You are on page 1of 79

,

,

n
L; .<

>. -\.

.

'32

; ,

'

TECHNICAL MANUAL
~,~,y-~v;-,\,l
! - l * ~ - , - , ~ ~ ' / np.pl

. ,lL'r:lT .

D5:c

- - - - - - - - - - Ucc,

No.

--------

SATURN V LAUNCH VEHICLE GROUND SUPPORT EQUIPMENT FACT BOOKLET
(THE BOEING CO.)

THE SAME PAGES OF PREVIOUS DATE
Insert changed pages into basic

PU6iISHED UNDER AUTHORITY OF THE NATIONAL AERONAUTICS AN0 SPACE ADMINISTRATION

MSFC-MAN- 100
Reproduction for non-government u s e of the information or illustrations contained in t h i s publication i s not permitted without specific approval of the i s s u i n g service.

I N S E R T L A T E S T C H A N G E D PAGES. DESTROY SUPERSEDED PAGES.
1

NOTE: The portion of the text affected by the changes is indicated by a vertical line in the outer margins of the page.

I

T O T A L NUMBER O F PAGES I N THIS P U B L I C A T I O N IS

344

CONSISTING O F T H E FOLLOWING:

I
~

. . . . . . . . . . ..226 AUK1907 . . . . . . . . . 5 Aug 1967 B.. . . . . . . . . . . Orlginal c Blank . . . . . . . . . Original I . . . . . . . . . . . . Orldnal 11 Blank . . . . . . . . . Orlglnal * ili . . . . . . . . . . .26 Aug 1967 iv . . . . . . . . . . . Origlnal v . . .......... Origlml vl . . . . . . . . . . .26 Aug 1967 vii . . . . . . . . . . . Orlgiml vlll . . . . . . . . . . . . . . . . . . . . . ..2 6 ~Orlgiml . . . . . . Orlginal u 1967 g x Blank . . * l - 1 thru 1-3 . . . . . . .2 6 A u g 1967 1-4 Blank . . . . . . . . Origilrpl 1-6 . . . . . . . . . . . Orlglnal 1-6 Blank . . . . . . . . Origlnal 1-7.. . . . . . . . . . Orlginal 1-8 lank . . . . . . . . Original *2-1 . . . . . . . . . . . 2 6 A u g l 9 6 7 2-2 . . . . . . . . . . . Origf~l * 2-3 thm 2-4 . . . . . . .26 Aug 1967 2-6.. . . . . . . . . . Original * 2 - 6 . . . . . . . . . . .26Aug1967 2-7 thru 2-0 . . . . . . . Orlgi~l *2-10 . . . . . . . . . .26Aug1987 2-11 thru2-14 . . . . . . Orlginnl *2-16 . . . . . . . . . . 26Aug1967 2-16 thru2-27 . . . . . . Origiml * 2-28 . . . . . . . . . .26 Aug 1967 Orlginal 2-29 thru2-33 . . . . . . '2-34 . . . . . . . . . ..26 Aug 1967 Orlgiml 2-36 thru2.-36 . . . . . *3-1 thru 3-3 . . . . . . . 2 6 Aug 1967 3-4 thru 3-6 . . . . . . . Orlginal '3-6 . . . . . . . . . . .26Aug 1967 3-7 thru 3-9 . . . . . . . Orlgirul *3-10 . . . . . . . . . .26 Aug 1967 3-11 . . . . . . . . . . Origi~l *3-12 . . . . . . . . . .26Aug 1967 9-13thru3-16. . . . . . Orldlvl 3-17 thru 3-26 . . . . . . 26 A u 1967 ~ *3-26A thru 3-26F Added . 26 Aug 1967 3-27 thru 3-29 . . . . . . 26 Aug 1967
* Title

*A.

*h

Deleted *3-31 thru3-34 3-36 *3-36 thru 3-37 3-38 * 3-39 thru 3-41 3-42 thru 3-49 * 3-60 thru 3-61 3-62 thru 3-63 3-64 . . . . . a s . 3-66 thru 3-77 * 3-78 3-79 thru 3-80 "3-81 3-82 thru 3-83 3-84 3-66 thru 3-89 * 3-90 3-91 thru 3-92 * 3-93 3-94 thru 3-96 * 3-97 3-98 thru 3-117 *3-118. 3-118 thru 3-128 * 3-130 3-131 *3-132 3-133 thru 3-134 * 3-136 3-136 thru 3-137 $3-138 thru 3-139 3-140 thru 3-141 * 3-142 thru 3-144 3-146 • 3-146 thru 3-147 3-148 * 3-149 3-160 Blank 4-1 thru4-21 * 4-22 4-23 thru4-36 4-36 Blank 5-1 thru 6-96. 6-86 Blank.

* 3-30

. . . . . . .26 Aug 1967 . . . . . . . . . .26Aug1867l~ . . . . . .2 O r6i g1967 ..... im . . . . . . Original . . . . . . . . . . 26 Aug 1967 . . . . . . .26 AO rui g1967l . . . . . . ~i m
. .

. . . . . . Orlglnal u g 1967 . . . . . .2266 AOrlglnnl . . . . . . . . . .. Aug 1967 . . . . . Orlginal . . . . .. .. .......2 6 AOgr1l9g6i7~ l . u . . . . . . . . . . 26 Aug 1967 . . . . . . Original . . . . . . . . . . 26 Aug 1967 . . . . . . Orlginal . . . . . . . . . . 26 Aug 1967 .... . . . . . . . . . .2 6 Aug 1967 . . . . . . Orlginal . . . . . . . . .2 5 AOrlglnal . . . . . Orlglnal ug1967 . . . . . . . . . . .26 Aug 1967 . . . . . . . . . .2 6 AOrlginnl . . . . . u g 1967 . . . . . . . . . . Original . . . . . . . . . .2 6 Aug 1967 . . . . . .26 Aug 1987 . . . . . Originnl . . . . .26 Aug 1967 Original .... . . . . . . . . . . 26 Aug 1967 .......... Origirul . . . .. .. .. . . . . 26 Aug 1967 Original ... . . . . . . . Originall . . . . . . Origlm . . . . . . . . . .26 Aug 1967 . . . . . . Original . . . . . . . Orlglml . . . . . . Origiml . . . . . . . Orlgiml
1

I
I

*

T h e asterisk indicates pages changed, added, or deleted by the current change.

I

D- 1
NASA

Changed 25 August 1967

MSFC-MAN- 100

DESIGN CHANGE

AFFECTED MANUAL

EFFECTIVITY

E C P BO-106

MSFC-MAN- 100
..
I

Frontispiece

MSFC-MAN- 100

T a b l e of Contents

T A B L E O F CONTENTS Section INTRODUCTION Page

I

I1 1

..................... GENERAL . . . . . . . . . . . . . . . . . . . . . . . . S a t u r n V Mobile L a u n c h e r . . . . . . . . . . . . . . . ................ UMBILICAL EQUIPMENT S a t u r n V Umbilical C a r r i e r s . . . . . . . . . . . . . . S - I C Stage U m b i l i c a l C a r r i e r s . . . . . . . . . . . . S - I C Stage Aft U m b i l i c a l C a r r i e r s . . . . . . . . . . S-IC Stage Intertank Umbilical C a r r i e r . . . . . . . . S -1C I n t e r t a n k U m b i l i c a l Ground C a r r i e r C o n t r o l Test Set . . . . . . . . . . . . . . . . . . . . . S - I C Stage F o r w a r d U m b i l i c a l C a r r i e r . . . . . . . . S-I1 S t a g e U m b i l i c a l C a r r i e r s . . . . . . . . . . . . . . S-I1 S t a g e I n t e r m e d i a t e U m b i l i c a l C a r r i e r . . . . . . . S-I1 S t a g e F o r w a r d U m b i l i c a l C a r r i e r . . . . . . . . . S-I1 S t a g e L O X / L H 2 P r o p e l l a n t Couplings . . . . . . . S - I V B S t a g e / I .U . U m b i l i c a l C a r r i e r s . . . . . . . . S-IVB S t a g e Aft U m b i l i c a l C a r r i e r . . . . . . . . . . S-IVB S t a g e F o r w a r d 1 1. U . U m b i l i c a l C a r r i e r . . . . . SERVICING EQUIPMENT . . . . . . . . . . . . . . . . .
'

S -1C P n e u m a t i c Ground S u p p o r t Equipment S - I C P n e u m a t i c Console S - I C P n e u m a t i c Checkout R a c k s S - I C F o r w a r d U m b i l i c a l S e r v i c e Console S-IC Pneumatic Portable T e s t e r s S - I C H y d r a u l i c Supply a n d Checkout Unit H y d r a u l i c P o w e r Unit Motor Control Center S y s t e m Checkout C o n s o l e S-IC GSE H y d r a u l i c P e r f o r m a n c e T e s t e r Console Assembly Manifold A s s e m b l y S-IC I n e r t P r e f i l l Unit . . . . . . . . . . H y d r a u l i c P u m p i n g Unit S y s t e m Checkout Console S-IC F l u s h a n d P u r g e S e r v i c e T r u c k S-IC R J - 1 / E t h y l e n e Glycol Mobile S e r v i c e r

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

......... ....... . .......... ......... ........ ....... ... .
Changed 25 August 1967
iii

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

Table of Contents

MSFC-MAN- 100

TABLE OF CONTENTS Section I11 S-11 Pneumatic Ground Support Equipment S-I1 Pneumatic Consoles (S7.41A. B. C. D) S-I1 LH2 Heat Exchanger (A7-71) S-I1 Pneumatic Console T e s t Set (C7.70) P o r t a b l e Vacuum P u m p Unit (S7-37) Stationary Vacuum P u m p (S7-29) E l e c t r i c a l Container A i r Servicing Unit (S7-34) Hydraulic Accumulator P r e c h a r g e Servicing Unit (S7-38) P u r g e and T h e r m a l Control Nitrogen Servicing Unit (S7.40) P n e u m a t i c Checkout Blanking P l a t e Set (C7-53) P n e u m a t i c Checkout Console Set (C7-603) E l e c t r i c a l Pneumatic Servicing Console (S7-42) S-IVB Pneumatic Ground Support Equipment S-IVB Pneumatic Console "A" (DSV-4B-432 & 432A) S-IVB Pneumatic Console "B" (DSV-4B-433 & 433A) S-IVB Gas Heat Exchanger (DSV-4B-438) S-IVB Pneumatic Console T e s t Set ( D S V - 4 ~ - 2 8 6 & 2 8 6 A ) S-IVB APS Propellant Servicing Unit ((36500- I & - 2 ) S-IVB APS Pneumatic Console (DSV-4B-436A) Page

.. .. .. .. .. .. .. .. ....................... ...... ........ ...... ....... .. .. ....... . .... . . . . . . S-IVBHydraulicPumpingUnit(DSV-4B-358) . . . . . . Nitrogen Fill T r u c k (DSV4- 186) . . . . . . . . . . . . . APS P n e u m a t i c Console P o r t a b l e T e s t Set (DSV-4B-186) . . Vacuum Pumping Unit (DSV4- 187) . . . . . . . . . . . . Battleship Pneumatic Console "A" (DSV-4B-327) . . . . . Battleship P n e u m a t i c Console "B" (DSV-4B-333) . . . . . Battleship Pneumatic Console "C" (DSV-4B-328) . . . . . Propellant T r a n s f e r and Interconnect Kit (DSV-4B472&-473) . . . . . . . . . . . . . . . . . . . . . APS Checkout A c c e s s o r i e s Kit (DSV-4B-493A) . . . . . . APS Instrumentation and Checkout Kit (DSV-4B- . 18748~-1875) . . . . . . . . . . . . . . . . . . . . I . U . P n e u m a t i c Ground Support Equipment . . . . . . . . I . U . Pneumatic Console . . . . . . . . . . . . . . . I . U . Pneumatic Console (500FS) . . . . . . . . . . . I . U . Pneumatic Console T e s t Set . . . . . . . . . . . I . U . Ground Support Cooling Unit . . . . . . . . . . . . Ground Support Cooling Unit Flow Control Valve Box (RM1801A) . . . . . . . . . . . . . . . . . . . . . I . U . Water Accumulator S e r v i c e r . . . . . . . . . . . .

