apollo description manual (applicable to boilerplate 13 only)

8/6/2019 Apollo Description Manual (Applicable to Boilerplate 13 Only)

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Accessions No. 28561

SM2A-O7-BP13

/

NASASUPPORT MANUAL,

APOLLODESCRIPTIONMANUAL_

(APPLICABLE TO BOILERPLATE 13 ONLY

/"(TITLE UNCLASSIFIED)

\ \ \,

""-......

CONTRACT NAS9-150EXHIBIT I; PARAGRAPH 10.3

/)

::D

4_

_._oz_ _ 02

THIS MANUAL REPLACES SM_-07-BP13, DATED 23 AUGUST 1963.

PUBLISHED UNDER AUTHORITY OF THE NATIONAL AERONAUTICS AND SPACE ADMINISTRATION


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!

J LISTOFEFFECTIVEAGES JINSERT LATEST CHANGED PAGES. DESTROY SUPERSEDED PAGES.

NOTE: '/'he port/on of the text affected by the changes is indicatedby a vertical line in the outer margins of the page.

TOTAL NUMBER OF PAGES IN THIS PUBLICATION IS 1 1 8,CONSISTING OF THE FOLLOWING:

Page No. Issue

Title ...........A i thru iii .........iv Blank .........

OriginalOriginalOriginalOriginal

I-I thru 1-9 ...... OriginalI - I0 Blank ....... Original2-Z thru Z-24 ..... Original3-1 thru 3-9 ......3 - 10 Blank .......4-1 thru 4-28 .....5-i thru 5-4 ...... Original6-1 thru 6-35 ..... Original6-36 Blank ....... Original

OriginalOriginalOriginal

%eThe asterisk indicates pages changed, added, or deleted by the current change.

Manuals will be dlstr_buted as directed by the NASA Apollo Project Office. All requests formanuals should be directed to the NASA Apollo Spacecraft Project Office at Houston, Texas.


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SM2A-07-BPI 3

TABLE OF CONTENTS

Section

I

II

III

IV

Title

INTRODUC TION ...............

l -l.i-3.i-5.i-7.i-9.

Purpose ..................Scope of Manual ..............Arrangement of Manual ............Supplementary Information ...........Support Equipment ..............

DESCRIPTION .................

2-I.2-3.2-5.2-7.2-9.2-17.2 -22.2 -30.2-32.2-38.

Purpose of Boilerplate 13 Configuration .......Apollo First Order Test Objectives .......Apollo Second Order Test Objectives ........Physical Description .............Launch Escape Assembly ............Command Module ..............Service Module and Adapters ...........Command Module to Service Module Tension Tie Bolts . .Umbilical Connectors .............Launch Vehicle ...............

LAUNCH ESCAPE SYSTEM ............

3-I. Purpose ..................3-3. Operational Description ............3-5. Tower Jettison Motor Ignition ..........3-7. Tower Separation ..............3-9. Launch Escape Motor .............3-11. Pitch Control Motor ..............3-13. Launch Escape Tower Jettison Motor ........3-15. Mission Sequencer ............3-17. Tower Sequencer ..............

COMMUNICATIONS AND INSTRUMENTATION ......

4-1. Purpose ..................

Page

i-I

i-ii-Ii-Ii-3I-6

2-I

2-I2-I2-I2-i2-2

2-I02-182 -222 -222 -24

3-1

3-I3-I3-i3-33-33-33-33-43-4

4-1

4-1


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SMZA-07-BPI 3

SectionV

VI

TitleEQUIPMENT COOLING SYSTEM .5-I. Purpose ..................5-3. System Description ..............5-5. Principles of Operation ...........ELECTRICAL POWER SYSTEM

6-16-3.6-5.6-9.

Purpose .................System Equipment ..............Principles of Operation ............Power Consumption ..............

Page

5-I

5-15-I5-I

6-I

6-I6-i6-26-Z

LIST OF ILLUSTRATIONS

Figure No. Title

1-1Z-l.2-Z.2-3.2-4.Z-5.2-6.Z-7.2-8.2-9.Z-IO.Z-ll.3-i.3-Z.3-3.4-I4-2.4-34-45-I5-2.6-1.6-2.

Booster Compatibility Space Vehicle .........Launch Escape Assembly ............Escape Tower Explosive Bolt ...........Launch Escape Motor and Structural Skirt Area .....LES Interstage Adapter Area Components .......Nose Cone and Pitch Control Motor Area .......Command Module ...............Command Module Interior ............Command Module Reference Axis .........Dummy Shock Strut and GSE Attach Fitting ......Service Module and Adapter ............Service Module Tension Tie ............Launch Escape System Functional Block Diagram ....Mission Sequencer Schematic Diagram ........Tower Sequencer Schematic Diagram ........R&D Instrumentation Block Diagram .........R&D Instrumentation Locations ..........Q-Ball ...................Q-Ball Block Diagram .............Equipment Cooling System ............Equipment Cooling System Schematic Diagram .....Electrical Power System Block Diagram .......Boilerplate 13 Schematic Diagram .........

Page

I-2 2-4 Z-5 Z-6 2-7 Z-8 2-11 Z-iZ 2-17 2-19 2 -20 2-23 3-2 3-5 3-7 4-2 4-4 4-12 4-13 5-3 5-4 6-3 6-5


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LIST OF TABLES

Table No.

i-I.I-2.2-i.2-2.2-3.3-1.3-2.

3-3.4-I.6-i.

