CREW BRIEFING

I NSTRUMEN'T UNIT STAGE PRESENTATION

INTRODUCTION

C. H. GRACE G. F. L. J. J. V. DOOLlTTlE G. KltMER M. OVERHULTZ E. LUNDBERG P. MULAK J. P. MUlAK

I NSTRUMEW UNIT
GU l DANCE ATTITUDE CONTROL I NSTRVMENTATION, TRACK1 NG & COMMAND ELECTR I CAL ENVI RONMENTAL CONTROL STRUCTURAL

1 U TEST H I STORY AND STATUS

t U CHANGE STATUS & SCHEDULE

J. M. FRI ZELL
J.

H. MOTES

I U EXPECTED LIFETIME ORBITAL "SAFI NG" STATUS UPDATE VEHICLE 1 NTERLOCKS

GROUND REQUEST ABORT LOOP PREMUNCH
OPEN

J. W. GLASS

DISCUSSION

MENT UNIT

C.H. G R l C t PROGRAM MAHAGER

GROUND S t R V l ( t R O O M

SHIPPING

RfCRY lMG

7
F A 5 STAND 1

VERTICAL INTERFACE PREPARATION

ALIGW. 01111, ROUT. IHSTALL I I S E R T S . POT.

ANTZblNA HOLE PREPARATION

LOCATE. DRILL. ROUT, I M S T A l l IRStRTS. PDT.

ST-'124 MOUNTING FRAME AND ACCELEROMETER PADS

OPTlChLLY ALIGM, MACHINE, lH$Tllll tPOXY PAD AHD VfBRkTlON DAMPEWEUS.

FORWARD INTERFACE PWEPARATIOW

DRILL, ROUT, POT. 11511~1FORWARD PROTtCllYl R l M G

FAB STAND 2

AFT IWTERFACE PREPARATtON

BRILL, ROUT, POT, PAlWf TOUCHUP. lH4Tlltl AFT PROfrfTlYE RING.

ASSEMBLY STAMDS

- I U ASSEMBLY -

SHIPMEMT/STORAGE

PREPARATION

I M S T A l l CABLE TRAY, MANIFOLDS, COLD PLATES, COMPQHfHTS, CAULIS. PERFORM MIGGIR, EMD ITEM fH#U YIBfHCAl, AHD PBEtlMlM~QYW/M SYSTEM LIhK TEST.

CHECKOUT STANDS

LEAK AND SYSTEM TESTirNG

RUM W/M AWI) FN 2 SYSTEM LfkM TESTS. PERFORM SYSTEM5 TEST ACTIVITIES

a Guidance And Control Load Bearing

Monitor And Originate Vehicle Events

Self Sustained m Range Safety And Orbit Determination

Ground Communications
a
0

Rel iabil ity

Hardware Commonality (IB And V )

I
I
I I I

I
I
EDS

AND ELMWRY

------A x Prqwklon SKtern % S W

stas%

SwnCh

t--t-----Telametry

!l L

S-1V1

s w

Data

203/205

MAJOR

COMPONENT

DIFFERENCES

GENERAL
2
9

M E A S U R I N G DlSTRIJ3ii'f O R S
MEASURING RACKS

i
4

MEASUR l N G DISTRIBUTOR

MEASURING RACKS

2
1

EXPERIMENTS [MSC, L O W - G ) C-BAND TRANSPONDER

N O EXPERIMENTS
2

C-BAND TRANSPONDERS

CONTINUOUS COOLANT T E M P C O N T R O L

DISCRETE CONTROL

2031205 MRJOR COMPONENT I3 1 FFERENCES

TELEMETRY
1

SI NGLE S I DEBANDIFM
FMlFM (ANALOG)
S-BANDTVTRANSMITTERWITH CONTROL UNIT

NO
1 NO 2

SENGLESIDEBANDJFM

2 2

FMJFM (ANALOG)
S-BAND TV XMTR's NOR CONTROL UNIT

1 410 MUX & 1RDSM MUX FOR PCM

410 MUX's FOR PCM, NO RDSM MUX

270MUX's -OM FOR FMIFM (ANALOG) AND ONE FOR PCM 1 TAPE RECORDER

270 MUX'S - BOTH FOR PCM

NO TAPERECORDER
CROSSOVER OF S-IVB AND 1 U PCM TELEMETRY

NO CROSSOVER OF S-IVB AND I U PCM TELEMETRY

IU TESTS-DESIGN VERIFICATION

VIBRATION A T E S T

-1

COMPONENT
MODR

lNTEGRATI ON

-C7
RIGHTS

THERMAL VACUUM

PRODUCTION TESTING

T'

COMPONENT TEST

SUBSYSTEM TEST

IU
MANUFACTURING CHECKOUT

CHECKOUT

S-IU -205 RELIABILITY GOAL

PREDICTED DESIGN RELIABILITY ESTIMAKB LOWER BOUND

GUIDANCE

a DES IGN REQU I REMENTS

a Direct Acceleration Vector To Meet End Conditions e Direct Acceleration Vector To Maxim ize Payload

a Orient Vehicle During Coast

a Determine Position During Coast
@

INSERTION ACCURACIES
a Velocity k2.6 mlsec (t8.6 ~ ~ 1 s )

a Path Angle k0.025'

-

e Altitude *l Km

(+_32um

GUIDANCE MODES

5-IVS BURN

S-IVB CUTOFF

IGM STEERING
BOOST NAV l GAT1 ON

PREPROGRAMMED STEER 1 NG

ORBITAL NAVIGATION CIO M INOR LOOPS ISE C. )

(25 MI NOR LOOPSISEC)

STORED TIME TILT

I GAT I ON 125 M NOR E

L l Flukt FROM KSC

EAKIH UKBI I

INSERTION

FO

ANCE

* REQU IRED PERFORMANCE

TYPICATJ ORBITAL

EVENTS

o o o o o

ORBITAL P I T C H R A T E

O R B I T A L S A F I N G C1k
20'