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

. . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

. . . . . . .

MSFC-MAN- 100

T a b l e of Contents

T A B L E OF CONTENTS ( C o n t ) Section S-111s-IVB Mobile H y d r a u l i c S e r v i c e r (DSV-4B-479) Mobile P n e u m a t i c Checkout Console Mobile P n e u m a t i c T e s t S e t P o r t a b l e P n e u m a t i c R e g u l a t o r s and H o s e Kits H a z a r d o u s G a s Detection S y s t e m Page

IV

. . . .......... ACCESSEQUIPMENT S-IC A c c e s s E q u i p m e n t ........ S-I1 A c c e s s E q u i p m e n t ........ LH2 T a n k S e r v i c i n g M e c h a n i s m (A7-35) . LH2 T a n k C l e a n Room (A7-39) . . . . .

. . . . . . ........ ........ ........ ........ ........ LHZ T a n k S e r v i c i n g A i r Conditioner (A7-40) . . . . . . . P r o p e l l a n t T a n k s P r e s s u r i z a t i o n S y s t e m (S7-44) . . . . . Engine C o m p a r t m e n t A u x i l i a r y P u r g e Manifold (A7- 57) . . S-IVB A c c e s s E q u i p m e n t . . . . . . . . . . . . . . . I .U. A c c e s s E q u i p m e n t . . . . . . . . . . . . . . .
. . S -IC Handling and A u x i l i a r y E q u i p m e n t S . Haudling and A u x i l i a r y E q u i p m e n t . . I1 S-IVB Handling and A u x i l i a r y E q u i p m e n t . . I . U . Handling and A u x i l i a r y E q u i p m e n t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

. . . .

3-137 3- 139 3-141 3-143 3- 146 4-1

HANDLING AND AUXILIARY EQUIPMENT

5-1 5-19 5. 51 5-80 5-91 5-95

L a u n c h Vehicle Handling and A u x i l i a r y E q u i p m e n t

....

L i s t of I l l u s t r a t i o n s

MSFC-MAN- 100

LIST O F ILLUSTRATIONS Fig

. No .

Title

Page

............ ............ ... ........ S a t u r n V Umbilical C a r r i e r s ........... S - I C Stage Umbilical C a r r i e r s . . . . . . . . . . . S - I C S t a g e Aft Umbilical C a r r i e r s . . . . . . . . .
S a t u r n V Mobile L a u n c h e r V e r t i c a l A s s e m b l y Building E l e c t r i c a l Equipment and Cabling A r r a n g e m e n t Mechanical Equipment Arrangement S - I C Stage I n t e r t a n k Umbilical C a r r i e r s S - I C I n t e r t a n k Umbilical Ground C a r r i e r Control T e s t S e t S - I C Stage F o r w a r d Umbilical C a r r i e r S-I1 S t a g e Umbilical C a r r i e r s S-I1 S t a g e I n t e r m e d i a t e Umbilical C a r r i e r s S-I1 S t a g e F o r w a r d Umbilical C a r r i e r S-I1 S t a g e LOX/LH2 P r o p e l l a n t Couplings S-IVB S t a g e / I U Umbilical C a r r i e r S-IVB S t a g e Aft Umbilical C a r r i e r S-IVB Stage Forward1I.U. Umbilical C a r r i e r S-IC P n e u m a t i c Ground S u p p o r t Equipment S -1C P n e u m a t i c Cons ole S - I C P n e u m a t i c Checkout Racks S - I C F o r w a r d Umbilical S e r v i c e Console S-IC Pneumatic Portable T e s t e r s S-IC H y d r a u l i c Supply a n d Checkout Unit S-IC H y d r a u l i c P o w e r Unit S-IC M o t o r C o n t r o l C e n t e r S -1C S y s t e m Checkout Console S-IC GSE H y d r a u l i c P e r f o r m a n c e T e s t e r Console A s s e m b l y Manifold A s s e m b l y S-IC I n e r t P r e f i l l Unit H y d r a u l i c P u m p i n g Unit S y s t e m Checkout Console S - I C F l u s h and P u r g e S e r v i c e T r u c k S-IC R J - 1 /Ethylene Glycol Mobile S e r v i c e r S-I1 P n e u m a t i c G r o u n d S u p p o r t E q u i p m e n t S - I I P n e u m a t i c Consoles(S7.41A. B. C. D) S-I1 LH2 H e a t E x c h a n g e r (A7- 71) S-I1 P n e u m a t i c Console T e s t S e t (C7-70) P o r t a b l e Vacuum P u m p Unit (S7- 37)

......

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

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

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

Changed 25 August 1967

MSFC-MAN- 100

L i s t of I l l u s t r a t i o n s

LIST OF ILLUSTRATIONS (Cont) Fig

. No .

Title S t a t i o n a r y Vacuum P u m p (S7-29) E l e c t r i c a l Container A i r S e r v i c i n g Unit (S7-34) Hydraulic Accumulator P r e charge Servicing Unit (S7-38) P u r g e and T h e r m a l C o n t r o l Nitrogen . S e r v i c i n g Unit (S7-40) P n e u m a t i c Checkout Blanking P l a t e S e t (C7-53) P n e u m a t i c Checkout Console Set (C7-603) E l e c t r i c a l P n e u m a t i c S e r v i c i n g Console (S7-42) S-IVB P n e u m a t i c Ground S u p p o r t E q u i p m e n t S-IVB P n e u m a t i c Console "A" (DSV-4B-432 & 432A) S-IVB P n e u m a t i c Console "B" (DSV-4B-433 & 433A) S-IVB G a s H e a t E x c h a n g e r (DSV-4B-438) S-IVB P n e u m a t i c Console T e s t S e t '(DSV-4B-286 & 286A) S-IVB APS P r o p e l l a n t S e r v i c i n g Unit (GS6500- 1 & - 2 ) S-IVB APS P n e u m a t i c Console (DSV.4B.436A) S-IVB H y d r a u l i c P u m p i n g Unit (DSV-4B-358) Nitrogen F i l l T r u c k (DSV4- 186) APS .Pneumatic Console P o r t a b l e T e s t S e t (DSV-4B- 186) Vacuum P u m p i n g Unit (DSV4- 187) B a t t l e s h i p P n e u m a t i c Console "A" (DSV-4B-327) B a t t l e s h i p P n e u m a t i c Console "B" . (DSV-4B-333) B a t t l e s h i p P n e u m a t i c Console "C1' (DSV-4B-328) P r o p e l l a n t T r a n s f e r and I n t e r c o n n e c t Kit (DSV-4B-472 & -473) A P S Checkout A c c e s s o r i e s Kit (DSV-4B-4934) APS I n s t r u m e n t a t i o n and Checkout Kit (DSV-4R- 1874 & -1875) I U P n e u m a t i c Ground Support E q u i p m e n t I U P n e u m a t i c Console I U P n e u m a t i c Console (500FS) I U P n e u m a t i c Console T e s t S e t I U Ground Support Cooling Unit GSCU F l o w C o n t r o l Valve Box I U Water Accumulator S e r v i c e r S-111s-IVB Mobile H y d r a u l i c S e r v i c e r (DSV-4B-479)

Page 3-59 3-61 3-63 3-65 3 - 67 3-69 3-72 3-74 3 76 3 .9 7 3-82 3-85 3-87 3-91 3-94 3-96

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

-

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

3-98 3- 100 3- 102 3- 104 3- 106 3-108 3-110 3-113 3-1 1 5 3-117 3- 119 3- 124 3- 126 3-131 3-133 3- 136

. . . . .

. .

. .
.

.
.

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

. . . . .
. . . .

. . . .
. . . .

L i s t of I l l u s t r a t i o n s

MSFC-MAN-100

LIST O F ILLUSTRATIONS (Cont) Fig

. No .

Title Mobile P n e u m a t i c Checkout Console Mobile P n e u m a t i c T e s t Set P o r t a b l e P n e u m a t i c R e g u l a t o r s and H o s e Kits Hazardous Gas Detector S a t u r n V HGD S e n s i n g Line Configuration Hazardous Gas Detector System Functional Block D i a g r a m

Page

. ........... S - I C A c c e s s Equipnlent . . . . . . . . . S-I1 A c c e s s E q u i p m e n t . . . . . . . . .

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

LH2 T a n k S e r v i c i n g M e c h a n i s m (A7-35) LH2 T a n k C l e a n Room (A7-39) LH2 T a n k S e r v i c i n g A i r Conditioner (A7-40) P r o p e l l a n t T a n k P r e s s u r i z a t i o n S y s t e m (S7-44) E n g i n e C o m p a r t m e n t A u x i l i a r y P u r g e Manifold (A7-57) S-IVB A c c e s s E q u i p m e n t I .U A c c e s s Equipment

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

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

. .

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

S-IC Handling and A u x i l i a r y E q u i p m e n t S-I1 Handling and A u x i l i a r y E q u i p m e n t S-IVB Handling and A u x i l i a r y E q u i p m e n t I . U Handling and A u x i l i a r y E q u i p m e n t Launch Vehicle Handling and A u x i l i a r y E q u i p m e n t

....... ..

MSFC-MAN- 1 0 0

Introduction

INTRODUCTION
T h i s booklet h a s b e e n p r e p a r e d to provide a quick r e f e r e n c e t o S a t u r n V s t a g e p e c u l i a r ground support equipment. I t c o n s i s t s of v i s u a l p r e s e n t a tions and a brief d e s c r i p t i o n of e a c h m a j o r component. I t i s intended t o quickly f a m i l i a r i z e concerned e l e m e n t s with the o v e r - a l l MSFC launch vehicle ground s u p p o r t equipment and i s not intended f o r design usage. T h e booklet h a s b e e n p r e p a r e d i n five sections. Section I contains the i n t r o d u c t o r y m a t e r i a l and a d e s c r i p t i o n of the S a t u r n V mobile l a u n c h e r (ML). Section I1 contains information on the umbilical equipment. Section I11 contains information on the s e r v i c i n g equipment, both fixed and mobile. Section IV contains information on the a c c e s s equipment. Section V contains information on the handling and a u x i l i a r y equipment.

SOURCE DATAPAGE P e r d i r e c t i o n f r o m R . Etheridge, I-V-G, on S e p t e m b e r 6, 1966 no GFD s o u r c e data l i s t i n g i s r e q u i r e d f o r this booklet.

Changed 2 5 August 1967

ix /x

MSFC-MAN- 1 0 0

SECTION I GENERAL

Section I General

F i g u r e 1- 1.

