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ENGINEERING DEPARTMENT
TECHNICAL MANUAL
SDES-64-415
/
urn I LAwdCFl VEHICLE SA-10
AND LAUNCH COMPLEX 37B FUNCTIONAL SYSTEMS DESCRIPTION
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Volume VI1 LAUNCH PAD ACCESSORIES
FUNCTIONAL DESCRIPTION, INDEX O F FINDING NUMBERS, AND MECHANICAL SCHEMATICS
1, CHRYSLER PAf CORPORATION SPACE DIVISION
Acquisitioned ~occrmcr-rt SQT
SDES-64-415
SATURN I LAUNCH VEHICLE SA-10
AND LAUNCH COMPLEX 37B
FUNCTIONA L SYSTEMS DESCRIPTION
VOLUME VII LAUNCH PAD ACCESSORIES
FUNCTIONAL DESCRIPTION, INDEX O F FINDING NUMBERS, AND MECHANICAL SCHEMATICS
July 1964
CHRYSLER CORPORATION SPACE DIVISION - NEW ORLEANS, LOUISIANA
I J
FOREWORD
This volume is one of a set of eleven volumes that descr ibe mechanical and elec- tromechanical systems of the Saturn I, SA-10 launch vehicle and launch complex 37B. The eleven volume set is prepared for the Functional Integration Section, Systems Integration and Operations Branch, Vehicle Systems Division, P&VE Laboratory, MSFC , by Systems Engineering Branch, Chrysler Corporation Space Division under Contract NAS 8-4016. Volume titles are listed below:
Volume I RP-1 Fuel System
Volume I1 LOX System
Volume I11
Volume IV
LH2 Fuel System
Nitrogen and Helium Storage Facility
Volume V Pneumatic Distribution System
Volume VI Environmental Conditioning Systems
Volume VI1 Launch Pad Accessories
Volume VI11 H-1 Engine and Hydraulic System
Volume IX RLlOA-3 Engine and Hydraulic System
Volume X Separation and Flight Termination Systems
Volume XI Supplement: Legend and Composite Schematic
T h e technical content of this volume reflects the most up-to-date design information available f rom the S-I/S-IB Project Engineer, R-P&VE on June 1, 1964.
System mechanical schematics are provided in section 3 to support the functional description of the system. and functional descriptions of components identified on the mechanical schematics.
The index of finding numbers in section 2 provides physical
iii
I
TABLE O F CONTENTS
Section
1
a 2
3
Figure
1-1
1-2
3-1
3-2
3-3
3-4
3-5
Subject Page
FUNCTIONAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1.2 UMBILICAL TOWER SWING ARMS . . . . . . . . . . . . . . 1.1
1.2.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.1
1 .2 .2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.3
1.3 SHORT CABLE MASTS . . . . . . . . . . . . . . . . . . . . . . 1.6
1.3.1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
1 .3 .2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.7
1 .4 FUEL AND LOXMASTS . . . . . . . . . . . . . . . . . . . . 1 . 9
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . 4 . 1 Description 1.9
1 .4 .2 Operation 1.10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1 . 5 HOLDDOWNARMS . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
1 . 5 . 1 Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
1 .5 .2 Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
INDEX OF FINDING NUMBERS . . . . . . . . . . . . . . . . . . . . . 2 . 1
MECHANICAL SCHEMATICS . . . . . . . . . . . . . . . . . . . . . . . 3.1
LIST OF ILLUSTRATIONS
Ti t le Page
Umbilical Tower Swing A r m s . . . . . . . . . . . . . . . . . . . . . . 1.15
Launcher Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.17
Swing Arm No . 1 - Mechanical Schematic . . . . . . . . . . . . . . 3 . 3
Swing Arm No . 2 - Mechanical Schematic . . . . . . . . . . . . . . . 3 .5
Swing Arm No . 3 - Mechanical Schematic . . . . . . . . . . . . . . 3.7
Fuel M a s t . LOX Mast? and Short Cable Masts - . . . . . . . . . . . . . . . . . . . . . . . . . . . Mechanical Schematic 3.9
Holddown Arms. Holddown A r m s Release Control Panel and Accessories . Mechanical Schematic . . . . . . . . . . 3.11
V
SECTION I
FUNCTIONAL DESCRIPTION
E3b549307o 1.1 INTRODUCTION
The launch pad accesso r i e s group consists of t h ree umbilical swing a r m s , two pro- pellant mas t s , two short cable masts , and eight holddown a r m assemblies. This group attaches the vehicle to the launcher and provides the necessary connections between the vehicle and the launch complex for propellant t r ans fe r , environmental conditioning, and pneumatic and electrical s e rv i ces required p r io r t o liftoff.
The th ree swing a r m s (figure 1-1) ca r ry se rv ice l ines to the S-I stage, the S - N stage, and the vehicle instrument unit. Swing a r m No. 1 i s connected to the forward a r e a of the S-I s tage, swing a r m No. 2 is connected to the aft a r e a of the S - N stage, and swing a r m No. 3 is connected to the vehicle instrument unit.
The tail area of the S-I stage is serviced by short cable masts No. 2 and No. 4, and by the LOX and fuel masts. (See figure 1-2. ) The holddown a r m s , one located at each of the eight f ins, support the vehicle on the launcher and r e s t r a in the vehicle during engine ignition and thrust build-up.
At launch commit t ime , the holddown a r m s r e l e a s e the vehicle. swing a r m s and mas t s release and swing c l ea r of the vehicle liftoff drift pattern.