Title

Supplementary Documents .............Ground Support Equipment .............Launch Escape Assembly Physical Characteristics .....Command Module Physical Characteristics .......Command Module Compartmentation .........Time History of Events Leading to Tower Jettison .....Operational Characteristics of Launch Escape Tower

Jettison Motor ................Mission Sequencer Functions ............Measurement List ................Battery Physical Characteristics ..........

Page

i-31-62-2

2-102-103-1

3-43-9

4-146-1


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SECTION IINTRODUC TION

1- i. PURPOSE.l-Z. This manual provides a description of boilerplate 13, which is the firstApollo vehicle used in the booster compatibility test series. (See figure i-i.)Boilerplate modules economically simulate flight rated modules for test purposes,incorporating only the structures and systems required for a particular test.These modules are combined to form spacecraft configurations for selected tests.Each boilerplate configuration is described in a separate manual.

I-3. SCOPE OF MANUAL.

I-4. A physical description of the overall boilerplate and its major components(modules) is provided in illustration, text, and tabular form. System operationis described in text, tables, and diagrams. Sufficient detail is provided toidentify the configuration of the flight test article and to differentiate it fromother boilerplates used in subsequent flight tests. The manual is system-orientedwith emphasis on system configurations intended for use in ultimate spacecraftflight-rated systems. Research and development (R&D) systems are treated ingross terms and in case of customer furnished equipment reference is made tocustomer documents for detailed information. No recovery of boilerpiate 13 isplanned; therefore, no complete flight rated systems are installed.

1-5. ARRANGEMENT OF MANUAL.

1-6. The manual is in six sections. This section contains information relativeto the manual only and includes references to supplementary documents. SectionII contains a physical description of the complete flight test article and operationaldescription of equipment other than R&D instrumentation and launch escapesystem. Abrief description of the launch vehicle Saturn I is included. SectionsIII, IV, V, and VI provide operational description of the launch escape system,communications and instrumentation system, environmental control system, andelectrical power system.


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I STATION 2259. 6487

LAUNCH ESCAPE MOTOR-__._._

LAUNCH ESCAPE TOWER_.._..._ jC__STAT,ON 1929.'336COMMAND MODULE

SERVICE MODULEINSERT

ADAPTER

BOOSTER iNSTRUMENT UNIT

STATION 1795.596STATION 1785.596

_STATION 1661,596_ STATION 1609.596

STATION 1517.596____,.._____-_STATION 1459.596

s-IV SECOND STAGE_

S-I/S-IV INTERSTAGEON 962.304

S-1 F_RST STAGE_ /

APOLLOSPACECRAFT

f

;TATION 1.0

SATURNLAUNCH rEHICLE

SM-2A229B


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1 -7. SUPPLEMENTARY INFORMATION.

I-8. Table i-i is a list of documents containing supplementary informationfor boilerplate 13.

Table l-l. Supplementary Documents

DocumentNo.

SM2A-01 -BPI3

SM2A-02

SMZA-05-BPI3

SM3A-201

SM3A-202

SM3A-204

SM3A-205

Title

Operation and Test Proceduresfor Assembly, Erection, andIntegrated Systems C/O andLaunch

Spacecraft FamiliarizationHandbook

Transportation and HandlingProcedures

Transportation and HandlingEquipment Maintenance DataSheets

Auxiliary Checkout and ServicingEquipment Maintenance DataSheets

Signal Conditioner Console,Model C14-135, Part No.G16-552500-I01

Radar Transponder and RecoveryBeacon Checkout Unit, ModelC14-112, Part No. G16-852900

Contents

Detailed instructions for assembly,installation, checkout, and launchof the boiierplate 13 configuration.

Description of spacecraft with allsystems in overall terms.

Instructions for handling,packaging, packing, shipping,transporting, and storing theApollo spacecraft for boilerplate13 and its associated groundsupport equipment.

Maintenance procedures for trans-portation and handling equipment.

Maintenance instructions coveringinspection, cleaning, lubrication,trouble analysis, and maintenanceof equipment.

Physical and functional descriptionand maintenance procedures con-sisting of functional tests andrepair.



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Table I-I. Supplementary Documents (Cont)Document

No.SM3A-ZI3

SM3A-2ZI

SM3A-Z22

SM3A-2Z6

SM3A-ZZ7

SM3A-Z28

SM3A-229

SM3A-235

TitleAntenna Checkout Group, ModelC14-032, Part No. G16-850400-i01

Ground Cooling Cart, ModelAI4-011

Launch Escape Tower SubstituteUnit, Model AI4-001, Part No.GI6-8Z0301-Z01

Pyrotechnics Bench MaintenanceEquipment, Model C14-051, PartNo. G16-85Z700-101

Launch Escape Sequencer BenchMaintenance Equipment, ModelNo. Cl4-0Z9, Part No. GI6-853400-Z01

Launch Vehicle Substitute Unit,Model AI4-0ZI, Part No.Gl6-8Zl300

Optical Alignment Set, ModelA14-028, Part No. GI7-824010

Launch Control Group, ModelC14-414, Part No. G16-853950-I01

ContentsPhysical and functional descriptionand maintenance procedures con-sisting of functional tests andrepair.



Physical and functional de scriptionand maintenance procedures con-sisting of functional tests andrepairs.

Physical and functional descriptionof test, trouble analysis, repair,servicing, packaging, and diagramEas related to boilerplate 13 con-figuration.





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Table I-i. Supplementary Documents (Cont)Do cume nt

No.