T H E S -1VB

PITCH D O W N W I T H ORBITAL PITCH R A T E

ASTRONAUT CONTROL OF THE Iu/S-IVB

CSM/S -IVB SEPARATION

II N E R T I A L H O L D

WITH ASTRONAUTS

" H E A D S UP")
o

RENDEZVOUS OF CSM & S - I V B

BLOCK DIAGRAM OF SATURN GUIDANCE SYSTEM

1 I

1
1

STAB I LIZED PLATFORM SUBSYSTEM

I I
Attitude --.. 1 -

Angles

Accelerometer

I U COMMAND RECEIVER AND DECODER

Information

Flight Sequence Corn ma nds

5-16 STAGE S W I TCH SELECTOR

S-IVB STAGE SWITCH SELECTOR

SWITCH SELECTOR

bE COMMAND 616NAL FLOW

(, 1 1

ATJ ITUDES
o

Zero Input
ExcessiveRate

(2)

ACCELEROMETER

o
o

Zero Inputs Excessive Rate (Reasonableness)

o
(3)

Disagreement

ATTITUDE ERROR

o
o

Rate Limiting Magnitude Limiting

PRESTORED TIME SEQUENCE (4TIME BASES)

1.

Liftoff ITB 1)

2.

3.
4.

S IB Low Level Sense S I B Outboard Engine Cutoff

S-IVB Engine Cutoff

CALCULATED FUNCT l ONS

ALLTIME BASE INITIATION BACKED-UP BY SOFlWARE

SEPARAT I ON
d.l~?VARD ENG CUTOFF INITIATE TI ME BASE #3

S l V B ENG OUT INITIATE T I hl BASE #4 NlT= 0:9:52. 7

LEVEL SENSOR
DRY INITIATE TIME BASE #2 NFT= 0:2:16. 1

ill ITOFt I N I31ATES TIME BASE #1 NFT- 0

NIT= NOMINAL FLIGHTTIME

SWITCH SELECTOR

Triple Modular I n Computer And Data Adapter

@

Quad Redundant I n Decoding

Feedback And Software Create Duplex Operation In lnput Side

Backup To Preprogramrned Operations

Receive Data From Decoder Verify Received Data

Verify Proper Redundant Data Format
Verify Val id Mode Corn ma nd

Verify Proper Sequence Of Commands For A Given Routine

Execute Corn ma nded Routine

DIGITAL

COMMAND

SYSTEM

(DCS}

T Y P I C A L DCS COMMANTjS
a

M A N E U V E R 1NHlBf3ErrS

o o
o

MANEUVER UPDATES
TIME BASE UPDATES
NAVIGATION UPDATES

G E N E R A L I Z E D S% I T C H S E L E C T O R
MEMORY SECTOR DUMPS

o
o

SINGLE MEMORY LOCATION DUMP

MANEUVER EXECUTES
R E T U R N T O TIMED M A N E U V E R S E Q U E N C E

o o

TERMINATE

Requ iremen-i For Mission Control And Postflight Two Hu ndred 8.VordsISecond
Simplex

Error Detect ion

Parity
9

Validity

e Systems Development Facil ity e S-1U-500FS

Testing
(Huntsville)

a I U Manufacturing Checkout Testing

*
@

Prelaunch Tests (KSC)

Flight Testing

FLIGHT PROGRAM DIFFERENCES -M3/205

MISSION CHANGES
VENTS SEQUENCE PITCH PROF11 E

INCREASED CAPABILITY MANEUVERS COMMANDS ORBITAL TIME BASE INITIATE FAST CUTOFF LOOP

Closed Loop Digital Simulation

0

ClosedLoopHybrid Simulation

Flight Hardware Checkout Simulation (Huntsville)

@

Flight Hardware Checkout Simulation (KSC)

lBd PWQGWAI VERIFICATION FACILITY

RECORDER

LAUNCH VEt4lCLE DIGITAL COMPUTER B L N K E IAGRAM

ST

TIMING
L

CVDA or LTE

MUNCH VEHICLE QATA ADAPTER

BLOCK DIAGRAM

PLATFOR M G I MBAL RESOLVERS

IN E G R A T I NG ACCELER QMETER S

LV DC

CONTROL DISTRIBUJOR C OMP UTER t NTER FACE UNIT TELEMETRY ESE

I)I G 1TAL

OUTPUT REG 1 STER S

I

BUFFER REG i STERS & INTERNAL COlK?OL

1

CONVERTERS
I

I
DIGITAL INPUT MULTI PLEXER
COMPUTER INTERFACE UNIT COMRMND RECEIVER CONTROL D l STR I B R n O ESE

CONTROL DISTRIBUTOR CONTROL COMPUTER

TR IPCE MODULAR REDUNDANCY

(MAJOR !TY VOTA NGI

TR I PLE REDUNDANCY (PAIR AND SPARE)

Worst Care Circuit Analysis

*
@

Prototype Evaluation ComponentQualification

System Qualification Program

Field Experience

Impact Shock Temperature Altitude Operat iona I Non-Operat ional

Coristant Acceleration
Vib rat ion Isolated Hard Mount

RFI Explosive Atmosphere Humidity Orbital Simulation Accoustic Noise Salt Fog Coola nt Tests Pressure Pressure Drop Leak

LVDCILVDh DIFFERENCES FROM S-IU-203

NOISE SUPPRESSION
NEW PRESSURE REl EASE VALVES
LV DA DUPLEX VOLTAGE INPUTS TQ SWITCH SELECTOR REGISTER MINOR RELIABILITY INCREASES NEW PRESSURE RELEASE VALVES REPLACING TEFLON COOLANT HOSE

LAUNCH

qem.

