.7 psia

approximately hr of nitrogen. map. net

pressure_ these

rates

The The

data adapter

obtained AP

from

plotted the Due to gross to

to create values the O-ring

a performance to obtain problems leakage IO0-cycle problem. improper replaced_ verify the

values were

were

deducted against unit and a

/_P values the

which test

plotted The

in the during

setup_ the

was (flow

rerun. vs AP) the

have to a test due were

performance to verify

test

subjected of a

life-test During test and the

that

leakage O-ring

was

result

setup to an

IO0 cycles_ The was test

another unit

became the

inoperative test adapter were

adapter. the test

O-ring

and

continued. did the

Additional either extreme

cycles O-ring.

performed multiple test.

to

that

normal

operation to

not affect

The

connector

was

subjected

additional

temperatures

66- 148,3
_ AIRESEARCH MANUFACTURING DIVISION LOS Angeles, California

Page

5-39

I
The operational forces before exposure_ during the high and the low temperaindicated insignificant tolerance. variation (The unit in

I I I I I I I I I I i I

ture tests_ and at laboratory conditions values.

The leakage through the specimen was within

is shown under test in Figure 5-21.) The umbilical assembly was subjected to insulation tric strength tests with the sameresults as outlined test were performed. resistance and dielecunder vibration. The burst test was IO min. rupture Then_

a burst test and a tether pull performed by internally

pressurizing

the specimen to 220 psig for

The pressure was then increased at a rate of 50 psi per min_ until occurred.

Rupture occurred at I I20 psig_ which is well above the minimum The tether pull test was performed by applying a in the system assembly] of
was increased ruptured (Figure at at a a rate force shows 600 of of -+20 lb

allowable of 330 psig. tensile
for

force to the tether (while still
30 sec. Then_ occurred. force the force The is

approximately rain until

IO0 -+50 I050 lb.

Ib per The

rupture

tether IO00 lb.

allowable

minimum

rupture

5-22

the

test

setup.) The and chamber test. to 4.5 during umbilical The in. assembly was was subjected to a a to a low temperature test of is the to be by leakage it

flexure a 2.5

specimen diameter

subjected at

flexure

bending

around was min. around minute.

rod while

temperature rate unwrap found

-60OF. I I std

Leakage cc per

determined The the

this

operation; moment lb.

maximum

allowable and was

maximum form

bending was 21 in.

required The leakage

to wrap rate

umbilical 5 std cc per

I

The loading ambient until

chamber tests.

umbilical This test The

assembly was

was

subjected on samples applied

to of at

low

temperature at of -60OF 1200

impact and pounds

I

performed load

tether a rate

temperature. rupture occurred.

impact

was

I I

66Page

1485 5-40 _ AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles,

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t

I I I I

!

Extreme Temp Leakage and O p e r a t i o n T e s t Setup ( M u l t i p l e Connector i n Temp Chamber and Pneumatic Setup. )

Extreme Temp Leakage and O p e r a t i o n Test Setup ( E x t e r n a l View o f Temp Chamber W i t h Pneumatic Setup. )

A

.c

L X

*

-l a

-#

. --.
7-

-

--9

-

Extreme Temp Leakage and O p e r a t i o n ( PushiPu 1 1 Sca le, Test Setup. Torque Wrench and P l u g f o r T e s t i n g M u l t i p l e Connector Performance).

F-2777

F i g u r e 5-21.

M u l t i p l e Connector T e s t s

AIRESEARCH MANUFACTURING DIVISION
Lor Angeles California

66- I 4 8 3
Page 5-41

I
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I 8
1 I
Figure 5-22.
F-2816

Tether Pull Test Setup for Umbilical System Assembly 800326-1-1, Serial No. 45-106

AIRESEARCH MANUFACTURING DIVISION
LOS

Angeles. California

66-I483 Page 5-42

I

I
A sample loads and was and stressed then at a slow until at room rate to determine occurred. The elongation Samples insulation and at were 375and

I I I
I

600-1b tested test ature

stressed tested

rupture

impact

elongation

temperature. explosive met

resistance low temper-

was

performed The

after

the

shock_ were loading and 1290

decompression, in all all

tests. Low

requirements impact IIO0 whether at 375 and tether

satisfactorily indicated the

cases. occurred at

temperature load_ slow between rate and

tests

ruptures was -60OF

the or

same at a

Ib_ whether

load was

applied or

abruptly The

I I I I ! 1' I I I

the and on

sample 600

temperature Ib were within

+70°F. on a

elongation sample cluded and to at

requirements low temperature the of

required temperature. for the

limits

samples

at ambient was

It was purpose

conintended

3 therefore, the extent and

material

satisfactory

the

loading valve

anticipated. was tested after medium the for the internal and external test. after leakage. Nitrogen the first

The The was 150 tests test_ after leakage During of the

fill

shutoff was

pressure authorized pressure on the the

cycling as cycles valve the

conducted

random

vibration of oxygen

pressurizing

in place 500

to complete were

required However, (See but

cycles. the

Initial subsequent A leakage

leakage pressure test

successful. damaged.

during

valve was

seat

became

Figure after a was

5-23.) few

rework was the unit

within After

requirements_ rework, the the breakup after

cycles_

excessive tested. the seat

noted. preceding to become

specimen of the

successfully filter

tests_

line

allowed

irregular

cycling.

l i
I
66- 1483
_ AIRESEARCH MANUFACTURING DIVISION Los Angeles, California

Page

5-43

I 8 8 8

I I
1

8

SEAT, F I L L VALVE 138983 AFTER 100 CYCLES W/02 QUAL TEST 1389R6-1 VALVE

F I L T E R , F I L L AND CHECK VALVE AFTER 100 O2 CYCLES QUAL TEST 138986-1 VALVE

E
8.

E
1

I I
t

I 8
1

BALL, F I L L VALVE AFTER I00
O 2 CYCLES

F-5619

QUAL TEST 138986- I VALVE

F i g u r e 5-23.

F i l l and Shutoff Valve Components A f t e r Pressure Cycling 100 Cycles

m

AI RESEARCH MANUFACTURING DIVISION
LOI

Angeks. California

66-I483 Page 5-44

-]
SECTION 6 DOCUMENTATION

)

J

.... j

• •J

LJ

J

I I I I l I I I I I I I I I I I I I
INTRODUCTION The design_ Program and the Table following development_ plans_ tables testing_ test give a

SECTION

6

DOCUMENTATION

summary

of

the and

documents delivery and

pertinent of the

to ELSS.

the

qualification_ plans_ are reports Test guide given

preliminary organization and quarterly the 6-4

standards in Table

specifications_ Table the 6-2 lists

preliminary monthly 6-3

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SECTION QUALITY

7

CONTROL

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I I I I I I I I I I I I I I I I I I
INTRODUCTION At for ments the the outset of and the ELSS SECTION QUALITY 7

CONTROL

program_ of NASA

a data

Quality as

Control by

Directive NASA

was

issued require-

collection

transmittal and

required

quality

Specification I.

NPC-200-2

rel iabi]ity

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Specification

NPC-250-

This bilities system DATA

procedure for each

translated participating

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department

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A course

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data

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information history_

regarding accumulated and

results_ time

inspection and cycles_

performed_ component LOG with

rework

running

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end-item

weight.

EQUIPMENT

Consistent panied record_ trouble each

NPC-200-2 unit. record_

data The

requirements_

an

equipment of

log

book

accom-

delivered

log principally and component NASA

consisted log_ use)

configuration test check data_ list.

modification reports_

systems forms_

acceptance log book

trouble

report

(for

and

CONFIGURATION Genera l

CHANGE

CONTROL

During introduced tated the

the under return

course the of

of IRAN

the

program_ of

a

significant the contract.

configuration This change

change necessicontrol to be

was

provisions for

end-items data

upgrading. with the

In order hardware

to maintain and new data

of

previously

generated

returned

g6-1483
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generated tive items and five was as during issued. the The course of the upgrading process_ a quality control direcfor such procedure defines organizational operation dividing responsibility and the inspection configuration data. A maintenance_ flow chart was assembly prepared records_ into

retest phases.

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I I I I I I

Accountability This bility shipping phase our

- Phase provided GFP

I for the transfer and of Government for property the accountaof

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configuration log book as

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- Phase

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60- 1483 Page 7-2 I_1 AIRESEARCH ANUFACTURINGCalifornia M DIVISION Los Angeles,

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were ponent prepared_ and Under copies systems the IRAN data of all file_ upgraded and this NASA serial the and end new item data were introduced report report to was that test was issued specific history_ origiinto the comnarrative prepared. for

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McDonnell and

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implementation

I I I I I I I I I

corrective

66- 1483

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AIRESEARCH

MANUFACTURING DIVISION Los Angeles, California

Page

7-3

!

SECTION

8

J
RELIABILITY
,! )

i

i

' i
.... J

L,J

1

SECTION RELIABI

8 LITY

INTRODUCTION The with was the reliability engineering The Program through period effort on the Gemini studies was the ELSS and chestpack program until a fairly several tasks the commenced program

feasibility first Plan_ December task which of

continued of through

completed.

preparation went

comprehensive revisions dur-

Reliability from ing June this

ultimately 1954. Other and

reliability Analyses_

performed

were

Failure and by the

Modes

Effects of

Quantitative analysis_ completion_ 90 percent of

Reliability followed and all

Analysis_ successively of

beginning

reporting

trouble

definition_ corrective employed placed

initiation_ action. for upon the

implementation_ Since upwards facets how of of

assessment reliability

required was be

funding will upon

various of

trouble reporting

reporting_ was

emphasis and

narration were its

trouble

conducted

what

precisely

objectives.

First_ quality est

it

is

important It

to emphasize that

the

objectives function the voids

of

any

first to or

class the the in great-

program.

is cIear avoid should as

reliability's of fill either the

should_

degree

possible_ but

duplication serve serve to in a be far is far thus of upon

engineering that always Since with both

quality these

function_ functions_ engineer and shop

exist the

as well will

liaison more

capacity.

relia-

I I I I I I I
_

bility areas quality

ordinarily he and

conversant upon

factory and other

personnel_ personnel same

less serves test

dependent as

inspection audit of

control The

a continuous and_

quality the changes finished of can

procedures. base be of

is true

all

facilities

therefore_ and in a

reliable

information

which

engineering discrepancy reported which

decisions discovered to reliability

made

is strengthened. was automatically trouble

Thus_ and

every routinely

article the

by means in

plant-wide A.

reporting

system_

is described

in detail

Appendix

AIRESEARCH

MANUFACTURING DIVISION LOS Angeles Cahfornla

66- 1483 Page 8- I

I
FLEXIBILITY The gram design with fewer ance open which was OF PROGRAM program practiced various trouble by AiResearch people The months a on the Gemini ELSS proof

I I I I I I I I I I
IBM EDP tabulation and of trouble reports_ was first on for been system symptoms_ into analyses_ the taken assessments_ and the introduced printout 12_ was reliability reports. the involved in details

reliability very

flexible_with individual For trouble

and the

with

reliability of May and team the

effort June under

fluctuated 1965_ the of no guid189

program. four senior

example_ analysts_

during formed

than of a

into

coherent in

reliability Many

analyst_ of these

were

involved trivial was

analysis

trouble had to or

reports. be

involved their be nature

in-process determined.

discrepancies Each such were proper

investigated trouble found to

until had to

reported either fashion The

alleged or

investigated incidents to

to

ensure

that

they

corrected at

be mere

discovered in

in an that of

entirely

inspection

stations being

designed familiar was

function every

precise the

capacity. and

trouble of flights

analyst_ the as

with

facet on Cape that

design

construction preceding His DATA

chestpack_

pressed

into

service at

several Kennedy arose

occasions and Houston. field.

the AiResearch invaluable

representative problems

presence

proved

in resolving

in the

PROCESSING

SYSTEM

A actions Gemini to NASA was trol

new

system

of

required_ ELSS program

actions

I
system Con-

in November Center huge since mass NASA

1965_

transmitted The

Manned

Spacecraft a

Reliability of detail had The

December the Apollo

1965.

I I I I I
California

devised System

to handle (ECS)_ and the applied

Environmental for Apollo_

funds

employed was an

it seemed and

fitting has since

to apply been

system

to GEMINI. U.

instant at

success

to other

S. Government

programs

Garrett/AiResearch_

66Page

1483 8-2

_

AIRESEARCH ANUFACTURING M DIVISION
LOS Angeles

I

I I I I I I I i I I I I I I I I I I
AIRESEARCH MANUFACTURING DIVISION
Los Angeles, California

including unique language in using

TITAN

III_ of the

all

of

which

have

benefited line

immediately of to printout a program was

and has to

directly. an English instructed on the

A

feature

system permits A

is that even a

every

abstract the

that

stranger of

be

printout. program all

variant

type this

printout was

instituted to only the

Gemi-nj ELSS except were all Both employ ARE upon that

in mid-1966; trouble particular out_ continue

variant were number number run;but

identical and troubles appeared analyst THE

first_ reports past but

closed I_a

reports part the

suppressed had had

open

tabulated. troubles types the of were

in the in the

closed

part

only the

printout. will REPORTS depends

printout

to be

ordinarly OPEN

variant_ while

identified the

as "LIMITED

DATA--ONLY in the

TROUBLE office

LISTED_" the

record-keeping which

function

program to the

complete

history_

is always

available

analyst.

CONCLUSIONS In program ing ment_ conclusion_ benefited it can from the be stated that many facets of the Gemini coverage_ and program ELSS includmanage-

complete

reliability quality Manned

engineering control_ Spacecraft

design both

engineering_ at

test

engineering_ and NASA

Garrett/AiResearch

Center.

66Page

1485 8-_

,i

l

1
SECTION 9 AEROSPACE GROUND EQUIPMENT "i

.)

J

I

,i

I I I I I I I I I I
I
SECTION AEROSPACE GROUND 9 EQUIPMENT

INTRODUCTION Table ELSS the 9-I shows This all major Aerospace could Ground be Equipment used for required to test the with

chestpack. proper

equipment

also

component

testing_

adapters.

I I I l I I I
66I_J AIRESEARCH MANUFACTURING LOS Angeles, DIVISION California

1483 9- I

Page

I I I I I I I I
ILl Z O n_

tD O_ oO _' ILl < ,,, n>-CD --Z --,-Z

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O0

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66- 148.3 Page 9-2

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I I I I I I I I
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66- 1483
_ AIRESEARCH MANUFACTURING Angeles, California DIVISION Los

Page 9-3

>, L _ l cO t_ r" C O oI U e_ L. °I _ ! Or-

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66Page

1483
_1 AIRESEARCH

9-4

MANUFACTURING DIVISION LosAngeles, Califorma

I I I
ELECTRICAL CC

FREQUENCY METER

I I I I I

PANEL ASSE

:OPE

IITAL VOLTMETER

:TRICAL PANEL

I I

POWER SUPPLY

HEAT TRANSFER SURFACE

'
I
I I I I I
[_ AIRESEARCH BRAKE

:L ASSEMBLY

SINK

_BELL

JAR

A-27794

Figure

9-I.

Low-Pressure

Bench

66MANUFACTURING DIVISION Los Angeles, California

1485 9-5

Page

I I
GAGE PANEL ASSEMBLY POWER SUPPLY ELECTRICAL CONNECTIONS GAGE PANEL ASSEMBLY

DIGITAL

MULTIMETER

ELECTRICAL METER ASSEMBLY

:

ELECTRICAL PANEL ASSEMBLY

I I I I I I I I I I I I I I I I

J_CONTROL

PANEL

ASSEMBLY (RH)

_CONTROL

PANEL ASSEMBLY (LH)

CABINET

HIGH

PRESSURETEST CHAMBER ASSEMBLY

A-27793

Figure

9-2.