SM3A-244

SM3A-263

SM3A-271

SM3A-272

SM3A-273

SM4A-200BPI3

Title

Pyrotechnics Initiators SubstituteSet, Model A14-003, Part No.G16-820500-201

Water-Glycol Cooling Unit, ModelS14-052, Part No. G16-848020

Spacecraft Ground Power Supply,Model C14-418, Part No. G16-853070

MSFC Patch and Logic Distri-bution Sub Unit, Model A14-075,Part No. G16-853060

Umbilical Junction Box, ModelC14-192, Part No. G16-852850

Maintenance Procedures (BP13)

Contents

Physical and functional descriptionand maintenance procedures con-sisting of functional tests andrepair,


Physical and functional descriptionand maintenance procedures con-sisting of functional tests andrepair.Physical and functional descriptionand maintenance procedures con-sisting of functional tests andrepair.

Physical and functional de s criptionand maintenance procedures con-sisting of functional tests andrepair.

Maintenance procedures, con-sisting of testing, troubleanalysis, repair, removal andinstallation, and calibration andadjustment as related to boilerplate13 configuration.


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1-9. SUPPORT EQUIPMENT.i-i0. Table 1-2 lists the ground support equipment (GSE) required for operationand maintenance of boilerplate 13. All listed GSE has been approved by NASAand has been shop released.

Table I-Z. Ground Support Equipment

ModelNo.

AI4-001

A14-007

A14-020

:A14-021

AI4-024

Nomenclature

Launch Escape TowerSubstitute Unit

LES Optical AlignmentSet

S/M Cover

Launch Vehicle Sub-stitute Unit-C l

Fluid and ElectricalUmbilical Dis conne ctSet

Part No.

G16-820301-201

G15-824040

G17-828003

G16-821300

GI6-828010-101

"Description

Provides electrical interfacenormally presented by the LESto the C/M.

Consists of two pieces, a tele-scope adapter and a target.The set provides the means ofaligning the thrust vector of theLE motor in relation to thegross cg of the abort configu-ration.

A light-weight, synthetic, im-pregnated fabric fitted to con-form to the shape of the S/Mand used to protect the S/M fromsand, rain, and salt sprayduring handling, transportation,and storage.

Provides interface for power tothe Q-ball heater and Q-ballelectronics. It also providesaccess to monitor signals thatmay be returned from theQ-ball electronics package.

Interconnects spacecraft auto-matic and manually activatedfluid servicing connectionswith appropriate fluid distri-bution systems.


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Table I-Z. Ground Support Equipment (Cont)ModelNo.

A14-026

A14-027

A14-035

C14-112

C14-191

Nomenclature

Cap and Plug Set

Adapter Cap and PlugSet

Vacuum Cleaner

C-Band Radar Trans-ponder Checkout Unit

Terminal Distributor

Part No.G14-828012-301

G14-828002

ME-901-0064-0001

G16-852900

G16-851300

Description

Consists of covers, caps, andplugs for all the electrical,hydraulic, and mechanicaldisconnects; duct, pipe, andinterface openings; and areas tobe protected from shipping andhandling damage.

Consists of covers, caps, and plugsfor all electrical, hydraulic, andmechanical disconnects; duct,pipe, and interface openings; andareas to be protected from shippingand handling damage.A mobile cart with 30 feet offlexible hose and miscellaneousattachments.

Rack mounted drawers. Rackis mounted on wheels and isapproximately five feet inheight. Drawers contain thefollowing equipment: electroniccounter, frequency meter,coax panel, signal generator,power control panel, blower,power meter drawer, oscillo-scope, pulse generator, andcabie drawer.

Cabinet mounted to floor in testarea and providing connectionpoints between the spacecraftand various GSE units. Cabinetcontains fuses, terminal blocks,and a power distribution panelwith circuit breakers.


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Table 1-2. Ground Support Equipment (Cont)

ModelNo.

C14-414

H14-016

H14-018

HI4-0ZI

H14-I09

Nomenclature

Launch Control Group

LES Weight andBalance Fixture

Escape Tower Support

GSE Handling Cart

S/M External AccessStand

Part No.

G16-853950

G15-810029

G15-810026

G14-810050

G17-810070

De scription

Group consists of five systempanels on drawer assembliesmounted in a five-bay equip-ment rack. The panels are:test conductor panel, electricalpower system panel, instru-mentation and communicationsystems panel, environmentalcontrol system panel, andlaunch escape system panel.

Fixture consists of two weldedsquare tubing structures boltedtogether and supported by shortjacks. The upper surface ofthe frame has six level mountingpads for mounting load cellsand a laterally and verticallyadjustable cradle to support andposition LES components.

Welded tubular structureequipped with four clamps tosecure the tower and four rollerassemblies to the rails of theHI4-011 Alignment Stand andthe H14-052 Positioning Trailer

Can be used to transport light-weight miscellaneous com-ponents, such as load cell kitsand removable pieces fromequipment, tools, etc.

Square platform having acircular cutout to clear theS/M, mounted on a scaffoldingerected to reach the topmostarea of the S/M. The platformis constructed of reinforced


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Table I-2. Ground Support Equipment (Cont)

ModelNo.

H14-9076

S14-052

Nomenclature

General PurposeDolly

Water-Glycol CoolingUnit

Part No.

G16-810033-I01

GI6-8480Z0

Description

Consists of a welded rectangularsteel frame, four lateralsupport brackets, and the neces-sary tie-down brackets. Unithas lockable casters bolted toeach corner of the frame and aremovable tow bar assemblywith swivel-type brackets infront and back of frame.

A steel enclosure mounted onskids and containing all neces-sary controls and instrumen-tation for local operation.