A ; ; . $5

e r r 4 9XL COFAPUTER IEQUIREBEMTS i

Stored PI 191 an,generil; purpose, serial, fixed point, binary

?, 048 Mc c M k , 4 clc~ks bit, 512 kilobits per second per 3 phases ger computation cycle r . I - ~ L*: ~ I <-:I, = !? bits P b a w A irrjttllction readlphases 8 & C, Instruction execution I DATA)
I -

Cornputat ion Speed:

n
I

rr .-ubtrat,t and mu itiply or divide concurrently.

Time Accu racy .- -- .

.xL-

Add Mu Itiply Mu E-Hold t Divide Time

82 usec, 26 bit 328 us%, 24 bit

410 usec, 24 bit 656 usec, 24 bit

Memory:
Storage Capacity

Random access teroirlal core

Gp to a maximum of 32,763 28-bit words in 4"6%-*wrd modules

Word Length:

Memory ward 28 bib; two instructions may t e storled in one memory word.
26 bits plus 2 parity bits

Data:
Instruction:

l bits plus 1 parity bit 3

bternal: Computer-programmed interrqation

T J Control: External interrupt provided ~

<

LAUNCH VEH
Computer nputlOutpu t Rate Power Suppl ies D iscretes

A ADAPT
DESCR l PTlON 512-kc serial r 6 pairs of duplexed supplies m &bit input register + 15-bit output register m 7 interrupt inputs 13discreteoutputs 32 discrete inputs m 26 bits provides cornmu nication with 9 bits the Ground Control Computer 6 bits land telemetry system m 8bitsplussign, 2-millisecondoperation, threeattitude commands, and two spare outputs Equivalentof1Jbitsfromatwo-spedresolver m 4 two-speed gimbal angle resolver inputs 10 resolver Inputs

Buffer Register Tag Register Mode Register Digital-to-Ana log Converter

Analog-to-D igital Converter Platform Spares Telemetry Cvii ma nd Receiver Data Transmitter
Telemetry Multiplexer Ground Control Computer Frqii~ncy Source

Ir

*
m

14 bits for input data 38dataandidentificationbitsplusvaliditybitandparity bit 15 bits address plus validity bit for output data, 10 bits for input data 41 data identifier bits plus interrupt - output data i14bitsforinputdataptusinterrugZ 2-1016 cps f r ~ ~ e n source cy

AS-205

ATTITUDE CONTROL SYSTEM

FUNCTION MAINTAIN V E H I C L E ORIENTATION

o o

TO GUIDANCE COMMANDS

IN T H E P R E S E N C E O F E N V I R O N M E N T A L D I S T U R B A N C E S ,
I . E . , WINDS

REQUIREMENTS

PROVIDE VEHICLE STABILITY & RESPONSE C H A R A C T E R ISTICS

Q

T O M A I N T A I N A D E Q U A T E S T A B I L I T Y MAR GINS

o o o o

T O MAINTAIN LINEAR-RANGE ACTUATOR C O N T R O L

T O P R O V I D E N E C E S S A R Y R E L I E F OF V E H I C L E B E N D I N G
MOMENTS

TO REGAIN CONTROL AFTER STAGE-SEPARATION

T O PROVIDE ORBITAL F L I G H T CAPABILITY

S T-124M
STAB1 LIZED PLATFORM
*

4
I

CONTROL

SWITCH SELECTOR
2

LVDC

LVDA

1
RIGHT

CONTRUL
-

EDS RATE GYRO1

CONTROL *-S I GNAL PROCESSOR

COMPUTER

J-2 ENGINE
ACTUATORS

CONTROL ACCELEROMETER

CONTROL RECAY PACKAGE

S-IYB AUXI-

LIARY PROPULS ION

sysm

AS-205

fir ATTl~m 3DE CONTRvr SYSTEM BLOCK' DIAGRAM I

Axis

Input Interface

PITCH

'

LVDA
Rate Gyro- CSP
Control Accel. P t k g

A@ - i -.
I

Jrrlplifier-Filter r'~lter
, ;
A.

ROLL

1 I LVDA
Rate Gyro- CSP

I
YAW
1
1

LVDA
Rate Gyro- CSP

3 9
,

T. -Filter
one of four

P mplifier - Fil ter

Filter

I f

Amplifier- Filter
Filter

one of four

Control Accel. P % g

C. A . T.-Filter

S-IB STAGE CONTROL COMPUTER DIAGRAM

GU I DANCE COMMAND

o o

a and dl ARE P IECEWl SE CONSTANT G A l NS

0

16

is RAMPED-IN, HELD, AND RAMPED-OUT DUR ING 30 TO SECONDS OF S-I B FLIGHT

o
0

F#, FG AND . ARE STABILIZATION FILTERS F 8

MISSILE DYNAMICS INCLUDE R I G I D BODY, ELASTIC BODY AND FliEL SLOSH MODELS

During A t : i t i ~ d e - H o l d (Steady S t a t e ) Operation, A P S p r o v i d e s

(1) A t t i t u d e T r r o r

I deg

(2)

Body R a t e s

. 05 d e g J s e c

For Spacecraft C o n t r o l , F C C l i m i t e r s c o n s t r a i n a t t i t u d e
error
5

2. 5 deg, itch a n d y a w 3. 5 deg, r o l l

The Comparators for Pair-Spare Redundancy of APS

Spatial Amplifiers have a threshotd of 5070 d u t y cycle

ADDITIONAL ACS DESIGN F E A T U R E S

Launch Escape T o w e r J e t t i s o n R e q u i r e s m a n u a l i n p u t ; S- IVB rate filters automatically switch a t T + 42 seconds

3

Capability f o r s p a c e c r a f t c o n t r o l ( A t t i t u d e e r r o r commands) during S-IVB flight.