High

Pressure

Bench

66-

1483 9-6

_

AIRESEARCH

MANUFACTURING DIVISION LosAngeles, California

Page

I I I I I I I I

I I
0

/

I I I I I I I
66- 1483 Figure 9-3. ELSS PDA Pneumatic Adapter 649204

I

AIRESEARCH

MANUFACTURING DIVISION LOS Angeles, California

Page

9-7

I I I I I I I I I I I I I
Figure 9-4. ELSS PDA Electrica] Adapter 649205-X

@

I I I I
AIRESEARCH MANUFACTURING DIVISION LOS Angeles, California

66-1483 Page 9-8
I_

I

I I I I I I I I I I I I I I I I ! I
AIRESEARCH MANUFACTURING DIVISION
California /, .....

/

i "X';":

"

:.:_. , =
PNEUMATIC OUTLET OR ADAPTER

INLET INTERFACE P/N 649212-X

/</_//

PNEUMATIC OUTLET OR _" .... :-_.//""-""_'_ INLET INTERFACE ADAPTER

!/i i

',/

r

]

,j-

.,,_._..

//_I./>,.

-

,.

,.,.

..-" l.f --_. _'_

l!,/

-//

\

I II_ I I .'.. ".f] "--_--:_: i t,"_' 4' i_ BENCH CONNECTOR -:.:<i/i ( ,.' ,_J ADAPTER P/N 6492!5-X
-,_.. _,_

Figure

9-5.

Pneumatic

Outlet

or

Inlet

Interface

Adapter

66Page

1483 9-9

Los Angeles.

I I I I I
\

\

I I I I I I I I I I I
MANUFACTURING DIVISION LOS Angeles. California

Figure

9-6.

Suit

Outflow

Valve

Adapter

649213-X

66- 1483 Page 9-10

_

AIRESEARCH

I.

3

....t

SECTION 10 MATERIALS

i1

I I I I I I
INTRODUCTION This areas section presents nonmetallic for use the results of and on materials metals the selection for basis the of for studies. tank. Two The SECTION MATERIALS I0

arecovemd; approved list All of the of

materials were selected

oxygen the

materials from the

design Gemini are at

requirements and the Apollo respon-

NASA-AiResearch studies_ and

approved

materials and

the

I I 1 I
i I I I I I I I

programs. sibility NONMETALLIC All Included history_ No. the METAL General

materials Materials

evaluations_ Engineering

selections Department

Process

AiResearch.

SELECTIONS nonmetal in the materials tabulation status_ u_ed are and in the Gemini ELSS are listed in Table I0-I. test Report B) describes

the material applicable IO-I

designation_

application_ AiResearch in Appendix

approval MR

specification. and included

SS-2108 procedure

(referenced AiResearch FOR OXYGEN

in Table uses

to select

nonmetallic

materials.

SELECTION

TANK

The tank were • • • • • •

materials to have High

used the

for

construction

of

the

high

pressure

gaseous

oxygen

following

properties:

strength resistance to stress corrosion and cracking

Corrosion Immunity Low notch

sensitivity availability to be shaped_ methods. 66-1485 machinedj welded_ and heat treated by

Commercial Ability

conventional

I_1

AIRESEARCH

LOS Angeles, DIVISION California MANUFACTURING

Page

I0-1

I
TABLE NONMETALLIC MATERIALS IO- I USED IN THE ELSS

Part Name and Number Material Application Pack Assembly 800308 System O-Ring Assy

Material Vendor Designation

Approval and Test

Status History

Specification MIL or AiResearch

I I I I I I I I I I I I I I I I I

Silicone Elastomer AiResearch Ethylene Propylene Rubber EPR Polycarbonate Resin "LEXAN" E. I. DuPont Polyurethane

Tested Use Tested

SS-2lO8

MR-Gemini

EMS-342

138563 and 138564 Inlet and Outlet Hoses 138594, Display 138625 138595 Panels Grommet

SS-2108

MR

EMS-664

Approved to 160°F Tested Gemini Tested Gemini

MAC 6792

MIL-LP-393

SS-2108 Use SS-2108 Use SS-2108 MR

EMS-363

138638

Cushion

Silicone Elastomer Polytet rafluoroethylene "TEFLON" DuPont Silicone Adhesive Dow Corning A-400

EMS-342

S8157AG

Washer

Approved MAC-6792

MR

S-8157-AG

I17-001-9002 Adhesive Insulation S-9051 Sleeving

Approved

MAC-6792

Ethylene Propylene Rubber "EPR" Silicone Adhesive Dow Cornlng RTV-731 Nylon E. I. 101 DuPont

Tested

SS-2108

MR

EMS-364

Sealant 219-016-9002 Cable Strap

Approved

MAC-6792

Approved MAC-6792 Item Tested SS-2108 Approved MAC-6792

MR

Potting Boot M9600-3-25 Potting Various Case Compound Parts

Nylon - Various Epoxy Epoxylite

Approved Corp. No. 801 Resin Cured wlth DETA Tested Per SS-2108 MR Approved MAC-6792 MIL-R-9300 MAC-6792 RS- 129

Assembly

Epoxy-Anhydrlde Epon 828 Shell Various

Chem.

Nameplates, Adhesive Sealant 219-050-9002

EMS-729

Type

I

Silicone

Elastomer

Approved

MAC-6792

Lubricant, Assembly 473,-0359001

Methyl-Phenyl Polysiloxane Dow Cornln9

DC-510

Chemically Similar DC-200 is approved MAC-6792, Extensive Gemini Use

L-9

66-1485 Page 10-2

_

AIRESEARCH ANUFACTURINGCalifornia M DIVISION LOS Angeles,

I ! ! I I I I I I I I I I I I I I I
l_ AIRESEARCHMANUFACTURING DIVISION
Los Angeles, Cahfornia

TABLE

I0-I

(Continued)

Part Name and Number Material Application Valve Group, Valve Life Assy Support

Vendor

Material Designation

Approval and Test

Status History

Specification MIL-or AiResearch

800282-3 Epoxy Adhesive Prod. A-2 Tested Extensive Tested Extensive Tested Extensive Approved SS-2108 Gemini SS-2108 Gemini SS-2108 Gemini MAC-6792 MR Use MIL-S-22473 MR Use MR Use EMS-345 EMS-345 Approved MAC-6792 RS-13

800283, Adhesive Diaphragm 138489 Diaphragm 138489

Armstrong Silicone G.E.

Elastomer

SE-550 Elastomer Mfg. Impregnated - Com'l American Grade-A

Silicone AiResearch Sleeve Silicone Fiberglass Locktite, Sealants and

Insulation S 9046-16 Thread

Locking

Grade-H Approved MAC-6792 as Teflon

138504 Stop

Diaphragm

Fluoroloy, Inorganic Fluorocarbon Corp. Filled Teflon FI uoro E. Elastomer Vi ton A

Packing (O-Ring) $8057 BF Fluid Heater, 800296-I-I

Tested

SS-2108 Gemini

MR Use

EMS-338

I. DuPont,

Extensive

Wire 58935JgSW Electrical Insulation

Polytetrafluoroethylene Teflon, E. I. DuPont Fluoroi nated lane I. DuPont

Approved

MAC-6792

Insulation $9051-2

Sleeving

Approved

MAC-6792

ethylene propy Teflon FEP E. Epoxy Epoxylite Corp.

Potting Compound Seals Electrical Connectors

Approved 801

MAC-6792

RS-129

66Page

1483 10-3

I I
TABLE IO-I (Continued)

I
Status History Specification MIL or AiRes rch Test

Part

Name

and

Number Vendor

Material Designation

Approval and Approved MAC-6792

Material Lubricant Assembly Aid NAS 1081C,

Application 473-042-9002 and Anti Gall

Grease, Oxygen Compatible Drilube Corp.

Screw Insert

Thread

Locking

Nylon I. Eo

DuPont

Approved MAC-6792

Gage, Gage

Quantity, 800386 H202,

H2O 2 Hermetic AMU Weston Epoxy Armstrong Epoxy Epoxylite Prod. A-2 Approved Corp. No. 801 Approved DuPont MAC-6792 MAC-6792 RS-129 Sealed Instruments Tested SS-2108 Approved as Assembly MR MAC-6792

Indicates Adhesive Bonds

I17-003-9002 Ring

Support

Potting Compound Pots Lead Wires Cable S8929FOgW Electrical

Insulation Conductor Valve Check

Polytetrafluoroethylene E. I. Teflon

850040-I-I Chlorosulfonatedpolyethylene Hypalon, AiResearch Silicone Elastomer AiResearch Tested Extensive SS-2108 Gemini MR Use EMS-352

850201-I Flapper

Valve

Seal Molded

S8520-7B Groove Seal

Used

on

95%

Gemini Tested

EMS-342

Components SS-2108 Approved

NAS Self Valve

I189C0GP3 Locking 850205 Flapper Exchanger 67880-2-2 Insert

Nylon E. I. DuPont Ethylene Propylene EPR AIResearch

MAC-6792

Tested

SS-2108

MR

EMS-364

Molded Heat

Adhesive Furane Plastics 167882-55 Wick

Epoxy Epibond Fine

- Anhydride 123W/931 Cellulose I. DuPont

Tested Extensive Tested

SS-2108 Gemini SS-2108

MR Use MR 02

Pore E.

Sponge,

E
EMS-338

at 160°F 100% 1007 R.H.

Packing 58057

BU

Fluoro Elastomer E. I. DuPont Viton

A.

Tested SS-2108 MR Extensive Gemini Use

I
66-1483 Page 10-4 _'_,_R_TT
_1

AIRESEARCHMANUFACTURINGDIVISION
Los Angeles Cahfornla

I

I I I
Part Name and Number Vendor Pressure

TABLE

I0-1

(Continued)

I I I I I I I I I
I

Material Valve,

Application Low

Material Designation

Approval and Test

Status History

Specification MIL or AiResearch

Relief,

800278-I-I

Adhesive I17-004-9002 Bonds Sleeve Molded On Seat

Epoxy Armstrong Silicone Mod. Prod. A-2

Approved

MAC-6792

Elastomer

Tested Gemini Tested Used on

SS-2108 Use SS-2108

MR

EMS-348

138513 9026 Seal E

SE-525-G.E. Elastomer

Packing O-Ring Lubricant Assembly

Silicone Aire

MR Parts

EMS-_"i2

95/, Gemini SS-2!08 .... MR

473-O51-9001 Aid

Methyl Phenyl siloxane Dow Corning

Po!yDC-510

Tes_d*_ Used on

L-"_ Parts

_rv

;_!

Gemini

Sealant Thread Compound Nut 9005

219-001 Locking

.... -_uu i

Locktite American

A and D Sealants

_pproveu

,,AC-6/_=

_1

L--

_oi,nv

Insert Locking

525-573Insert Connector and

Nylon DuPont (SCD)

Approved IOl

MAC-6792

Multiple O-Ring Dynamic Detent -

"Y" Static Seals

Silicone/TFE 6071 Acetal Delerin (GE.

Modified LS-53+TFE)

Tested

SS-2108

MR

Resin G.E,

Approved

MAC-6792

Seal/Guide Anti-Friction Adhesive Bonds, Seat and Seat

Tetrafluoroethylene Teflon E. I. Epoxy

DuPont

Approved Used on

MAC-6792 Suit

I I I I ,I

Body

Pittsburgh M-777

Plate

Present Connector

Gemini

Umbilical

Assembly

and

Electrical Silicone W/Dacron R. E.

Cable Elastomer Wrap and Co. MAC-6792 MI L-C-16878 Tested SS-2108 MIL-H-22489

Hose Assy Oxygen Line

Darling

Electrical Insulation

Conductor

Polytet ethylene, Hi-Temp

raf luoroTeflon Wire Co.

66-1483 [_ AIRESEARCHMANUFACTURINGDIVISION
LOS Angeles. California

Page

10-5

I
TABLE I0-1 (Continued) Part Name and Number Vendor Polyimid "Nomex" Material Designation Yarn E. I. 66 Tested DuPont MAC-6792 As Nylon SS-2108 MR MI L-W-5625D Approval and Test Status History MR Specification MIL or AiResearch

I I I I I I

Material Overbraid (800326-4-I Tether Line

Application

Per

SS-2108

&

-5-I)

Nylon Type Chemstrand

Potting Compound Pot Electric Connectors Thread Tether Sewing

Polyurethane Products Research 1527 Nylon E. I. DuPont

Tested

SS-2108

MR

MI L-T-7807

Thermal

Insulation

(800326-5-I)

Aluminized Mylar Dacron Scrim

Tested

SS-2108

MR

I I I I I I I I I
66- 1483 Page I 0-6

l_I

AIRESEARCHMANUFACTURING DIVISION LOS AnEeles, California

I

I I I I I I I I I I I I I I I I I I
I_[ AIRESEARCH MANUFACTURING DIVISION
Los Angeles. California

Subsequent Candidate I.

paragraphs Materials Alloys alloys is not be

discuss

the

materials

considered

for

this

application.

Titanium Titanium

were

considered_ with

but high

were

almost

immediately Barrier approach

eliminated. coatings in the or

Bare a

titanium would the

compatible for

pressure tank. of

oxygen. Neither

bladder of Heat There

required the

a titanium degree

present

state 2.

art

offered Steels

required

safety

and

reliability.

Treatable are ]evels_

several e.g._ poor stress

low alloy 4335

steels

which D6AC_

could 4340_ low the

be 300

heat-treated M_ etc. The

to

high

strength common

modified_

disadvantages and have the

to all

are to

corrosion corrosion. are

reslstance_ Although

temperature heat

brittleness_ steels of

susceptibility several difficulty 3.

treatable

advantages_

they

considered and

unsuitabie reliable

primarily

because

in providing Stainless

adequate Steels AM

corrosion

protection.

Hardenable Only

two were

considered_ stage.

355 and

AFC

77.

AFC

77

is a

new in

alloy

now of

in the welding

development appear to

Development

problems_

particularly development work

the area would be

be formidable. in the be - 200 AM given ksi 355 area

Considerable of forming 77. AM

required_

particularly could 190

and 355

welding_ heat-treated to

before

serious strength

consideration levels_ cracking. 4. e.g._

to AFC displays becomes

to high corrosion subzero

susceptibility quite

stress at

Further_ Steels

notch-sensitive

temperatures.

Ma ragi nq These

steels

offer of

a very

attractive corrosion

strength-to-weight protection_ to stress and recent

ratio.

They

have data

the show

disadvantage considerable

requiring

published Some heats

variation

in resistance

corrosion.

66Page

1485 10-7

display remarkable resistance to stress corrosion, very poor resistance to stress corrosion.

while other heats show is obvious. Ha-

I I I I I I I I

The implication

raging steels at present would require thorough screening tests before release to production. 5.
Nickel Several have several Base age Alloys hardenable over as: good stress at corrosion corrosion subzero Ren_. 41, resistance cracking nickel steels, base alloys were steels_ considered. and the These hardenable alloys

advantages steels_ such

maraging

stainless • • • Some difficult Inconel Ren_ reason 718 was 62

Exceptionally Immunity Good of to

toughness alloys,

temperatures Inconel X 750_ for examplej and present heat rather

these

manufacturing 718 is and Ren_ 62,

problems, however, new serious the oxygen

particularly present allQy of no limited at

in welding serious

treating. problems. for this Inconel

manufacturing and Therefore_

a comparatively be given for

availability present.