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SMZA-07-BP13 _

SECTION IIDESCRIPTION

Z-I. PURPOSE OF BOILERPLATE 13 CONFIGURATION.Z-Z. The Apollo-Saturn compatibility tests have the initial objectives ofdeveloping and qualifying the spacecraft and systems to be used for mannedearth-orbital flight. The unmannedboilerplate 13 configuration is the first ofthese launch vehicle and spacecraft compatibility tests. This test will alsoserve to demonstrate certain environmental and systems compatibilities.

Z-3. APOLLO FIRST ORDER TEST OBJECTIVES.

The following are the primary test objectives of the boilerplate 13 flight

a. Demonstrate the physical compatibility of the launch vehicle and spacecraftunder preflight and flight conditions.

b. Determine the launch and exit environmental parameters for verificationof design criteria.

Z-5. APOLLO SECOND ORDER TEST OBJECTIVES.

The following are the secondary test objectives of the boilerplate 13 flight

a. Demonstrate the structural integrity of the launch escape system underflight loading conditions.

b. Demonstrate satisfactory launch escape tower jettison.

c. Demonstrate compatibility of the R&D communications and instrumentationsystems with launch vehicle systems.

2.-7. PHYSICAL DESCRIPTION.

2.-8. The boilerplate 13 configuration consists of a launch escape assembly,command module, service module, insert, and adapter. The boilerplate 13


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SMZA-07-BPI 3Z-9. LAUNCH ESCAPE ASSEMBLY.Z-10. Structural relationship and physical location of the components of theassembly are shown in figure 2-i. Pertinent physical characteristics arecontained in table 2-1.

Table Z-l. Launch Escape Assembly Physical Characteristics

Overall Dimensions

Length 33 feetWeight 6871. 7 pounds

Tower Structure

LengthWidth (top of tower)Width (bottom of tower)Weight

Structural Skirt

LengthDiameterWeight

Launch Escape Motor

LengthDiameter at nozzle exitDiameter of motor structureWeight

Tower Jettison Motor

LengthDiameter at nozzle exitDiameter of motor structureWeight

Pitch Control Motor Structure

Length (includes ballast andmotor structure)

Diameter

118 inche s36 inches

50.6 inches540. 3 pounds

18.25 inches48.8 inchesZZ6 pounds

185. 3 inchesZ 8 inchesZ 6 inches

4788.5 pounds

55.6 inchesZ8 inchesZ 6 inches

528.0 pounds

18.6Z inches

Z 6 inches


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SMZA-07-BPI 3Table 2-1. Launch Escape Assembly Physical Characteristics (Cont)

Pitch Control MotorLengthDiameter of bodyDiameter of flangeWeight

BallastDiameter of lead discsThi cknessWeight

Ballast EnclosureLengthDiameter (forward end)Diameter (aft end)Weight

Nose Cone (Q-Bail)LengthDiameter (forward end)Diameter (aft end)Weight

22 inches8.79 inchesI0.51 inches55. Z pounds

20.5 inches1.13 inches467.5 pounds

29 inches13. 1 inches26 inches74. 1 pounds

19.09 inches2 inches13.03 inches35.1 pounds

2-11. STRUCTURE. The truss-type tower structure is the base of the launchescape assembly. It is an open frame of welded titanium tubing covered withsilica-filled Buna-N rubber for thermal insulation. Each of the four legs isattached to the command module by an explosive bolt. (See figure 2-2. )Attachments at the top of eachtower leg facilitate tower alignment. (See figure2-3.) The structural skirt is attached between the top of the tower structureand the base of the launch escape motor. The housing of the launch escapemotor forms the structure between the structual skirt and the interstagestructure. The interstage structure (figure 2-4), is a welded-sheet aluminumstructure which houses the tower jettison motor exhaust nozzles and variouselectrical components. Two access doors facilitate installation and removalof the components. The ballast housing and the nose cone are of welded Inconelsheet construction, and are bolted together to form a single conical structureto house the sheet lead ballast and the Q-ball. (See figure 2-5.)


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NOSE CONE_ "_

TOWER JETTISONMOTOR

INTERSTAGE

ADAPTER

LAUNCH ESCAPE MOTOR(INERT)

--IG

I"v

ESCAPE TOWER TRUSS--_

COMMAND MODULEATTACH FITTINGS

il////_._--" BALLAST ENCLOSURECOVER

._-- PITCH CONTROLf MOTOR (INERT)

_......,......_ TOW ER JETTISONMOTOR NOZZLE

_ _?_V_cERsSTRUCTURAL SKIRT

!ZPOWER SYSTEMS ANDINSTRUMENTATION


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EXPLOSIVE BOLT INITI,

UPPER N UT ---.----_.

I I _-Tt 1

SHAPED CHARGEIi I

.I I

EXPLOSIVE BOLT CHARGE

ISHAPED CHARGE INITIATOR

NUT __

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lAUNCHESCAPE MOTOR

ALIGNMENT ADJUSTMENT /(TYPICAL 4 PLACES)

NG HARNESS

THRUDOORS

"_ - _--- _ TOWER SEQUENCERS

SM- 2A- 266A


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_ ETTISON MOTORHOT WIRE

_INALBOARD

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"Q" BALL CONNECTOR_

CONE

HOUSING

SHEET LEAD

ACCESS

PITCH CONTROLMOTOR (INERT)

TERMINAL BOARD

/',//

CONTROLMOTOR HOUSING

ACCESS DOOR

TERMINAL BOARD

SM-2A-231

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Z-I2. LAUNCH ESCAPE SYSTEM MOTORS. The three launch escape systemmotors are stacked above the tower structure. Boilerplate 13 launch escapemotor and pitch control motor are inert. The tower jettison motor utilizes astar-grain solid propellant of a polysulfide ammonium perchlorate formulation.The jettison motor has two fixed nozzles. Passive thrust vector control is usedto obtain proper jettison trajectories.