FLIGHT CONTROL COMPUTER VALIDATION TEST BLOCK DIAGRAM

7
7
Wind

M - E G'fRO ~; ; ; ; T H FFL 1 GHT TY PE1

FLI GHT
CONTROL COMPUTER

. TORQUER & ACCELERQMETER (RIGHT TYPE)

.

VEHI CLE DYMAMI CS

ANALOG Sl MULATION OF (i) SENSOR DYNAMICS tii) CONTROL COMPUTER F1LTERS

PC

I
ANALOG S I MULATION OF wcs

Oc

S I G N I F I C A N T A T 11I ' U D E T O N T I O L ,SYSTEM ! f 1'1 -'UETJTA TIOX C':+IANGTS A S - 2 2 1 TIIJ''3WGH = I F - 2 0 '

Component (a) Control Signal Process or (CSP)

Modification

Effectivity
A S - 2 0 2 and

1111pl r1: 6 . 3 t a d u a l r rate switch

A i ~f f i l t e r to t h . Ynlergency D e t e c t i o n S y s tern - E D S ) R a t e Switch

subsequent.
A S - 2 0 2 and subsequent.

(b) CSP

( c ) S-IVB stage

attitude e r r o r D. C. amplifiers
(d)

Spacecraft D. C. G a i n compatibility irnple mentation

AS-205 and
subs eguent CSM1s AS-202 and subsequent

Auxiliary Propulsion Sys tern ( A P S ) spatial amplifiers

Synchronization ~f A P S r o l l engine f i r i n g duxing S-IVB burn

A d d i t i o n of redundant inves ter

(e)

12 ma. magnetic amplifiers

AS-202 and
subsequent

If)

Flight C o n t r o l Computer F C C

E l i m i n a t i o n of undesirable s i g n a l paths.

ALL ATTITUDE CONTROL SYSTEM COMPONENTS HAVE BEEN QUALIFIED

N
T
16
% m

MMA

TELEMETRY SYSTEM

MPUTTR DATA STR

FLIGHT CONTROL D l SCRETES

DDAS OUTPUT

C
C

ENGR D l SCRETES

--

301
r 410 MUX

DDAS

A A

PCM XMTR (VHF)

TO ANTENNA SYSTEM

ESE ANALOGS
FLl GHT COMROL ANALOGS ENGR ANALOGS

FM XMTR - , IVHF)

TO ANTENNA SYSTEM

NOTE; HEAVY LiNES INDICATE FLI GHT CONTROL DATA

ToS-'VBPCMIDDASASSY AOTIME SLOT

FROM S-IVB 270 MUX BO TIME SLOTS (ALLS-IVBFLIGHTCONTROLDATA)

MULTIPLEX CAPABFLITZES T E C H N I Q U E S A C C U R A C Y-FREQ. RESPONSE

0

PARAMETERS
ACCELERATION, F L O W RATE, 400 C P S F R E Q .
NONE ON 205

1050 CPS

40 CPS

I2 S P S ( 2 . 4

CPS)

A L L TEMP, PRESS. VOLTAGES

ACT POSITION

120 S P S ( 2 4 C P S )

GYRO ANGLES
ACCELERATION

240 S P S

LVDC DIGITAL WORD

#G SYSTEM
Xmt. 5675 Mc
C-BAND TRANS PONDER
9

Rec. 5690 Mc

-I nhibit

C-BAND TRAMS PONDER SST-135C

L Rec.
C-Ba nd Sub-system

LV DA

I nhibit

Both C-Ba nd Tra nsponders Operate At Same Frequency

Xmt. 5QOO Mc

Rec. 5060.194 Mc

AZUSA TRANS PONDER TY PE-C

RADIO E NTERFERENCE F1 LTER

I

Azusa Sub-System

COMMAND SYSTEM

Corn mand Uplink

Grou nd Station - Each Message Verified Before Tra nsm ission Of A New Cornma nd.

PROBLEMS

AND

CORRECTIVE

ACTION

C-BAND COVERAGE

DESIGNED DUAL C-BAND COMPUTER INHIBITED

FAILURE OF R F CONNECTOR

ESTABLISHED PROCEDURE

TO ELIMINATE FAILURE

QUALIFICATION

STATUS

37
20

UNITS ( 2 8 UNIQUE)
TRANSDUCERS (13 UNIQUE)

ALL, Q U A L I F I E D
11 Q U A L I F I E D

UNQUALIFIED

TRANSDUCERS Q U A L I F I E D B Y NOV. 15, 1967

F-1 FLOWMETER

0-3 PSI P R E S S U R E G A G E

QUALIFXED B Y F E B . I S , 1998

t
Flight

INERTIAL STA

AC POWER SUPPLY

ST-124 # STABLE PLATFORM

PLATFORM SERVO AMPLIFIER

A. ACCELERATION SENSING AND REFERENCE, 8, VEHICLE ATTITUDE AND PROGRAMING. C-GUIDANCE REFERENCE COORDINATES. D. EARTH REFERENCE COORDINATES UNTIL GWR.

I .-

TYPlCAL GIMBAL SERVO BLOCK DIAGRAM

a,

-,

J S ~

AM Pl OEhr100. F I LTER
k

TORQUER

GIMBAL DYNAMICS

H?