At the s a m e t ime , the 0 This section contains the description and operation of the launch pad accesso r i e s group. Each launch pad accessory i s given a general description followed by a more detailed description of major components. The operation of each launch pad accessory includes those operations that a r e performed to p repa re the accessory for vehicle launch a s well as the operation at launch commit.
1 .2 UMBILICAL TOWER SWING ARMS
T h r e e swing a r m s a re attached to the umbilical tower to support the various se rv ice l ines that connect the vehicle to the ground support equipment. The th ree swing a r m s are located at different levels on the umbilical tower. Swing a r m No. 1 is located between the 108- and 118-foot levels , swing a r m No. 2 is between the 128- and 138- foot leve ls , and swing a r m No. 3 is between the 158- and 168-foot levels.
Pneumatic and hydraulic p r e s s u r e s a r e used to uncouple the se rv ice l ines from the vehicle. and to rotate the swing a r m s c l ea r of the vehicle liftoff drift pattern. above, swing a r m No. 1 rotates counterclockwise, while No. 2 and No. 3 a r m s rotate clockwise.
Viewed from
1 . 2 . 1 Description - Major components of each swing a r m assembly include the basic a r m , hinge assembly, quick-release mechanism, rotary hydraulic actuator , lanyard release cable, bumper assembly and swing a r m control panel. briefly described in the following paragraphs.
These components are a
1.1
I 1.2 .1 .1 Basic Arm (Figure 1-1). The basic a r m is a four-sided t r u s s s t ruc tu re with an attachment plate assembly located a t each end. The main attachment plate, on the tower end of t he swing a r m , is fastened to the hinge assembly. Swing a r m s No. 2 and No. 3 a r e equipped with an extension a r m that is fastened to the attachment plate on the vehicle end of the basic a rm. T h e s e extensions increase the length of the basic a r m to compensate for the difference in the distance between the umbilical tower and the vehicle at the upper stage attachment points. A sheet metal t r a y , running the length of the swing a r m , supports the various vehicle servicing lines.
1 . 2 . 1 . 2 Hinge Assembly (Figure 1-1). The hinge assembly is connected to a weld- ment on the umbilical tower. The bottom hinge contains a lockpin assembly that s e c u r e s the a r m in the servicing position. caused by wind loads o r hydraulic leakage. A coil spr ing in the lockpin assembly holds the lockpin piston in the extended o r locked position until hydraulic p r e s s u r e is applied. Retracting the lockpin, mechanically opens a mechanical valve in the hydraulic supply line; thus ensuring that the swing a r m is free t o rotate before hydraulic p r e s s u r e is applied to the lanyard r e t r ac t cylinder o r the rotary actuator. A cam-operated valve located on the top portion of the hinge assembly is actuated by a camplate. A s the a r m rotates away from the vehicle, the cam gradually c loses the valve and r e s t r i c t s flow in the hydraulic return line, progressively reducing the r a t e of a r m travel as the a r m approaches the bumper assembly.
The lockpin prevents a r m rotation, which might b e
a 1 . 2 . 1 . 3 Quick-Release Mechanism (Figure 1-1). The quick-release mechanism is located a t the outer extremity of each swing a r m . se rv i ce l ines to the vehicle during ground operation, then r e l e a s e s and ejects these l ines from the vehicle at liftoff. The quick-release mechanism for swing a r m s No. 1 and No. 3 (figure 3-1 and 3-3) consists of a housing, a ball-lock device, and four pneumatically actuated kickoff pistons. ball-lock devices on swing a r m s No. 1 and No. 3 to unlock the swing a r m s .
The mechanism s e c u r e s the various
A t liftoff, pneumatic p r e s s u r e is applied to the
The quick-release mechanism for swing a r m No. 2 (figure 3-2) consis ts of a connector plate and two pneumatic kickoff cyl inders , each of which also incorporates two a r m s that hook over pins on the S-lV stage umbilical plate. A t liftoff, pneumatic p r e s s u r e is applied to the kickoff cylinders to r e l ease the a r m s from the pins and sepa ra t e the connector plate from the vehicle.
The GH2 vent l ine on swing a r m No. 3 connects to the vehicle through a 6-inch quick- disconnect coupling. The coupling is secured to the vehicle by a spr ing lock assembly inside the coupling. A t liftoff , t he outer shell of the coupling is kicked back by two kickoff pistons and the spring lock releases and sepa ra t e s the vent l ine from the vehicle.
1 . 2 . 1 . 4 Rotary Hydraulic Actuator (Figure 1-1). T h e vane-type ro t a ry hydraulic actuator develops the 210,000 inch-pounds of torque required to rotate the swing a r m 135 degrees. A s the swing a r m pivots a cam-operated valve gradually c loses and causes the swing arm to decelerate. deg rees , the valve is fully closed and r e tu rn hydraulic fluid is metered through an orifice to limit back p r e s s u r e on the rotary actuator. rotary actuator f r o m excess back p res su re .
1 . 2
When the a r m has traveled approximately 120
A relief valve protects the
1.2.1.5 Lanyard Release Cable (Figure 1-1). Mechanical pull from the lanyard release cables r e l eases any umbilical connector that has failed t o disconnect. release cable is connected to a hydraulic cylinder that receives hydraulic fluid at 1500 psig when the swing a r m lockpin is retracted. in the hydraulic supply line and hydraulic p re s su re fo rces the piston to the bottom of the cylinder. The lanyard r e l ease cable then pulls the umbilical housing o r connector plate away from the vehicle.