S a t u r n V Mobile L a u n c h e r

Changed 25 August 1967

1-1

Section I General

NSFC-MAN- 100

SATURN V MOBILE LAUNCHER T h e mobile launcher (ML) s e r v e s a s the launch platform f o r the S a t u r n V launch vehicle, and contains operational t e s t and launch equipment used during checkout and launch. This i s equipment which is in'stalled within the b a s e of t h e ML and tower s t r u c t u r e a s well as v a r i o u s i t e m s of mobile servicing equipment located on t h e pad a r e a immediately surrounding the LUT.

The launch platform i s a two-story s t e e l s t r u c t u r e 2 5 f e e t high, 160 f e e t long, and 1 3 5 f e e t wide. The tower mounted on one end of the launch platform extends 380 f e e t above the deck.
S e r v i c e a r m s , varying in length f r o m 35 to 45 feet, c a r r y e l e c t r i c a l , pneumatic, and propellant lines to the launch vehicle. They a l s o provide walkways f o r checkout personnel entering the i n t e r s t a g e a r e a s .

1-2

Changed 25 August 1967

MSFC-MAN- 100

Section I General

F i g u r e 1-2.

V e r t i c a l A s s e m b l y Building

Changed 25 August 1967

1-3/1-4

Section 1 General

MSFC-MAN- 100

Section 11 Umbilical Equipment

SECTION ll UMBILICAL EQUIPMENT
This section p r e s e n t s information on the various stage umbilical s y s t e m s and a s s o c i a t e d t e s t and checkout equipment, with a brief d e s c r i p t i o n and a v i s u a l presentation of e a c h individual i t e m of equipment. The umbilical equipment i s used to provide e l e c t r i c a l , pneumatic, hydraulic, and f u e l s e r v i c e to the S a t u r n V vehicle emplaced on the ML. This section will be revised a n d / o r added to a s m o r e data on the umbilical equipment beconles available.

I

Changed 25 August 1967

2-1

Section I1 Umbilical Equipment

Figure 2- 1.

Saturn V Umbilical C a r r i e r s

MSFC-MAN- 100

Section I1 Umbilical Equipment

SATURN V UMBILICAL CARRIERS A t o t a l of ten umbilical c a r r i e r s and two propellant couplings s e c u r e the v a r i o u s umbilical l i n e s t o the Saturn V vehicle. T h e c a r r i e r s and couplings a r e located a t the vehicle end of the s e r v i c e a r m s extending f r o m the tower o r a t the end of the t a i l s e r v i c e m a s t s a t t h e b a s e of the ML. The c a r r i e r s and t h e supporting b r a c k e t s o r l e g s extending below the c a r r i e r s t r a n s f e r a portion of the weight of t h e s e r v i c e lines t o the vehicle s t r u c t u r e . Eight of the umbilical c a r r i e r s and the two propellant couplings a r e inflight disconnects, disconnecting a t vehicle lift-off. Two of the umbilical c a r r i e r s a r e pre-flight disconnects, disconnecting f r o m t e n t o fifteen seconds p r i o r t o lift-off.

I

Changed 25 August 1967

2-3

Section I1 Umbilical Equipment

MSFC-MAN- 100

S-IC STAGE UMBILICAL CARRIERS

AFT

NQ. 2

MSFC-MAN- 100

Section I1 Umbilical Equipment

S-IC STAGE UMBILICAL CARRIERS

r

S-IC STAGE AFT UMBILICAL CARRIER WINCH

Figure 2-2.

S-IC Stage Umbilical C a r r i e r s (Sheet 2 of 2 )
2- 5

Section I1 MSFC-MAN- 100 Um bilical Equipment S-IC STAGE UMBILICAL CARRIERS The S-IC stage umbilical s y s t e m c o n s i s t s of t h r e e a f t umbilical c a r r i e r s , a n intertank umbilical c a r r i e r , and a f o r w a r d umbilical c a r r i e r . The c a r r i e r s a r e located a t the vehicle end of the s e r v i c e a r m s exterrding f r o m the tower o r a t the ends of the tail s e r v i c e m a s t s on the deck of the ML, and s e c u r e the following s e r v i c e l i n e s to the S-IC stage of the S a t u r n V vehicle: a. b. c. d. e. Electrical. Pneumatic. Gaseous nitrogen (GN2). Gaseous helium (GHe). Liquid oxygen (LOX).

1

g

.

A i r conditioning.

The t h r e e aft c a r r i e r s a r e in-flight disconnects, disconnecting a t vehicle lift-off. The intertank and forward c a r r i e r s a r e p r e -flight disconnects, disconnecting a t T-minus -15 seconds and T-minus -10 seconds respectively.

2-6

Changed 25 August 1967

MSFC-MAN- 100

Section I1 Umbilical Equipment

S-IC STAGE UMBILICAL CARRIERS

Figure 2-3.

S-IC: Stage Aft Umbilical C a r r i e r (Shcct 1 of 3 )
2-7

Section I1 Umbilical Equipment

MSFC-MAN- 100

S-IC STAGE UMBILICAL CARRIERS

Figure 2-3.

S-IC Stage Aft Umbilical C a r r i e r (Sheet 2 of 3 )

MSFC-MAN- 100

Section I1 TTrnbilical Equipment

S-IC STAGE UMBILICAL CARRIERS

ITAIL SERVICE MAST

Figure 2-3.

S-IC Stage Aft U m b i l i c a l C a r r i e r (Sheet 3 of 3 )

Section I1 Umbilic a1 Equipment S-IC STAGE AFT UMBILICAL CARRIERS 1. Functional Description

a . Although the t h r e e aft c a r r i e r s a r e physically s i m i l a r , e a c h c a r r i e r s e c u r e s different umbilical s e r v i c e lines to the S-IC stage of the S a t u r n V launch vehicle.

)

( 1 ) Aft Umbilical C a r r i e r #1 i s located 12O 39' 22 112" off Position I11 toward Position IV. It consists of various pneumatic couplings, eight e l e c t r i c a l connectors, and a 6-inch LOX connector. The e l e c t r i c a l connectors can be ejected independently of the c a r r i e r a s s e m b l y f o r simulated flight t e s t and checkout purposes. ( 2 ) Aft Umbilical C a r r i e r #2 i s located 12O 39' 22 1/2" off 1 Position I toward Position 1 . It consists of various pneumatic couplings, eight e l e c t r i c a l connectors, and a 6-inch fuel connector. The e l e c t r i c a l connectors can be ejected independently of the c a r r i e r a s s e m b l y f o r simulated flight t e s t and checkout purposes. ( 3 ) Aft Umbilical C a r r i e r #3 i s located 120 39' 22 112" off Position 111 toward Position 11. It consists of various pneumatic couplings and two 4-inch a i r conditioning couplings. This c a r r i e r does not contain any e l e c t r i c a l connectors. The S-IC Aft Umbilical Flight P l a t e contains fluid disconnect b. couplings and connectors. All couplings and connectors on the flight plate a r e rigidly mounted. The c a r r i e r provides f o r coupling and connector alignment during mating. The v e r t i c a l motion of the vehicle during lift-off r e l e a s e s an identical locking mechanism on e a c h aft c a r r i e r , resulting i n disconnection of the t h r e e c a r r i e r s f r o m the vehicle. ( 1 ) P r i m a r y Ejection Method: The four telescoping rods follow the r i s i n g motion of the vehicle. As the vehicle moves upward, m e c h a n i c a l linkage of the t a i l s e r v i c e m a s t withdrawal m e c h a n i s m f o r c e s the yoke of the locking piston away f r o m the vehicle. The locking piston r e t r a c t s , r e l e a s i n g the locking fingers. The f i n g e r s collapse t o a d i a m e t e r s m a l l e r than the minimum diameter of the vehicle plate receptacle. F u r t h e r r e t r a c t i o n of the locking piston r e l e a s e s the t r i g g e r pins. The pneumatically loaded push off foot then f o r c e s the c a r r i e r away f r o m the vehicle plate. After disconnection, pneumatic p r e s s u r e r e l e a s e d f r o m a coupling on the c a r r i e r a s s e m b l y c a u s e s the s p r i n g r e t u r n operational control valve in the t a i l s e r v i c e m a s t t o open. Hydraulic fluid then flows f r o m the t a i l s e r v i c e m a s t r e t r a c t cylinder and the t a i l s e r v i c e m a s t withdraws the c a r r i e r assembly. 2-10

Changed 25 August 1967

MSFC-MAN- 100

S e c t i o n I1 Umbilical Equipment

( 2 ) S e c o n d a r y E j e c t i o n Method: If p n e u m a t i c f a i l u r e o c c u r s , t h e r i s i n g m o t i o n of t h e t e l e s c o p i n g r o d s f o r c e s t h e f o u r pushoff p i s t o n s a g a i n s t t h e v e h i c l e p l a t e , disconnecting t h e c a r r i e r f r o m t h e v e h i c l e . T h e l o c k i n g p i s t o n is s i m u l t a n e o u s l y r e t r a c t e d t h r o u g h m e c h a n i c a l l i n k a g e . T h e c a r r i e r i s t h e n unlocked f r o m t h e vehicle. A f t e r d i s c o n n e c t i o n , a n e l e c t r i c a l s w i t c h on t h e c a r r i e r a s s e m b l y i s a c t u a t e d , c a u s i n g a n e l e c t r i c a l l y ope r a t e d c o n t r o l valve, p a r a l l e l with t h e pneurrlatic c o n t r o l v a l v e , t o open. T h e t a i l s e r v i c e m a s t t h e n w i t h d r a w s t h e c a r r i e r . If t h e r e i s h y d r a u l i c o r p n e u m a t i c f a i l u r e i n t h e m a s t r e t r a c t i o n s y s t e m , counterweights i n the t a i l s e r v i c e m a s t will complete retraction. 2. Remarks

T h e following p r e c a u t i o n s a r e t a k e n t o p r e v e n t p o s s i b l e explos i v e conditions i n t h e vicinity of t h e c a r r i e r s . T h e s h i e l d of e a c h e l e c t r i c a l c o n n e c t o r i s grounded a. t h r o u g h a c o m m o n w i r e t o t h e vehicle. b. GN2. 3. General a. Weight, pounds ( A p p r o x i m a t e ) Aft U m b i l i c a l C a r r i e r A s s e m b l y # 1 Aft U m b i l i c a l C a r r i e r A s s e m b l y # 2 Aft U m b i l i c a l C a r r i e r A s s e m b l y # 3 T h e e l e c t r i c a l connectors i n e a c h c a r r i e r a r e purged with

630 630 630

b.

Envelope Dimension, inches (Approximate) 32 x 4 0 x 45 Aft U m b i l i c a l C a r r i e r A s s e m b l y # 1 32 x 4 0 x 45 Aft U m b i l i c a l C a r r i e r A s s e m b l y #2 32 x 4 0 x 45 Aft U m b i l i c a l C a r r i e r A s s e m b l y # 3

Section I1 Umbilical Equipment

MSFC-MAN- 100

S-IC STAGE UMBILICAL CARRIERS

CARRIER ENVELOPE DIMENSIONS APPRQXIMATE

Figure 2-4.

S-IC Stage Intertank Umbilical C a r r i e r

MSFC-MAN- 100

Section 11 Umbilical Equipment

S -1C STAGE INTERTANK UMBILICAL CARRIER
1.