I I I I I I

cannot selected

consideration tank.

Material The having the

Selected material following Ftu Fry Elong. (percent properties, heat in 2 in.) necessary selected for the ELSS emergency properties 190,000 1653000 12.0 to select were heats of Inconel and all 718 agreed oxygen at psi psi room tank was Inconel 718

guaranteed

minimum

temperature.

To obtain and

these

it was

to control

treatment. to the

Three above

suppliers

contacted,

to supply

Incone]

718

requirements.

I I I
DIVISION
California

66-1483 Page I0-8

I_l

AIRESEARCH

MANUFACTURING
Los Angllles,

I

,!

-.]
SECTION 11

J
FLIGHT HISTORY

....

_J

]

_

AIRESEARCH MANUFACTURING DIVISION LO_ Angeles [_ahforma

I II I I I I I I I I I I I I I I
• FLIGHT GT-8 HISTORY (Launch The a thruster first Date)_ 3-16-66 use on of the

SECTION FLIGHT

II

HISTORY

intended

ELSS

was

on

Gemini mission

VIII. was

However_

due early_

to

malfunction the

the

spacecraft_ activity was

the not

terminated

therefore, GT-9 (Launch The

extravehicular 6-3-66 first used were: the the

performed.

Date]_ was

ELSS

during

Gemini

IX.

The

primary

objectives

of

the

extravehicular • • After adapter that was high his to To To

activity evaluate evaluate tether for

astronaut dynamics

maneuvering and limitations

unit

(AMU)

(Experiment

D-12) tethers

-,f extravehicular Cernan during moved this to

the

dynamics the AMU

evaluation_ experiment. of The of this fogging 3000 Btu

Astronaut It was foggingj has per

the

prepare

preparation mission unusually of the

visor

fogged. at this (in

Because time. excess

the

extravehicular to an

terminated metabolic of

been

attributed is

load the

hr) 3 which

in excess

capabilities Total GT-IO

suit-ELSS time was 2 hr_ 9 min.

extravehicular Date) 7-18-66

(Launch The

primary To

objectives the

of

the

extravehicular of the

activities

on life

Gemini support

X were: system

evaluate

operation

extravehicular

(ELSS) To evaluate of the Hand of Held Maneuvering supply on Unit the (HHMU) spacecraft_ his neither objec-

Because tive was

depletion

the

fuel

completely prior to

achieved. the planned

Astronaut completion was 36

Collins time. min.

terminated

extravehicular

I
I

activity

Total

extravehicular

time

F_

AIRESEARCH

MANUFACTURING

DIVISION LosAo_e,esC,,f0rn,_

66-

Pagel_83 I I- I

I I
GT-II [.Launch The • • • primary To To To Date, 9-12-66) of the extravehicular of the activities life on Gemini support X1 were: objectives the the a tether attached so

I I I I I I

evaluate evaluate attach Gordon 3 he before

operation HHMU for between the exhausted

extravehicular in space. Agena.

system.

maneuvering spacecraft tether that be heat

and

Astronaut In be doing this

between the

the

spacecraft

and activity

the

Agena. had to

became the the

extravehicular The again ELSS much

terminated

HHMU could metabolic

evaluated. loads were

operated higher

satisthan anti-

factorily; cipated. Total GT-12 (Launch The • • • • • The Astronaut lar

however3

extravehicular Date_

time 11-11-66_ of

was

37

min.

primary To To To To To

objectives a tether the the

the from

extravehicular spacecraft

activity to Agena.

on

Gemini

XII

were:

I I I I

attach evaluate evaluate evaluate evaluate

ELSS use

operation. of work waist station wrench. mission was the accomplished noted without problems. extravehicuwith tethers. tasks.

adapter

antitorque

entire Aldrin

extravehicular encountered as float-out

none

of

problems or high

in previous rates

I I I I I

flightsj

such

tendencies

metabolic

resultant Total

overheating. extravehicular time was 2 hr 9 min.

66-1483 Page 11-2

_

AIRESF_ARCH MANUFACTURING DIVISION Los Angeles, California

I

i] -]
SECTION OPERATING 12 INSTRUCTIONS

]

J

oi
• J

'AJ

I I I I I I I I I I I I I I I I I I
[_

SECTION

12

OPERATING

INSTRUCTIONS

INTRODUCTION All connectors_ controls_ and indicators involved in the manual the chest pack are identified and functionally described in Table in Figure 12-1. TABLE OPERATING CONNECTORS, 12-1 CONTROLS, AND INDICATORS operation 12-I and

of

shown

Index (Figure

No.

Connector, Control, or Indicator Suit Return Connector

Function

Routes expelled, carbon dioxide and moisture laden oxygen through dualline connector from suit to chestpack suit pressure outflow valve and heat exchanger.

Suit

Supply

Connector

Provides

regulated

oxygen

supply

from chest pack ejector and recircularing vent gas for application to suit through dual-line connector. Provides chest pack with oxygen supply through an umbilical cord from astronaut maneuvering unit (AMU back pack) when astronaut desires to function independent of spacecraft oxygen source. Provides chestpack with from spacecraft through cord. oxygen supply an umbilical

AMU

0 2 CONNECTOR

4

UMBILICAL

02

CONNECTOR

5

ELECTRICAL

CONNECTOR

Electrically connects chestpack to either spacecraft and suit or AMU and suit, depending upon source of input oxygen supply (spacecraft or AMU). Lights to indicate that hydrogen peroxide supply in AMU is low. Indicates that breathing oxygen supply in AMU is low when lighted.

6

H202

LIGHT

02

PRESS

LIGHT

AIRESEARCH

MANUFACTURING DIVISION Los Angeles, Cahforma

66Page

1483 12-I

I I
TABLE Index (Figure No, 12-1 12-1. OPERATING CONNECTORS CONTROLS, AND INDICATORS (Continued) Connector, Control or Indicator EMERG 02 LIGHT Gives oxygen indication reserve Function

I
high-pressure in chest pack is being Lights 67 psig. in AMU

that

contained

I I I I I I I I I I I I I I I

emergency oxygen supply tank used to supply suit oxygen. when or RCS LIGHT external air source falls AMU) pressure below

(spacecraft

Lights to indicate malfunction reactance control system, LIGHT Indicates low. Valve Controls normal set for (MEDIUM other tions that fuel supply

lO

FUEL PRESS

in AMU

is

ll

02

FLOW

SELECTOR

amount operation.

of vent

oxygen gas This

added valve

to during can be

recirculating

supply

normal operating conditions position), excessive heat or condibe used

high oxygen consumption (HIGH position), or can

to stop chestpack ejector oxygen supply to suit (OFF position) when BYPASS/NORMAL valve is in NORMAL position. 12 BYPASS/NORMAL Valve BYPASS position provides quantities of oxygen to cooling under excessive or any other suit condition oxygen greater additional suit for rapid heat condition requiring input than is a

obtainable with 02 FLOW valve in HIGH position. position closes valve.

SELECTOR NORMAL

13

TEST/DIM/BRIGHT

Switch

Selects illumination level hand and left-hand control

of rightpanel Also for

background and warning lamps. provides mobile test capability

six warning lamps on left-hand control panel and audio warning circuits in chestpack. DIM position provides 14 vdc to lamps, and BRIGHT position provides 28 vdc to lamps. TEST position provides 28 vdc directly to

EMERG O_ and SUIT PRESS warning lamps, 28 vdc _o AMU to complete a ground path to H202, FUEL PRESS, RCS, and

66-1483 Page 12-2

i_

AIRESEARCH

MANUFACTURING DIVISION Los Angeles, California

I I I I I I I I I I I I I I I I I I
Index (Figure

TABLE No. 12-I

12-I.

OPERATING

CONNECTORS,

CONTROLS,

AND

INDICATORS Function

(Continued)

Connector, Control, or Indicator TEST/DIM/BRIGHT Switch O^ PRESS dfrectly

13

(cont)
14
02 PRESSURE Gauge

warning lamps, and 28 vdc to audio warning circuits

in chestpack. Indicates psig) of pressurization oxygen reserve level (in in

contained supply

chestpack tank.

emergency

oxygen

15

AUDIO

Reset

Switch

When

depressed,

resets

audio

warning

signal generated by chestpack whenever suit pressure falls to approximately source falls oxygen oxygen suit, 3.3 below psig, 67 external or AMU) and oxygen pressure pressure high (spacecraft psi% reserve supply an alarm

in chestpack emergency tank begins to flow to trigger to the switch circuit that generated by chest pack, or is placed in in AMU. suit pressure prespsig. 3.3

AMU is supplied TEST/DIM/BRIGHT TEST alarm position. trigger

Simultaneously_resets

16

SUIT

PRESS

Light

Gives is too sure

indication low. falls when to

Lights

when

suit

to approximately spacecraft chestpack power

17

S/C

POWER

Lights applied

is being

18

H202

QUANTITY

Gauge

Indicates bulk quantity full tank) of hydrogen propellant remaining heat

(in percent of peroxide liquid

in AMU. exchanger proper to moisture

19

EVAPORANT

CONTROL

Valve

Allows content placed placed is used system.

chestpack

automatically

maintain

of recirculating in ON position. in ON as position

vent gas when This valve is before chest pack

extravehicular

life

support

2O

BATTERY

SWITCH

Applies tronic

28 vdc control

to chest and

pack

eleccir-

monitoring

cuits when Right-hand panel

placed in ON and left-hand lamps

position. control light when

background

66-1483
AIRESEARCH MANUFACTURING DIVISION Los Angeles Califorma

Page

12-3

TABLE Index (Figure 20 (cont) No, 12-1)

12-1.

OPERATING

CONNECTORS

CONTROLS,

AND

INDICATORS

(Continued)

I I
With

Connector, Control, or Indicator switch

Function

is placed

in ON

position.

BATTERY SWITCH K1 automatically

in ON position, relay applies battery power

to chestpack if sPacecraft power is discontinued. This switch is placed in ON positio_ before chest pack is strapped 21 SHUT OFF VALVE to astronaut.

Allows high pressure oxygen reserve contained in chestpack emergency oxygen supply tank to automatically be used if external oxygen source (spacecraft or AMU) pressure falls below 67 psig. before chestpack astronaut. This valve is opened is strapped to

I I I I I I I I I I I I I I I I

Right-Hand Control Lights

and

Left-Hand Background

Provides right-hand Lamps placed pack

background and

lighting

for panels

Panel

left-hand

control

light when BATTERY SWITCH is in ON position, indicating chest is electrically activated.

66- 148.3
_1 AIRESEARCH

Page

12-4

MANUFACTURING DIVISION Los Angeles, California

I I =_ __
6 7 8 9 10

I

._

I I

o_ _*\_ ____'_ ,, _, .:.--/"//"

EJ_)

'

®
19

I I I
Figure 12-I. Chestpack Controls Operating Connectors_ and Indicators 66_ AIRESEARCH MANUFACTURING Caqforma DIVISION LOS Angeles Page

A-27769

1483 12-5

I

SECTION 13
i

PARTS LIST

)

1

• ii
• i

I I I I I I I I I I I I I I I I I I I
-7
Fig. & Index No. Units Description Part CHESTPACK No. ASSEMBLY l 2 3 4 5 6 7 AND CONTROL PANEL ASSEMBLY) per Assy

(LESS

HOUSING ASSEMBLY (SHEET I OF 3)

13-2

No

Numbe r

-l -2

$9026E022 800282-5 NAS679C3M NAS620ClOL

CHESTPACK ASSEMBLY (Less housing assembly and control pane] assembly) (35, Figure 13-1) • PACKING, PREFORMED .......................... • VALVE GROUP, LIFE SUPPORT SYSTEM ............ (ATTACHING PARTS)

.....


NUT .........................................
WASHER ...................................... SCREW ....................................... WASHER ...................................... SHIM, CLAMP ................................. GAGE, PRESSURE (ATTACHING
NUT

-3 -4 -5 -6

NAS1352C06-6 AN960C6L 138635-I 800300-I MS2i044C04 AN960C4L NAS1352C04-6 800284-I MS21044C08 AN960C8L

• •

.............................. PARTS)

eI.,,•le•oee.°o°o°°°ee*eee°oeooe,eaooeooI

WASHER ...................................... SCREW ....................................... REGULATOR, OXYGEN PRESSURE (ATTACHING PARTS) NUT ......................................... WASHER ...................................... TUBE ASSEMBLY, • • METAL ..................

-8 -9
-0

138603-I 138597-I 138604-I 800294-I
2

........................ ........

---3 --4 -

AN507C440R6 AN960C4L MS21044C04 138500-I 138609-I NAS1352C06-4 AN960C6L

• • • •

BRACKET ASSEMBLY, REGULATOR MOUNTING TUBE ASSEMBLY, METAL ........................ SENSOR ASSEMBLY, THERMAL ..................... SCREW ....................................... WASHER ...................................... NUT .........................................

5

BRACKET ASSEMBLY, NON REPAIRABLE ............ CLAMP ASSEMBLY, MULTIPLE TUBE ............... (ATTACHING PARTS) SCREW ....................................... WASHER ...................................... TUBE ASSEMBLY, METAL ........................ PACKING, PREFORMED .......................... PACKING, PREFORMED .......................... NIPPLE (11362) .............................. (ATTACHING PARTS) SCREW ....................................... WASHER, SPECIAL, 0.032 in. thick ............

l l l l 12 12 12 I l

-17 -18 -19 -20

138606 $9028E904 S9026EOll 57195 NAS1352CO8LL6 S8157N182-O32K

• •

6 6

66-1483
I_[ AIRESEARCH MANUFACTURING DIVISION Los Angeles. California

Page

13-5

8 I

D
I I

I I I

F-6657

Figure 13-2.

Chestpack Assembly (Less Housing Assembly and

Control Panel Assembly) (Sheet I o f 3 )
AIRESEARCH MANUFACTURING DIVISION
LOI ~ n g e k s Cahfornia

66- I 4 8 3 Page 13-6

I I I i
I

Fig. & Index No.

Units Desc ri pt ion Part No. | 2 3 4 5 6 7 I OF 3) per Assy

FIGURE 13-2-21 -22 -23 -24 138591-I 138564-I 2721JI.125 138969-I 138607 S9026E024 800278-6 NAS1352CO8LL6 AN960C8L -28 138966-I 800298-2 MS35233-41 -30 800318-2

13-2

(SHEET

HOUSING ASSEMBLY, NIPPLE .................... HOSE, PREFORMED OUTLET ...................... CLAMP ASSEMBLY (94581) ...................... DUCT AND HEATER ASSEMBLY, GAS ............... TUBE ASSEMBLY, METAL ........................ PACKING, PREFORMED .......................... VALVE, SUIT LOW PRESSURE RELIEF ............. (ATTACHING PARTS) SCREW ....................................... WASHER ...................................... BRACKET, RELAY MOUNTING TRANSDUCER, SUIT OXYGEN (ATTACH ING PARTS) SCREW ....................................... ...................... PRESSURE ............

-25

I I I I I I I I I I I I I
I_l

-26 -27

4 4

-29

4
..............