Each lanyard
The Jockpin opens a mechanical valve
1.2.1.6 Bumper Assembly. vertically on the tower a t each swing a r m installation. that the forward end of the swing a r m contacts the bumper when the swing a r m is swung away from the vehicle. microswitch mounted on each bumper assembly i s actuated and t ransmits a signal t o the launch control center when the a rm is fully re t racted
A bumper assembly is attached t o a channel beam mounted Each bumper is installed so
Rubber pads cover the contact a r e a and absorb the shock. A
1 . 2 . 1 . 7 Swing Arm Control Panel ( Figures 3-1, 3-2, and 3 - 3 ) . panel located on the umbilical tower adjacent to each swing a r m , i s provided for con- troll ing swing a r m hydraulic and pneumatic systems.
A swing a r m control
The hydraulic system provides the fluid medium required to operate the rotary hy- draulic actuator, the lockpin assembly, and the lanyard r e t r ac t cylinder. hydraulic fluid is supplied to the system from a hydraulic power c a r t located in the Automatic Ground Control Station (AGCS).
Pressurized
The pneumatic system provides the GN2 control p r e s s u r e required to actuate tnt! swing a r m s . Three GN2 l ines supply all three swing a r m s . A 3000 psig l ine is used to precharge the hydraulic accumulator and pneumatic reservoir in the swing a r m control panel. A 750-psig line i s used to actuate control valvesand the quick-release mechanism. The 750-psig line is a l so used to purge the umbilical housing on swing a r m No. 1 and swing a r m No. 3 . The third line supplies a 50-psig GN2 purge to components in the swing a r m control panel.
The GN2 is also used to purge various a r e a s of each swing a r m .
1.2.2 Operation - The description of the operation of the swing a r m s i s divided into the following separate discussions: System preparation, rotation of the swing a r m into the vehicle servicing position, and the umbilical r e l ease and swing a r m rotation at liftoff. only swing No. 1 is discussed; therefore, finding number references a r e to figure 3-1 only.
Since the operation of each of the three swing a r m s is essentially the same ,
1.2.2.1 System Preparation. accumulator must b e filled and the pneumatic sy.stem must be pressurized. accomplished a s follows:
Before the swing a r m can be operated, the hydraulic This i s
a. Solenoid Valve A3043, Manual .Valve A3007, and Pneumatic Valves A3012 and A3036 are closed. ing Solenoid Valve A3018.
Pneumatic Valves A3012 and A3036 a r e closed by energiz-
1. 3
b.
C.
d.
e.
f.
g*
h.
The hydraulic pump motor on Hydraulic Power Car t A4850 is s tar ted and the flow control valve is opened. Hydraulic fluid flows up the tower through the tower hydraulic supply line.
Manual Valve A5500 is opened to allow hydraulic fluid to flow into Hydraulic Accumulator A3000, through Filter A3020, and Check Valve A3003.
Hydraulic Accumulator A3000 is filled until the fluid fo rces a piston within the accumulator to the bottom and actuates the accumulator full Indicator Switch A3022.
Pump p res su re increases to 1700 psig, at which t ime fluid flow to Hydraulic Accumulator A3000 ceases.
Manual Valve A3001, located on the swing a r m control panel, is opened and 3000-psig GN2 from valve panel No. 5 (volume V) flows to pneumatic Pres- s u r e Regulator A3006 through Check Valve A3027.
Pneumatic P r e s s u r e Regulator A3006 is opened until Pneumatic Reservoir A3002 is pressurized to 1500 psig a s indicated by P r e s s u r e Gage A3005 and P res su re Transducer A3016. Manual Valve A3001 is closed.
When 1500-psig p r e s s u r e is obtained,
A manual valve (A2130, volume V) on valve panel No. 5 is opened and 750- psig GN for valve actuation, umbilical housing purge, and umbilical housing release is supplied to the system, 2
1.2.2.2 Rotation of Swing Arm into Vehicle Servicing Position. the swing a r m must be rotated into position and the umbilical housing fastened to the vehicle a s follows:
To se rv ice the vehicle,
a.
b.
C.
A toggle switch, located on the swing a r m control panel, is moved to the CLOSE position. Normally closed Solenoid Valve A3018 i s energized and 750-psig GN2 p r e s s u r e closes Pneumatic Valves A3012 and A3036 in the main hydraulic supply line.
Manual Valve A3007 is opened and hydraulic fluid flows from Hydraulic Accumulator A3000 through A3007 to four-way Manual Valve A3008. The four-way valve is opened and hydraulic fluid flows through the extend line to Rotary Hydraulic Actuator A3013 which rotates the swing a r m toward the vehicle. Return hydraulic fluid flows back through the r e t r ac t line to A3008 and through Check Valve A3038 to the hydraulic r e tu rn line and Reservoir A4851.
When the swing a r m reaches the launch vehicle servicing position, four- way Manual Valve A3008 is closed and Manual Valve A3028 is opened.
