Project Gemini - Extravehicular Life Support System ELSS Final Report, 30 Jan. 1964 - 31 Mar. 1967

I _AsA e_
20
I
I
Final Rcport
I
I
PROJECT GEM INI
I EXTRAVEHICULAR LIFE SUPPORT
I SYSTEM (E LSS)
I NASA (:ONTRA(iT NAS-9-2il2
66-1.ig
Ecbruarv 1967
I
I THE NASA
Prcparcd
MANNED
tbr
SPACECRAFT CENTER
HOUSTON, TEXAS
I
I
,..I. "N
I /:_..) v <,,
,I j
,=_"
I \W. J. OREILLY
Progranl M:magcr
I
I AIRESEARCH MANUFACTURING DIVISION
Los Angeles, California
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I
I
CONTENTS
I Section
Page
I INTRODUCTION I-I
General I-I
I Events and Information I-I
2 SUMMARY 2-1
I Introduction 2-1
Selection of Semi-Open-Loop System 2-1
I Required Changes in Program 2-2
Addition of Aerospace Ground Equipment 2-2
I Major Milestones 2-2
3 PROGRAM HISTORY 3-1
3-1
Introduction
Major Events .3-2
System Study3 Definition and Packaging .3-2
Mounting .3-10
I Addition of Aerospace Ground Equipment (AGE) 3-10
Major Milestones .3-11
I Funding .3-12
DESIGN AND DEVELOPMENT 4-1
I Introduction 4-1
General Design Requirements 4-2
I Environmental Specifications 4-2
4-2
I
Reliability
Quality Assurance 4-2
4-9
I Summary
Series
of Suit Pressurization-Ventilation Test
Introduction
I Summary and Conclusions
I
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CONTENTS (Continued)
I
Sect on
Test Facility and ECS 4-13

I
Test Procedure 4-18
I
Chestpack Assembly 4-23
General 4-23 I
Purpose 4-24
Description 4-24
4-40
I
Performance
Development 4-47
I
Chestpack Components 4-76
General 4-76
Evaporator-Condensor (Heat Exchanger) 167880 4-76
Suit Pressure Relief Valve 800278 4-105
4-111
Oxygen Tank3 800310 (baffled) and 800312
(plain)
Oxygen Pressure Regulator and Relief Valve 4-115

I
800284
Duct (Ejector) and Heater Assembly 138969 4-126 I

Valve Group 800282 4-133
Fill and Shutoff Valve 800286 4-142
4-146
I
Suit Loop Check Valve 850040
4-152
Pressure
Housing
Gauge
Assemblies
800300
4-154 I
Electrical Components 4-156
H202 Quantity Gauge 800386 4-160 I

Umbil ical Assembly 800526 4-1 83
General 4-183
I
Purpose 4-1 83
Description (See Figure 4-97) 4-1 83 I

Performance 4-1 83
Development 4-1 86 I
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I Section
I Umbilical Assembly 4-199
General 4-199
I Oxygen Supply Hose 138441 4-199
Oxygen Hose Quick Disconnects 4-201
I Tether
Tether
Line
Hook3 138642
4-204
4-207
I Tether
Electrical
Line
Jumper
and
Cable
Tether Hook 3
800372
138642 4-211
4-214
I Purpose 4-214
Description 4-214
f Performance 4-214
Development 4-214
Multiple Connector 800566 4-218
Purpose 4-218
I Description
Performance
4-218
4-218
I Development 4-220
QUALIFICATION TEST PROGRAM 5-1
I Introduction 5-1
General Qualification Test Plan 5-2
I Qualification Tests 5-3
Introduction 5-3
I Test
Test
Requirements
Procedures and Results

5-3
5-3
I 6 DOCUMENTATION 6-1
Introduction 6-1
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Sect i on
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7 QUALITY CONTROL 7-1
I
Introduction 7-1
Data File 7-1
7-1
I
Equipment Log
Configuration Change Control 7-I