Functional Description

The Intertank Umbilical C a r r i e r contains two 6-inch liquid a. oxygen ( L O X ) f i l l and d r a i n couplings. The c a r r i e r i s r e m o t e l y disconnected and withdrawn f r o m the vehicle a t approximately T - m i n u s - 1 5 s e c onds. In c a s e of a hold o r a b o r t , the c a r r i e r c a n be automatically r e c o n nected to t h e vehicle to replenish o r d r a i n the LOX tank. Ejection: The LOX lines a r e drained and then purged with GNz b. just before engine ignition. The c a r r i e r a s s e m b l y i s pneumatically d i s connected by applying GN2 a t 750 psig to the locking m e c h a n i s m . The locking piston i s r e t r a c t e d , r e l e a s i n g the locking f i n g e r s to a d i a m e t e r s m a l l e r than the minimum d i a m e t e r of the vehicle plate r e c e p t a c l e . Pneum a t i c p r e s s u r e simultaneously actuates a switch i n the locking m e c h a n i s m , indicating the locking f i n g e r s a r e r e l e a s e d . A solenoid valve then c a u s e s the r e t r a c t cylinder to withdraw the c a r r i e r a s s e m b l y f r o m the vehicle. After the c a r r i e r a s s e m b l y i s c l e a r of the vehicle d r i f t envelope, a switch i s actuated, initiating s e r v i c e a r m rotation. The s e r v i c e a r m i s then hydraulically rotated to the tower and locked.

2.

Remarks

The i n t e r i o r of the c a r r i e r i s purged with GN2 a s a precaution to prevent possible explosive conditions in the vicinity of the c a r r i e r . 3. General a. b. Weight, pounds (Approximate) 5, 850 Envelope Dimensions, inches (Approximate) 110 x 63 x 180

Section I1 Um bilical Equipment

B-H 1077

F i g u r e 2-5.

S-IC Intertank Umbilical Ground Control T e s t Set

MSFC-MAN- 100

Section I1 Umbilical Equipment

S -1C INTERTANK UMBILICAL GROUND CARRIER CONTROL TEST S E T

Functional Description The I n t e r t a n k Umbilical Ground C a r r i e r Control T e s t s e t i s r e a. q u i r e d to s i m u l a t e ML c o n t r o l of t h e S-IC i n t e r t a n k u m b i l i c a l ground c a r r i e r . The s e t i s used i n m a n u a l o r automatic m o d e s t o check out p r o p e r o p e r a t i o n of the i n t e r t a n k umbilical ground c a r r i e r . The t e s t s e t p r o v i d e s nlanual c o n t r o l of a l l valves except t h e c a r r i e r latch, lock r e l e a s e , and purge v a l v e s . The t e s t s e t i s portable, with the upper half of t h e s e t u s e d t o b. s t o r e t h e two 18 foot c a b l e s and the lower half containing t h e c i r c u i t r y f o r monitoring and controlling t h e intertank umbilical ground c a r r i e r . I t contains switches and i n d i c a t o r s f o r operation of t h e i n t e r t a n k u m b i l i c a l ground c a r r i e r on initial installation and following component r e p l a c e m e n t t o indic a t e p r o p e r a d j u s t m e n t and c o r r e c t . o p e r a t i o n of the c a r r i e r . The m a n u a l mode of operation provides individual c o n t r o l of t h e c. solenoid valves i n t h e i n t e r t a n k umbilical ground c a r r i e r . This p e r m i t s the c a r r i e r to be stopped a t any point of t r a v e l . After t h e c a r r i e r h a s stopped, the p r e s s u r e r e g u l a t o r s o r l i m i t s w i t c h e s c a n be adjusted. d. T h e a u t o m a t i c m o d e o f connectionis u s e d t o c h e c k o u t p r o p e r o p e r a t i o n of t h e i n t e r t a n k umbilical ground c a r r i e r through a complete connection sequence. The switch lights on the t e s t s e t illuminate i n s e q u e n c e to indicate p r o p e r operation of t h e solenoid valves and l i m i t s w i t c h e s i n t h e c a r r i e r . Automatic r e t r a c t i o n i s used t o check out p r o p e r o p e r a t i o n of t h e c a r r i e r through a complete r e t r a c t sequence. Facility Requirements Power 2 8 vdc
3.

I

Demand 10 amps

General a. b. Weight, pounds (Approximate) Dinlensions, i n c h e s (Approximate)

4.

Remarks F o r additional information, r e f e r t o MSFC-MA.N- 00 1

Changed 25 August 1967

2-15

Section I1 Umbilical Equipment

MSFC-MAN- 100

S-IC STAGE UMBILICAL CARRIERS

F i g u r e 2-6.
2-16

S-IC Stage F o r w a r d Umbilical C a r r i e r (Sheet 1 of 3 )

M S F C - M A N - 100

Section I1 Umbilical Equipment

S-IC STAGE UMBILICAL CARRIERS

Figure 2-6.

S-IC Stage Forward Umbilical C a r r i e r (Sheet 2 of 3 )
2-17

S e c t i o n I1 Umbilical Equipment

MSFC-MAN- 100

S-IC STAGE UMBILICAL CARRIERS

F i g u r e 2-6. 2-18

S - I C S t a g e F o r w a r d U m b i l i c a l C a r r i e r ( S h e e t 3 of 3 )

MSFC-MAN- 100

Section I1 Umbilical Equipment

S-IC STAGE FORWARD UMBILICAL CARRIER 1. Functional D e s c r i ~ t i o n

The F o r w a r d Umbilical C a r r i e r contains v a r i o u s pneumatic a. couplings, eight e l e c t r i c a l connectors, and one 4-inch a i r conditioning coupling. It i s a p r e -flight disconnect, disconnecting a t approximately T - m i n u s - 10 seconds p r i o r to lift-off. The S-IC F o r w a r d Umbilical Flight P l a t e contains fluid d i s b. connect couplings and e l e c t r i c a l connectors. All couplings and c o n n e c t o r s on the flight plate a r e rigidly mounted. The c a r r i e r provides f o r coupling and connector alignment during mating. The c a r r i e r provides both p r i m a r y and s e c o n d a r y methods of ejecting the s e r v i c e lines f r o m the vehicle. ( 1 ) P r i m a r y Ejection Method: The c a r r i e r a s s e m b l y is ejected pneumatically f r o m the vehicle by applying GN2 a t 750 psig to the locking m e c h a n i s m . The r e l e a s e pin r e t r a c t s , r e l e a s i n g the locking m e c h a n i s m . Pneumatic p r e s s u r e simultaneously f o r c e s four pushoff pistons against the vehicle plate, disconnecting the c a r r i e r f r o m the plate. A lanyard routed f r o m the c a r r i e r to the pneumatically d r i v e n block and tackle r e t r a c t i o n device then pulls the c a r r i e r to the s e r v i c e a r m .
( 2 ) Secondary Ejection Method: If pneumatic f a i l u r e o c c u r s , the lanyard a c t u a t e s a m e c h a n i c a l r e l e a s e linkage on the c a r r i e r that d i s connects the umbilical c a r r i e r . As the lanyard i s withdrawn, the r e l e a s e a r m of the mechanical r e l e a s e linkage m o v e s outward, contacting the m a n u a l r e l e a s e knob on the locking m e c h a n i s m , and retricting the r e l e a s e pin. The locking m e c h a n i s m i s r e l e a s e d , and the pulloff a r m s on the s i d e s of the c a r r i e r Force the c a r r i e r away f r o m the vehicle plate. Additional lanyard motion then pulls the c a r r i e r to the s e r v i c e a r m . 2.

Remarks

The following precautions a r e taken to prevent possible explosive conditions i n the vicinity of the c a r r i e r . The shield of each e l e c t r i c a l connector i s grounded through a. a common w i r e to the vehicle.
b. 3.

The e l e c t r i c a l connectors in the c a r r i e r a r e purged with GN2.

General a. b. Weight, pounds (Approximate) 57 Envelope Dimensions, inches (Approximate) 3 4 x 30 x 15

Section 1 1 Umbilical Equipment

MSFC-MAN- 100

S-ll STAGE UMBILICAL CARRIERS

F i g u r e 2-7.

S-I1 Stage Umbilical C a r r i e r s

MSFC-MAN- 100 S-I1 STAGE UMBILICAL CARRIERS

Section I1 Umbilical Equipment

The S-I1 stage umbilical sys tem consists of a n intermediate umbilical c a r r i e r , a forward umbilical c a r r i e r , and two propellant f i l l and drain couplings. The c a r r i e r s and couplings a r e located a t the vehicle end of the service a r m s extending from the tower and secure the following service lines to the S-I1 stage of the Saturn V vehicle:
a. Electrical.

b. c. d. e
f

Pneumatic. Gaseous nitrogen (GN2). Liquid oxygen (LOX). Liquid hydrogen (LH2). Air conditioning. Hydrogen vent.

.
.

g.

The c a r r i e r s and the couplings provide primary and secondary methods of ejecting the service lines from the vehicle a t lift-off.

Section I1 Umbilical Equipment

MSFC-MAN- 100

S-ll STAGE UMBILICAL CARRIERS

Figure 2-8.

S-I1 Stage Intermediate Umbilical C a r r i e r

MSFC-MAN- 100

Section I1 Umbilical Equipment

S-I1 STAGE INTERMEDIATE UMBILICAL CARRIER 1. Functional Description

The Intermediate Umbilical C a r r i e r i s located 73O f r o m a. Position I toward P o s i t i o n 11. I t contains 30 pneumatic couplings, 12 e l e c t r i c a l c o n n e c t o r s , and two a i r conditioning couplings. The e l e c t r i c a l connectors can be ejected independently of the c a r r i e r a s s e m b l y f o r simulated flight t e s t and checkout p u r p o s e s . The c a r r i e r provides p r i m a r y and s e c o n d a r y methods of b. ejecting the s e r v i c e l i n e s f r o m the vehicle a t lift-off. : (1) P r i m a r y ~ j e c t i o n ' ~ e t h o dThe c a r r i e r i s disconnected f r o m the vehicle a f t e r the rise-off switches have been actuated. The c a r r i e r a s s e m b l y i s ejected pneumatically by applying GN2 a t 1250 psig simultaneously to the pushoff pis tons. The r e l e a s e pins then r e t r a c t , r e l e a s i n g the locking m e c h a n i s m . The pushoff pistons a r e f o r c e d . a g a i n s t the vehicle plate, disconnecting the c a r r i e r f r o m the vehicle. (2) Secondary Ejection Method: If p r i m a r y pneumatic f a i l u r e o c c u r s , a pneumatically d r i v e n lanyard a r r a n g e m e n t a c t u a t e s the mechanical r e l e a s e linkage, t h e r e b y disconnecting the c a r r i e r f r o m the vehicle.
( 3 ) If both p r i m a r y and s e c o n d a r y pneumatic f a i l u r e s o c c u r , the upward motion of the vehicle tightens the lanyard and c a u s e s the m e c h a n i c a l r e l e a s e linkage to actuate and' disconnect the c a r r i e r f r o m the vehicle.

2.

Remarks

The following precautions a r e taken to prevent possible explosive conditions i n the vicinity of the c a r r i e r s : a. The shield of e a c h e l e c t r i c a l connector i s grounded through a common w i r e to the vehicle. b. with G N 2 . 3. General a. b. Weight, pounds (Approximate) 500 Envelope Dimensions, inches (Approximate) 70 x 75 x 15 The e l e c t r i c a l connectors i n the c a r r i e r a r e purged

Section I1 Umbilical Equipment

MSFC-MAN- 100

S-ll STAGE UMBILICAL CARRIERS

F i g u r e 2-9.