TYPICAL ACCELEROMETER SERVO BLOCK DIAGRAM

CAT!9MS
Gyro Drift
Accelerometer Bias
Accelerometer Scale Factor
I I

075"lhrlg and 0.075"lhr

2x lo5

- x 10"
20 arc s

slg

Accelerometer Orthogonality
Azimuth Position

5 arc sec

Alignment To Local Travity

32: 1 Multispeed Resolvers

12 arc sec

NQTL: AII Values it3 6

32 Speed (Fine)

I0 arc see resolution

10 arc mechanical accuracy

20 arc sec

Single Speed (Coarse)

30 arc min

PI-ATFORM SYSTEM T'TFFERENCES 115 -333 - IU-?I5

CHANGE

PURPOSE
INCREASE RELIABILITY

I. GYRO MOTORS MONEL TO ELKON ETE

ELIMINATE POSSIBLE ERRONEOUS PULSES AT LIFTOFF

VE;RIFZ:CATION P R O G R A M

DEtVELO?\,TENT

TESTTYG

o
Q

QUALZFiLATTON T E S T I N G
ROCKET S L E D TEST FLTGHT TEST

o o
o

IU 500 F S T E S T

ACCEPTANCE TEST
o

VENDORS HUNTSVILLE

o
o

SYSTEM TEST

POWER CONTROL POWER

I

CONDITION RFORM E.D.S. LOGIC

,iINCTPLEDESIGN REQ5IREhENTS

FR 1 r; ,ARY YATTER IES - 80% OF CAPAC IT Y

C;{?tlNG AND WIRING SAFETY FACTOR O F 2

MIN WIRE - A W G 24 CABLING VOLTAGE DROP - 2V MAX,
MEAS. POWER SUPPLY

- 5V

2 0.1%

BEdCTRlCAL %YS-;EM BLOCK DF86RMM

I

*----------I
I

I ESE OR 1 SWITCH SELECTOR 1 SWITCHING

.-

--

I I
L,,---------

BAT'TERY LOAD PROFILE

?.hiED CURRENT

DISCHARGE DEPTH -6.8 HRS.

ELECTRICAL SYSTEM DFFFERFNCES U-XI3 - IU-205

PURPOSE:

RESUCED MEASUREMENTS 362 to202 AND ELIMINATE MEASUREMENT RACKS SUPPORT OTHER SUBSYSTEM CMAWGES

HARDWARE CHANGES:

ELIMINATE ONE MEASURING DISPR. REDUCE BATTERIES FROM 4 TO 3 CABLES REDUCED FROM 190 TO 315

COMPONENTS

SYSTEM

DESIGN ANRCYSIq

CRITICAL DESIGN REVIEW

QUALIFICATION TEST

LRE C R I T I C A L "SIGN R E V I E W

ACCEPT. TEST

CONFIGURATION AUDIT

SYSTEM TEST

C O N T I MU I T Y A N D MEGGER

UMBILICAL TO END ITEM I U SYSTEM CHECKOUT

EMERGENCY DETECTION SYSTEM FUNC'I IONS SENSE AND ACT ON EMERGENCY SITUATIONS

DUR ING BOOST.

PROTECT APOLLO CREW AGAIN;? VEHICLE FAILURE.

SENSE EXCESSIVE A N G ~ L A R RATE

RATE LEh'l!T CI-tANGE

MAJORITY VOTE
o o
EXCESSIVE AFJGULAR RATE ENG INE THRUST

IMHI I3 IT ENGINE% CYT ACORT.

INi4IBlT EXCiSSIVE I?,"'3BORT

B5.8 SEC. IC FTtR LIR OFF

135.4 SEC AFTER LIROFF

1 DEWIFY ATTITUDE REFERENCE FA1 LURE

RESPOND TO CREW INHI 6 IT REQUEST AND LIFT OFF ENABLE

PREVENT ENGINE CUT OFF FOR 40 SEC.

PROVIDE SIVB ENGINE STATUS

1U PORTION OF EDS

EDS DIFFERENCES 203 -205

EDS ENGINE CUTOFF IWbBlTED ON S-IU 203

26 EDS MEASUREMENTS ON .S-bU 203

16 ENG I NE OUT C PER ENG I NE) 2

2 LAUNCH VEHICLE EXCESSIVE RATE 2 LAUNCH VEHICLE ATTITUDE REFERENCE FA IL 1ABORT REQUEST 2 EDS LIFTOFF 3 AUTO ABORT
ON S-IU 205 ABOVE SIGNALS GO DIRECTLY TO SPACECRAFT.

S-IU 205 EDS SYSTEM CHANGED TO ACCOMMODATE SPACECRAFT 101 (BLOCK 11 1.

ELIMINATED 20 SECOND TIMER - SWITCH SELECTOR PERFORMS EXCESSIVE RATE SWITCH - IMPROVED RELIABILITY.

CIRCUIT ADDED TO PREVENT LAUNCH VEHICLE CUTOFF AT T + 40 SECONDS 0 OCCURS PRIOR TO 40 SECONDS.

IF AN ABORT

VER 1 FICATION PROGRAM

COMPONENTS RELIABILITY PERFORMANCE (CHRYSLERI SYSTEM ICD CONTROLLED (MSFC AND MSC)

DESIGN ANALYSIS
QUAL E S T
ACCEPT TEST

+
t

CR IJICAL DESIGN REVIEW

CRE CRITICAL DESIGN REVIEW CONFIG. AUDIT

SYSTEM EST

CONTINUITY AND MEGGER 1 UMBILICAL TO END ITEM

EDS SYSTEM CHECKOUT
IU SYSTEM CHECKOUT

+ t +

SWITCH SELECTOR

SWITCH SELECTOR BLOCK DIAGRAM

112

I NPUT
..