2-13. LAUNCH ESCAPE SYSTEM ELECTRICAL AND ELECTRONICCOMPONENTS. The electrical and electronic components in the launch escapesystem consist of launch escape sequencers (contained in the command moduleand on the structural skirt), hot wire initiators, and associated wiring harnessesand attachements. Redundant wiring harnesses are bonded to the exterior of thelaunch escape motor, and associated redudant harnesses are integral to thetower structure. Each tower structure harness has a breakaway plug that allowsthe harness to detach itself from the command module when the launch escapetower is jettisoned. The wiring harnesses provide the means of connecting therocket motor and separation circuits with the sequence controllers, and theinstrumentation components with the communications equipment.

2-14. SEQUENCERS. Three sequencers are provided to program the sequenceof events during the mission. Two tower sequencers located on the structuralskirt are identical in size and shape. Each tower sequencer is approximately2. 5 inches in width, 8.25 inches deep, and 3. 75 inches high. See figure 2-3for location. A mission sequencer is installed in the command module. It isa single enclosed assembly approximately 15 inches in width, 8.25 inches deep,and 7 inches high.

2-15. HOT WIRE INITIATORS. The two hot wire initiators for the towerjettison motor are threaded plug devices. Both initiators contain the electricalcircuitry and explosive necessary to detonate the motor igniters. The initiatorbody is 1 inch long with 0.75-inch flange, 0.45 inch from the threaded end.Threads are located on one end and an electrical connector at the other end.The electrical connector contains four pins to supply power to two independentbridge wire circuits.

2-16. LAUNCH ESCAPE TOWER UMBILICAL CONNECTORS. Two electricalumbilical connectors join the electrical systems of the launch escape assemblyand the command module. These connectors are located on the plane ofseparation adjacent to the escape tower leg wells of the forward heat shield ofthe command module. (See figure Z-2.) The receptacle portion of the connectoris attached to the command module structure. The plug is attached to thenearest tower leg by a lanyard. When the escape tower separates from thecommand module the lanyard pulls the plug from the receptacle. The plugs arepart of the launch escape tower wiring installation and separate with the tower.

CONFIDENTIAL


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2-17. COMMAND MODULE. (See figures g-6, and Z-7.)

2-18. The boilerplate command module simulates the production commandmodule in external size and shape. Physical characteristics for the commandmodule are listed in table 2-2. The reference axes are shown in figure 2-8.

Table 2-2. Command Module Physical Characteristics

Shape ConicalHeight 134 inche sDiameter 154 inchesWeight 9088 pounds

2-19. STRUCTURE. The command module structure is conical with a convexbase and a rounded apex. The sides are semi-monocoque, aluminum structuresand terminate in the forward and aft heat shields. The command module iscovered with a cork material to protect the aluminum structure against aero-dynamic heating. The crew compartment area is insulated from the side wallswith a quilted fiberglass material. The insulation helps to provide and maintaina constant temperatue of not greater than 150 degrees Fahrenheit and to reducethe heat flow inside the compartment. A main hatch in the side of the primarystructure permits access to the interior. Shelves and brackets along the innerwall afford mounting provisions for equipment. Compartmentation is describedin table Z-3.

Table Z-3. Command Module Compartmentation

CompartmentProduction ConfigurationFunction

Primary Structure Crew compartment

Forward Compart-ment

iAft Compartment

Houses parachute systemof ELS, reaction thrustjets, and associatede quipm e nt.

House s impact attenuationstruts, environmental

Boilerplate 13 Contents

Launch escape tower sequencer,R&D communications and instru-mentation. Ballast to simulateweight and center of gravity.Egress tube to simulate productiontube volume and main hatch.R&D cooling system.

Radome and telemetry antenna.

Aft heat shield attachment fittings,GSE attach fittings, umbilical

SMgA-07-BPI 3


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FWD COMPARTMENT COVER(HEAT SHIELD)

TOWER LEG WELL(4 PLACES)

MAIN HATCH

/

PRESSURE ORIFICE(TYP 40 PLACES)

DUMMY SHOCKSTRUT ACCESS DOOR GSE ATTACH FITTING

(4 PLACES)

AFT COMPARTMENT EQUIPMENTACCESS DOOR (4 PLACES)

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OMNI ANTENNA

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CALC

CALORIME"

VIEW O

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DC AMPLIFIER RACKS---/_

_RERASNSUREcER--_. - _ / X_ _ SIGNAL CONDITIONING PKG

,,.o __/L_f-_,._/-*_'__,0;_x%TU_,._M,ox-_ _ -_---._,_-___,,jj _ _ .__uv,o.COMMUTATOR

TERMINAL BOARD _/:b?-'_._'.d_- , ,_-.._ __

;_,_u._,..EX__'/_,_ ____:__ ___.o

T,'MODU,ATOR___, l!i'_,_x TERM'NALOARD

_-i " "

_=._____ TE RMI NAL BOARD

SMZA-07-BPI 3


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/I TRANSDUCERI/ I//_RESSURE T

VIEW

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t ---CALORIMETERS

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-y

+Z

+Y

MAINHATCH

-ZVIEW ON X AXIS

+X +X

_MAIN

-Y_7_[[__'%_ +Y -Z_ '_ _+Z

-X -XVIEW ON Z AXIS VIEW ON Y AXIS

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2-20. FORWARD HEAT SHIELD. The forward heat shield forms the apex ofthe command module. It consists of a sheet-metal cover and a fiberglasshoneycomb radome assembled together, with the assembly bolted to the com-mand module. There are no provisions for separating the forward heat shield,since recovery is not planned.