S-I1 Stage F o r w a r d Umbilical C a r r i e r

MSFC-MAN- 100

Section I1 Umbilical Equipment

S-I1 STAGE FORWARD UMBILICAL CARRIER 1. Functional Description

The F o r w a r d Umbilical C a r r i e r c o n s i s t s of v a r i o u s a. pneumatic couplings, eight e l e c t r i c a l c o n n e c t o r s , and two 7 -inch GH2 vent couplings. The e l e c t r i c a l connectors can be ejected independently of the c a r r i e r a s s e m b l y for simulated flight t e s t and checkout p u r p o s e s . b. The c a r r i e r provides p r i m a r y and s e c o n d a r y methods of ejecting the s e r v i c e l i n e s f r o m the vehicle a t lift-off. ( 1) P r i m a r y Ejection Method: After the vehicle r i s e -off switches have been a c t u a t e d , the c a r r i e r i s ejected pneumatically by applying GN2 a t 1250 psig simultaneously to each locking m e c h a n i s m and the pushoff pistons. The r e l e a s e pins then r e t r a c t , r e l e a s i n g the locking m e c h a n i s m . The p r e s s u r i z e d pushoff pistons then f o r c e the c a r r i e r away f r o m the vehicle, and the pneumatic withdrawal cylinder moves the c a r r i e r to the s e r v i c e a r m .

(2) Secondary Ejection M c thod: If p r i m a r y pneumatic f a i l u i e o c c u r s , a pneumatically d r i v e n lanyard a r r a n g e m e n t actuate's the mechanical r e l e a s e linkage, disconnecting the c a r r i e r f r o m the vehicle.
( 3 ) If both p r i m a r y and s e c o n d a r y pneumatic f a i l u r e s o c c u r , the upward motion of the vehicle tightens the lanyard and c a u s e s the mechanical r e l e a s e linkage to disconnect the c a r r i e r f r o m the vehicle

2.

Remarks

The following precautions a r e taken to prevent possible explosive conditions in the vicinity of the c a r r i e r s . The shield of e a c h e l e c t r i c a l connector i s grounded a. through a common w i r e to the vehicle. The c a r r i e r i s purged between the e l e c t r i c a l connectors b. and the fuel tank vent line with GN2.

3.

General a. b.

580 Weight, pounds (Approximate) Envelope Dimensions, inches (Approximate) 6 3 x 6 4 x 2 3

Section I1 U m b i l i c a l Equipment

MSFC-MAN-100
S-ll STAGE UMBILICAL CARRIERS

CARRIER ENVELOPE DIMENSIONS APPROXIMA

F i g u r e 2-10.
2-26

S-I1 S t a g e LOX/LH2 P r o p e l l a n t Couplings (Sheet 1 of 2 )

MSFC-MAN- 100

Section I1 Umbilical Equipment

S-II STAGE UMBILICAL CARRIERS

F i g u r e 2 - 10.

S-I1 S t a g e L O X / L H 2 P r o p e l l a n t Couplings (Sheet 2 of 2 )
2 - 27

Section I1 Umbilical Equipment

MSFC-MAN- 100

S-I1 STAGE LOXILH2 PROPELLANT COUPLINGS 1. Functional Description

a. The two 8-inch propellant couplings a r e identical. They s e c u r e the liquid hydrogen (LH2) and liquid oxygen (LOX) s e r v i c e lines t o the S-I1 stage of the vehicle. Debris valves a r e used on t h e s e couplings t o prevent d e b r i s f r o m contaminating the propellant lines at disconnect. b. Since the couplings a r e independent of the main c a r r i e r , they r e q u i r e t h e i r own r e l e a s e systems, both p r i m a r y and secondary. (1) P r i m a r y Ejection Method: The two propellant couplings a r e ejected by appling G H at 750 psig simultaneously to the locking ~ mechanisms and pushoff pistons. The r e l e a s e pins then r e t r a c t , releasing the locking mechanism. The pushoff pistons then eject the two couplings f r o m the vehicle. A lanyard attached t o the r e l e a s e pin of each locking mechanism pulls the couplings and attached propellant lines t o the s e r v i c e arm. (2) Secondary Ejection Method: If pneumatic f a i l u r e o c c u r s , the lanyards r e l e a s e the locking mechanisms by r e t r a c t i n g the r e l e a s e pins and then pull the couplings t o the s e r v i c e a r m . 2. General a. b. Weight, pounds (Approximate) 125 (each) Envelope Dimensions, inches (Approximate) 21 x 17 x 30 (each)

Changed 25 August 1967

MSFC-MAN- 1 0 0

S e c t i o n I1 Umbilical Equipment

S-IVB STAGE/I.U. UMBILICAL CARRIERS

F i g u r e 2-1 1.

S - I V B S t a g e / I . U. U m b i l i c a l C a r r i e r s

Section I1 MSFC-.VAN- 100 Umbilical Equipment , *, S-IVB STAGE /I. U. UMBILICAL CARRIERS

...

I

The S -1VB stage /I. U. umbilical s y s t e m c o n s i s t s of the S-IVB a f t umbilical c a r r i e r and the S-IVB f o r w a r d / I . U. umbilical c a r r i e r s b r a c k e t e d together a s a common unit. The c a r r i e r s a r e located a t the vehicle end of the s e r v i c e a r m s extending f r o m the tower and s e c u r e the following s e r v i c e l i n e s to the S -1VB stage /I. U. of the S a t u r n V vehicle: a.
b.

Electrical. Pneumatic. Gaseous nitrogen (GN2). Liquid oxygen (LOX). Liquid hydrogen (LH2). A i r conditioning Hydrogen vent. A i r bearing s p h e r e .

c, d. e.
f.

.

g. h.

The c a r r i e r s provide p r i m a r y and s e c o n d a r y methods of ejecting the s e r v i c e l i n e s f r o m the vehicle a t lift-off.

M S F C - M A N - 100

S e c t i o n I1 Unlbilical Equipment

S-IVB STAGE/I.U. UMBILICAL CARRIERS

CARRIER ENVELOPE DIMENSIONS APPROXIMATE

F i g u r e 2-12.

S - I V B S t a g e Aft U m b i l i c a l C a r r i e r

2-31

S e c t i o n I1 Umbilical Equipment

MSFC-MAN- 100

S-IVB S T A G E A F T UMBILICAL CARRIER 1. Functional Desc r i ~ t i o n

a . T h e Aft U n l b i l i c a l C a r r i e r c o n t a i n s v a r i o u s p n e u n l a t i c c o u p l i n g s , s i x e l e c t r i c a l c o n n e c t o r s , a n d t w o 4 - i n c h LOX a n d LM2 c o u p l i n g s . T h e e l e c t r i c a l c o n n e c t o r s c a n be e j e c t e d i n d e p e n d e n t l y of t h e c a r r i e r a s s e m b l y f o r s i m u l a t e d flight t e s t a n d c h e c k o u t p u r p o s e s . T h e LOX a n d LH2 c o u p l i n g s a r e c o n t a i n e d i n t h e m a i n c a r r i e r a n d d i s c o n n e c t a s a unit. a b. T h e c a r r i e r p r o v i d e s p r i n ~ a r y n d s e c o n d a r y m e t h o d s of e j e c t i n g t h e s e r v i c e l i n e s f r o m t h e v e h i c l e a t lift-off. ( 1 ) P r i m a r y E j e c t i o n Method: T h e c a r r i e r i s u n l o c k e d f r o m t h e v e h i c l e by t h e two s i d e - m o u n t e d p n e u n l a t i c l o c k i n g n ~ e c h a n i s n l s a f t e r the vehicle rise-off switches have been actuated. T o r e l e a s e the l o c k i n g m e c h a n i s m s , GN2 a t 1250 p s i g i s s i m u l t a n e o u s l y a p p l i e d t o e a c h m e c h a n i s m a n d t h e pushoff p i s t o n s . T h e r e l e a s e p i n s r e t r a c t , u n l o c k i n g t h e c a r r i e r f r o m t h e v e h i c l e . T h e p r e s s u r i z e d pushoff p i s t o n s t h e n f o r c e the c a r r i e r away f r o m the vehicle, and the pneumatic withdrawal cylinder moves it to the service a r m .

( 2 ) S e c o n d a r y E j e c t i o n Method: If p r i m a r y p n e u m a t i c f a i l u r e o c c u r s , a pneuulatically driven l a n y a r d a r r a n g e m e n t a c t u a t e s t h e nlechanical r e l e a s e linkage, thereby disconnecting the c a r r i e r f r o m the vehicle.
( 3 ) If b o t h p r i m a r y a n d s e c o n d a r y p n e u m a t i c f a i l u r e s o c c u r , t h e r i s i n g m o t i o n of t h e v e h i c l e t i g h t e n s t h e l a n y a r d a n d c a u s e s t h e rmechanical r e l e a s e l i n k a g e t o a c t u a t e a n d d i s c o n n e c t t h e c a r r i e r f r o m t h e vehicle.
2.

Remarks

T h e following p r e c a u t i o n s a r e t a k e n t o p r e v e n t p o s s i b l e e x p l o s i v e c o n d i t i o n s i n t h e v i c i n i t y of t h e c a r r i e r . a. t h e vehicle.
b.

T h e s h i e l d of e a c h e l e c t r i c a l c o n n e c t o r i s g r o u n d e d t o

T h e i n t e r i o r of t h e c a r r i e r i s p u r g e d i n f o u r l o c a t i o n s

with GN2.

MSFC-MAN- 100

Section I1 Umbilical Equipment

3.

General a.
b.

Weight, pounds (Approximate) 293 Envelope Dimensions, i n c h e s (Approximate) 57 x 45 x 2 1

Section I1 Urn bilical Equipment

MSFC-MAN- 100

S-IVB STAGE/I.U. UMBILICAL CARRIERS

MSFC-MAN- 100

Section I1 U m b i l i c a l Equipment

S-IVB STAGE FORWARD /I. U. UMBILICAL CARRIER Functional D e s c r i p t i o n T h e S-IVB F o r w a r d Umbilical C a r r i e r contains eight a. e l e c t r i c a l c o n n e c t o r s and one 6-inch GH2 vent coupling. T h e e l e c t r i c a l c o n n e c t o r s c a n b e e j e c t e d independently of t h e c a r r i e r a s s e m b l y f o r s i m ulated flight t e s t a n d checkout p u r p o s e s . T h i s c a r r i e r i s connected t o t h e I. U. Umbilical C a r r i e r by s i d e b r a c k e t s and they a r e disconnected a s a unit. b. T h e I . U. Umbilical C a r r i e r c o n s i s t s of five pneumatic couplings, s i x t e e n e l e c t r i c a l c o n n e c t o r s , and one 6-inch a i r conditioning coupling.

c. T h e S-IVB f o r w a r d c a r r i e r and I. U. c a r r i e r a r e held t o g e t h e r by s i d e b r a c k e t s a t t h e end of one c o m m o n s e r v i c e a r m . T h e ends of t h e b r a c k e t s , which extend down p a s t t h e f o r w a r d c a r r i e r , s e r v e a s pivot points f o r the c a r r i e r a s s e m b l i e s when they a r e d i s c o n n e c t e d .
( 1 ) P r i m a r y Ejection Method: T h e S-IVB f o r w a r d c a r r i e r and I . U. c a r r i e r a r e disconnected f r o m t h e vehicle a f t e r t h e vehicle rise-off s w i t c h e s have b e e n actuated. T o r e l e a s e t h e locking m e c h a n i s m , GN2 a t 7 5 0 p s i g i s simultaneously applied t o t h e f o u r pushoff p i s t o n s contained i n t h e I. U. c a r r i e r . The r e l e a s e pin r e t r a c t s , unlocking t h e c a r r i e r s f r o m the vehicle. T h e pushoff pistons a r e f o r c e d a g a i n s t t h e vehicle p l a t e , r e l e a s i n g t h e c a r r i e r s f r o m t h e vehicle. T h e pneumatic w i t h d r a w a l c y l i n d e r then m o v e s the c a r r i e r s t o the s e r v i c e a r m . ( 2 ) Secondary E j e c t i o n Method: If p r i m a r y pneumatic f a i l u r e o c c u r s , a pneumatically driven l a n y a r d a r r a n g e m e n t a c t u a t e s t h e m e c h a n i c a l r e l e a s e linkage, disconnecting t h e c a r r i e r s f r o m t h e vehicle. ( 3 ) If both p r i m a r y and s e c o n d a r y pneumatic f a i l u r e s o c c u r , t h e upward motion of t h e vehicle tightens t h e l a n y a r d and c a u s e s t h e m e c h a n i c a l r e l e a s e linkage t o a c t u a t e and disconnect t h e c a r r i e r s f r o m the vehicle.