MODULE, CONTROL AND OSCILLATOR TEMPERATURE

MS35233-26 -31 167880-2 NAS1352C08-10 AN960C8 -32 -33 -34 138965-I 138634-I 850040-2 •

(ATTACHING PARTS) SCREW ....................................... EXCHANGER, CHEST PACK HEAT .................. (ATTACH ING PARTS) SCREW ....................................... WASHER ...................................... BRACKET, FUSE MOUNTING ...................... SHIM, BRACKET ............................... VALVE, CHEST PACK SUIT LOOP CHECK ...........

4 1
2 2 1 AR 1

AIRESEARCH

MANUFACTURING DIVISION [ os AnRe_es Cahto_nla

u
I
Fig. & Index No. Description Part CHESTPACK No. ASSEMBLY l 2 3 4 5 6 7 PANEL ASSEMBLY) Units per Assy I (LESS HOUSING ASSEMBLY AND CONTROL (SHEET 2 OF 3) • • . • • • • • • • • • .

I
l

13-2-35 -36 -37 -38 -39

NAS1352C06-8 AN960C6 $8154-139C010 138964-1 138622-I NAS1352C06-4 NAS620C6L

SCREW ....................................... WASHER ........ WASHER, in. thick WIRING HARNESS, NON REPAIRABLE BRANCHED ..... BRACKET, SENSOR CONNECTOR ................... (ATTACH I NG PARTS) SCREW ....................................... WASHER ......................................
mn_mm

;;E_iI'_÷EEZ';_iA,'G:6i6 AR :.:::.:: ..

'I 'I 2I
l 2 2

-4O

138620-I NASI352C06-4 NAS620C6L

BRACKET, HEATER CONNECTOR ................... (ATTACHING PARTS) SCREW ....................................... WASHER ...................................... TUBE ASSEMBLY, METAL ........................ PACKING PREFORMED ........................... UNION, TUBE .................................

-41 -42 -43

138605 S9028E904 138567- l

CHESTPACK

ASSEMBLY

(LESS HOUSING ASSEMBLY AND CONTROL (SHEET 3 OF 3) • •

PANEL

ASSEMBLY)

I 'l 4I
1 1 1

138618 800374-I

AN526C632R4 AN960C6L -46 -47 -48 138563- l 138663-4 No Number 138636- l 138555-2 800296-1 NAS1352CO8LL4 AN960C8L

. , • • • • • • • •

TUBE ASSEMBLY, METAL ........................ MODULE, OSCILLATOR CONTROL AND VOLTAGE ...... REGU LATO R (ATTACHING PARTS) SCREW ....................................... WASHER ...................................... HOSE, INLET ................................. TANK ASSEMBLY, HIGH PRESSURE STORAGE ........ CLAMP ASSEMBLY .............................. . . . . . PAD, CUSHIONING .......................... CLAMP ASSEMBLY, OXYGEN BOTTLE ............ HEATER, FLUID ............................ (ATTACHING PARTS) SCREW .................................... WASHER ...................................

-49

'I ,I
2

66-1483 Page 13-8

[_1

AIRESEARCH

MANUFACTURING DIVISION Los Angeles, California

2I I I I

F-6659

Figure 13-2.

Chestpack Assembly (Less Housing Assembly and Control Panel Assembly) (Sheet 2 o f 3)
66- I483

AIRESEARCH MANUFACTURING DIVISION
LOS

~ngeiesc a i h r n i a

Page 13-9

I

F-6658

Figure 13-2.

II

Chestpack Assembly (Less Housing Assembly and Control Panel Assembly) (Sheet 3 o f 3)

AIRESEARCH MANUFACTURING DIVISION
Los Angeles C a l h n l a

66- I483 Page 13-10

I I I I I I I I I I I I I I I I I i
66-1483
I_ AIRESEARCH MANUFACTURING DIVISION Los Angeles. Califc_rm,i

VENDOR

CODES

The following vendor code numbers are used in the parts list vendor parts. When a vendor has not been assigned a code number, name and address of the vendor is included in the parts list. Code 03838 ...... Vendor Name and Address

to indicate the full

Long-Lok Corp Los Angeles, California Symet rics Inc 2919 Nebraska Santa 90404 Monica, California

I1362

......

78189

......

Shakeproof of Illinois Elgin,

Div Tool

Works

Illinois Utilities Corp Railroad Ave California

94581

......

National !35 East Monrovia, 91016 Ai r-Lock Milford,

97375

......

Inc Connecticut

Page

13-II

J

!r" i

7
SECTION INSPECTION
J

14 (IRAN)

AND REPAIR AS NECESSARY

I

J

J

i

_J

t

I I I I I I I I I I I I I I I I I I
INTRODUCTION This Life section System Support was

SECTION INSPECTION AND REPAIR

14 AS NECESSARY (IRAN)

contains (ELSS)

the

final

report and

of Repair

the as

Project

Gemini

Extravehicular The

Inspection

Necessary

(IRAN).

program

conducted under

by AiResearch Contract

Manufacturing

Division

of The

Garrett

Corporation SUMMARY

NASA

NAS 9-2412.

The February as were the

ELSS 1967.

IRAN The flight as a

program primary program result

was

started was

in February to repair

1966

and

continued hardware

through

purpose

returned changes and

3 however_ which IRAN

Gemini

progressed_ this activity

design were

modifications under the

required

of

also

covered

provi s ions. The serial suit and chestpacks I05 relief that through valve_ were repaired and modified were under made valve_ to this the gas contract fill were

numbers pressure

II4.

Modifications harness

valve_ battery

wiring

3 bypass

ejectorj

the

chestpack AND the

assembly.

OPERATION At directive procedure Design

HISTORY of the IRAN program_ the quality control for department IRAN. issued This a

start

covering is shown

the

data

acquisition C.

procedure

chestpack

in Appendix

Modifications After the IRAN because phase of of the program was started_ design modifications human The factors design inputs_ modifi-

were flight

required history

a change manned follows:

in mission and unmanned

requirements_ test inputs.

inputs_and were as

cations

required

66-1483 AIRESEARCH ANUFACTURING M DIVISION
Los Angeles, California

Page

14-I

I
1. Emergency Oxygen FIll Port Check Valve

The from it a was

fill

port Nitron to

check

valve

poppet Because elastomer

was of

of

an two

elastomer fires with in one

design the of check all

compounded valve area, While

special decided

formula. the

replace

design

metal.

this readily same being

compound than time,it used.

is metal was This

approved when believed was

for exposed best

use to to

in a

high flame

pressure or a to

oxygen, hydrocarbon locking the

it

will

ignite

more At the

I
I

impurities. compound that torque. verify its

delete by

thread

was

accomplished a qualification

controlling test on the

installation change to

AiResearch

performed

new

I

integrity. 2. Addition of an Ejector Heater and Bypass Valve Modification

I
a series nitrogen during of cooled tests performed the at NASA in their ejector of altitude was the chamber to using J

During
a

liquid

enclosure, off-design

chestpack

subject potential

freezing

certain

conditions.

Because

I
I
the

hazard and to

to

an extravehicular the bypass

crewma_ outlet

NASA

elected

to of

add the

an

ejector

heater Due to

place

valve

downstream

ejector.

added the

power chestpack

required to use

to

operate

these by

heaters, the

a

relay

also during to be

was

added of

to allow the

I
I

power

supplied Since

spacecraft was

part

extravehicular

mission.

this

modification

incorporated

for

I
modi]i

use

on

GT.8 at

and. Cape

since Kennedy

time

wase×tremely and AiResearch

critical, made the

MSC rnade bypass

this

first at

ejector Los

I
fication modification Angeles..

After all

the

GT-8

flight, and directed that

it was controls

decided were this

that placed

the

program one on

could

best

be

served As a

if

I
I

modifications was

under

jurisdiction. all chestpacks_in a partial

result_
I

AiResearch to several test

to make were

modification NASA-MSC this

addition qualifi-

I

others

in process. ncorporating

performed

cation

on a chestpack

design

modification.

b6- 1483 Page 14-2
I_ I AIRESEARCH MANUFACTURING DIVISION LOS Angeles+ California

I I I

I I I I I I I I I I I I I I I I I I
3. Addition The As was to this GT-9 would to the of Evaporator-Condenser plan the called for Seals a stand-up EVA to an Because before hour of the umbilical vacuum_ not EVA. a seal flight expose be

evaporator-condenser for the to unit.

hard was

thought perform

required

enough seal

time was

available before were was

required the seals_

testing the were

determine had to be

if the started B port was

required the tests seal and

manufacturing completed. designed to the Two for Cape.

design made of

before plugs

designs steam test

the A and

and tested,

a

the The

exhaust. results one hour the

The hardware were then

built_ and

shipped the within

complete,

it was and used.

determined perform

chestpack

could

stand

exposure seal

to hard was

vacuum never

still

specification. 4. Design Because initiated. between to leak and the out. cells.

Therefore, Change of of the

hardware Battery with the

Chestpack problems

continued

battery primer

3 an

investigation to assure case_ cells

was a good bond

This

investigation and the

showed cell an was

that was

the

used the

potting This

cases

attacking contact and

causing and

electrolyte the

provided result was to

electrical short

between

between

case An

The primer test of the

circuits two

unpredictable batteries

battery were

life. to

acceptable

located_and verify Relief the

redesigned

subjected

a qualification S. Redesign The suit

new

design

integrity.

Suit valve field.

Valve a complete the redesign the as a result valve of was sub-

relief in the

underwent To test verify

malfunctions jected 6. to

redesign_

relief

a qualification

program.

Evaporator-Condenser As test time of the was

Modification accumulating on the chestpacks_ it was noticed An that the

performance program was

evaporator-condenser to determine the

was

deteriorating. and to find

investigative to restore

undertaken

reason

a method

66-1483 AIRESEARCH MANUFACTURINGDIVISION Los Angeles, California Page 14-3

I I
the units.
deterioration, followed which was were directed A to

The results showeda
and verify in excess a method this of and the of

combination

of was

effects

for

the A

performance series of tests

refurbishing

implemented. heat In adding rejection addition_ a water

I

to determine design the was

maximum

capabilities AiResearch injection modification the risk

requirements. of

to investigate prototype unit

possibility manufactured mission

mechanism. was of 7. never adding GT-12 Because output Actual

and duration

tested. did not

This

incorporated a new system

because to the

the

warrant

chestpack.

Modification there were no provisions the GT-12 for monitoring the pressure _ransducer

I I I I

it was

removed

from and

chestpacks.

Modification

Refurbishment

I I
of

Chestpack refurbishment the In design addition, were

serial at least

numbem once.

I05

through the

I14 were

all

sent

to AiResearch all or

for part

During

refurbishment foregoing

processj

modifications several also

covered

in the

paragraphs

were

incorporated. made by

external incorporated.

chestpack

modifications

previously

NASA-MSC

I I I

I

I I I I I
66Page 1483 14-4 _ AIRESEARCH ANUFACTURINGCalifornia M Los Angeles, DIVISION

I

"i

.i

7
APPENDIX
t

A ORGANIZATION, SYSTEM AND

AIRESEARCH DATA SYSTEM AIRESEARrCH

RELIABILITY SECTION REPORT

PHILOSOPHY 5: TROUBLE

REPORTING

NO. RC-56-R

i

....

I I I I I I I I
APPENDIX A ORGAN IZATION_ AND REPORTING SYSTEM RC- 56 - R

I I I I I I I I I

AIRESEARCH RELIABILITY PHILOSOPHY DATA SYSTEM SECTION 5: TROUBLE AIRESEARCH REPORT NO.

66-

148,5 A I

I

i_l

AIRESEARCH

MANUFACTURING Angeles DIVISION Los Cahtorma

Page

I I

I
I I I I I I I I I I I
RE¥ISIONS

¢ORP_ORATBOH

_i_esearch ManuFacturing Division
LOS ANGELES 45, CALIFORNIA

REPORT

NO.

.RC-Sb-R_

Rev.

I

AIRESEARCH

RELIABILITY AND

PHILOSOPHY_ DATA SYSTEM

ORGANIZATION_

RC-56-R_,

Rev.

I

,_u_u_. A ......

a.

7y

)o,_ av_.

|

Revised

By

G. F.

A. K.

Burfless Greene

(8-7-62)

NO.OF

PAGES

23

PREPARED

BY

DATE

July

21_

]962

EDITED

BY

W.

I.

McAulIffe

APPROVED

BY

W.

I.

McAuilffe

i

ADDITIONS
PAGE DATE PAGE DATE PAGE DATE

I I I I

PAGE

DATE

I I I I I I I I I I I I I I I I I I

AIRESEARCH

RELIABILITY AND

PHILOSOPHY DATA SYSTEM

ORGANIZATION_

TABLE

OF

CONTENTS

REPORT

SECTION INTRODUCTION TROUBLE AND SCOPE SYSTEMS

PAGE I I 2 4 SYSTEM 6 12 20 IBM UTRS TABULATION TABULATION FORMS REPORT 24 26 27 29

REPORTING

RELIABILITY EDUCATION UNIVERSAL MATHEMATICAL THE AIRESEARCH I-I 2: 3-I 4:

PHILOSOPHY AND TRAINING REPORTING AND

TROUBLE MODELS

METHODOLOGY ORGANIZATION TYPICAL OVERLAY UTRS FOR

RELIABILITY AND I-2:

FIGURES FIGURE FIGURES FIGURE

AND

3-2:

UTRS

TROUBLE FIELD

REPORT SERVICE

TYPICAL

AIRESEARCH MANUFACTURING
Los

DIVISION
California

An£.e]es

I I I
INTRODUCTION AND

AIRESEARCH

RELIABILITY AND

PHILOSOPHY., DATA SYSTEM

ORGANIZATION,

SCOPE

I I I I I I I I I I I I I I I

The reliability program outlined herein reflects approximately five years of AiResearch experience in reliability engineering. This experience has been obtained from a wide range of products., and has resulted in increased emphasis in the areas of system design and trouble reporting., and somewhat less emphasis upon purely predictive techniques. This allocation of emphases has resulted rather from than the desire serve only to have rel lability participate in a staff or technical service in hardware function. programs

AiResearch has at present several contracts requiring formal rel iabil ity support and/or rel iabil ity demonstration. Among these are components or subsystems for the Project Mercury Capsule Life Support System (McDonneIl)., Titan ICBM Inertial Guidance Cooling (AC Spark Plug)., Polaris FBM Spin Generator., and Vector Steering (Lockheed)_ B-70 Central Air Data System (North American)_ Dyna-Soar Re-entry GI ider Cool ing (Boeing)., and SUBROC ASW Missile Control and Auxil iary Power Supply (NOL-Goodyear). TROUBLE REPORTING SYSTEMS has recently designed a major modification of the trouble re-

AiResearch

porting system which was oriented heavily

had been used since February 1957. The earl ier system toward production_ and did yeomen service for the 4.,946

Auxiliary Power Units supplied to Douglas for the Nike-Hercules Missile. The older system made inadequate provision for coping with the early development and qualification phases of a program. The new system., called the Universal Trouble Reporting System (UTRS)., is implemented at the inception of a development program3 and is not terminated until the hardware has been obsoleted; AiResearch Field Service Engineering reports are an integral part of this system. This new system first went into effect in February 1961 in the USN SUBROC ASW Missile program., and is being placed into effect on four other programs (Polaris FBM., Nike Zeus_ Dyna-Soar., and Saint). In all new proposals by AiResearch3 this data system is being proposed for rel iabil ity programs for weapon and space systems where MIL-R-275/_2 is spelled out as applicable. The primary purpose of the system is the earl lest possible disclosure of each and every deficiency., in order that most or all of these will have been remedied by the start of qualification testing. The system reporting does not confine itself to hardware deficiencies_ but also covers such things as engineering assembly and test instructions., test equipment., test calibration and instrumentation., and final assembly operations. It overlaps the existing quality control procedures only to the extent of major subassembly and assembly_ and functional test., and is not concerned with items rejected by Inspection but only with items accepted by Inspection. The reporting system is under the cognizance of rel lability engineering., not quality control., and is intended to achieve its major contribution to rel iabil ity prior to series product ion.