1.4
d. Manual Valve A3026 is opened long enough to allow the hydraulic fluid in Lockpin Assembly A3021 to drain through Check Valve A3038 into the hydrau- lic return line and Reservoir A4851. Venting the lockpin assembly allows the lockpin to extend and lock the swing a r m in the servicing position.
e. Manual Valve A3009 is opened momentarily to allow the lockpin to r e t r ac t enough to open Mechanical Valve A3023. The piston of lanyard r e t r ac t Hy- draulic Cylinder A3011 is manually extended. This forces hydraulic fluid from the cylinder through Orifice A3078,Mechanical Valve A3023, Manual Valve A3028, and Check Valve A3038 into Reservoir A4851. When the lanyard r e t r ac t piston is at maximum extension, A3009 is closed.
f . Umbilical Housing Assembly A3060 is positioned against the vehicle umbilical plate and ball-lock device is secured. Manual Valve A3028 is closed and Manual Valve A3068 is opened.
g.. Hydraulic Accumulator A3000 and Pneumatic Reservoir'A3002 are recharged and Solenoid Valve A3018 is deenergized. vehicle servicing and automatic retraction at liftoff.
The swing a r m is now ready for
1.2.2.3 Operation at Liftoff. A t vehicle liftoff, the umbilical housing assembly i s re leased and pulled away from the vehicle, and the swing a r m is rotated out of the vehicle liftoff drift pattern. The swing a r m re t rac t actuation signal i s sent by either of two swing a r m retract switches located on two of the holddown a r m s . 0
a. The signal from the swing arm re t r ac t switches energizes Solenoid Valve A3039 which permits 750-psig GN2 to flow to the r e l ease mechanism and to the kickoff cylinders. The release mechanism re l eases the umbilical housing assembly from the vehicle, and the kickoff cylinders separate it from the v ehic 1 e.
b. Simultaneously, the signal from the swing a r m control switches energizes Solenoid Valves A3017 apd A3041; 750-psig pneumatic p r e s s u r e then opens Pneumatic Valves A3012 and A3036 in the hydraulic supply line. Fluid from Hydraulic Accumulator A3000 flows through A3012, A3036, and Check Valve A3004 into swing a r m Lockpin Assembly A3021. P res su r i zed hydraulic fluid in A3021 causes the lockpin to r e t r a c t , and allows the swing a r m to rotate.
c . Retraction of the. lockpin opens Mechanical Valve A3023. Hydraulic fluid flows through A3023 and Orifice A3078 to Hydraulic Cylinder A3011. re t rac t cylinder pulls the umbilical housing and se rv ice lines from the vehicle. Hydraulic fluid flow through A3023 is also directed through Check Valve A3031 and the retract l ine t o Rotary Hydraulic Actuator A3013. Return flow i s through the extend line, Manual Valve A3068, Cam-operated Valve A3032, Orifice A3077, and Check Valve A3038 to Reservoir A4851.
The lanyard
d. Hydraulic fluid flow through Rotary Hydraulic Actuator A3013 causes the swing a r m to swing away f rom the vehicle. A s the a r m completes 55 degrees of
1.5
rotation, Cam-operated Valve A3032 is gradually closed by the cam on top of the hinge assembly. A s the valve closes , the flow of hydraulic fluid from the return s ide of the rotary hydraulic actuator i s res t r ic ted and the swing a r m decelerates. When the swing a r m has completed approximately 120 degrees of rotation, the cam-operated valve i s completely closed. the hydraulic fluid to flow through Orifice A3044 and causes further deceleration of the a r m . Relief Valve A3067, which rel ieves a t 2000 psig, prevents ex- cessive p re s su re buildup in the rotary hydraulic actuator. The hydraulic fluid flows through Orifice A3077 and into the tower hydraulic re turn line through Check Valve A3038.
This action forces
e. A s the swing a r m completes 130 to 135 degrees of rotation, it contacts the tower bumper assembly. launch control center that the swing a r m i s fully re t racted.
A microswitch in the bumper assembly signals the
1 . 3 SHORT CABLE MASTS
Two short cable masts a r e mounted on the launcher to provide quick-disconnect capa- bility for electrical cables and pneumatic lines that connect the ground support equip- ment to the s-I stage. Short cable mas t s No. 2 and No. 4 a r e s imi l a r in construction and identical in operation. of cables and pneumatic lines required for each mast. Because of these s imi la r i t i es , only the description and operation of short cable mast No. 2 is given in the following paragraphs.
Significant differences a r e type, s ize , quantity, and routing
1.3.1 Description (Figure 1-2) - Each short cable mast assembly consis ts of a support platform, a mast weldment, two kickoff cylinders, a quick-release housing, a latch-back mechanism, and a trunion.
1 .3 .1 .1 Support Platform. fo rms the s t ructural base of the short cable mast. a ladder that furnishes a c c e s s to the r e s t of the cable mast. T h e support platform provides sufficient elevation so that the quick-release housing will mate with the vehicle umbilical plate. Two detachable work platforms and one extension platform a r e attached to the top of the support platform to furnish a working a r e a during prelaunch operations. The detachable work platforms a re relfioved and the extension platform is folded and secured pr ior to launch.
The support platform is a four-sided t r u s s s t ruc tu re that One s ide of the support platform i s
1 .3 .1 .2 Mast Weldment . The mas t weldment extends from the top of the support platform to the vehicle umbilical plate. The weldment consis ts of four bracket a r m s and two hinge assemblies which allow the quick-release housing and se rv ice l ines t o pivot away from the vehicle a t liftoff. hinges, pivots the mast backward and pulls the quick-release housing c l e a r of the vehicle a t liftoff.