Section I1 Umbilical Equipment
2.

MSFC-MAN- 100

Remarks

-

The following precautions a r e taken to prevent pos sible explosive conditions in the vicinity of both c a r r i e r s . a . The shield of e a c h e l e c t r i c a l connector i s grounded through a common w i r e to the vehicle.

b.
3.

The i n t e r i o r of the c a r r i e r i s purged with GN

2'

General a. Weight, pounds (Approximate) S-IVB F o r w a r d Umbilical C a r r i e r I . U . Umbilical C a r r i e r b.

135
100

Envelope Dimensions, inche s (Approximate) S-IVB F o r w a r d / I . U. Umbilical C a r r i e r

70 x 1 9 x 1'

MSFC-MAN- 100

Section I11 Servicing Equipment

SECTION Ill SERVICING EQUIPMENT
This section p r e s e n t s information on the various launch vehicle ground support s e r v i c e units, with a brief description and a visual presentation of e a c h unit. The section i s sub-divided into the S-IC stage s e r v i c i n g equipment, the S-I1 stage, t h e S-IVB stage, the I. U. , and the Launch Vehicle s e r v i c i n g equipment. The s e r v i c i n g equipment provides ground support t o t h e S a t u r n V vehicle b e f o r e lift-off a s well a s the nece-ssary auxiliary support f o r s e r v i c e , checkout, and launch operations. T h i s section will b e r e v i s e d a n d / o r added t o a s m o r e information on the s e r v i c i n g equipment becomes available.

I

Changed 25 August 1967

Section I11 Servicing Equipment

I

S-IC FORWARD INTERFACE PLATE

I

JST

I
T A I L SERVICE MAST NO. 12 INTERFACE PLATE

I

I

I
T A I L SERVICE MAST NO. 32 INTERFACE PLATE

I
T A I L SERVICE MAST NO. 34 INTERFACE PLATE

1
H O L D DOWN ARM Ill INTERFACE PLATE

F i g u r e 3 - 1. 3-2

S-IC Pneumatic Ground Support Equipment

Changed 25 August 1967

MSFC-MAN- 100

Section I11 Servicing Equipment

S-IC PNEUMATIC GROUND SUPPORT EQUIPMENT 1. Functional D e s c r i ~ t i o n

The S -1C Pneumatic Ground Support Equipment supplies p r e s s u r e a. regulated nitrogen and helium g a s e s to the S-IC stage t o s a t i s f y both o p e r ational and t e s t and checkout requirements. The equipment, located i n the M L b a s e , c o n s i s t s of the pneumatic console, the pneumatic checkout r a c k s , the f o r w a r d umbilical s e r v i c e console, and the portable t e s t e r s . The pneumatic console consists of two groups of r a c k s with f o u r b. r a c k s in each group. The pneumatic checkout r a c k s consist of four r a c k s in one group. The forward umbilical s e r v i c e console i s i n a s e p a r a t e cabinet. The portable t e s t e r s c o n s i s t of two t e s t e r s , e a c h in i t s own "suitcase", f o r the pneumatic console, and four t e s t e r s , two t o a "suitc a s e " , f o r the pneumatic checkout r a c k s . In addition, t h e r e i s a s e p a r a t e t e s t s e t f o r the forward umbilical s e r v i c e console. 2. Facilitv Requirements a. Power (1) 110 vac, 60 c p s , single phase (2) 28 vdc Demand To be determined To be determined

I

b.

Gaseous Media Nitrogen a t 3800 psig minimum t o 6600 psig m a x i m u m . (1) Helium a t 3800 psig m i n i m u m to 6600 psig maximum. (2)

Changed 2 5 August 1967

3-3

Section 1 1 1 Yervicing E q u i p m e n t

MSFC-MAN- 100

S-IC PNEUMATIC GROUND SUPPORT EQUIPMENT

F i g u r e 3-2.

S-IC P n e u m a t i c C o n s o l e

MSFC-MAN- 100 S-IC PNEUMATIC CONSOLE 1. Functional D e s c r i ~ t i o n

Section I11 Servicing Equipment

The S-IC Pneumatic Console c o n s i s t s of a p r i m a r y regulation a. module and eleven s e c o n d a r y regulation modules. The p r i m a r y regulation m o d a l e r e g u l a t e s facility g a s e s t o provide stable input to the s e c o n d a r y regulation modules. The secondary regulation modules supply operating p r e s s u r e s d i r e c t l y t o the S-IC s t a g e and t o the pneumatic checkout r a c k s .

u. The pneumatic console modules and t h e i r p r i m a r y functions a r e a s follows:
The helium and nitrogen p r i m a r y regulation module i s t h e (1) f i r s t s t a g e of pneumatic regulation i n the pneumatic console. I t is capable of regulating t o approximately 3500 psig e r r a t i c facility supplies of helium and n i t r o g e n varying f r o m 3800 t o 6600 psig. The LOX tank p r e p r e s s u r i z a t i o n module supplies h e l i u m a t (2) approximately 1840 psig a t a flow r a t e of 240. 0 pounds p e r m i n u t e to the LOX tank ullage t o e n s u r e -a positive LOX supply a t the turbopumps. The LOX and fuel tank purge module supplies a positive (3) p r e s s u r e i n both s t a g e tanks to prevent a t m o s p h e r i c contamination o r tank damage during e x t r e m e t e m p e r a t u r e drops. The module h a s an output of five t o eight psig a t low f16w r a t e s . The fuel tank p r e p r e s s u r i z a t i o n module supplies h e l i u m a t (4) 2065 (t25). psig to the tank ullage, p r i o r to engine ignition, t o e n s u r e a positive f u e l supply a t the turbopumps. Flow r a t e i s 240 pounds p e r minute, m a x i m u m . The LOX bubbling module introduces h e l i u m into t h e LOX (5) suction l i n e s above the prevalves t o prevent g e y s e r i n g and t e m p e r a t u r e stratification. Module output i s approximately 395 psig a t 0. 78 pounds p e r minute. The h e l i u m bottle f i l l module p r e s s u r i z e s the a i r b o r n e h e l i u m bottles i n two s e p a r a t e s t e p s . The f i r s t r e q u i r e m e n t is s e t by the d e s i g n s t r e n g t h of t h e bottles a t ambient t e m p e r a t u r e s , which i s limited to approximately 1600 psig. Normal loading r a t e i s 3 1 pounds p e r minute. This p r e s s u r e i s reached before LOX loading when the bottles a r e w a r m . The second r e q u i r e m e n t i s based on the amount of helium used by the s t a g e during flight f o r p r e s s u r i z a t i o n of the fuel tank ullage. This p r e s s u r e , 3260 psig,is reached a f t e r LOX loading when the bottles a r e cold. The nominal loading r a t e i s 58 pounds p e r minute.

(6)

Section I11 Servicing Equipment

MSFC-MAN- 100

The valve control module supplies nitrogen t o operate t h r e e (7) LOX f i l l and d r a i n valves, the fuel f i l l and d r a i n valve, the LOX i n t e r connect valve no. 2, and the LOX and fuel prevalves. Delivered flow r a t e to each valve i s approximately 6.0 pounds p e r minute a t approximately 725 psig. The control p r e s s u r e bottle fill module p r e s s u r i z e s t h e (8) stage nitrogen s t o r a g e s p h e r e s during two p r e s s u r i z a t i o n cycles. The f i r s t cycle c a l l s for a p r e s s u r e of approximately 1500 psig p r i o r t o fuel loading. The second cycle c a l l s f o r approximately 3250 psig, the d e s i r e d in-flight supply. Delivered flow r a t e i s 36. 0 pounds per minute. The high and low p r e s s u r e t e s t module supplies high p r e s (9) s u r e nitrogen a t approximately 3300 psig and 42.0 pounds p e r minute and low p r e s s u r e nitrogen a t approximately 750 psig a t 6.0 pounds per minute t o the pneumatic checkout r a c k s . ( 10) The fuel bubbling module injects nitrogen a t approximately 105 psig a t 0.60 pounds p e r minute and a flow of 15, 000 scirn into the fuel suction duct during LOX loading and replenishing. This nitrogen agitates the fuel and r e d u c e s t e m p e r a t u r e and density variations i n the fuel. (11) The LOX dome purge module prevents contaminants f r o m e n t e r i n g the LOX injection p a r t s of the F - 1 engine and gas generator. The module provides two nitrogen purge r a t e s a t s e p a r a t e t i m e i n t e r v a l s . The lower purge r a t e , 95 psig and 75. 0 pounds p e r minute, i s initiated whene v e r the c o v e r s a r e removed f r o m the engines o r when the fuel i s aboard the stage. The higher purge r a t e , 755 psig and 525.0 pounds p e r minute, i s initiated just p r i o r t o engine ignition and provides a blowout of t h e LOX i n j e c t o r s i n c a s e of engine cutoff and abort. 2. General a. b. Weight, pounds (Approximate) Location i n M L ( B a s e ) 6000 Compartment A - 13

Ill

3-6

Changed 25 August 1967

M S F C - M A N - 100

Section 1 1 1 Servicing Equipment

S-IC PNEUMATIC GROUND SUPPORT EQUIPMENT

Figure 3-3.

S-IC P n e u m a t i c Checkout R a c k s 1 and 2 (Sheet 1 of 2 )

Section I11 S e r v i c i n g Equipment

MSFC-MAN- 100

S-lC PNEUMATIC GROUND SUPPORT EQUIPMENT

Figure 3-3.

S - I C P n e u m a t i c Checkout Racks 3 a n d 4 (Sheet 2 of 2 )

MSFC-MAN- 100

Section III Servicing Equipment

S-IC PNEUMATIC CHECKOUT RACKS 1. Functional Description

The S-IC Pneumatic Checkout Racks provide p r e s s u r e regulated a. nitrogen gas f o r t e s t and checkout of p r e s s u r e switches and pneumatically actuated valves i n the S-IC stage propulsion systems. The r a c k s regulate, control, and monitor the gaseous media required to check out the S-IC stage. Normal operation i s by commands f r o m the computer; c e r t a i n functions can a l s o be commanded by the launch crew i n the Launch Control Center (LCC) when required. The S-IC Pneumatic Checkout Racks consist of four r a c k s which directly to the stage to check operation of various p r e s supply s u r e switches and pneumatically actuated valves.

b.