2-21. AFT HEAT SHIELD. The aft heat shield forms the convex base of thecommand module. It is constructed of aluminum honeycomb bonded to the innerand outer skins of the laminated fiberglass and is attached to the primarystructure of the command module by four adjustable struts. Three of the strutsare dummy shock struts (figure 2-9) installed at longerons No. 2, No. 3, andNo. 4. The tension tie at No. 1 longeron contains a flange that allows it to beused as a dummy strut and a tension tie. Two holes are provided in the shieldfor installation of the umbilical electrical connectors. Six holes in the shieldallow the command module bearing points to protrude, and three holes permitattachment of the command module to the service module. (See figure 2-11.)

2-2Z. SERVICE MODULE AND ADAPTER. (See figure 2-i0.)

2-Z3. The service module includes the insert and is used in the boilerplate 13configuration primarily to transmit loads from the launch vehicle to the space-craft. The command module rests on the service module at six compressionbearing points. Three tension tie bolts hold the command module matingbearing points firmly seated. The six bearing bolts are adjusted to facilitatecommand module to service module alignment. An exterior non-structuralfairing is located between the command module and the service module. Thefairing houses a non-functioning separation mechanism, a support structurefor distributing basic loads imposed by the command module to the servicemodule, and fixed umbilical connections between the two modules. The com-mand module and service module will not be separated during the mission; and,therefore, no pyrotechnics are installed. The service module-to-insert andinsert-to-adapter interfaces are joined with 12 bolts each. The adapter isbolted to the instrument unit using 32 bolts. The holes for these 3Z bolts arecadmium plated to provide electrical bonding.

2-24. A part of the spacecraft instrumentation system is located in the servicemodule as follows:

a. Service module (between stations 1785. 596 and 1661. 596, figure l-l).

i. Seven calorimeters

2. Two strain gages

3. Twelve fluctuating pressure transducers

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\ \

HEAT SHIELDMOUNTING

GSE FI

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SERVICEMODULE _C-BANDANTENNAS(4 PLACES)_

S/M TO INSERTCONNECTOR'.

LONGERONS(6 PLACES)

LONGERONS(6 PLACES)

,'--- C/M TO S/M CONNECTORS

GSE UMBILICAL

_) CONNECTORS)

__ I/ii MOTORS_PLACES_[IX',U'_ .._ /1 (SIMULATED)I' - j

STRINGERS(28 PLACES

INSERTON _

(6 PLACES)

ADAP"(28 PLACES)

DAPTER TOBOOSTERINSTRUMENTUNIT CONNECTORS

PRESSURE VENT HOLES(4 PLACES)

AIR CONDITIONING

SM2A-07-BP13


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4. Three vibration transducers

5. Two accelerometers

6. One acoustical sensing device.

b. Insert (between stations 1661.596 and 1609.596, figure l-l).

1. One pressure transducer.

c. Adapter (between stations 1609.596 and 1517.596, figure l-l).

i. Four strain gages

2. One calorimeter

3. Two vibration transducers.

2-25. Ballast is installed in the service module and adapter to simulate weightand center of gravity of the spacecraft. Fiberglass reaction co.__tro! systemnozzles are mounted in place on the service module to simulate external confi-guration.

2-26. The adapter contains Apollo-Saturn interface wiring and an air conditioningbarrier in addition to the instrumentation (paragraph 3-24). The air conditioningbarrier consists of a double layer of nylon cloth impregnated on both sides witha chloroprene rubber compound. The barrier forms a bulkhead at the extremeaft end of the adapter.

2-27. STRUCTURE. The service module, insert, and adapter are cylindrical,of semi-monocoque type structure, 154 inches in diameter, with aluminum outerskin. The service module (less insert) is 124 inches in length. The skin isriveted to aluminum ring frames attached to six longerons. The longerons areT-shaped, the rim part being fabricated of steel and the web of aluminum.

2-28. The insert is 52 inches in length. The skin is riveted to upper and lowerring frames. The upper frame is composed of aluminum angles and websriveted together; the lower frame is constructed of rectangular aluminum tubing.The upper and lower ring frames are riveted to six steel and aluminum longeronsand 28 aluminum stringers.

2-29. The adapter is 92 inches in length. The skin is riveted to longerons andstringers. Four holes in the aluminum skin, located symmetrically around theaft end of the adapter, provide venting for pressures which may build up in the