I
General 7-1
Accountability - Phase I 7-2
7-2
I
Investigation - Phase II
Program
Repair and
Planning
Upgrading
- Phase
- Phase
III
IV
7-2
7-2
I
Delivery - Phase V 7-2
8 RELIABILITY 8-1
Introduction 8-2
Flexibility of Program 8-2
Data
Conclusions
Processing System 8-2
8-3
I
9 AEROSPACE GROUND EQUIPMENT 9-I
9-1
I
Introduction
IO MATERIALS I0-1 I
Introduction I0-1
Nonmetallic Selections I0-1 I

General I0-1
Candidate Materials 10-7 I

Material Selected 10-8
II FLIGHT HISTORY I1-1 I

I1-1
GT-8
GT-9
(Launch
(Launch
Date)s 3-16-66
Date) 3 6-3-66 II-I !

I1-1
GT-IO (Launch Date)s 7-18-66
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I Section
I GT-I I (Launch Date_ 9-12-66) II-2
GT-12 (Launch Date) II-11-66) I I-2
I 12 OPERATING INSTRUCTIONS 12-1
Introduction 12-1
I 13 PARTS LIST 13-I
I Introduction
Vendor Codes
13-I
13-11
I 14 INSPECTION AND REPAIR AS NECESSARY (IRAN) 14-I
Introduction 14-I
Summary 14-I
Operation and History 14-I
Design Modifications 14-I
Actual Modification and Refurbishment 14-4
I APPENDIX A AIRESEARCH
DATA SYSTEM
RELIABILITY
SECTION 5:
PHILOSOPHY ORGANIZATION3
TROUBLE REPORTING
AND
SYSTEM
A-I
AIRESEARCH REPORT NO. RC-S6-R
I APPENDIX B PROCEDURES FOR QUALIFYING

IN OXYGEN BREATHING
NONMETALLIC
SYSTEMS AIRESEARCH
MATERIALS FOR USE
REPORT NO.
B-I
SS-2108-MR
I APPENDIX C DATA ACQUISITION PROCEDURE 210-A7 C-I
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I LLUSTRATI ON S
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Figure Page
3-I Zero Gravity Tank Heating 3-.3 I

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

3-4 Zero Gravity Tank Heating 3-6
3-5
4-I
Funding
Random
and
Vibration
Expenditures
Power Spectral Density

3-14
4-5
I
4-2 Random Vibration. Power Spectral Density 4-6
4-3 Acoustic Environment Spectrum in Pressurized Cabin 4-7

I
of Reentry Module
4-4 Design Limit Load Factors Area II (Main Cabin Section) 4-8
4-5 Mass Flow vs AP for Gemini Astronaut Extravehicular Suit 4-12
4-6 Sectioned View of AiResearch Altitude Chamber Facility 4-14

Showing Thermocouple Locations
4-7 Schematic Diagram - AiResearch Altitude Chamber 4-15

Environmental Control System and Instrumentation
4-8 Schematic Diagram Showing Location of the Suit Parameter 4-16

and Gas Analysis Instrumentation
4-9 Preflight Preparation of Test Subject 4-20 I

4-10 Closeup of Subject Showing Location of Helmet C02 4-21
4-11
Analyzer
Test Subject
in Front of Subject's
During
Head
Exercise Period on Treadmill 4-22

I
4-12 Chestpack Assembly--Front and Left Side as Viewed by an 4-25
Observer I
4-13 Chestpack Assembly--Front and Right Side as Viewed by an 4-26
Observer
4-14 Chestpack Assembly--Back_ as Viewed by an Observer 4-27

I
4-15 Chestpack Assembly--Top (Control Panels) as Viewed by 4-28
an Observer
I
4-16 Pneumatic System 4-31
4-17
4-18
Electrical
Ejector
System
Primary Inlet Pressure as a Function of Umbilical