Pneumatic Checkout Rack #1 provides regulated GN2 to the c. following stage components f o r the following purposes :
(1)

Calibration verification of the engine cutoff p r e s s u r e switches

a t 47 psig.
(2)

Calibration verification of the LOX tank p r e s s u r e switches

a t 25 psig.
(3)

T e s t actuation of the COX flow control valve a t 1 0 psig.

Pneumatic Checkout Rack # 2 provides regulated GN2 to the d. following stage components f o r the following purposes :
(1)

Calibration verification of the fuel tank p r e s s u r e switches

a t 50 psig.
( 2 ) Calibration verification of the purge s y s t e m p r e s s u r e switches a t '190 psig.

(3)

T e s t actuation of the ignition monitor valve a t 50 psig.

S e c t i o n I11 Servicing Equipment

MSFC-MAN- 100

P n e u m a t i c Checkout R a c k #3 p r o v i d e s r e g u l a t e d GN2 t o t h e e. following s t a g e components f o r t h e following p u r p o s e s : C a l i b r a t i o n v e r i f i c a t i o n of the c o n t r o l p r e s s u r e s y s t e m (1) p r e s s u r e s w i t c h e s a t 3 , 2 0 0 psig. C a l i b r a t i o n v e r i f i c a t i o n of t h e c o n t r o l p r e s s u r e s y s t e m (2) p r e s s u r e s w i t c h e s a t 750 psig. (3) T e s t a c t u a t i o n of the GOX flow c o n t r o l v a l v e a t 1, 500 psig.

P n e u m a t i c Checkout R a c k # 4 p r o v i d e s r e g u l a t e d GN2 t o the f. following s t a g e c o m p o n e n t s f o r t h e following p u r p o s e s : (1) a t 3 , 2 0 0 psig. C a l i b r a t i o n v e r i f i c a t i o n of t h e h e l i u m p r e s s u r e s w i t c h e s

C a l i b r a t i o n v e r i f i c a t i o n of the " T h r u s t OK" p r e s s u r e (2) s w i t c h e s a t 1 , 7 7 5 psig. 2. General a. b. Weight, pounds ( A p p r o x i m a t e ) Location i n ML (Base) 3,600 C o m p a r t m e n t B - 13

Changed 2 5 August 196 7

MSFC-MAN- 100

S e c t i o n I11 Servicing Equipment

Figure 3-4.

S - I C F o r w a r d U m b i l i c a l S e r v i c e C o n s o l e a n d T e s t Set

3-11

S e c t i o n I11 S e r v i c i n g Equipment

MSFC-MAN- 100

S - I C FORWARD UMBILICAL SERVICE CONSOLE 1. Functional Description

"

T h e f o r w a r d u m b i l i c a l s e r v i c e console c o n s i s t s of t h r e e n i t r o g e n a. r e g u l a t i o n m o d u l e s and a n e l e c t r i c a l d i s t r i b u t i o n d r a w e r . F a c i l i t i e s a i r at 1248 (-2 50) SCIM and 50 p s i g i s supplied to t h e console f o r continuous t p u r g e of t h e cabinet i n t e r i o r . E s c a p e of p u r g e a i r f r o m t h e cabinet i s c o n t r o l l e d by a c a l i b r a t e d bleed. The f o r w a r d u m b i l i c a l s e r v i c e console m o d u l e s and t h e i r p r i m a r y b. functions a r e a s follows: The c a m e r a l e n s p u r g e module s u p p l i e s heated n i t r o g e n a t (1) 350 p s i g and 4 . 0 pounds p e r m i n u t e , and a t 100 psig and 0.75 pounds p e r m i n u t e , t o the c a m e r a s y s t e m f o r l e n s p u r g e and s t r o b e light purge. The c a m e r a e j e c t s p h e r e f i l l module s u p p l i e s n i t r o g e n a t (2) 3000 p s i g and 10 pounds p e r m i n u t e ( m a x i m u m ) t o a s t o r a g e c o n t a i n e r f o r c a m e r a ejection. I t a l s o s u p p l i e s n i t r o g e n regulated t o 3000 psig t o t h e c a m e r a l e n s p u r g e module. T h e COX tunnel purge module supplies n i t r o g e n a t 3000 (3) psig and 81 pounds p e r m i n u t e t o t h e f o r w a r d u m b i l i c a l plate f o r GOX tunnel purging. 2. General a. b. Weight, pounds ( A p p r o x i m a t e ) Location i n ML (Base) 3,000 C o m p a r t m e n t A - 13

a

Changed 25 August 1967

MSFC-MAN-100

S e c t i o n I11 Servicing Equipment

S-IC PNEUMATIC GROUND SUPPORT EQUIPMENT

B-H 1082

HELIUM I TESTER

F i g u r e 3-5.

S - I C P n e u m a t i c P o r t a b l e T e s t e r s ( S h e e t 1 of 3 )

3-13

ction 1 1 1 rvicing Equipment

MSFC-MAN- 100

S-IC PNEUMATIC GROUND SUPPORT EQUIPMENT

NITROGEN I TESTER

F i g u r e 3-5.
14

S-IC P n e u m a t i c P o r t a b l e T e s t e r s (Sheet 2 of 3 )

MSFC-MAN- 100 S e r v i c i n g equip men^

F i g u r e 3-5.

S - I C P n e u m a t i c P o r t a b l e T e s t e r s (Sheet 3 of 3 )

S e c t i o n I11 Servicing Equipment

MSFC-MAN-100

S - I C PNEUMATIC PORTABLE TESTERS 1. Functional Description

T h e S - I C P n e u m a t i c P o r t a b l e T e s t e r s a r e provided f o r checking a. continuity of e l e c t r i c a l components of the pneumatic c o n s o l e and checkout r a c k s . Two t e s t e r s a r e used f o r t e s t i n g the pneumatic c o n s o l e , e a c h i n i t s own " s u i t c a s e " , and f o u r t e s t e r s a r e u s e d f o r t e s t i n g the checkout r a c k s , two t o a " s u i t c a s e " . In addition t o t h e s e , a s e p a r a t e t e s t e r i s p r o v i d e d , i n i t s own " s u i t c a s e " , f o r t h e f o r w a r d u m b i l i c a l s e r v i c e c o n s o l e . T h e pneumatic console t e s t e r s c o n s i s t of a s e l e c t o r s w i t c h , v o l t b. m e t e r , t o g g l e s w i t c h e s , and i n d i c a t o r lights mounted on a panel in a "suitcase". T h e s e l e c t o r switch and v o l t m e t e r a r e used t o t e s t p r e s s u r e t r a n s d u c e r s i n t h e console. E l e c t r i c a l power i s applied t o solenoid v a l v e s i n t h e c o n s o l e by t h e toggle s w i t c h e s . Position s w i t c h e s on t h e v a l v e s c o n t r o l l i g h t s on t h e t e s t e r panel indicating when the valves a r e opened o r c l o s e d . O t h e r lights on t h e t e s t e r panels i n d i c a t e w h e t h e r p r e s s u r e s w i t c h e s a r e actuated o r deactuated. The p r e s s u r e s w i t c h e s and t r a n s d u c e r s a r e a c t u a t e d by applying p n e u m a t i c p r e s s u r e to the s y s t e m .

A s e p a r a t e t e s t e r i s provided f o r e a c h of the four p n e u m a t i c c. checkout r a c k s . E a c h t e s t e r c o n s i s t s of a v o l t n l e t e r , toggle s u i t c h e s , and i n d i c a t o r l i g h t s mounted on a panel. The v o l t m e t e r s a r e used to c h e c k t h e output of t h e checkout r a c k p r e s s u r e t r a n s d u c e r s and s e r v o a m p l i f i e r s . T h e v o l t m e t e r d i a l s a r e c a l i b r a t e d in p s i and indicate line p r e s s u r e s . E l e c t r i c a l power i s applied t o solenoid v a l v e s i n the checkout r a c k s by the toggle s w i t c h e s . P o s i t i o n s w i t c h e s on t h e v a l v e s c o n t r o l lights on t h e t e s t e r p a n e l s indicating v a l v e s a r e open o r closed. O t h e r lights on the t e s t e r p a n e l s i n d i c a t e w h e t h e r the p r e s s u r e s w i t c h e s a r e actuated o r d e a c u a t e d . The p r e s s u r e s w i t c h e s and t r a n s d u c e r s a r e a c t u a t e d by applying p n e u m a t i c p r e s s u r e t o the s y s t e m .
d. T h e f o r w a r d u m b i l i c a l s e r v i c e console t e s t e r i s used t o t e s t t h e two r a c k s of t h e s e r v i c e c o n s o l e t h a t supply g a s e s to the forwarcl s t a g e u m b i l i c a l and contain t h e following n>odules: (1) (2) (3) C a m e r a e j e c t s p h e r e fill module C a m e r a l e n s p u r g e module GOX - tunnel p u r g e m o d u l e .

2.

General a. b. Weight, pounds ( A p p r o x i m a t e ) Dimensions, inches (Approxinlate)

45 (each) 23 x 19 x 12

MSFC-MAN- 100

S e c t i o n I11 Servicing Equipment

LAUNCHER OFF-ML

-- II

ENGINE SERVICING GROUND TOMOBILELAUNCHER I/F PLATE
I

I

RJ-I/ ETHYLENE GLYCOL TRUCK

F i g u r e 3-6.

S - I C H y d r a u l i c Supply a n d Checkout Unit Changed 25 August 1967 3-17

S e c t i o n I11 Servicing Equipment

MSFC-MAN- 100

S-IC HYDRAULIC S U P. P -L Y AND CHECKOUT UNIT . 1. Functional Description

a. T h e S-IC H y d r a u l i c Supply a n d Checkout Unit i s r e q u i r e d f o r functional g i m b a l of t h e f o u r o u t b o a r d engines of t h e S-IC s t a g e , checkout of t h e S - I C " T h r u s t OK" p r e s s u r e s w i t c h e s , a n d c o n t r o l of t h e engine v a l v e s of t h e five F-1 engines d u r i n g i n i t i a l f i r i n g a n d t h r u s t buildup. S i x p r i m a r y s y s t e m s a c c o m p l i s h t h e s e functions; t h e y a r e t h e fuel, s e r v o h y d r a u l i c , p n e u m a t i c , cooling w a t e r , h y d r a u l i c w a s t e , a n d electrical systems. ( 1 ) T h e f u e l s y s t e m s u p p l i e s fluid, a t a c o n t r o l l e d p r e s s u r e o v e r a wide r a n g e of flow r a t e s , t o t h e f u e l s y s t e m of t h e S-IC b o o s t e r . P r e s s u r e s r a n g e f r o m 0 t o 2500 p s i g a n d flows r a n g e f r o m 0 t o 2 6 0 gpm. ( 2 ) T h e s e r v o h y d r a u l i c s y s t e m p r o v i d e s high p r e s s u r e h y d r a u l i c fluid t o o p e r a t e t h e s e r v o v a l v e s on t h e t h r e e m a i n p u m p s . T h e s e v a l v e s c o n t r o l t h e d i s p l a c e m e n t of t h e t h r e e m a i n p u m p s t o m a i n t a i n a c o n s t a n t output p r e s s u r e d e s p i t e c h a n g e s i n flow demand.
( 3 ) T h e p n e u m a t i c s y s t e m u s e s GNZ f o r supplying a low p r e s s u r e blanket on t o p of t h e m a i n h y d r a u l i c r e s e r v o i r a s a f i r e p r o t e c t i o n d e v i c e , providing p r e c h a r g e gas t o t h e a c c u m u l a t o r s i n t h e f u e l a n d . s e r v o o i l s y s t e m s , a n d p r o v i d i n g g a s p r e s s u r e f o r t h e o p e r a t i o n of t h e t h r e e l a r g e s e l e c t o r v a l v e s which c o n t r o l t h e m a i n h y d r a u l i c fluid loop.
( 4 ) T h e cooling w a t e r s y s t e m i s e s s e n t i a l t o t h e p r o p e r o p e r a t i o n of t h e unit t o p r e v e n t o v e r h e a t i n g .