A r e t r ac t cylinder, secured between the two
1.3.1.3 Kickoff Cylinders. Spring-loaded kickoff cylinder assemblies mechanically eject the quick-release housing from the vehicle. T h e cylinders a r e secured to the upper bracket a r m s of the mast weldment by hinges and the cylinder piston rods a r e inserted in pin-holddown devices on the vehicle. At l if toff , vehicle movement causes
1 . 6
the piston to compress the cylinder springs. Af te r approximately two inches of vehicle motion, the pistons bottom within the cylinders and mechanically eject the mast from the vehicle. short cable mast is free to be pivoted clear of the vehicle drift pattern.
The kickoff cylinder rods slip out of the pin-holddown devices and the 0
1.3.1.4 Retract Cylinder. A double-acting pneumatic retract cylinder supplies the force necessary to pivot the short cable mast. At liftoff, 750-psig GN2 flowing into the top of the r e t r ac t cylinder pivots the mast backward. Fifty-psig GN2 is constantly vented at the bottom of the cylinder to cushion the backward swing of the mast.
1.3.1.5 Quick-Release Housing. The quick-release housing, mounted at the upper end of the mast weldment, contains electrical cable and pneumatic service l ine con- nectors which link the vehicle to the ground support equipment. The housing i s secured to the S-I stage umbilical plate by a ball-lock release pin assembly. A r e l ease a r m is attached to the pin assembly to re t rac t it from the ball-lock mechanism . A s the vehi- cle l if ts approximately two inches, a roller mounted on the other end of the r e l ease a r m moves down a groove in the mast arm. The r e l ease a r m pivots about a hinge and forces the pin to re t rac t ; thus the quick-release housing is freed from the S-I stage umbilical plate.
1.3.1.6 Latch-Back Mechanism. A latch-back mechanism, bracketed between the mast weldment and the trunnion, provides a positive lock for the mast in either of t h ree retracted positions. The lock prevents the mast from rebounding into the vehicle liftoff drift pattern. The first position holds the mast approximately four inches from the vehi- cle to prevent the mast from striking the vehicle during mast erection. The mid-position s e c u r e s the mast out of the vehicle liftoff drift pattern. The kickoff cylinders should force the mast to this position even if a failure occurs in the pneumatic retraction system. The third position is the fully retracted position; normally, the retraction system positions the mast to this position.
0
1.3.1.7 Trunnion. The trunnion provides a mounting point and pivot for the mast weld- ment. mounted on the trunnion. The trunnion provides a means of adjusting the vertical position of the mast.
The latch rod bracket and the lower r e t r ac t cylinder hinge assembly a r e a lso
1.3.2 Operation (Figure 3-4) - Short cable mast operation includes the sequence for prelaunch erection and automatic launch retraction. The operation of short cable mast No. 2 and short cable mast No. 4 is identical; therefore.,only the operation of short cable mast No. 2 is discussed.
1.3.2.1 Mast Erection. The short cable mas t is erected as follows:
a. The latch-back mechanism is manually released and the mast is manually moved toward the vehicle.
b. The piston rods of kickoff Cylinders Assemblies A6511 and A6526 a r e inserted into the vehicle pin holddown devices.
1. 7
C.
d.
e.
f.
Vent port Check Valve A6523 is removed and a variable (250-to 750-psig) GN2 supply is attached to Orifice A6516 to supply pneumatic p r e s s u r e t o the bottom of Retract Cylinder A6522.
A s Retract Cylinder A6522 is gradually pressurized, the mast moves forward and Release Pin Assembly A6500 is guided into the S-I Stage umbilical plate receptacle. The kickoff cylinders are further compressed as the mast moves toward the vehicle.
After the housing is secured to the S-I stage umbilical plate, p r e s s u r e is bled from the auxiliary supply l ine and the r e t r ac t cylinder. The auxiliary supply line i s then removed and vent port Check Valve A6523 is re-installed.
All service lines are connected to the proper nipples and connectors on the quick-release housing and a re secured.
1.3.2.2 Automatic Mast Retraction. Automatic mas t retraction is as follows:
a.
b.
C.
d.
e.
A t T minus 5 seconds, a solenoid valve (A5602, volume V) in the launcher is energized and 750-psig GN2 flows through Check Valve A6514 to pre-pressurize the upper part of Retract Cylinder A6522. The 750-psig GN2 a l so flows through P r e s s u r e Regulator A6518 and Check Valve A6517 into the lower pa r t of the r e t r ac t cylinder, through Orifice A6516 and Check Valve A6523. seconds a second signal concurrent with the launch commit signal, opens another solenoid valve (A5603,volume V) in the launcher. This allows 750- psig GN2 to flow through Check Valve A6520 to provide backup p r e s s u r e f o r the mast re t ract system.
P r e s s u r e in the bottom of the cylinder is constantly vented At approximately T plus 3
At vehicle liftoff, the quick-release housing moves upward with the vehcile. This upward movement causes the pistons in the kickoff cylinders to fur ther compress the kickoff cylinder springs.
The quick-release housing r e l ease a r m ro l le r moves along the mas t groove for approximately two inches of vehicle motion. release a r m , disengages Release Pin Assembly A6500, and frees the quick- r e l ease housing from the vehicle. off Cylinder Assemblies A6511 and A6526 provide an outward force on the mast weldment.
The ro l le r movement pivots the
Simultaneously, the pistons within kick-
Kickoff Cylinder Assemblies A6511 and A6526 provide enough outward force to disconnect the cable and line connectors f rom the vehicle. within the cylinders help accelerate the mast away from the vehicle.