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2-30. COMMAND MODULE TO SERVICE MODULE TENSION TIE BOLTS.(See figure 2-11.)2-31. The tension tie bolts utilized to bolt the command module to the servicemodule are steel rod and turnbuckle assemblies. The assemblies are cadmiumplated. The turnbuckle is used to preload the command module to the servicemodule compression bearing points. The assemblies are approximately 42 incheslong. Two of the assemblies use 7/8-inch hexagon steel rods 28.5 inches long.The third tie at longeron No. 1 uses l-i/4-inch round steel rod 28.6 inches longon which hexagonal wrench flats have been machined. No pyrotechnic chargesare installed on boilerplate 13 configuration. The tension tie at longeron No. 1also is utilized as a vertical strut to help hold the aft heat shield in place.2-32. UMBILICAL CONNECTORS.2-33. The umbilical connectors onboilerplate 13 consist of electrical connectorsand plugs located in the planes of separation of the modules; a GSE umbilicalconnector for ground support equipment, and a coolant umbilical connector.These connectors join the electrical systems of the modules while the modulesare attached and provide a means of disconnecting the electrical systems uponmodule separation. There is no requirement for module separation duringboilerplate 13 mission; therefore, the necessary hardware for umbilical discon-nect is omitted except for GSE separation. The GSE umbilical supplies theelectrical power while the boilerplate is on the pad. The coolant umbilicalsupplies the fluid coolant from GSE equipment on the pad.Z-34. GSE UMBILICAL CONNECTOR. A GSE umbilical is located in theskin of the service module approximately 18 inches below the top, on the +Zplane. (See figure 2-8. ) This umbilical is equipped with a primary (pneumatic)and a backup (hydraulic) release mechanism. Both systems are armed by asignal from NASA control GSE. Pneumatic and hydraulic pressures are suppliedby facility equipment. On initial command, a solenoid actuates the nitrogenpressure which ejects the umbilical. If this system fails to operate, i0 milli-seconds later a hydraulic actuator trips a lanyard which then disconnects theumbilical.2-35. COMMAND MODULE TO SERVICE MODULE UMBILICAL CONNECTORS.Umbilical connector receptacles are recessed into the outer surface of the aftheat shield of the command module. They are approximately IZ inches fromthe outer edge and located near longeron No. 6. The receptacles are part ofthe command module aft compartment wiring installation. The plug portionsof the connectors are part of the service module wiring installation.2-36. SERVICE MODULE TO INSERT UMBILICAL CONNECTOR. Umbilicalconnector receptacles on the aft separation plane of the service module connect

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COMMAND

TENSION TIE

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C/M COMPRESSIONBEARING PAD

_--_ S/M COMPRESSIONBEARING BOLT

SERVICEMODULE,

SION TIE ATTACH BOLT

S/M TENSION TIEATTACH

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2-37. ADAPTER TO INSTRUMENT UNIT UMBILICAL CONNECTOR. Umbilicalconnector receptacles on the aft separation plane of the adapter connect to plugslocated in the forward end of the booster instrument unit. The instrument unitwill not be separated from the adapter.2-38. LAUNCH VEHICLE. (See figure I-i.)2-39. The boilerplate 13 launch vehicle is a Saturn I configuration (designatedSA-6) consisting of a Saturn S-I booster, a Saturn S-IV second stage, and abooster instrument unit.2-40. The S-I stage is powered by eight Rocketdyne H-I engines with a totalthrust of 1,500,000 pounds. Propellants for these engines consist of 850,000pounds of oxidizer (LOz) and fuel (RP-I). The general appearance is cylindricalwith aerodynamic stabilizing fins at the extreme aft end of the cylinder. Theairframe is approximately Zl feet in diameter and is approximately 80 feet inlength. First stage engine cutoff is at 150.92 seconds after ignition. AnS-I/S-IV interstage section 18 feet in diameter is jettisoned with the first stage.2-41. The S-IV stage is powered by six Pratt & Whitney RLI0-A3 engines witha total thrust of 90,000 pounds. Propellants for these engines consist of I00,000pounds of oxidizer (LOz) and fuel (LHz). The airframe is approximately 18 feetin diameter with the forward end tapering to 13 feet to interface with the instru-ment unit and the spacecraft. The S-IV booster burns 464 seconds, placing thebooster, instrument unit, and spacecraft into a 90- to 120-mile orbit. Norecovery is planned.2-42. The instrument unit interfaces with the booster and spacecraft. It isapproximately 18 feet in diameter and contains the guidance and control system,flight sequencers, telemetry system, tracking system, and electrical powersystem.

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SECTION III

LAUNCH ESCAPE SYSTEM

3 - I. PURPOSE.

3-2. .The boilerplate 13 launch escape system will demonstrate the structuraladequacy of the design by the static and dynamic loads imposed while on theground, and during lift-off and boost phases.

3-3. OPERATIONAL DESCRIPTION.

3-4. The prototype launch escape system for boilerplate 13 is structurallysimilar to those throughout the program; the launch escape motor and pitchcontrol motor are inert. (See figure 2-I.) The escape tower will be jettisonedi0 seconds after S-IV ignition at an a!tih1_l_ of about 266, 300 feet. Towcrjettison is initiated 12 seconds after S-I/S-IV separation by a booster flightprogrammer. Figure 3-1 is a functional block diagram showing sequence ofevents. Table 3-i is a time history of the events leading to tower jettison.

Table 3-1. Time History of Events Leading to Tower Jettison

Time(Seconds

fromIgnition)

T+0T+ 3.42T+ 72.92T+ 145. 12

T+ 151. iZT+ 154. iZT+ 164. 12

Event

S-I IgnitionLift-offMax QS-I InboardEng. CutoffS-I BurnoutS-IV IgnitionEscape Tower

Velocity(Feet/

JSecond)

0

1595

874187078800

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0

41,29Z197, 5O2222,409232,043266,300

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Foot Z)

0

76022.4

10.06.64

FlightPathAngle(Deg)

9053

2424

21.9

Range(KM)

0

5O5567

MachNo.

0

1.65

8.989.22

3-5. TOWER JETTISON MOTOR IGNITION.

3-6. The tower jettison motor ignition system contains two electrical hot wireinitiators threaded into pyrotechnic cartridges which fire the igniter of the motor.

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flange, 0.45 inch from the threaded end. The electrical header contains twoindependent hot wire circuits and four pins. The initiator ignites within i0 milli-seconds when one bridge wire is subjected to a firing current of 3.5 amperes.The pressure level of the explosive charge is produced within iZ millisecondsafter application of current. The igniter for the tower jettison motor is installedin the aft dome of the rocket motor. The propellant grain is an 8-point confi-guration of boron potassium nitrate.