( 5 ) T h e h y d r a u l i c w a s t e s y s t e m i s r e q u i r e d due t o t h e t h r e e s e r v o v a l v e s having a b u i l t - i n l e a k a g e f a c t o r t o m a i n t a i n a d y n a m i c e r r o r i n the servo control system a t all times.

( 6 ) T h e e l e c t r i c a l s y s t e m provides power t o operate the various p u m p m o t o r s on t h e h y d r a u l i c power unit, p r o v i d e s c o n t r o l c i r c u i t s f o r s e l e c t i n g t h e m o d e of o p e r a t i o n a n d providing n e c e s s a r y i n t e r l o c k s and control programming, provides a n electronic s e r v o s y s t e m which c o n t r o l s t h e d i s p l a c e m e n t of t h e m a i n p u m p s t o m a i n t a i n a u n i f o r m output p r e s s u r e , a n d p r o v i d e s i n s t r u m e n t a t i o n f o r m o n i t o r i n g t h e o p e r a t i o n of c r i t i c a l functional e l e m e n t s .

Changed 25 August 1967

MSFC-MAN- 100

Section 1 1 1 Servicing Equipment

The unit i s activated a t approximately T-minus -8 h o u r s and b. continues t o o p e r a t e until it i s automatically shut down a t approximately T - p l u s - 5 seconds by the " T h r u s t OK" p r e s s u r e switches. The S-IC hydraulic supply and checkout unit c o n s i s t s of the c. hydraulic power unit, the motor control c e n t e r , and the s y s t e m checkout cons ole. 2. Facility Requirements a. Power ( 1 ) 480 vac, 60 cps, 3 phase ( 2 ) 120 vac, 400 c p s , single phase ( 3 ) 28 vdc Cooling water 125 gpm a t 60 psig and 45O F. Gaseous Nitrogen (GN2) 3,000 psig m a x i m u m Demand 600 a m p s 5 amps 25 a m p s

b.

c.

3.

General Weight, pounds (Approximate) 38, 100 ( t o t a l unit)

4.

Remarks F o r additional information, r e f e r t o MSFC-MAN-006.

Changed 25 August 1967

3- 19

Section I11 Servicing Equipment

MSFC-MAN-100

S-IC HYDRAULIC SUPPLY AND CHECKOUT UNIT

F i g u r e 3 - 7 . Hydraulic Power Unit
3-20

Changed 25 August 1967

MSFC-MAN-100

Section 1 1 1 Servicing Equipment

HYDRAULIC P O W E R UNIT 1. Functional Description

T h e H y d r a u l i c P o w e r Unit contains t h e 800 g a l l o n f u e l r e s e r a. v o i r , t h r e e high p r e s s u r e pumps d r i v e n by 150 hp m o t o r s , the s u p e r c h a r g e pump, and a s s o c i a t e d f i l t e r s , valves, a c c u m u l a t o r s , and o t h e r hydraulic components. The hydraulic power unit i s connected to the S-IC s t a g e by a hydraulic line, with a p r e s s u r e t r a n s d u c e r located a t the booster end of t h i s l i n e providing the p r e s s u r e sensing input t o t h e s e r v o s y s t e m which controls the output p r e s s u r e of t h e hydraulic power unit. The unit i s built i n t h r e e m o d u l e s , Module I containing t h e r e s e r v o i r and a s s o c i a t e d f i l l and d r a i n connections, and Modules I1 and I11 containing the high p r e s s u r e pumps and a s s o c i a t e d hydraulic components. This m o d u l a r c o n s t r u c t i o n f a c i l i t a t e s shipment and installation of the unit. The hydraulic power unit p e r f o r m s t h r e e m a i n functions; s t a g e , b. f l u s h , and d r a i n .
(1) The s t a g e function i s the p r i m a r y operating function when t h e unit i s connected to the booster. Fluid i s drawn f r o m t h e r e s e r v o i r through a f i l t e r t o the s u p e r c h a r g e pump. T h i s pump i n c r e a s e s t h e p r e s s u r e of the fluid f o r application to the m a i n pumps, and f i l t e r s t h e fluid through t h e f i r s t and second s t a g e f i l t e r s . The high p r e s s u r e fluid f r o m the t h r e e m a i n pumps p a s s e s through two s t a g e s of f i l t r a t i o n and i s applied t o t h e u m b i l i c a l line. F l u i d i s r e t u r n e d f r o m the b o o s t e r to the heat exchanger and f r o m the heat exchanger t o the r e s e r v o i r .

(2) The f l u s h function i s used t o c i r c u l a t e the fluid through t h e unit a t r e l a t i v e l y low p r e s s u r e to purify the fluid a s i t p a s s e s through t h e f i l t e r s . After the fluid i n the unit h a s been flushed, t h e unit m a y a l s o be used to f l u s h the fluid i n the b o o s t e r .
( 3 ) The d r a i n function i s used to d r a i n the f u e l r e s e r v o i r , to r e duce a l l possible e x c e s s weight before moving the ML. T h e fluid i s pumped to a n outside r e c e i v e r using the s u p e r c h a r g e pump, down to a p p r o x i m a t e l y 170 gallons. Additional fluid m a y be d r a i n e d , i f n e c e s s a r y , by u s e of a m a n u a l d r a i n valve.

II

2.

General a. Weight, pounds, (Approximate) (1) D r y (2) Wet

Changed 25 August 1967

3-21

Section I11 Servicing Equipment
b.

MSFC-MAN- 100

Reservoir (1) Fluid capacity, gallons (Approximate) ( 2 ) Fluid ( 3 ) Fluid specific gravity Dimensions, inches (Approximate) Location i n M L ( B a s e )

1,000 R J-1 0.863 168 x 94 x 102 Compartment AB - 4

c.
d.

3.

Remarks F o r additional information, r e f e r to MSFC-MAN-006

3-22

Changed 25 August 1967

MSFC-MAN- 100

Section 111 S e r v i c i n g Equipment

S-IC HYDRAULIC SUPPLY AND CHECKOUT UNIT

F i g u r e 3-8.

Motor Control C e n t e r

Changed 25 August 1967

3-23

Section 1 1 1 Servicing Equipment

MSFC-MAN- 100

MOTOR CONTROL CENTER
1.

Functional Description

a. The Motor Control Center contains c i r c u i t b r e a k e r s , t r a n s f o r m e r s , r e l a y s , and safety interlocks f o r distributing e l e c t r i c a l power to the hydraulic power unit and the s y s t e m checkout console. It i s divided into four modules. The f i r s t module contains c i r c u i t b r e a k e r s and e l e c t r i c a l controls f o r the incoming line and auxiliary equipment, such a s the s u p e r c h a r g e pump, s e r v o pump, and recirculating pump. The o t h e r t h r e e identi c a l modules contain c i r c u i t b r e a k e r s and control c i r c u i t s f o r each of the t h r e e 150 hp high p r e s s u r e pump m o t o r s . To energize the s y s t e m , c i r c u i t b r e a k e r s i n the motor control b. c e n t e r m u s t f i r s t be closed. Single phase c i r c u i t b r e a k e r s o p e r a t e the m o t o r control c i r c u i t s which protect the m o t o r s against overheating, and i n c o r r e c t phasing. The motor control c i r c u i t s a l s o control s p a c e h e a t e r s in the m o t o r s and i n the m o t o r control c e n t e r cabinets. In addition, they include t i m e delay r e l a y s which prevent overloading the line by s t a r t i n g a l l m o t o r s a t once. T h r e e phase c i r c u i t b r e a k e r s apply driving power to the various pump m o t o r s . T h e s e c i r c u i t b r e a k e r s a r e located on the f r o n t panels of the motor control center and, when closed, lock these panels shut a s a safety m e a s u r e . M e t e r s a r e located on the f r o n t of the m o t o r control c e n t e r panels f o r monitoring line voltage and c u r r e n t in the various c i r c u i t s . Hour m e t e r s a r e included f o r each pump motor to m e a s u r e individual running t i m e s . 2. General a. b. c. 3. Weight, pounds (Approximate) Dimensions, inches (Approximate) Location i n ML ( B a s e ) 10,000 204 x 112 x 42 Compartment A-2

Remarks F o r additional information, r e f e r t o MSFC-MAN-006

Changed 25 August 1967

MSFC-MAN-100

S e c t i o n I11 Servicing Equipment

S-IC HYDRAULIC SUPPLY AND CHECKOUT UNIT

B-H 1087

F i g u r e 3-9.

S y s t e m Checkout Console

Changed 25 August 1967

3-25

Section I11 S e r v i c i n g Equipment

MSFC-MAN- 100

a
1.

SYSTEM CHECKOUT CONSOLE Functional Description

a . The S y s t e m Checkout Console contains two s e r v i c e panels and s i x d r a w e r s . The upper l e f t s e r v i c e panel contains the p r i m a r y c o n t r o l s and i n d i c a t o r s f o r operating t h e Hydraulic Supply and Checkout Unit. The upper right monitor panel contains s e c o n d a r y c o n t r o l s and i n d i c a t o r s . The s i x d r a w e r s i n t h e b a s e of the console contain r e l a y s , a m p l i f i e r s , c o n t r o l c i r c u i t c a r d s , and interconnecting wiring. One d r a w e r i s left empty f o r t h e installation of communications equipment by NASA. The two panels and s i x d r a w e r s of the console may be r e p l a c e d a s modules t o f a c i l i t a t e maintenance.

b. Numerous indicator lights located on both the s e r v i c e panel and t h e m o n i t o r panel provide indication of n o r m a l o r a b n o r m a l s y s t e m o p e r a t i n g conditions. All f i l t e r s i n the s y s t e m have p r e s s u r e switches connected to t h e m to s e n s e a clogged condition. T h e s e p r e s s u r e switches a c t i v a t e i n d i c a t o r s on t h e monitor panel. T e m p e r a t u r e , p r e s s u r e , and r e s e r v o i r l e v e l i n d i c a t o r s on the monitor panel a l l indicate a b n o r m a l conditions. R e s e t switches a r e provided f o r s e v e r a l of t h e s e i n d i c a t o r s s i n c e f a l s e warnings m a y o c c u r during s t a r t u p .
2. General
a. b. c.

Weight, pounds (Approximate) Dimensions, inches (Approximate) Location i n ML ( B a s e )

1,100 52 x 53 x 26 C o m p a r t m e n t A-2

3.

Remarks F o r additional information, r e f e r t o MSFC-MAN-006.

3-26

Changed 25 August 1967

MSFC-MAN-100

S e c t i o n I11 Servicing Equipment

S-IC GSE HYDRAULIC PERFORMANCE TESTER

CONSOLE ASSEMBLY

F i g u r e 3-9A.

S-IC GSE H y d r a u l i c P e r f o r m a n c e T e s t e r

Changed 25 August 1967

3-26A