The spr ings
After disconnect occur s , Retract Cylinder A6522 pulls the mast away from the vehicle. The 50-psig GN2 constantly venting f rom the bottom of the re- t rac t cylinder cushions mast travel.
1.8
f. A s the mas t reaches the end of t rave l , t he latch-back mechanism engages and prevents the mast f rom rebounding into the vehicle liftoff drift pat tern, o r in the event of pneumatic failure, f rom falling back against the vehicle.
1 .4 FUEL AND LOX MASTS
The fuel and LOX mas t s connect propellant t ransfer l ines to the vehicle s torage tanks. The LOX mast is located on the launch pedestal between stub fin 2 and fin III. The fuel mast is located on the launch pedestal between fin I and stub fin 1.
1.4.1 Description (Figure 1-2) - The two mas t s a r e s imi l a r in construction; however, the fuel mas t is 18 inches longer and contains the turbine exhaust duct. Major com- ponents of both mas ts a r e a retractable coupling assembly , cylinder assembl ies , a mas t a r r e s t o r , a r e t r ac t assembly, a mounting assembly , and a valve box assembly. The description of the two mas ts i s essentially the same ; therefore,only the fuel mas t is described. Differences, where applicable, a r e described.
1 .4 .1 .1 Retractable Coupling Assembly. The retractable coupling assembly is a mechanically actuated, telescoping device used to mate the fuel mas t to the S-I stage fuel fill and drain nozzle. P r imary components of the coupling a r e guide vanes and a bellows which is mounted in a shield assembly. coupling with the fuel nozzle during mast erection while the bellows control the coupling action. during fuel t ransfer operations.
The guide vanes align the retractable
A Teflon sea l between the coupling and the fuel nozzle provides a positive sea l The shield assembly protects the bellows. 0
1.4 .1 .2 Cylinder Assemblies. contraction and expansion of the bellows in the retractable coupling assembly. cylinder assembly consis ts of two clevises , a piston rod , a spr ing, a p r e s s u r e port and a cylinder body. The top clevis i s connected to the retractable coupling assembly and the bottom clevis is connected to the upper pipe weldment of the mast. The spr ing in the cylinder is preloaded to maintain the piston, with the attached retractable coupling assembly, in the extended position. When 750-psig GN2 is applied to the p r e s s u r e port , the piston is forced down in the cylinder body and the spr ing is compressed. The piston rod causes the bellows to contract and r e t r ac t the coupling assembly. s u r e in the cylinder is vented, the spring forces the piston to re turn to the original position.
Two cylinder assembl ies a r e used to control the Each
When the p re s -
This action expands the bellows and extends the coupling assembly.
1 .4 .1 .3 Mast Arres tor . re t rac ted position. pat tern o r falling against the vehicle in t h e event of pneumatic failure. The mast a r r e s t - o r consis ts of a mounting bracket attached to a cylinder assembly, a dual a r r e s t o r hook, an a r r e s t o r cylinder assembly that is spring-loaded t o the a r res t ing position. The spr ing load on the a r r e s t o r cylinder assembly keeps the a r r e s t o r hook in the locked position until pneumatic p re s su re overcomes spring tension and pivots the a r r e s t o r hook to the released Dosition.
The mast a r r e s to r automatically secu res the mast in the This prevents the mas t f rom rebounding into the vehicle liftoff drift
1 .4 .1 .4 Retract Assembly. The retract assembly is an adjustable pneumatic cylin- d e r that pivots the upper portion of the mas t e i ther into position under the fuel nozzle,
1. 9
'
o r away from the vehicle. The re t rac t assembly consists of a r e t r ac t cylinder a s sem- bly with extend and retract por t s , a cylinder support, a clevis, and an adjustment wheel. The r e t r ac t cylinder assembly is connected to the upper portion of the mast by the cyl- inder support and the clevis. Application of 750-psig pneumatic p r e s s u r e to the cyl- inder assembly retract port forces the cylinder piston down and causes the upper portion of the mast to swing away from the vehicle. The adjustment wheel controls the amount of swing by lengthening o r shortening the re t rac t assembly. Pneumatic p r e s s u r e applied to the erect port , and vented from the retract port , moves the cylinder piston to the original position and swings the upper portion'of the mast to the servicing position under the fuel nozzle.
1.4.1.5 Mounting Assembly. The mounting assembly is the connecting link between the upper and lower pipe weldments, and is secured to the support stand. ing assembly contains a trunnion support assembly, to which the r e t r ac t cylinder assem- bly and a support bracket assembly a r e connected. ment s c rews on the mounting assembly provide mast assembly adjustment. The ring permits height adjustment of the mast to attain co r rec t c learance between the retractable coupling assembly aiid the fuel nozzle. adjustments to align the mast with the fuel nozzle.
The mount-
An adjustment r ing and two adjust-
The adjustment s c rews a r e used to make la teral
1 .4 .1 .6 Valve Box Assembly. The valve box assembly, located on the support stand, provides manual and automatic control of mast operation. Manual control of c i rcui ts for mast erection, retraction, and checkout is accomplished through u s e of pushbutton valves located on the valve box assembly.