RC -56-R [_ AIRESEARCH MANUFACTURING DIVISION
Lo Alf_ele,s Cahlorr, la

Page

I

I I I I I I I I I I I I I I I I I I
RELIABILITY PHILOSOPHY AiResearch_ position to as a vendor to the aircraft evaluate the modus operandi and and missile industry_ effectiveness of has been the re] ia-

in a

bil ity organizations of its many customers. AiResearch has benefited greatly from this exposure to a multipl icity of philosophies and organizations_ and has formulated its own philosophy in a conscious attempt to avoid the less desirable facets_ and incorporate the more desirable ones of its customers. Found on Page is a discussion of and specific points 9 of USAF Bulletin 510: Guides For Reliability Or_anization_ such organization. A!Research concurs with both the general raised with respect to in-l _ne authority and function_ and

has placed its primary rel iability emphasis in the existing engineering line organization (projects) where, incidentally_ the real responslbil ity for designing reliable hardware and subsystems always has resided. When this route is followed, there immediately occurs the quest'on where and how can the technical reliabil ity staff functlon best? A;Research has placed its technical rel iabil ity staff in its Prel imlnary Design Department in engineering, where the technical reliability function first was exercised in 1954 (by one man_ part-time). Since all proposal activity is centered in pre] imlnary design_ it accords the rel iabil ity technical staff greater scope to affect design at its inception.

It is frequently component designers_

difficult but it is

to make specific recommendations relatively easy to make specific

to experienced recommendations

as to the orientation of components in a subsystem. ful designers of components are, upon investigation_ to proceed to ally speaking_ improve components of require some testing

For example_ most skillquite well aware of how of design generThe selection

their own design. Faults to discover and evaluate. appllcat_on it best to are allow

of suitable ball bearings for a particular example. AiResearch reliability believes

a good illustrative the project people

and the Bearing Coordination Group to make such selections, and the very successful experience of AiResearch in high speed rotating machinery (nominal speed ratings of up to I00,000 rprn) justifies this approach. In mechanical design, the proper cate what a] ready bil ity trouble design function is being of rel iabil ity seems to be not to attempt accomplished, but to discover areas where bona fide need. Such areas in development programs, and a to duplirel ia-

function can and failure and analysis.

fill an existing reporting early

exist_ in in system

AiResearch rel iabll ity has found system and subsystem design fertile area for rel iabll ity assistance. For example, a reliable

to be a life support

system for a manned spacecraft can be defined as a system .vlth a large tolerance for component failure_ the opposite being true for an unrel iable system. This philosophy has paid off in the life support system al ready delivered to McDonnell for their Project Mercury capsule. This llfe support system has an astonishingly good resistance component is essential and is Even the method of activating example, the astronauts space of fresh function to chance type failures_ since where a system not a static device_ :t has been made redundant. such redundant elements ;s made redundant. For su_t compressor_ wh'ch assures the circulation have Should the compressor to be aborted within

air through the suit, is electrlc-motor-drlven. fail, the orbital mission would of necessity

RC-56-R
E_l
.

AIRESEARCH MANUFACTURING
Los A',gele=

DIVISION
Cahfornia

Page

2

I I I I I I I I I I I I I I I I I I
minutes. McDonnell and AiResearch placed a second compressor in the engineering space suit (and reliability) circuit_ but also not only backed up the pressure loss sensing switch required to cut in the standby compressor by a manual override toggle switch that selects between compressors. Such concepts have been developed as a logical solution to very real problems of the space age. A distinction is made between intended mission. This is an safety of flight and important dlstinction_ the abllity and_ in a to complete narrow mission concern do not one itse-

the

sense_ rel iabil ity is concerned primarily with success. In actual fact_ however_ rel iabil ity self with safety and human factors_ since most parate these AND in any clear-cut manner_ and all

the probability of at AiResearch does problem statements three impinge upon

another.

EDUCATION

TRAINING has since the early summer of 1958 conducted rel iability

AiResearch

orientation and training lectures on company premises during working hours. The emphasis of these lectures (they are a continuing series) has changed from time to time, to fit existing needs as interpreted by the rel iabil ity technical staff. The lectures in 1958 and 1959 concerned themselves with the concept .... l led of constant hazard both to electronic (chance failure) o,,u ,o non-electronic PERT {Program the reliability this subject and reliabil ity ,-Ha; ..... prediction as Th ..... phil,< to of the it

currently is how to employ further the objectives of I-hour weekly lectures on l iabil ity staff.

Evaiuation _ev.ew Technique,'.' program, and thus_ a series is being given by a member of

re-

give

From time to time_ authorities in related fields have been lectures in their fields of specialty. Thus, in 1959_ Dr.

brought in to Mario Juncosa

of the Rand Corporation presented a series of 20 lectures on a graduate levei in his field of probability theory. Members of prel iminary design_ rel iabil ity_ and qual ity control engineering attended_ with text books suppl led by the company. In 1960_ Dr. Alexander Boldyreff, Professor of Systems Engineering at the University of California in Los Angeles, presented lectures to top Division and Corporate management_ and to the senior engineering staff_ on the importance of rel lability in the design of future weapon and space systems. For the past 18 months_ Professor Boldyreff has been a senior consultant to the AiResearch Los Angeles Division in the fields of rel _abll ityj systems englneering_ and operations research. AiResearch has continued to encourage and sponsor engineers with rel lability assignments to enroll for courses at local universities ;n the areas of rel iabil ity, stochastic processes_ statistlcs_ and probabil ;ty theory. The qual ificatlons of personnel with rel iabil ity assignments are those of engineers_ plus additional training (company sponsored) in rel iabil ity_ probability theory_ stochastic processes, and statistics. All project engineers assigned to rel iability tasks have had a minimum of five years hardware (design_ development_ or testing) experience in one special ized area of product. AiResearch has never considered a grasp of mathematical theory to qual ify a man to contribute to or to determine and other rel iability detail or component

RC -56-R AIRESEARCH MANUFACTURING DIVISION
Los A_ei_s (_al,fornta

Page

5

I I I I I I I I I I I I I I I I I I
design. Therefore; AiResearch considers it to be mandatory tel iabil ity assignments be thoroughly knowledgeable in the details of his assignment. UNIVERSAL This TROUBLE section REPORTING is intended SYSTEM to describe the AiResearch Universal Trouble that basic everyone with engineering

Reporting System in sufficient detail so as to constitute a useful and instructive guide to those people who will implement it. In order to require of the casual reader the minimum of effort_ the system is described in reverse, from an explanation of the objectives of the IBM 407 print-out_ the print-out itself_ the over-lay to failure reporting forms them out. Objectives of the System read the print-out; 3113A and 3113-1A_ to and the how precise details of to assign personnel the to fill

The Universal Trouble Reporting System permits cognizant engineering management and project engineers to monitor a development program's health and progress. It generates its own documentation of trouble_ the area in which trouble is encountered, and the effort being made to rectify the trouble. Every * _rouble pnrn,,nter_d ;s r_u_rte,J _,,c; ] ..... ,,UL,_u in I o th i5 repo_ ;_q Sysi _m " m_ hod_ and this includes not only product defects but deficiencies of test _ equipment; calibration_ instrumentation; assembly techniques_ etc. While the
.......... , ......... j . , L ,It . _ _.,.i

emphasis of ing, provision by inclusion In rcadily tion of

the

system is very heavy during development and qualification has been made for coverage throughout a product's service of Field Service Engineering Reports into the system. to be able to cope with a large amount of data, and to make

testlife

order

it

available corrective of of

upon short notice; action_ individual

every report of and collective

trouble; acts of

analysis; correction_ IBM are

definiand

confirmation or summaries on the

correction_ troubles; possible

generates an and the status notice.

IBM punch card. Thus; of c_rrective actions;

tabulations obtainable

shortest

It is perfectly apparent that any properly managed program should perform those activities included in the Universal Trouble Reporting System. All the system can do is to make it difficult to conceal from view troubles which; sooner or later_ must be rectified. The reporting system is intended_ first and primarily_ as a working tool for the project engineer. Its success or failure depends primarily upon the support he gives to the system. The occurrence of an increasingly large difference between number of reports of trouble, their analysis_ and acts of correction_ is a sure sign of trouble; in and of itself. The effort required to analyze each trouble_ and to define in precise terms what must be done to correct it_ must be made sooner or later if the trouble is to be corrected. The UTRS is a very convenient medium for keeping track of such analysis and definition of corrective action. In addition_ increasingly of late_ D.O.D._ the armed services; and NASA_ are requi ring documentation of everything accomplished; and the UTRS performs this documentation automatically and in sufficient detail to satisfy the requirements of MIL-R27542 and other appl icable military specifications and bulletins on rel iabil ity.

AIRESEARCH MANUFACTURING DIVISION
[0s Angeles CaJifcrma

RC-56-R Page 4

I I
Description of the System

I

The IBM tions system through The punched of is

new

Universal card system of

Trouble which

Reporting permits encountered monitoring of

System routine during from prototype and

is_ (,and any the and

in

brief_

a sorts

fully and program.

automated tabulaThe

special) development inception early

I I I I I
I

reports intended

troubles to provide (and to

of

development hardware. analysis corrective required system orderly the primary does and duty actlon_ not

the

shipping is intended

rece;pt_ enhance the clear areas of me_eIy

production

system each

competent definition

prompt of the test_

engineering required QC) of

of

trouble including test these

reported, the

action, and do

various

(engineering_ successful provides

finally, any of

confirmation th!ngs_ of but

correction. the medium for It keep any

The the is the

systematic of the

reporting rel lability and of lye current the act ion.

troubles

and

their to a

correction. program lag and to between

engineer on the and trouble,

assigned amount between of

project of

engineer report and

informed analysis correct

time analysis

trouble

completion

indicated

If ]93-II_ the UTRS

the he in

reader will see

will two

refer

to

Figures pages

l-I of

and an

]-2

(Reports IBM in 407

158-]

through from for a

successive a complex ;-,gure

actual currently

print-o_t

operation

for

equipment __ ShO_S the 3-Z

development

,:_a_ifi_d rea,4 and the

.......... w_pf_n prinL-out_ Those but find

_.y_rn.. ..... and who

trar,.SE,_FenL show the find or Trouble the who

,_,,_lay_._.. _:_H_,._ _n._ , Report overlay read the a Forms 3i13A

FTg-res use the iar

3-i

and

31]3-IA.

system with the

routinely system,

convenient

reference_ weekly,

those

unfamil

print-outs

the are no

overlay Field

indispenslble. Service enters Reports, service, Form format. as such_ in in contained the field 4, in this be print-out. reported

There

I I
I I

When on oF

the Lhe this

weapon will

system the

troubles 7030 shown

will and

Field

Service follow

Engineering same

Figure

print-outs

Referring number are lO appears possible

to to

Figure the

l-l, suff;_es,

it

can

be

seen from

that by zero nine

an a dash

orlglnal number for for

trouble suff:x. the the original final by deck

report There

extreme

left,

followed

report of

,anglng

_-0) (-9),

unexpanded Lhat The has the IBM been

report corrective system printed_ reports report, Thus. is

trouble action

s_mptom, taken so happen phases has to of

through proved whenever be correction and to

report testing). which

successful dash zero related

confirmed _-0_ in to report the this in phase report one cards

designed and of there later cards

that_

number

additlonal

represent trouble

particular suffix of numerical

the the

are time from

stacked ,equired the right

therefore complete dates is of

pr:nted each the as

I
I I

order. is

elapsed

correction which 1961),

immediately in the

apparent column to

respective the lear

suffix, I =

appear

the

shown

digit;

A

tabulation

of

each

suffix

_ith

explanatory

comment

;s

presented

belo_

I
I
AIRESEARCH MANUFACTURINGDIVISION RC-56-R Page 5

I I
Surf ix

I
I

Generated Any Any authorized authorized

By_ dept. engineer Original Analysis_ corrective

Description report of trouble symptom. of required

-0 -I

plus definition action. of

I I I I
I I I I I I I I I I

-2

Reliability

Engineer

Report of completion one area. Report of completion one _ area. Report of completion one _ area. Report of completion one area. Report action. Report action of completion

correction

in

-3

Rel lability

Engineer

of

correction

in

-4

Reliability

Engineer

of

correction

in

-5

Reliability

Engineer

of

correction

in

-6

Reliability

Engineer

of

all

defined

-7

Any

authorized

engineer

o¢ additional required. completion action. confirmation

analysis

and

-8

Reliability

Engineer

Report of corrective Report of

of

additional

-9

Reliability

Engineer

of

correction.

Continuing the reading of the tabulation from left to right in Figure !-I for the dash zero (-0) suffix reports_ there is the date_ an abbreviation of the agency reporting the trouble symptom (it can be and sometimes is other than AiResearch)_ and the single digit indicating the level of hardware tested_ which is in accordance with the following code. Code 0 I 2 5 Hardware Detail One Part Level :*:Examples Fastener_ Any An An dlode_ of Nard_are Level ball of detail less with bearing. parts. motor. motor.

transistor_ assemblage driven driven

Subassembly Component Component

incomplete electrically electrically

[ncomplete Complete

pump, pump_

NOTE NOTF

There shown These

are

also

ten

possible merely

areas

of

required each

corrective program

action can make

as its own.

in Form 5113A. distinctions are

convenient;

AIRESEARCH MANUFACTURING DIVISION
Los Angeles California

RC-56-R Page 6

I I I I I I I I I I I I I I I I I I

Code 4 5 6 7 8

Hardware

Level

Examples Any A unit logical or assembly, and more

of

Hardware

Level as such.

Two One One

or

More

Components

replaceable end that are

Package Subsystem (Test Only) Trial) Use) are

deliverable

item. used together. system.

Two

packages

System System System

Complete

AiResearch

manufactured

(Service (Service

*

NOTE:

These

distinctions

merely

convenient;

each

program

can

make

its own.

Continuing the (-0) suffix reports_ and Serial Number.

reading of the tabulation from left to right for dash zero there is the AiResearch End Item or System Outline Number If no serial number appears_ it signifies that the hardware

is at a lower level. Following is the package and its serial number_ followed by the component and its serial number. There then appears a four digit space which_ in the IBM tabulation included in this report, is the test run number. In most programs_ fewer test runs can be expected on any one build-up, and the first two of the four digits can represent assembly or build-up number_ and the second two digits can then represent test run number for the indicated buildup number. the unit of The last entry is time (s = seconds, the elapsed time of the test m = minutes_ h = hours). run (3 digits) plus

The dash one (-I) suffix port the number_ data_ total (3 digits), the unit of time

reports shown (reading from left to right) retime accumulated on the failed or faulty component (I digit)_ component name (noun plus modifier), or subassembly number_ areas of corrective ac-

detail or subassembly name (noun plus modifier)_ detail manufacturer_ a trouble verb, and_ most important_ the tion in engineering_ testing_ and quality control. AiResearch has found it significant to categorize

I0

distinct

areas

of

corrective action. The first four are engineering's responsibility_ three are the laboratories'_ and the last three are quality control's sibility. These areas are shown both on the basic trouble report_ (Flgure 3-I) and on the IBM tabulation overlay (Figure 2).

the next responForm 3113A

Each phase (suffix -0 through -9) of a report is punched on just one IBM card. Only the -0 and -I reports use all of the space available on one card. The tabulation shown (Figures I-I and I-2) has dispensed with separate reports of each act of correction in each area of corrective action; thus_ there are no -2 through -5 reports. The newer programs at AiResearch will report these. It will be noted that there is considerable room for explanatory English text on all -2 through -9 reports.