REG1 STER

DECOD I NG MATRIX

OUTPUT DRIVERS

Discrete Outputs
Telernetr ic Output

I nput Verificaticn
io LVDCILV DA

I
Design Featu res: Quad Redundant Circu its

Dual Redundancy in Register

Triple Redundant Command Functions

Dual Electrical Connectors

DESIGN GROUND R U E S
AEQU l REMENTS

I MPLEMNTATI ON

AUTO ABORT

2 08 MORE ENG F lVES LOSE TMR UST

EXCESSIVE VEHICLE ANGULAR RATE
MANUAL ABORT

2 OUT OF 3 VOTE

FOR EACH ENG INE 2 OUT O F 3 VOTE FOR EACH AXIS

2 OUT OF 3 VOTE FOR EACH ENG 1 r\lE LIGHT I NDI CAT1 ON REDUNDANT
LIGHT INDICATION REDUNDAVW LIGHT INDICATION REDUNDANT LIGHT I NDICATI QN REDUNDANT

ENGINE STATUS (SIBS E f f i I F E STATUS (SIVB)

EXCESSIVE VEHICLE ANGGIIAR RATES LV AITITUDE REFERENCE FA1L

ABORT REQUEST GENERAL NO SINGLE POI NT FA1LURE SHALL CAUSE AN ABORT

LIGHT I MDI CAT1ON REDUNDANT

TRIPLE REDUNDANT C'ERCUlTS FOR AUTO ABORT WITH DUAL REDUNDANT CIRCUITS FOR MANUAL ABORT. REDUNDANT S FGNALS ARE ROUTED THROUGH SEPARATE CABLES, CONNECTORS AND P, W, BOARDS.

BATTER IES ARE ELECTR 1 CALLY I SOMTED FROM EACH OTHER

3 BUS SYSTEM (EDS NO 1 NO 2, NO 3) ,

Design Analysis

Qua lif icat ion Test

Pre-accepta nce Test

Acceptance Test

t I

DESIGN REQUIREMENTS

ENVIRONMENTAL CONTROL SYSTEM

P

NON-HAZARDOUS

ENV IRONMENT

COMPARTMENT TEMPERATURE

I GAS BEAR lNG SUPPLY 1

PRESSURE REGULATION

I-

SUB-SYSTEM

TEMPERATURE CONTROL

3
'THEtCMHL CQND ITION I NG
SUB-SYSTEM

GKOUND HEAT LOADS

FLIGHT HEAT LOADS TEMPERATURE CONTROL

Environmental Control System

ST-124M-3 INERTIAL PLATFORM ASSEMBLY
SUPPLY SYSTEM

CONDITIONING PANEL S-1VB THERMAL GONDITIONING PANEL

PURGE DUCT SYZBEA

Pressu re Regulator

WIM Out

Thermal Conditioning System

PRE-FLIGHT HEAT EXCHANGER

COOLANT PUMP MIW ACCUMULATOR

ELECTRONIC

S-IV8 DOME

A S 205 MJW TEMPERATURE PREDICTIONS

MAX4MUM ALLOWABLE TEMPERATURE

70

ON OFF

ION OFF

ON

OFf

ON

OFF

ON OFF

ON OFF -

45

-1

MINIMUM ALLOWABLE TEMPERATURE

T!NE FROM LAUNCH (HOURrS)

Test Verification Program

SUBSYSTEM VERIFICATION

DEV, & ENGR. EVAL TESTS

QUALlFlCATlON TESTS 0 COMPONENTS INDUCED & NATURAL ENY IRONMENTS 0 SUBSYSTEMS

R Elr

D FLIGHTS

8 COMPONENT & SUBSYSTEM

0 AS 201
0 SA203

0 SYSTEM - TOWISOOV VIBRATION TESTS 0 SYSTEM - 50QFS THERMAL VACUUM TESTS

0 AS 202

SAFETY CONS I DERATI ONS

1 .

GN2 PURGE WJMLEAKAGE

INERTENVIRONMENT DURING&AFTERPROPELLANTLOADING
MAX. LEAKAGE.OI%OFAMT. REQ'D FOR COMBUSTION

2.

3.

THERMAL SHROUDS

- REPLACED WITH MOM FLAMMABLE ALUM1 NUM TAPE

5.

SYSTZMPROCEDUREREVkEW

ENSURECOMPATABlLlTYWI"SSAFETY REQUI REMENTS

ECS FACTORS OF SAFETY

1.

EXPENDABLES:

PLATFORM GN2 SUPPLY

2OOO10

OF REQ'D* CAPAC ITY

WIMGN2PRESSURIZATION SUBLIMTOR WATER

115%OF REQ'D* CAPACITY

225% OF REQID* CAPACITY * REQ'D MISSION TIME 6.8 HRS.

HOT CONDITIONS (NOWIM CIRCULATION)

COLDCONDITIONS ISUBLl MATOR FULL ON)

20 MI N. TO COMPONENT RED LINE - PIATFORM

2 112 HRS. TO FAILURE - LVDC o

20 MI M. TO COMPONENT RED LINE LVDC & PIATFORM REACH STEADY STATE 3 0 ' ~ - NO FAILURES

PR IMARY
0

Transfer Load Between The S-IVB And SLA

e Provide Mount For Equipment

SECONDARY
0

Provide Personnel Access Door

Provide Umbilical Plate For Ground Checkout

-Provide Cable And Purge Duct Tray

"

I-'