4-36
4-54
I
Inlet Pressure and Average Temperature
4-19 Umbilical
sure and
Flow
Temperature
Rate Variation with Umbilical Inlet Pres- 4-55 I
4-20 Ejector
Primary
Primary
Pressure
Flow
and
Rate as a
Temperature
Function of Ejector 4-56
I
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I ILLUSTRATIONS (Continued)
I Fiflure
I 4-21 Total Cooling

Pressure and
Effect Variation
Temperature
with Umbilical Inlet 4-57
4-22 Suit Inlet C02 Partial Pressure Variation with 4-58
I Umbilical
Metabolic
Inlet
Rate
Pressure and Temperature and Subject
4-23 Ejector Inlet Pressure Variation with MMU Oxygen Supply 4-59
I 4-24
Pressure
Ejector Primary Flow Rate Variation with MMU Oxygen 4-60

Supply Pressure and Temperature
I 4-25 Cooling Effect as a Function of MMU Oxygen Supply Pres- 4-61

sure and Temperature
I 4-26 Suit Inlet

Oxygen
C02 Partial
Supply Pressure
Pressure Variation
and Temperature
with MMU 4-62
4-27 Cooling Effect as a Function of Emergency Oxygen 4-63

Supply Pressure - Selector Valve Low-Flow Rate
Setting
4-28 Suit Inlet C02 Partial Pressure Variation with Emergency 4-64
Oxygen Supply Pressure and Subject Metabolic Rate -
Selector Valve Low-Flow Rate Setting
4-29
I
ELSS Ejector Altitude Performance Test Setup 4-69
4-30 Umbilical Outlet Pressure as a Function of Primary Flow 4-70
4-31 Umbilical Outlet Pressure as a Function of Umbilical 4-71
I 4-32
Flow
Umbilical Outlet Pressure as a Function of Total Flow 4-72
I 4-33
4-34
Umbilical
Umbilical
Outlet
Outlet
Pressure
Pressure
as
as
a Function
a Function
of
of
Total
Total
Flow
Flow
4-73
4-74
4-35 EVLSS Vibration Test 4-75

I 4-36 Evaporator-Condenser 4-77
4-37 Evaporator-Condenser 4-78
I 4-38 Evaporator-Condenser 4-79
4-39 Evaporator-Condenser 4-80
I 4-40
4-41
Schematic
Evaporator-Condenser
of Evaporator-Condenser
Test Module PA 48696 (Sintered

4-81
4-85
Porous Metal Used as the Condensing Wick)
I 4-42 Evaporator-Condenser Test Core-Module PA 48696 4-86
4-43 Evaporator-Condenser Test Module PA 60215 (Felt Metal 4-87
I Vaporizing Wick_ Separate Air Trap)
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ILLUSTRATIONS (Continued)
I
Fi .qure
4-44 Evaporator-Condenser Test Module PA 60215 4-88 i

4-45 Evaporator-Condenser Test Resu]ts- Module PA 60215 4-93
4-46
Test Date September
Evaporator-Condenser
16,
Test
1964
Results - Module PA 60215 4-94 I

Test Date September 18, 1964
4-47 Evaporator-Condenser
(Boiler Inverted) -
Test
Test
Results - Module
Date September 21,
PA 60215
1964
4-95
I
4-48 Test Setup - Evaporator-Condenser Test Module PA 60215 - 4-96
Unit Equipped with Steam Duct and Back Pressure Valve
4-98
I
4-49 Evaporator-Condenser Dry Isothermal Oxygen Pressure
4-50
Drop
Suit
Test
Pressure Relief Valve 4-104 I

4-51 Schematic of Suit Pressure Relief Valve 4-105
4-52 Suit Relief Valve Pressure Drop 4-107 I

4-55 ELSS Suit Outflow Valve (8002781 Icing Test Setup 4-108
"t
4-54 4-109
ELSS Suit Outflow Valve (800278) Icing Test Setup
4-55 Emergency Oxygen Tank 4-112
4-56 Results of the P/N 800310 Tank, Burst Pressure Test 4-115
4-57 Oxygen Pressure Regulator and Relief Valve 4-116
4-117
4-58
4-59
Oxygen
Schematic
Pressure
of
Regulator
Oxygen Pressure
and Relief
Regulator
Va]ve
and Relief Valve 4-118 I