RC-SO-R
AIRESEARCH MANUFACTURING DIVISION [o Area'he ' Ii'_Ifonla

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I I
MATHEMATICAL MODELS AND METHODOLOGY

I I I I I I

Abstract

The basic premises of reliability Reliability_ hazard_ failure rate and derived and hazard is shown to be the case of complete and probability Assumptions The
I .

analysis mean time reciprocal

and prediction are summarized. to failure (MTF) are defined or of mean time to failure for the probability expand upon distributions basic ideas.

randomness of failure. Some cumulative density functions are shown in order to

following

premises

of

reliability

analysis

are

considered

self-evident:

The procurement must be assumed use_ maintenance_ mission for the

specification and other applicable documents to have defined adequately the conditions of qualification_ the required function and with sufficient margin of safety

time in precise terms intended application.

°

The validity of any chance failure developed designs capable of being test conditions. The analysis which repeat when presupposes themselves in

analysis qualified

applies to the

only to specified

.

I I I I I I
R(t) Definitions

only random failures. Failures are considered to be correctable phase of any program.

encountered

the development

The quality control exercised for all components and the subsystem is presumed to be fully equal to or better than the levels achieved for the qualification test samples.

Reliability is defined will successfully complete conditions of maintenance_ R(t) = Q-'-

as the mathematical probability that an equipment a mission of specified duration_ under specified operation and environment. Thus_ where l_(t) = probability to time t surviving equipments = of survival

Qo Q

quantity at time

of t

=

I

-

F(t)

Q
o

I
Qo-Q

starting quantity of equipments at time t = 0

I I I
_

F(t)

:

Q
o

F(t)

=

probability time t

of

failure

to

AIRESEARCH MANUFACTURING
L _':: ,i

DIVIS!ON
, r _h ....

RC-S6-R Page 8

I I
Hazard IX) is the ratio of the time rate of change in the number of sur-

I I I I I I I I I I I I
I

vivors at time t compared to the number of survivors at time t. Nazard may be viewed as the generating force to failure, and reflects the collective severity of the conditions of use. Thus_ k =

I
Q

-dQ
dt probability distribution densiLy function, divided {completely of lifetimes_ is equal by the probability of occurrence of to the success.

Hazard, for any lifetime probability In the hazard

case of maximum entropy is constant with time.

random

Failure)_

of

Failure survivors

rate (X') is the ratio of at time t compared to the

the time quantity

rate of at time

change t = O.

in the number _.hus_

I
Q
0

-dQ
dt

the

_ailure constant

rate is not constant with time, hazard (chance failurei period_

but and

decreases _mcreases

with time throughout as it enters the

wearout in turn failure.

period. is the This

Note that X is the failure probability density function which first derivative of the probabilitg cumulative distribution of latter distribution is the distribution function _(t) of llfetime t, and _reliability) is always to time the t. compleSince

times, a cumulative probability of failure to ment of the cumulative probability of success

failure and success probabilities are complementary expressions, their first derivatives ,time rate of change) are equal but of opposite slgn The distribution function is the integral of the density Function, and F(t) = I R(t)o The lifetime density function ¢ (t) is the time rate at which failures occur divided by the original or starting quantity at time - O. In writing the equations for this section_ starting quantity (Q) and surviving quantity {Q) hove not been further defined. However. it s_ould always be understood thaL the (the population of equipments), fraction of the the reliability, Thus, failure in rellability_ is that constant starting and the starting quantity and the number is always set equal to I of survivors then becomes some fraction is_ by definltlon_ vaIJes of the reliability.

quantity. Q_s reduce the I.

This surviving to the various

rate becomes since Qo =

time rate of change, or the rate of decrease_ An interesting result of these relationships rate divided by the

reliability hazard, as Models

is at all times equal to the failure demonstrated in the next section.

Mathematical

hazard

The three are

mathematical

quantities

of

reliability_

Cailure

rate

and

1
R = X /h -

-d_
-

Qo dt 1_ _ Q dt

Q/Qo

I
RC-56-R I _]
Lo_ _r,_eles. Cah_c,rma AIRESEARCH MANUFACTURING DIVISION

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9

l
X' - Qo l -d_ - Q dt

-dq
dt

-dR
dt l -dR R dt

-

d__: -XR = -X
R

dt Integrating the
"t r

last

equation

we

have,

-_
o

Xdt = e -Xt

R = e

to

It is generally assumed that failure, is constant (uniformly

for complex distr!buted

systems the in time •

haza-d_ Wear-out

or force failure

generally is assumed to be normally_ and in accordance with the followin 9 Gauss;an

not uniformly, dist-ibuted in time, p-ubability-density Function: where F(t_ = probability to time t = probability fa I lure = mean = time to of failure

I I I I I I I. I I I

-it-l_i 2
F _t) dF(t) dt _ _1 oF 2 ,j e

F i t)

density

of

I_
c

failure of

standard deviation the distribution

Mean time to failure c_ irrespective of the probability distribJtion of failure with respect to time (or cycles_ starts_ etc.)_ is the summation of the time to failure of each equipment_ divided by the number of such equipment • Thus_ where n t n i=1 t.
I

n = number tested = time r.o

of to

equipments failure of i th

failure

samp l e It can be shown that, provided the particula r form of the distribution

is determined by nothing but a constant hazard_ the probabili_.y distribution of time to chance failure_ and hence its centroid, the mean _ime to Failure, is defined. Since the reliability function itself is the applicable probability distributionj is greater than some it represents the p_obability mission time t. This may be that any expressed life time, x,

RC-S6-R
[_ AIRESEARCH MANUFACTURING DIVISION l es Angeles California

Pa9e

I0

I I
P(x > t) = F'(x) dx = R(t)

I
thus where P F(x) _-_ = _" dR d _t °° F'(x) dx = -F'(t) R(t) and = = probability = frequency of life reliability that distribution times at time t x > t

I I I I I
For failure

F'(t)

-

-dR(t) dt

= ke-Xt

Therefore,

the

centroid_

or

mean

time

to

failure_

may be

expressed:

=

L
n x i=!

tF'(t)

dt

=

R(t)

dt

=

L where -t/{

e -X

dt

=

IIX

any series system, of the system_ the

where reliability

the

failure of any is expressed: r. X. X
S

one

component

causes

I
R=

n

I

= component = = = component series series

reliability hazard hazard MTF are

-tT. i_l r, I = e

X.

I = e

"ks

t = e

i

I I I I I I I I I
For required theory. as it is ponents, arranged

system system techniques

a

system

which

incorporates

redundancy_

special

that are available from well-established theorems from probability To employ such theory_ it is necessary to stipulate that redundancy_ employed in reliability theory_ requires that two (or more) comor a collection of components (not necessarily identical) be so functionally that the failure of one does not and can not result in or or other failure failure of of redundant the system elements performance. in a system In are other words_ independent of

a degradation the success

one another. In certain critical redundant elements ponents (in series)_

general_ entire systems are not made elements are made so. Thus_ a series and the required failure detection has a reliability:

redundant_ but only system possessing and isolation com-

RC-5b-R
_ AIRESEARCH MANUFACTURING DIVISION Los An_,elesCaHforn,a

Page

I I

I I I l ! I l l I ! I I I I I I I I
k
R _

whe re

R
S.

=

reliability elements

of

series

R
n

= Pj

R i=1 si k -£ X.t ! i=l
= e

_ j=k+l

R Pj

joint reliability of paralleled elements hazard of .th i element

=
I

Xs -X
= e S

=

collective series

hazard el ement s of elements

of

R
S, I

t k = number series = l r. J R
n

in

n

th
m

Rpj

I

x j=k+l (I-rl)n

(]-rj)

r.

reliability element reliability paralleled

of

i

series

Rn =

I

=

th of j element

R

= e'Xn t
n

=

collective reliability of n identical elements in parallel_ each of r I of in n with

reliability X = collective identical parallel

hazard elements

RC-56-R
_ AIRESEARCH MANUFACTURING DIVISION Los Angeies California

Page

12

References AGREE of the Commlttee_ Asst. Secty J,_ Reliabili'ty of Defense_ of Hilltary 4 June Electronic 1957. Lifetime Journal Distributions of Resea,ch Equipment, Office

I

.

.

Flehinger_ B. for Reliability and Development_ Henney_ Ground Lopatin_ Electronlc

and Lewis_ P. A._ Two Parameter Studies of Renewal Processes_ IBM January ]959. Zimme% Adler and Equipme_t_ (Rome of Maresky_ Reliability ADC)_ McGraw-Hi]l,

II II II JI I I I I I I I I I I

.

Factors 1956.

fo_

L#,o

U. S. Dept of Commerce Office (NAVSHIPS 900-193)_ Reliabi]ity This document is a reprint of 1958.

Technical Services Bulletin PS 131678 Stress Analysis for Electronic E_uipment, RCA Report TR 1100_ dated 28 November

_]

DIVISION AIRESEARCH MANUFACTURING
Los Angees Cal:fornla

RC-56-R Page 13

I 1
Met hodol o_ty The application of the mathematical upon one theory of the incidence theory assumes that the hazard of model to of failure failure of reliability prediction in complex equipments. any one component part is is

II
II II II PI I I I I I I I I I I

based This

sma11j that there is a very large number of such components and the failure of any one is sufficient to induce failure of some specified system function. Degradation of performance in excess of that specified as allowable tolerance is considered a failure_ so that the hazard assigned each component is intended to reflect both catastrophic and degradation hazards. The hazard also is intended to reflect the environmental conditions and their cumulative effects., which always increase the degree of hazard.

It is implicit in the preceding section that the computed reliability of a system requires the summation of the hazards of all contributing components. This summation represents the cumulative constant hazard for all its known contributors. Tile assumption is that survival probability for any _jiven mission duration is independent of the age of the components. This assumption results in the diminishing exponential expression for reliability. It is interesting to observe that the entire basis for this theory is

one of chance failures. This concept presupposes that no design or quality control deficiency exists_ since such deficiencies result in failures which tend to repeat. Thus., it is deemed to be a primary objective of reliability engineering not only to predict a realizable mean time to failure_ but also to ensure that the objective of the various test programs is realized. These objectives are the inception of remedial action whenever such deficiencies are disclosed by test. Included in this is the reliability review of all proposed engineering changes in already qualified components and the decision as to what testing., {f any_ is required to qualify the change. The belief in the success of prediction techniques has led to the inclusion of MTF among the detail design and test requirements for both components and entire systems. The primary responsibility of reliability engineering is to ensure that the cognizant design team is kept informed of is implied by the summation of individual keep the inherent hazard within allowable THE AIRESEARCH RELIABILITY ORGANIZATION the magnitude of component hazards_ bounds. system hazard in order to that

The Reliability Organization within the AiResearch Manufacturing Company at Los Angeles has evolved into its present configuration through the continuing investigation and incorporation of those concepts best suited to the company's activities. The Reliability Organization conforms in all respects to that outlined in Part II of U.S. Air Force Specification Bulletin No. 510: Guides criteria For Reliabili_ utilized in Oy___OE_Eization_ although defining the AiResearch this bulletin organization. was not the only

on to

The structure of the AiResearch Reliability Organization the included chart. The entire Reliability Organization and under the overall direction of the Division Manager. activity is under the control of and reports

is illustrated is responsible All engineering Chief Engineer_

reliability

to the

AIRESEARCH MANUFACTURING
Los

RC-56-R
DIVISION
California

Amgeres

Page

I Z_

I I I I I I I I I I I I I I I I I I

through functions of the The

the

Chief

of

Reliability.

The allocated

following to and

discussion performed by

outlines each

the major group

and Rellablllty

responsibilities Organization. Council Council is

Reliability The Reliability

comprised

of

the

managers

of

the

Hanufacturlng_ Departments. Hanager_ The

Engineering_ O.uality Control_ Purchaslng_ Support Servlcej and Sales This council is convened for major policy decisions by the Division who Is the chairman_ or at the request of the Rellabllity Committee. functions and responslbilitles of the council are' To administer pollcles and the dlvlslonal rellablllty procedures establlshed rellabllity program dlvislon problems

I

.

by

and Implement management. through the

the

.

To coordinate interdlvlslon Division Manager. To review and evaluate the

3.

progress reliabllity actlvltles

of

all

rellablllty the

activities. asslgndepartments. on con-

To assure compllance wlth ment of speclflc rellabllity
o

commltments by to the varlous

To revlew tractural To by resolve Rellablllty

rellabllity obllgatlons items of

commltments wlth speclflc and cost conslderatlons. controverslal actlon. nature which

emphasls

,

cannot

be

settled

Commlttee

The

Rellabillty

Committee of the with personnel designated Reliability Councll_ the general problem by each basis_ by the and inareas

The Reliability Committee is comprised managers of each department represented on cludes those personnel most closely allied under consideration. Council members in turn This on

committee Is chaired a slx-months-rotatlon

of the Rellabllity and meets whenever

an Interdepartmental problem arises which Reliability. The Chief of Reliability is mittee. The functions and responsibllitles To by To To for To assure proper the Reliability coordinate establish review advise and Implementation Council. resolve

cannot be resolved by the Chief of a non-voting member of this comof the committee are: of declsions and rulings established

I

.

2.

Interdepartmental periodlc Council Council of

rellabillty

problems.

4

by the

and coordinate the Reliability Rellablllty resolution,

reports of reliability progress and Corporate Management. unresolved problems and to

request

thelr

RC-56-R [_ AIRESEARCH MANUFACTURING DIVISION
Los AnReles California

Page

15

I I
The Reliability The Staff Staff is made up of engineers from key groups in the

I I I I I I I I I I I I I I I I

Reliability

Preliminary Design Department and reports technically to The staff members perform reliability tasks within their group_ and also provide assistance in reliability matters projects. functions_ Enqineerinq These engineers_ are experienced Project in addition in tile many to being phases of competent equipment

the Chief of Reliability. own Preliminary Design to all engineering in their testing. reliability

Reliability

Enqineers

The Engineering Project Reliability Engineers consist of experienced hardware specialists who are assigned the responsibility of accomplishing either specific contractual reliability requirements or the routine duties necessary to achieving reliability in equipment. These engineers report directly to their project leaders and are technically responsible to the Chief of Reliability for all reliability activities. The Chief The of Reliability of Reliability reports directly to the Chief Engineer_ and acts

Chief

in an advisory matters. The
I ,

capacity to major duties establish

divisional management and responsibilities reliability

with respect to all reliability of the Chief of Reliability are: policy_ in concert with the in all

To

divisional

Division matters
.

Manager_ Chief Engineer_ that pertain to AiResearch

and all department heads_ reliability activities.

To assist all engineering project teams in their early design activities in order to ensure that AiResearch design leadership in reliability is maintained. To of establish AiResearch and maintain contact with customers and vendors. the reliability departments

.

To conceive_ plan_ design and place into effect failure-reporting systems for engineering_ field service and other departments requiring such systems.
.