TYPICAL SECTION OF HOIEYCOHB SANDWICH FQW IHSTRUHENT UNITS

a2001n-3

SIA INTERFACE

QO Alum Alloy 7075 T6 Inner Skin

0.030 Alum. Outer Skln

- 7075 T6

S-IV8 INTERFACE

Ring

QUALITY ASSURANCE PROGRAM

NON-DESTRUCTIVE MEASUREMENTS
DESTRUCTt VE TESTS

Dimensional

Confirmation Test
Segment

Ultrasonic

Portashear
Proof Load Bonded Assemblies Welds & Castings

Bonded And Tested To Destruction Prior To Production And After Each 15th Segment

Test Tab

Bonded With Each Segment And

Specimens Tested

FLIGHT LOAD REQUIREMENTS

FACTOR OF SAFETY

i U DESIGN TO SATURN V LOADS JEMONSTHATED BY TEST RESULTS

1111 STRUCTURAL QUALl

Test Veh icEe

20015UOS

2W500S-l l

Pu rpose

Qual ify Design

Qua l ify New Structure Source Saturn V

Qua 1 ify Design

Qua lify New Sou sce

Saturn V FlightAxis Sine Sweep & Ra ndom

Envr ronment

Loads Greater Than Saturn I B Ultimate

Ultimate
Lmds
New Structure Source Qua lif ied

Saturn V MuIti Axissinesweep And Random

Results

Design Qua i f ied

DesignQualified

Newstructure Source Qualified

STATIC LOADING TEST STAND

SWING ARM

TEST STAND

IU TEST HISTORY & STATUS

INSTRUMENT UNIT 205 LIFE HISTORY

3/5/66

posT MFG. CHECKOUT

IIIIIIIIIHI

STORAGE: IBM

POST MANEFACTUR INE CHECKOUT

S IMPLlFlED FLOW DIAGRAM UPRATED SATURN 'I l NSTRUMENT UNIT

UPDATE C/O STATI ON

UMBI LICALIEND ITEM PRESSURE & LEAK TESTS

VAL1 DATE C / O STATI ON

4
SUB SYSTEM o GlblD, & C O N . o NETWORKS

I UIESE HOOKUP
TESTS o INST. & TM a ECS

I-J

o RF
76 TOTAL TESTS: 34 AUTOMAT1 C TESTS 42 MANUAL TESTS
SUB SYSTEM o GUI D. & CON[. o I NST. & TM

l NTEGRATED

TESTS .o ECS

TEST1 NG COMPLETED: 19 SEPTEMBER, 1966

12
TESTS

1 NTEGRAED --. SUB SvSTEM . o EDS . o SIMULATED PLUG D W P o SI, MSILATED F t l GHT

UP DATE C/O STAT1 ON

MODK I T INSTALLATION& INSPECTION I

/PRESSURE & LEAK TESTS

I
I
-

VAL, DATE C/O STAT, ON

lUlESE HOOKUP
SUBSYSTEM TESTS

I--'
TOTAL NUMBER OF TESTS

o GLJ I D. & C O N , o NETWORKS a INST, &TM

o ECS o RF

1 NTEGRATED SUBSYSTEM TSPSm

o G U l D . & CONT, c INST. f TM

t;

ECS

INTEGRATED SYSTEM TESTS

I
-

o EDS o SIMULATED FLIGHT o SIMULATED PLUG DROP

76

23

49

S-I U-205

RELIABILITY GOAL
PREDICTED DESIGN RELIABILITY

EST1MATED LOWER BOUND

PERCENT CONTR IBLJTlON TO I 9

FAILURE

RISK

INERTIAL SUBSYSTEM GAS BEAR I NG S WPLY BAllERY 1 1 30 56 VOLT POWER SUPPLY

THERMAL CONQ ITIONING SUBSYSTEM BATTERY D40

ALL OTHER COMPONENTS

HISTORY OF

SINGLE POINT FAILURES IN CRITICAL COMPONENTS

0
0

F t l GHT CONTROL COMPUTER

ST-124M l NERTl AL PLATFORM
AUX POWER D l STR T BUTOR

0
0

FIRST STAGE PRESSURE REGULATOR

K-SEAL LEAKAGE

0 0 0

BAnTRY
LVDA

ANALYSIS OF POSSIBLE FLIGHT CRITICAL FAILURES

CREW LOSS POSS IBLE MI SS I ON LOSS

NO SINGLE POINT FAILURES

53 COMPONENTS CONTAI N S I NGLE POI NT FA1 LURE

MODES

INSTRUMENT UNIT 204 CHANGE ACTIVITY

MOD KIT INSTALLATION

TOTAL = 23

TOTAL = 30

o
o

NETWORKS-

8
6

ECS -

MAJOR CHANGES:

MAJOR CHANGES:

ELIMINATE SINGLE POINT FAILURE FOR INDICATION OF J2 ENGINE

s)-1maowrt

TEMPERATURE CONTROL BY REGUIATI ON OF SUBLI MATOR WATER FLOW.

o o

DOC. AMPLIFIERCHANGETOMONPOLAR IZED CAPACITORS

"FIX" FOR QUALI FI CAT1 ON TEST FA1 LURES ITM UNITS)

o o

REOES l GNED WATERIMETHANOL

ACCUMUUTOR

MODIFYEDSDISTRIBDORTO PREVENT AUTOMATIC CUTOFF OF BOOSTER ENG I NES 1 F AN ABORT OCCURS PRIOR TOEDS ENGINE CUTOFF TI ME.

SATURN [B/V COMPOSlTE SCHEDULE TO LEVEL H MASTER

PHAslNG SCHEDULE

C.H. GRACE P R O G U M MAHAGIF

L

I WGI+I

P t C t l d P (O#IPSL

IU CHANGE STATUS &-SCHEDULE

IlJ MODIFICATION KIT STATUS 205

TOTAL Dl RECTED S IMCE LAST SYSEMS TEST

ALREADY 1 NSTALLED

35
2

TO BE I NSTALLED PR 1 OR TO RETEST
TO BE KlllED TO KSC

32 I*

* Spotfaci ng of Control Signal Processor. Flight Unit Being Recycled To

Vendor; Change Will Be I n CSP When It Arrives At KSC.