4-120
I
4-60 Oxygen Pressure Regulator and Relief Valve 800284-1
Discharge Pressure Performance Envelope
4-61 Emergency Oxygen Pressure Regulator Test Data 4-122
4-62
4-63
Emergency Oxygen Pressure Regulator Test Data 4- 25 I
Emergency Oxygen Pressure Regulator Test Data 4- 24
4-64
4-65
Emergency
Duct (Ejector)
Oxygen Pressure
Without
Regulator
Heater Assembly
Test Data 4-
4-
25
27
I
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4-66 Schematic of Duct (Ejector) and Heater Assembly 4- 28
4-67 Emergency Oxygen Pressure Regulator Test Data 4- 29
4-68 Ejector Performance Test 4- 51
4-69 Ejector Performance Test 4- 52 I

4-70 Schematic of Valve Group 4- 54
4-71 Valve Group 4- 35 I

4-72 Valve Group 4- 36
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I Figure
I 4-75
4-74
Valve Group 4-141
Valve Group Altitude Test Configuration 4-141
I 4-75
4-76
Fill
Schematic
and Shutoff
of Fill
Valve
and Shutoff Valve

4-143
4-144
4-77
I 4-78
Suit
Suit
Loop
Loop
Check
Check
Valve
Valve
(Upstream
(Down
Side)
Stream Side)
4-147
4-148
4-79 Suit Loop Check Valve 4-149
I 4-80 Suit Loop Check Valve After Humidity Test: Left and 4-151
Right - P/N 850040-I; Middle - P/N 850040-2 Incorporating
New Flapper Material
I 4-81 Pressure Gauge 4-153
4-82 Chestpack Lower Case Mold for Plaster Plug 4-155
I 4-83 Chestpack Lower Case Plaster Plug for Fiberglass Lay-up 4-155
4-84 Schematic of Electrical System 4-157
4-85 H202 Quantity Gauge 4-161
4-86 Temperature Sensor 4-165
4-87 Oxygen Heater and Temperature Sensor 4-165
4-88 Schematic of Oxygen Heater 4-166
4-89
I 4-90
Temperature
Electrical
Control
System
and Oscillator Module 4-
4-
68
69
4-91 Pressure Transducer 4- 72
I 4-92 Pressure Transducer Cycling Test Setup 4- 73

4-93 Pressure Transducer Linearity Test Configuration 4- 74
I 4-94
4-95
Battery
Battery
4- 76
4- 77
I 4-96
4-97
Osci
Umbi
lator
ical
Control
Assembly
and Voltage Regulator Module 4-
4-
81
84
4-98
I 4-99
Umbi
Umbi
ical
ical
Assembly
Oxygen
Pressure
Outlet
Drop
Temperature
4-
4-
85
88
4-I00 Umbi ical Oxygen Outlet Temperature 4- 89
I 4-101 Umbi ical Oxygen Outlet Temperature 4-190

4-102 Original Umbilical Assembly Mockup 4- 192
I 4-103 Umbilical
Evaluation
System
IX-Ray
Insulation
Showing
Resistance
Kinked Wires)
Failure 4-195
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Figures
4-104 4-196
Umbilical System Insulation Resistance Failure
Evaluation [Kink in Teflon Covering Over Shields)
4-105 4-197
Umbilical System Insulation Resistance Failure
Evaluation tKink in Shield Over a Fair of Wires)
4-198
I
4-106 Umbilical System Insulation Resistance Failure
Evaluation [Wire Showing Through Ruptured Insulation)
4-107 Current Umbilical Assembly 4-200 I

4- 08 Umbilical Pressure-Drop Test Results 4-202
4- 09 Umbilical Pressure Drop Test-Coiled (Figure 8 position) 4-205 I