To initiate and reports intended To provide liability

supervise the preparation for AiResearch customers

of divisional and vendors. to the

reliability

.

guidance_ counsel and Council and Reliability

continuity Committee. maintenance

Division

Re-

.

To assist Quality Control in the vendors in Reliability matters. To exercise Engineering

of

cognizance

over

.

technical supervision of the Reliability Project Reliability Engineers.

staff

and

RC-56-R _ AIRESEARCH MANUFACTURING DIVISION
Los Angeles. California

Page

16

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RC-56-R_ Page 17

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RC-Sb-R Page 20

I

MANUFACTURING

DIVISION Los Angeles, Cahfornla

(_il_esearc_ Manufacturing Company x_¢,_,.o! /"-'_ _

UNIVERSAL TROUBLE REPORTING SYSTEM

TROUBLE REPORT NO ........... DATE .............................

CONTRACT TASK OBJECTIVE_

NAME__

*AGENCY REPORTING ............... EWO **TEST

'__

OR ASSY, LEVEL ........................ "

SYSTEM NO .......................... TROUBLE SYMPTOM SIN SUBSYS NO S/N COMPONENT DISPOSITION_
ORIGINATOR DEPT. NO. DATE

..

NO.

S/N BUILD UP NO RUN NUMBER.

TROUBLE ANALYSIS

TEST DATA NO, RUN DURATION TOTAL TIME
-DO NOT WRITE BELOW THIB LINE --

***NOMENCLATURE: COMPONENT

I I I I I I I I I I
ANALYST DATE PROJECT ENGINEER DATE ANALYST DEPT. NO. DATE

DETAIL NAME. DETAIL P/N TROUBLE AREAS OF ACTION REQUIRED DESIGN/DRAWING PROCESS SPECIFICATION ASSEMBLY INSTRUCTION TEST INSTRUCTION TEST METHOD/CONDITION TEST EQUIPMENT TEST CALIB/INSTRUMENT PROCESS/MANUFACTURE INSPECTION VENDOR ACTION TAKEN AREAS OF ACTION TAKEN (QC) 1 2 3 4 5 6 '7 8 9 O ( )

ACTION

REQUIRED

ENGINEER

DATE

CORRECTION

CONFIRMED
PROJECT ENGINEER DATE

FORM 3113 10M 2-62 LC

NOTES: *WRITE LAB, MFG, INS, OR ENG **SYSTEM, SUBSYS, OR COMPONENT ***USE GENERIC NOUNS ONLY, SUCH AS VALVE, DIODE, ETC., FOLLOWED BY DESCRIPTIVE ADJECTIVE RC-Sb-Rj Page ZI

I I I I I I
DISPOSITION TROUBLE (hl_esearch Manufacturing Compang
'mmuq

UNIVERSAL TROUBLE REPORTING SYSTEM

TROUBLE DATE

REPORT NO ..........

CONTRACT NAME. TASK OBJECTIVE

*AGENCY REPORTING .................... EWO__ **TEST OR ASSY. LEVEL .............

SYSTEM NO. SYMPTOM. SIN SUBSYS NO. S/N COMPONENT S/N BUILD UP NO..
ORIGINATOR DEPT. NO. DATE

NO,

I I I I I I I I I I I
4. COMMENTS:

RUN NUMBER, TEST DATA NO. AS THE TROUBLE IS ISOLATED TO SUCCESSIVELY LOWER LEVELS OF THE ASSEMBLY, TRANSFER THIS FORM TO THE SUSPECTED ARTICLE IN TURN UNTIL THE BASIC CAUSE OF TROUBLE IS ISOLATED. AFTER COMPLETING THE LOWER PART OF THIS FORM, FORWARD IT TO THE PROGRAM RELIABILITY ENGINEER, RESULTS OF DISASSEMBLY INVESTIGATION 1. FAULTY PART OR COMPONENT:
(IF APPLICABLE)

RUN DURATION TOTAL TIME

OR TESTS TO DETERMINE PART NO., PART NAME

CAUSE OF TROUBLE: S/N

2. FAULTY CONDITION: .......

3. CAUSE (IF POSSIBLE TO DETERMINE): .......................................................................

ORIGINATOR

DEPT.

NO.

DATE RC-Sb-R Page 22

I

I I I I I I I
I Illlt lOS ....

......

"-_._

_l'li_[llti_;

i.i.i.i_'__fO__4 uoolt _

SERiALI_I.__KIIO. 1 !'_POSitIONt... !!

__
Slllill,

_T_,4___ ,,_.____
___i_1
NO. * SERIAL NO.

I "1 i I I l i
NO.

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-_ .....

ii, !

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Bit sEll'IS

I I I I I I L_.L_
NO.

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NO.

i I
--;

I I I I i

OR SERIES

"M_IFI'CAI'ION'OR'IERIE|

_71

i |. 7. OI_IIJITINO i_ I I,, ii i I , _: , I

I , I. , I

I lie , I I

I

I I l"

HRS

i OIECEiVlNG l. I-"l ROUTINE 9. IAILUR[ 3 ROUBLE 4._TARTIttG ,

INSPECT/TEll INSPECTION NOT P DURIN_ litOOTiNG

, --_ I, i-_. _] AI)IUII I-M_Mi6TATE foil ACTION DISPOSITION ll."i'_i_OtLOWS 12, ACIIOitiANSWIR _ _ :: I_Q;O

,

i.,

_; _- r:].'JJ ;IH ii

* ,.L CYCS C',,,ir,l!l.l-, IIi_tRS

3.'O.EPAI, 4. EIHOLD II. It. I.

/l_iNO_O._,

B.r'iTAKE S. ElGItOUetO OFFRUN.Or |, [] LAHI)II_I ,, (":_ OlliilUil i Off / R. ,GilT S, (_ TEAR DOWN

[] RETURN TO SureLY I_]R[TURNTOAIRESEARCH m

I li. '1 lUMMA-II-V_I}E

I II

l t.l ..... I t
'J.I I_' _

li
I

•l IB NO $'N1£, 0 AVAILAILE D AI_P - SPICIAL EQUIP. AVAILABLE

I I I I
TYPICAL FIELD SERVICE 4 REPORT FIGURE

I I
_ AIRESEARCH MANUFACTURING
Los Arlgeres

DIVISION
California

RC--56-R Page 23

oi

J

APPENDIX B PROCEDURES MATERIALS AIRESERCH FOR QUALIFYING REPORT NONMETALLIC BREATHING SYSTEMS _

FOR USE IN OXYGEN

NO. SS-2108-MR

i

"i

I I I I I I I I
APPENDIX B

I I I I I I _I
j,

PROCEDURES FOR QUALIFYING NONMETALLIC MATERIALS FOR USE IN OXYGEN BREATHING SYSTEMS AIRESEARCH REPORT NO. SS-2108-MR

I I

66_] AIRESEARCH MANUFACTURING DIVISION Los Angeles. California

1483 BI

Page

I I I I I I I I I I I I I I I I I I
FOR

THE

coRpORATION

i_il_esearch Manu_'acturincj Divisions
LOS ANGIEtES 45, CALIFORNIA

It£PORT

NO.

SS-2108-MR

_,ev

PROCEDURES FOR QUALIFYING NONMETALLIC MATERIALS USE IN OXYGEN BREATHING SYSTEMS

SS-2108-MR

_ev

I I I I I I
This inform used, of Tile document Buyer or is of the the property status for Corporation. any of of The Garrett Corporation. and the is prior not It to written is furnished be duplicate_ permission to Seller's purpose performance without disclosed other

I I I I I I I I

Garrett

I

I
AIRESEARCH MANUFACTURING DIVISION
( al,h_',,=,_

I
I _Jl
L _,_ A,,ge_e,,

I

I I I I I I I I I I I I I I I I I I
[_ DIVISION AIRESEARCH MANUFACTURING I _ A_,gele_ Cahforn,a

PROCEDURES FOR QUALIFYING NONMETALLIC MATERIALS FOR USE IN OXYGEN BREATHING SYSTEMS

SS-2108-MR, I. OBJECT I.I This

Rev_

,

A_gult

2_

1965

report

prescribes materials

a procedure for use in

for oxygen

the

qualification systems.

of

nonmetallic 1o2 The for in 2. TEST 2.1

breathing

intent is to the selection oxygen breathing

establish mutually acceptable methods and criteria of elastomers_ lubricants 3 and plastics for use systems at pressures not to exceed 20 psig.

CONDITIONS The 2.1.1 2.1.2 2.1.3 exposure conditions I00 hr 160°F, 200°F_ 250°F_ 300°F are as follows: oxygen at 5.0 psia

Atmosphere: Time: 48

percent

Temperatures: CRITERIA

3.

ACCEPTANCE

The acceptability of a material shall be determined by tests_ herein_ for odor characteristics, susceptibility to oxidation, toxicity. The criteria for acceptability shall be as fo]lows"
3.1 Odor

described and

3.1.1

A material temperature use at that The material temperatures was discerned. The level

exhibiting an objectionable level shall be considered and higher temperatures. may be established below that at which

odor at a particular as unacceptable for

3.1.2

suitable for use the objectionable

by

tests odor

at

3.1.3

of

acceptability

shall temperatures conditions

be

established established required by

for a

each

material tested_ at the 2o!.3_ or at temperature component or system.

in paragraph particular

SS-2108-HR,Rc_v Page I of 6

I I I I I I I I I I I I I I I I I I
I_l

3°2

Oxidation The physical properties of materia!s shall be compared after exposure to the test conditions° Acceptability oxidation shall be based on the Following criteria: 3.2.1 Elastomers 3.2.1.1 3.2ol.2 No cracking_ Tensile strength 20 percent. Elongation Weight n.5 Shore shall hardness shall not blistering_ shall or not charring change of more the than surface. before relative and to

3.2.1.3 3.2.1.4 3.2. 3.2.2

not

change more

more than

than

20

percent.

change shall not

_0 percent° more than I0 points

change

Lubricants 3.2.2._ 5.2.2.2 No evidence of fire or shall coking. not change more than

For oils_ viscosity I0 percent°

5.2.2.5

For greases_ change in dropping than :±6°F_ if applicable. For oils, the i_O percent° weight shall not

point

shall

be

less

5.2.2.4

change

more

than

5.2.2.5

For greases the weight shall not change more than 5.0 percent_ unless the grease is designed with a volatile fluid_ in which case weight loss shall not apply.

3.2.3

Plastics 3.2.3. 3.2.3.2 I No cracking_ Plastics weight. shall blistering_ not lose or more charring than 5°0 of the surface. by

percent

3.2.3.3

Where applicable, than ±I0 points tester° Tensile strength PO percent.

as

hardness determined

shall by

not change more Barco] hardness

3.2.3.4

shall

not

change

more

than

SS-2108-MR
AIRESEARCH MANUFACTURING DIVISION t os Angeles California

Revo 6

i

Page

2 of

I I I I I I I I I I I I I I I I I I

3°3

Toxicity 3.3.1 A material as intended for use shall not contain unreacted_ known noxious or toxic compounds; nor shall it produce any noxious or toxic gasses at the extremes of its operating temperature. 3.3.2 When possible, materials utilized by are those whose basic

formulation 3.3.3 An acceptable condition of

is controlled

specification; but not sufficient properties,

odor shall be a necessary qualiflcation for nontoxic

TEST

PROCEDURE to determine are the acceptability descrlbed of e!astomers, lubricants_ and

Methods plastics 4.1

separately

herein_

Elastomers 4.I.I Elastomers 4.1oi.I Oxidation Conduct Test Procedure and hardness respectively for the are exposure 'tests; s For control required. in a desiccator of 2.5 per ASTM D.&I2.64T purposes. each

tensile

and ASTM D-676-59_ Three determ!nations exposure 4.!.I.2 Place the test

control and for

condition for

samples

to 2_7 l!ters vo!ume. Evacuate and fill with gaseous oxygen_ per MIL-O-27210, a minimum of three times. The final fill shall be to the desired test pressure. 4.1.1.3 Place the temperaturey desiccator for 48 in an hours_ oven_ at the desired test

4.1.1.4

Upon completion of the exposurej examine the specimens at fOX magnification for visual evidence of surface damage s and reevaluate the physical properties as described in paragraph 4.! !,!o Odor Test Procedure of IO to 12 cm 2 surface one (I) gm. Weigh the place on a 2-in_

4.1.2

Elastomers 4.1.2.1

Prepare a material specimen area weighing approximately specimen to watch glass. the nearest

mg and

4.1o2.2

Expose described desiccator

the

sample

to

a

gaseous

oxygen using

atmosphere a separate

as

in paragraph 4 1oI.2_ for the odor evaluation° desiccator for 48 of ho, th_ in s, exposure ic pressure "emove from an oven

4.1.2.3

Place

the

at

the

desired

test

temperature 4.1.2,4 Upon completion

period

bring

the

desiccator temperature

to atmosphe air, and

with oventhe oven immediately.

SS-2!08-MR
_ AIRESEARCH MANUFACTURING DIVISION LOS Angeles Cal,fornla

Revo

Page

3 of 6

I I I I I I I I
! 4.2 4.2.1

4.1.2.5

In an odor-freej draft-free room, open desiccator containing odor test sample while it is still at temperature. Each of four subjects shall independently quickly smell the desiccator atmosphere and record their finding as: "not detectable_" "detectabie_ but not objectionable3" or "objectionable." Report the consensus. Following from the whole mg. odor evaluationj remove the watch glass desiccator and reweigh to the nearest Record the percent change in weight.

4.1.2.6

Lubricants Lubricants 4.2.1.1 Oxidation Test Procedure point" per "cup" for oxygen oils shall be per to oxygen at

For greases_ determine the "dropping ASTM D-566--4_ and prepare a second exposure° Oxidation resistance of evaluated by ASTM D--445-6_ the desired sample greases_ determination before and test of after

viscosity exposure

,temperature. use a standard glass for oils for viscosity in the dropping (About testing.) described cup

4.2.1.2
I

For for

containment_ and a watch is required

I0 m} 4.2.1.3

of oil

I I I
4.2.2

Expose the in paragraph Place the

samples to 4.1.1o2o desiccator for 48 of hr. the

oxygen

manner

4.2.1.4

in

an

oven

at

the

desired

test

temperature 4.2.1.5 Upon

completion

exposure the

period

remove physical

the

samples and property. Lubricants 4o2.2'. I Odor Test

reevaluate

appropriate

Procedure

I I I I

For grease odor test, weigh approximately I gram sample to the nearest whole mg on a 2-in, watch glass. Spread the grease evenly over the glass to a uniform thickness° For oil sample glass° Place odor tests weigh approximately a to the nearest whole mg on a 2-ino l-gm watch

4°2.2.2

4.2.2.3

samples

in separate

desiccator_ and fil! 3 times. pressure°

of

2.5

to

2.7 oxygen_

liters by volume and evacuate per MIL-O-272!O_a minimum of shall be to the desired test

with gaseous Final fill

I I

t_1

AIRESEARCH MANUFACTURING DIVISION Los Al_geles California

SS-2108-MRo Page 4 of 6

Rev

I

I

I
I

I I I I I i I
/+.3 Plastics 4.3.1

4.2.2.4

Place

desiccators for 48

in hr. of

an

oven

at

the

desired

test

temperature 4.2.2.5 At the

completion to I and

the

exposure pressure remove

period,

bring

the

desiccator ture air 4.2.2.6

atmospheric immediately

with oven temperathe desiccators.