3- 7. TOWER SEPARATION.

3-8. The tower separation system consists of four explosive bolts that securethe tower to the command module, figure Z-Z. Each bolt contains two charges,the explosive bolt charge and the shaped charge. The explosive bolt charge iscontained in the center of the boll and the shaped charge is just below the bolthead. Both charges are fired simultaneously. Release of the tower is accom-plished by simultaneous detonation of the four explosive bolts. The hot wireinitiators for the bolts are ignited by Z8-volt d-c signals received from themission sequencer through the tower sequencers. The initiators will detonateto fire the explosive bolts within 5 milliseconds. To accomplish tower jettison*_ _i_ _quencer simultaneously _+_+_ _+_=*_g _=I_ +_ +_ .... I_bolts and to the tower jettison motor hot wire initiators. The entire launchescape assembly is released and pulled clear of the spacecraft trajectory. Thetower to command module umbilical connections are disconnected automaticallywhen tower separates from the command module.

3-9. LAUNCH ESCAPE MOTOR.

3-10. Boilerplate 13 uses an inert launch escape motor which contains ballastto simulate the weight of a live launch escape rocket motor. The motor willweigh approximately 4900 pounds with ballast installed. (See figure 2-i.)

3-11. PITCH CONTROL MOTOR.

3-1Z. Boilerplate 13 uses an inert pitch control motor which contains ballastto simulate the weight of a live pitch control motor. The motor weighs approxi-mately 55. 7 pounds with ballast installed. (See figure 2-I. )

3-13. LAUNCH ESCAPE TOWER JETTISON MOTOR.

3-14. The tower jettison motor is a solid propellant motor that provides thethrust for separation of the launch escape tower and related equipment from thecommand module. The jettison motor is mounted on top of the inert escapemotor. Passive thrust vector control in the form of offset exhaust nozzlesprovide a trajectory that arcs slightly in the pitch up direction. For operational

SMZA-07-BPI 3


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Table 3-2. Operational Characteristics of Launch EscapeTower Jettison Motor

Thrust

Duration

Time required to reach 90 percentmaximum thrust

33, 000 pounds

I second

75 to 125 milliseconds

Angles between resultant thrust axis and motor:

Pitch plane

Yaw plane

2 degrees, 30 minutes30 minutes

0 degree 30 minutes

3-15. MISSION SEQUENCER. (See figures 2-7 and 3-2.)

3-16. The mission sequencer located in the command module controls thesequence of events that are necessary to execute a successful launch escapetower jettison operation. The sequencer contains the logic circuits to directthe timing and order of the electrically initiated steps of the mission. Completeredundance of the entire sequential network is provided for reliability. Themission sequencer logic circuits send the electrical signals to operate themotor switches in the tower sequencer for firing the explosive bolt squibs andigniting the tower jettison motor. Table 3-3 gives mission sequencer functions.In addition, the mission sequencer provides compatibility of monitoring criticalevents as they occur, thus providing an input to the instrumentation system.

3-17. TOWER SEQUENCERS. (See figures 2-3 and 3-3.)

3-18. Two tower sequencers are attached to the underside of the structuralskirt. The sequencers receive input signals from the mission sequencer. Thetower sequencers provide electrical signals to fire the tower separation squibsand the tower jettison motor provides electrical signals to separate the launchescape assembly from the command module. The sequencers provide circuitsfor monitoring the functional status of the critical control circuits via GSEduring checkout operations. The sequencers also include circuits that controlthe operation of the sequencer and, if necessary, reset an armed condition ofthe subsystem within the tower assembly during checkout operations. Use oftwo sequencers provides total redundancy for reliability.


43/104

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NOTE: UNLESS OTHERWISE SPECIFIED1 FOR ASSY SEE DWG NO. V15-4525502 FOR WIRING INFORMATION SEE DWG NO. B15-4502103 INFORMATION SHOWN OUTSIDE SEQUENCER FOR REF. ONLY4 ALL RESISTORS ARE IN OHMS, :E5 /o, 1 W ATT5 P IN ASS IGNMENT RESERVED6 UNDERLINED LETTERS DENOTE LOWER CASE

Figure 3-3.

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SECTION IVCOMMUNICATIONS AND INSTRUMENTATION

4-1. PURPOSE.

4-2. The communications and instrumentation system provides a means ofacquiring and conditioning preselected information and of transmitting thisinformation to earth monitoring equipment. (Refer to table 4-1 for measurementlist.) The system also provides for tracking of the spacecraft during the mission.The Q-ball contains some instrumentation equipment, the information being usedfor guidance. The Q-ball system is not connected functionally with the Apollocommunications and instrumentation system but is described in this section.

4-3. DESCRIPTION. (See figure 4-i.)

NOTE

For detailed descriptive and checkout informationfor the R&D electronic equipment furnished byNASA, refer to applicable NASA document.

4-4. COMMUNICATIONS EQUIPMENT.

4-5. Communications R&D equipment consists of the telemetry system andradar transponders.

4-6. TELEMETRY SYSTEM. The telemetry system consists of three FM/FMtelemetry subsystems; one subsystem containing two PAM channels, the trans-mitters of each operating into the antenna system. In addition to the transmitter,each telemetry subsystem includes subcarrier oscillators and subsystem Acontains a 90 x i0 and a 90 x i-1/4 commutator, the latter commutator beingused for temperature measurements.

4-7. Transmitting frequencies of the three systems are as follows:

a. Telemetry system A Z37.8 mc

b. Telemetry system B 247. 3 mc

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