1.4.1.7 Turbine Exhaust. plates welded together t o form a vent for hot exhaust gas ses from the No. 5 H-1 engine turbine. stand to the atmosphere. The turbine exhaust duct is a pa r t of the fuel mast only and i s not on the LOX mast. Due to the flammable nature of RP-1 fuel, the fuel mast a lso incorporates a flame a r r e s to r . The flame a r r e s t o r consis ts of an inner and an outer s c reen arrangement installed in the fuel flow path between the upper pipe weldment and the retractable coupling assembly. The flame a r r e s t o r prevents flame from enter- ing the fuel line through the retractable coupling assembly a t liftoff.
The turbine exhaust duct consists of several 1/4-in. thick
The duct collects and routes the exhaust gas ses down through the mast support
1 .4 .2 Operation (Figure 3-4) - The fuel and LOX mas t s a r e erected and aligned p r io r to launch by using the valve box assembly. The fuel and LOX mas t s a r e re t racted automatically during the launch operation. The two mas t s operate in the s a m e manner; thcrefore,only the fuel mast operation i s discussed.
1 .4 .2 .1 Mast Erection. The fuel mast i s erected to the servicing position a s follows:
a. Button-operated Manual Valve A4511 on the valve box assembly i s opened, allowing 750-psig G N 2 f rom valve panel No. 10 to flow through A4511 and Check Valve A4515 to Cylinder Assemblies A4502, A4503, and A4508. G N 2 also flows through Check Valve A4512 and Orifice A4527 to the r e t r ac t port of Cylinder Assembly A4504 and through Pressure Regulator A4522 to the erect port of A4504.
1.10
b.
C.
d.
e.
f.
Cylinder Assemblies A4502, A4503, and A4508 a r e brought to operating p r e s s u r e before Cylinder Assembly A4504 reaches operating p r e s s u r e due to the low flowrate through Orifice A4527. This allows Retractable Coupling Assembly A4500 to re t ract and the a r r e s t o r hook to pivot to the released position p r io r to movement of the mast. of the r e t r ac t assembly is reduced to approximately 185 psig and serves a s cushion p r e s s u r e against sudden movement of the retract assembly piston. Check Valve A4518 and button-operated Manual Valve A4516 prevent 750-psig GN2 from entering the retract assembly e rec t port.
P r e s s u r e at t he erect port
Button-operated Manual Valve A4511 is released and pneumatic p r e s s u r e is trapped in the system. The trapped p r e s s u r e keeps Retractable Coupling Assembly A4500, Cylinder Assembly A4504, and m a s t a r r e s t o r Cylinder Assembly A4508 in the retracted position.
Button-operated Manual Valves A4514 and A4516 are mechanically linked for simultaneous operation. When actuated, A4514 vents the r e t r ac t port of Cylinder Assembly A4504 and A4516 allows 750-psig GN2 to flow to the erect port of the cylinder assembly. S-I stage fuel fill and drain nozzle. Speed of mast movement is limited by restricting the release of p re s su re from the r e t r ac t port by Orifice A4513.
The mas t then moves into position under the
Button-operated Manual Valves A4514 and A4516 are closed when the mast is in position under the fuel nozzle. A4502, A4503, and A4508 keeps the a r r e s t o r hook in the released position and Retractable Coupling Assembly A4500 in the retracted position.
Trapped p r e s s u r e in Cylinder Assemblies
Button-operated Manual Valve A4521 is opened to vent the ent i re mast a s sem- bly. This allows Retractable Coupling Assembly A4500 to mate with the fuel nozzle and the a r r e s t o r hook to r e tu rn to the a r r e s t ing position.
1.4.2.2 Automatic Mast Retraction. Automatic mas t retraction at vehicle launch occur s as follows:
a.
b.
C.
A holddown a r m re l ease signal energizes a solenoid valve (A5601, volume V) in the launcher which allows 750-psig GN2 from valve panel No. 10 t o flow through Check Valve A4523 to the retract port of Cylinder Assembly A4504. The 750-psig GN forces the piston to the bottom of the cylinder and the piston t ravel retracts the mast.
2
GN2 a t 750 psig also flows to P r e s s u r e Regulator A4522 and is reduced to approximately 185 psig. The 185-psig GN2 then flows through Relief Valve A4520 and Check Valve A4519 to the erect port of Cylinder Assembly A4504 to decelerate the mast and cushion the retracting motion.
The a r r e s t o r hook is spring loaded to the a r r e s t ing position to provide positive engagement with the pivot pin in the mounting bracket assembly. The a r r e s t o r hook locks the mas t in the fully re t racted position and prevents the mast f rom
1.11
rebounding into the vehicle liftoff drift pattern o r falling forward in the event of pneumatic failure.
1 .5 HOLDDOWN ARMS
The eight holddown a r m assemblies (figure 1-2) support the vehicle on the launcher and prevent liftoff until engine thrust builds up and stabil izes and the engine hydraulic sys- t e m s reach operating pressure . fin. the launcher. exhaust during ignition and liftoff. f r a m e provide access for replacing the shea r pin module and for repositioning the t ip of the ball-lock separator af ter the re lease operation. A removable winch assembly is used for positioning the holddown a r m assemblies in the proper holddown position.