In an odor-free_ draft-free room_ open desiccator containing odor test sample while it is still at temperature. Each of four subjects shall independently quickly smell the desiccator atmosphere and record their finding as: "not detectable_" "detectable_ but not objectionables" or "obJectionable." Report the consensus. Fol_owingodor evaluation_ remove the watch glass

4.2.2.7

with the samples from the desiccator and reweigh to the nearest whole mg and record percent change in weight. Examine samples at fOX magnification for evidence of charring.

I,
I I I I I I I I I I
[_I

Plastics 4.3.1.I

Oxidation Conduct according (Barcol

Test

Procedure

tensile strength and hardness determinations to ASTM D-638-64T and ASTM D-1706-61 hardness testor)_ respectively. Three for are the control required. and for each exposure

determinations test condition 4.3.1.2

Place the samples 2.5 to 2°7 liters gaseous oxygen, The final fill

for exposure in a desiccator of volume. Evacuate and fill with a minimum of 3 times. desired test pressure. at the desired test

per MIL-O-27210_ shall be to the in hr. an oven

4.3.

I.3

Place

the

desiccator for 48

temperature 4.3.1.4

Upon completion of the exposure examine the specimens at fOX magnification for visual evidence of surface damage_ and reevaluate the physical properties as described in paragraph 4.3oi. Io Odo_ l Test Procedure

4.3.2

Plastics 4.3.2ol

For odor evaluation, weigh approximately one gm sample to the nearest whole mg on a 2-in. watch The sample shall expose I0 to 12 cm 2 of surface

glass. area.

AIRESEARCH MANUFACTURING DIVISION
los Angeles Caldomla

SS-2108-MR, Revo Page 5 of 6

i

I
I 4.3.2.2 Place the sample in a desiccator of 2.5 to 2.7 liters oxygen fill

I
i 4.3.2.3 4.3.2.4

by volume and evacuate and fill with gaseous per MIL-O-27210 a minimum of 3 times. Final shall be to the desired testpressure. Place desiccator for in an 48 hr. oven at the desired

test

temperature

I
I 4.3.2.5

At the completion of the exposure period bring the desiccator to atmospheric pressure with oven temperature air and remove the desiccator immediately. In an odor-free, draft-free room_ open desiccator containing odor test sample while it is still at temperature. Each of four subjects shall independently quickly smell the desiccator atmosphere and record their finding as: "not detectable," "detectable but not objectionable_ or "objectionable. " Report the consensus.
,l

I
4..3.2.6

Follc Following odor and r and reweigh to percent change

evaluation, the nearest in weight.

remove the whole mg.

desiccator Record the

5. i_

REPORTING 5.1 A material (U) at each shall of perc( v be reported as satisfactory the t( test conditions. the is found unsatisfactory at a is f( testing at higher temperatures testir (S) or unsatisfactory

particular shall not

temperature be performed.

I

5.2

When a material further level,

I
I I A 0W PP
APPROVED V. A PPROVED : _J'_ K. K. C rawf_'rd ._qr(__ . Jackson ' I Engineer_ APPROVED: L/_),'_. W. J. _eilly
Program
,I

W. A. Lyons Materials and

Process

APPROVED.: _'T'_. Iles

.__J

,

/

.

f_.___P_rogr_3m.Engineer, APPROVED :R ._C. ('_e_ Program Manager, _'__,.

EVLSS

Project

I I I I I
_

................ " Project Gemini

Chief Project

Program Gemini

Manager_

EVLSS

Project

AIRESEARCH MANUFACTURING DIVISION lo_ Angeqes Cahlomla

SS-2108-MR., Page 6 of 6

RleVo I

I I I I I I I I
APPENDIX C 210-A7

I I I I I I I I I I

DATA ACQUISITION

PROCEDURE

AIRESEARCHMANUFACTURING DIVISION
LOS Angeles, California

I I I I I I I I
APPENDIX C 210-A7

I I I I I I I I I I

DATA

ACQUISITION

PROCEDURE

AIRESEARCHMANUFACTURINGDIVISION
LOS Angeles, California

66-1483 Page CI

I.

210-A7
LOS ANGELES

i

AIRESEARCH MANUFACTURING DIVISION QUALITY CONTROL DIRECTIVE

i

DATA

ACQUISITION PROCEDURE ELSS - CHESTPACK IRAN
i

I

Page

I

!
I I 1 I I I

I ,

GENERAL A. This procedure provides a means by which selected AiResearch

documents may be acquired and/or maintained during the "Inspect and Repair as Necessary" (IRAN) activity and the upgrading and refurbishment of the Extravehicular Life Support System (ELSS) B. The acquisition, retention, and transmittal of this data will

satisfy the requirements for Aerospace Equipment Historical Process and Performance information, by NASA Reliability Document NPC-250-1 and NASA Assurance Document NPC-200-2. II. SCOPE A. Departments I. affected

Contractor as defined Quality

Manufacturing ao b Furnish Upgrade Interim Interim AOIR AOIR, for as each unit.

required.

2.

inspection ao Accumulate Control. Assemble data, as noted data and to forwarded accompany to Quality

I I I
I I ! I I
FORM 2674-B

b. 3.

deliverable

unit.

Quality a. b.

Control

Prepare Narrative End Item report. Accumulate all data and maintain fileo Administration as required by

4.

Contract/Sales ao

Direct repair and/or upgrading, issuance of task sales order. Laboratory copies of test instrumentation system

5o

Engineering a. b. co Provide Provide

data sheets. records. and component logs returned

Maintain existing with unit.

CONT:

EFFECTIVE:

3-7 -66

2;0-A7 DATAACQU TIONPROCEDURE I SU ELSS- CHESTPACK i RAN

I
AIRESEARCH MANUFACTURING DIVISION QUALITY
LOS ANGIr CONTROL Lit $ DIRECTIVE

Page

2,

I I

Ill.

COMPONENT A.

DATA

FiLE

!
Component Log (Form No. 3139). the component Forms (initiated acceptance test. against

Documents
I •

Sys_-em and

2.

T_ouDie Report at _unctional AI de data ivery

o

generation, acquisition, will be limited to the 850040 800562 800562 800386 800374 800318 800298 800296 800294 800670 800284 800282 800278 167880 138594 138793 138541 138663 800562 800600 800362 Operation and and

retention and items listed below.

I I I I

Va ve Nipple Nipple Gage Modu _e Module Press Trans Heater Sensor Battery Regu !ator Vaive Group Vaive Relief Heat Exchanger Panel Pane i Duct Assembly Tank Assembly Multi Connector Electrical Umbilical 4. 5. 6o 7o Interim Jumper Ass'y•

o

J

Assembly

Inspection Record

Record

inspection Functional

Transfer Test Data

Rejection

Sheets.

instrumentation

Record

CONT:

'EFFECTIVE:

3-7-66

FORM 2674-1B

21 O-A7

QUALITY

..NoO'V"'O" ANo, IL, s ,NOtos cT,.,,
DATA CONTROL D_RECTIVE ACQUISITION PROCEDURE ELSS - CHESTPACK IRAN and Component Log

Page

3_

Procedure I. System
ao

The Laboratory, when performing a test, either acceptance or investigation, will enter, on the SACL returned with the equipment, the time in hours and minutes expended in performing such test. Reports and/or Inspection personnel malfunctions or discrepancies repair, test, or modification

2.

Trouble
a.

Laboratory, Manufacturing, will initiate T/R's when are detected cycle. during the

I
bo

Reliability wil_ process T/R.'s in the same fashion, as occurred during ¢he production program and will maintain T/R file. Assembly Operation and Inspection Record

3.
,

Interim
al

I I
bl

Manufacturing will prepare, in coordination with Engineering and Quality Control, an interim AOIR each unit received. This document shall contain necessary instruction the specific unit to

for the

to refurbish, repair or upgrade satisfy customer requirements.

I
i

The final inspector shall review each AOIR for completeness of entry, including evidence of Government Inspection witness when required. The completed AOIR shall be placed in the data book accompanying the unit. Transfer and Rejection prepare against and Report (ITRR)

4.

Inspection

I !

a.

Materials completed

Review shall ITRR written III. A. 3.

a copy of each the components to Quality

listed Control.

in paragraph

forward

i
I I
FORM 2674-B EFFECTIVE: 3-7-66

CONT:

210-A7 DATA ACQUISITION PROCEDURE ELSS - CHESTPACK JRAN
LOS ANGELES

i AIRESEARCH MANUFACTURING DIVISION QUALITY CONTROL DIRECTIVE

I I
I

Page

4.

i o

Functional
ao

Test

Data

Sheets

(IDS)

The Laboratory will data sheet prepared paragraph Ill. A. 3.

reproduce one copy of each against the items listed in

bo

The will

Laboratory review

the

Quality data

Control sheets for

representative completeness and insert

of

entries, the data instrumentation
a.

government witness, into the data book. Record

etc.,

I I I I

o

The Laboratory shall initiate the instrumentation record prior to performing each test, recording each instrument type, registry number and calibration due date. The completed instrumentation record shall be placed in the component data book. FI LE

IV.

SYSTEMS A.

DATA

Documents I. 2. 3. 4. 5. 6. 7. 8. 9. Systems Data Folder Record Component Test Test Data Data Forms Forms Record Record
t

I
Log Sheets Sheets

Modification System and

Functional Acceptance Trouble Trouble

Report Report

I I I I

Instruction

Configuration Instrumentation

CONT:

i 4
I
FORM 2674-1B

• EFFECTIVE:

3-7-66

I

! I 11 I ! ! I I I II
B.

QUALITY

CONTROL

DIRECTIVE

°'v"'oN I
DATA

210-A7

ACQUISITION PROCEDURE ELSS - CHESTPACK IRAN

Page

5.

I0o Iio 12o 13. 14.

Interim Trouble Rejection Test

AOIR Reports Reports Sheets Data (ITRR's) (iDS) Package

Data

Component

Procedure I. Systems ao bo Data Fo_der

Quality Control will furnish a supply of Data folders to final inspection° Fina_ _nspection will identify the folder with the part number, name, and serial number. Record

2.

Modification

ao

The final inspector will make the required entries in the existing m,d. record, indicating the component removed by part name, part number, and serial number. Entries will be made for new components installed.

3.

Configuration
a.

Record inspector will make entries on the the listed

I I
4.

The

final

existing configuration record, components changed by order of in the mod° record° System
a.

indicating change as

and

Component

Log SACL's shall

I ! I I I
FORM 2674-B

The Laboratory returned with

shall make entry on existing the equipment° These entries

indicate the actual time accumulated during tests or any other running time of the equipment. The time shall be expressed in minutes and/or hours and the minutes. The data book. SACL (original) shal_ remain in

CONT:

EFFECTIVE:

3-7-66

21O-A7 DATAACQUISITION PROCEDURE ELSS- CHESTPACK IRAN

LOS

ANGELES

AIRESEARCH MANUFACTURING DIVISION QUALITY CONTROL DIRECTIVE

Page

6.

.

Functional ao

Test

Data

Sheets record (IDS) T.I. test results and provide two on

The Laboratory Internal Data

will Sheets

bo

additional copies. The Laboratory Quality Control Representative will review the ATP data sheets for completeness of entries, government witness, the data in the data folder. etc., and place

,.

Acceptance

Test

Data

a.

b.

The Laboratory will perform the acceptance test per the ATP, record and retain in the data folder. Laboratory Quality Control representative will review the Government folder. ATP data witness, sheets for completeness etc., and retain in the of entry,... data

.

Trouble

Reports

a.

The salmon copy of trouble reports generated during any phase of testing will be retained in the data folder. Vellum copies will be forwarded to Reliability 93-3 via the normal Laboratory method. Reliability will retain all completed trouble reports.

I I l I I l I I I
FORM 2674-1B

b.

The final inspector will and clarity of entry and on the interim AOIR. Record shall

review each TR for completeness inclusion of the TR data

.

Instrumentation The Laboratory

a.

initiate

the

instrumentation

record prior to performing instrument type, registry date. The completed form folder.

tests, recording each number, and calibration due shall remain in the data

CONT:

EFFECTIVE: 3-7-66

I,

210-A7

I
QUALITY

"ANU'CTO''N°LO, AN.ELE, i
CONTROL DIRECTIVE DATA ACQUISITION PROCEDURE ELSS - CHESTPACK IRAN Operation and Inspection Record Manufacturing will prepare an interim AOIR in coordination with Engineering and Quality Control for each ELSS end item to be processed. The final inspector shall make entries as required during the IRAN process and acquire government witness evidence as directed. Inspection evidence shall also be provided. Data Folders

I I I I I I I I I I I I I I I I
FORM 2674-B

Page 7.

.

interim Assembly a.

bo

I0.

System and Component a. b.

The final inspector shall prepare the system data folder, as instructed in paragraph V. The final inspector shall verify that the systems data folder contains a copy of each of the following documents. i. Configuration Record Original and one copy ATP Data Sheets Original 3. and two copies Record

2.

instrumentation Original

and two copies

4.

System and Component Log Original and one copy Trouble Reports (system and components) Original (salmon) and one copy Inspection Transfer and Rejection Report One copy of each ITRR which has an MRB disposition only. Test Instruction Data Sheets (IDS)

5.

.

7.

Original
C.

and one copy

The final inspector shall verify that there is a complete component data folder for each component listed in the modification record.

CONT:

EFFECTIVE:

3-7-66

i

210-A7 DATA ACQUISITION PROCEDURE ELSS - CHESTPACK I RAN
LOS ANGELES

AIRESEARCH MANUFACTURING DIVISION QUALITY CONTROL DiRECTiVE

I

Page

8o

I
Data (to be shipped with the equipment)

Vo

System A.

Travel

Documents Configuration Upgrading Modificat;on Upgrade
o

i

.

Record existing Record existing sheets I_ne copy

record

and

one

copy

I I I I I I I I I I I I I I

o

record

and

one

copy

AoToPo One

data blue

o

Instrumentation One blue

Record line copy

5_

SoA.CoLo Upgrade
o

exist;ng

SACL

(original)

TrouDIe Reports B_ue line copy of all TR's generated during processing of unit, including components. I oToRoRo One copy onlyo of al iTRRVs which have an MRB disposition

o

0

Trouble Ten Trouble One

Report Forms blank forms Report copy of Forms instruction

o

instruction

B.

Procedure The finaO inspector will initiate two copies of Travel folder check _ist and remove one copy of of the documents noted thereon from the systems folder. When all documents on the check list have been the each data

I

o

assembled, one

the final inspector shall place them together with copy of the check list, into the travel folder and forward to shipping with the equipmeni.

CONT:

EFFECTIVE:

3-7-66

FORM 2674-1B

.

210-A7

I I I I

AIRESEARCHMANUFACTURINGDIVISION
LOS ANGELES

QUALITY

CONTROL DIRECTIVE

DATA ACQUI S I T I ON PROCEDURE ELSS - CHESTPACK I RAN

Page 9.

.

The remaining copy of the document check list shell be placed in the data package for the quality control file. Quality Control, in coordinatlon with project englneerlng will prepare an End Item Narrative Report in accordance wlth the requirements and format set forth by NPC-200-2. This report shall be completed and transmitted to Contracts Administration wlthln four working days from time of equipment shipment, fifteen (15) copies required plus file coples.

.

I I I I I ! I I I I I I I
FORM2674-B

L. C. Harrlson

M. WI [bur Project Superi ntendent

L.,,J -

0 'r')

''
- ELSS

W. J.'-e_Reilly Program Manager Prepared by :

_eorge Roberts Quality Control

Engineer

-END-

EFFECTIVE:3-7-66

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