IU EXPECTED LIFE TIME

S-1U-205 ACTIVE LIFETIME

REQU IRED DES 1 GN GOAL

4.5 HOURS

68 HOURS .
1 HOURS EST) 0

END
C-BAND TRANSPONDER

EXTENDED ( 3 -2 DAYS)

PRELl MI NARY EST1 MATES OF RES IDUAL 191s-IVB RATES FA1 LURE MODE LVDA LOW VOLTAGE, EDS RATE GYROS NOT RUNNl NG

EFFECT
LADDER OUTPUTS FULL ON, NO RATE COMPENSATI ON

RESULTANT RAE*

3 TO 6 ' 1 3 ~ ~ y ~** - , 15 TO 30 ISEC-R

3 TO ~ ' I ~ E c - PYL' , 15 TO 30 ISEC -R*

ST-124M GYROS AND EDS GYROS FA1 l

ST-124M GYRO FA1 LURE

ATTITUDE E R R 5 INCREASES TO LIMIT OF2.5 NO RATE COMPENSATION

ATTITUDE E R R 0 5 INCREASES TO LIMIT OF 2.5 LADDER OUTPUTS FULL ON

0 5 TO L O ~ ~ S E C - P , R . Y,
3'1s~~-P, R Y,

LVDCJDA FAILURE

"ESTIMATED MAXIMUM RATE BUILD UP WHICH MAY OCCUR WITHIN 60 SEC.

""DEPETZ ON OF FUEL GOVERNS MAXI MUM RAT REACHED,

IU/SC INTERFACE

FUNCTIONS OF THE IUESC INTERFACE (EDS FUNCT IONS COVERED UNDER ELECTR ICAL SYSTEM)

Q %ALL
POWERED FROM IU D I FERENTIAL PRESSURES (P&Y) 1 NTZRNAL TEMPERATURE
SC DISPLAYS

TM FROM I U

LV ATTITUDE REFERENCE FAIL LVDC MAS DETERMINED UNREASONABLE ONE OR MORE OF THE BACK-UP PLATFORM RESOLVER READ 1 NGS.

EU 1 DANCE REFERENCE RELEASE INDICATES TO AGC THAT THE PLATFORM HAS BEEN RELEASED. OCCURS 5 SECONDS PR IOU 60 L I FTOFF
AGC L 1 FTQFF INDICATES LIFTOFF. GENERATED 'BY Ill UMBILICAL RELEASE.

I
T,IF.:OFF
~1~i1n. ,SEF
C+LA

CSM
IU

fi

4b

S'T:

RE LEAS E

1
P:p : ,
Am-

CON ; 0-L
0 1 .5AJ

r."

P,?,Y ATYJ--ll?E E C F'"0T 7

A 7

*--..----

I J P A

LVPC/DA

Fa,' E S m
T -

S-IVB SW. SEL

ENGINE C U T O F F

IU/SC

INTERFACE

205 ORBITAL SAFING FOR S-IVB AND SPACECRAR CLOSE PRQXl MITY RENDEZVOUS

GROUND RULES

BE OUT OF PROPELLANT TANKS WITHlN 4 112 HOURS AFTER ORBITAL INSERTION

ALL LIQUID MUST
COLD HELI UM AND HYDROGEN BOITUES MUST BE STAB I LIZED

OR DECREASING AT 1OOO P S I A OR LESS WITHIN 4 1/2 HOURS

AFTER ORBITAL 1 NSERTION

AMBIENT HELIUM BOlTlES MEED NOT BE DUMPED BUT WILL

OR LESS WITH I N 4 112 HOURS ASTER ORBITAL INSERTION IF NO HARDWARE MODIFICATIONS ARE
BE DUNPED TO 1000 PS I A

REQU l RED

MODIFICAT1ONS FOR ORBITAL SAFING KIT

FUEL VENT LINE
ADDITION OF: ONE PNEUMATIC VALVE PNEUMATI C CONTROL MODULE TWO SWITCH SELECTOR FUNCTIONS A ONE-INCH Ll NE OPEN AND CLOSE TM 1NDICATI ONS FOR VALVE

LOX VENl Ll N
ADDITION OF: ONE PNEUMATIC VALVE PNEUMATIC CONTROL MODULE TWO SWITCH SELECTOR FUNCTIONS A ONE-INCH LINE WHICH RUNS 180 DEGREES AROUND STAGE OPEN AND CLOSE TM I NP1CATIONS FOR VALVE TEMPERATURE & PRESSURE MEASUREMENTS I N EACH NOZZEL OF NEW LI NE

COLD HELIUM BOTTLE NO MODIFICATIONS

PNEUMATIC BOTTLE NO MODIFICATIONS

o
lo

ENGINEC0NTROLBOlTL.E
NO MODIFICATIONS

o
o 0

ENG I NE START BOTTLE ADD BLANKING FLANGES IN RECHARGE LINES

APS BOTTLES NO MODIFICATIONS REQUIRED

DUMP LOX&FUELTHROUGHENG1NE ELECTR I CAL MOD IF1CAT 1 ONS EIGHT SWITCH SELECTOR FUMCTI ONS

OPEN CLOSED

APS BOTTLE

P NEUMAT
BOTTLE

START BOTTLE CONTROL BOTTLE

PRELIMINARY 205 ORBITAL TI ME11NE

LH2 NPV (PR I MARY)

LH2 NPV (SECONDARY)
LOX PROPULSIVE VENT

3 2 0 Min
I 2

(appro=

~n j m

I
3 to 4 Min

LOX NPV

COLD HELE UM DUMP

2 Min

ENGINE DUMP
LOX

I
I

I
I

I I I

FUEL
9-2 CONTROL BOTTLE
STAGE PNEUMATt C BOTTLE
APS HEL1UM BOlrTLES
APS PROPELL4NT DUMP
I

First Pass Over U.S.

90 Min

I 180 Min Second Pass

O v e r U.S.

I 270 Min Third Pass O v e r U.S.

VEH Z CLE 1 NTERLOCKS

(SEPARATE HANDOUT PROVI DED)

GROUND REQUEST ABORT LOOP

(SEPARATE HANDOUT PROVIDED)

PRELAUNCH SEQUENCE
(OPEN DISCUSSION)