Similar a r m assembl ies a r e located under each vehicle The c a s t steel holddown a r m assemblies a re 7-foot s t ruc tures that a r e bolted to
A blast shield protects the linkage and separa tor device f rom engine Doors located on both s ides of the holddown a r m
1 .5 .1 Description (Figure 3-5) - Each hold down a r m consis ts pr imar i ly of an a r m and two pin-jointed links. The a r m is joined t o the hold-down f r a m e a t pin joint 'IA" which allows the a r m to pivot upward and away from the vehicle tie- down points. The other end of the a r m is supported at pin joint "B" by an a s sem- bly composed of two pin-jointed links. These links a r e jointed end to end and a r e attached to the holddown f r a m e a t pin joint "D". these two links, pin joint "C", is connected to pneumatically-operated Quick-Release Mechanism A4400. The links a r e mounted s o that they s lant inward toward the vehicle. A swivel nut moves the linkage outward when torqued to the required value. the holddown a r m to clamp down on the vehicle holddown fitting. When pneumatic p re s - s u r e is applied t o the quick-release mechanism, the link assembly is re leased at pin joint "C". This forces the a r m to rotate around pin joint "A" and r e l ease the vehicle. T h e link assembly folds downward, rotating around pin joint I1Dt1. The lower link en- counters a replaceable shea r pin module which absorbs kinetic energy and dece lera tes the motion of the a r m and link. With the holddown a r m In the r e t r ac t position, Micro- switch A4411 t ransmits a signal to t h e launch control cen ter to indicate that the hold- down a r m has been released. Two liftoff switches are located on holddown a r m s I and I11 and two swing a rm control switches a r e located on holddown a r m s XI and IV. The switches are spr ing operated and a r e held open by the weight of the vehicle. At liftoff the switches a r e released.. The liftoff switches signal the launch control cen ter that liftoff has been accomplished. The swing a r m control switches send a signal t o the swing a r m s to initiate swing a r m retraction. To provide environmental protection against fire and explosion due t o e lectr ical sparks , the switches a r e purged with 50- psig GN2 f rom a regulator (A2121, volume V) located in valve panel No. 5. The purge begins immediately before propellant loading and continues until liftoff.
The connecting joint between
This causes
1 .5 .2 Operation (Figure 3-5) - The operation of the holddown a r m s cons is t s of attachment of the a r m s to the vehicle, pressurizat ion of the holddown a r m s release control panel, and holddown a r m s r e l ease a t vehicle liftoff.
1 .5 .2 .1 Attachment to the Vehicle. The holddown a r m s are attached to the vehicle a s follows:
1.12
a. A winch assembly is attached to the holddown a r m assembly and used to position the holddown a r m on the vehicle fin holddown fitting.
b. Two access doors are removed f rom the holddown a r m housing and a shea r pin module is installed. Quick-Release Mechanism A4400 is connected and the required torque is applied to the swivel nut; af ter which,the access doors a r e replaced and the winch assembly i s removed.
1.5.2.2 System Pressurization. The holddown a r m s release control panel is pres- aur ized a s follows:
a. Manual Valves A4431 through A4438 a r e opened.
b. Manual Valve A4444 is opened, allowing 750-psig helium (He) t o flow from valve panel No. 10 (volume V) through Check Valve A4443, into Pneumatic Reservoir A4441. Gage A4440.
The p res su re within the system is indicated by P res su re
c. P r e s s u r e Switch A4418 actuates a t 625 (i20) psig to a r m the engine ignition system.
1.5.2.3 Liftoff and Release Sequence. The holddown a r m s r e l ease sequence is a s follows:
a. After the H-1 engines ignite and build up maximum thrust and the hydrau- 'au- l ic sys tems reach operating p res su re , a signal f rom the launch control center energizes Solenoid Valves A4416 and A4417 allowing 750-psig He from Pneu- matic Reservoir A4441 to flow to Shuttle Valve A4439 and Manifold A5687. System p r e s s u r e t o the manifold is supplemented by 750-psig He flow from valve panel No. 10 (volume V) through Check Valve A4443 , Manual Valve A4444, t he solenoid valves and the shuttle valve.
b. Helium a t 750-psig flows from Manifold A5687 to each holddown a r m assembly simultaneously. Helium flows to Quick-Release Mechanism A4400 , located a t holddown a r m No. I, through Manual Valve A4431. l ea ses the quick-release mechanism which allows the link assembly to fold to the r e t r ac t position. shea r pin module and comes to rest. Microswitch A4411 energizes the fin I r e l ease indicator in the launch control center.
Pneumatic p re s su re re-
The lower link of the assembly shea r s the pins in the
1. 13
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SECTION 2
INDEX OF FINDING NUMBERS
This section contains an alpha-numerical list, by finding number, of the launch pad accessories components that function during a prelaunch countdown. The finding numbers l isted identify components on system mechanical schematics provided in section 3. Additional columns in the index of finding numbers provide such pertinent information as component description and function, par t number, and the suppl ier’s name and p a r t number. A break will occur in the alpha-numeric sequence of finding numbers when a component, o r component series is non-functional during the count- down, functional only in the event of a malfunction, functional in t e r m s of a mainte- nance operation only, o r is par t of another functional system.
The le t ter prefix of a finding number identifies the component location with respect to e i ther the launch complex or an a r e a of the launch vehicle. The le t ter prefixes used in this eleven-volume se t a r e listed below.
FINDING NUMBER PREFIX DESIGNATED AREA
A
B
E
G
H
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S-I stage
S-IV stage
Instrument unit
Payload
2 . 1
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SECTION 3
MECHANICAL SCHEMATICS
This section contains mechanical schematics that show the functional arrangement of launch pad accessories components listed in section 2.
Foe a definition of the mechanical symbols used, see MSFC-STD-162A.
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