4- I0 Umbilical Pressure Drop Test - Straight Position 4-205
4-11 Tether Line Test Samples I through 6 4-206
4-206
I
4-12 Tether Line Test Samples 7 through 9
4-13 Instron Tensile Test Machine 4-206
4- 14 4-209
Ultimate Tether Strength vs Temperature
4-15 Tether Hook-Assembled and Disassembled Views 4-2 0
4- 16 4-2 2
Tether Test Specimen After Conclusion of Test
4-17 Production Tether Hook-Disassembled View 4-2 5
4-18 Electrical Jumper Cable 4-2 5
4- 19 Electrical Jumper Cable 4-2 6
4- 2O Multiple Connector 4-2 9

I
5- Chestpack at Completion of Humidity Test 5-9
5-2
5-3
Pressure-Temperature
Temperature Cycle Test

Test
Setup
Setup
Showing Chestpack in
5-11
5-15
I
Pressure Chamber
5-4 Explosive
on Third
Decompression
Side of Chestpack
Test Location
Assembly
of
800308
Dial Indicator 5-15 I
Explosive
Battery 800670-2-2,
Decompression
Serial
Sequence
No. 65-102 in Explosive

5-16
5-17
I
Decompression Test Setup
5-7 Emergency
Assembly
Oxygen
Burst
Tank
Test
With
Setup
Fill and Shutoff Valve 5-20
I
5-8 5-21
5-9
Pressure
Suit Circuit
Regulator
System
Burst
Burst
Test
Test
Setup
Results (Closeup) 5-22 I

5-10 Burst Test Results 5-25
Top:
Lower
Oxygen
Left:
Tank
Oxygen
with Fill
Pressure
and Shutoff
Gauge
Valve
I
Lower Right: Pressure Regulator
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I ILLUSTRATIONS (Continued)
Fi9ure
I 5-11 Burst Test

800526-I-I_
Setups
Serial
for Umbilical
No. 45-I06
System Assembly 5-25
5-12
I Test Setup
Chestpack
Only)3
for Broadband
Assembly
Frequency
Bonded
Range
Radiated EMI Test with
to Groundplane
0.15 to 25 mc
(Chestpack
5-26
I 5-13
5-14
Chestpack
Random
Random
Vibration
Vibration
Test Setups
Test 5-28
5-30
5-15 Random Vibration Test Setup with Top Cover of Test 5-31
I 5-16
Fixture Removed
View of Split Teflon Insulation Cover Surrounding a 5-32

Conductor Cable (Stranded Wire)
I 5-17 Chamber Umbilical Assembly Random Vibration Test Setups 5-35
5-18 Chestpack Acceleration Test 5-35
I 5-19 Chestpack Mounted to Shock Simulator_ 30g Test 5-36
5-20 Salt Spray Test Setup for Suit Relief Valve 5-38
5-21 Multiple Connector Tests 5-41

5-22 Tether Pull Test Setup for Umbilical System Assembly 5-42
800326-I-I_ Serial No. 45-106
5-23 Fill and Shutoff Valve Components After Pressure Cycling 5-44
I00 Cycles
I 9-1
9-2
Low-Pressure
High-Pressure
Bench
Bench
9-5
9-6
I 9-3
9-4
ELSS
ELSS
PDA Pneumatic
PDA Electrical
Adapter_
Adapter_
P/N
P/N
649204
649205-X
9-7
9-8
9-5 Pneumatic Outlet or Inlet Interface Adapter 9-9

I 9-6 Suit Outflow Valve Adapter_ P/N 649213-X 9-10
12-1 Chestpack Operating Connectors, Controls and Indicators 12-5
I 13-1 Extravehicular
800308-8-2
Life Support System Chestpack_ Part No. 15-2
13-2
I Chestpack Assembly
Panel Assembly)
(Less Housing
(Sheet I of 3)
Assembly and Control 13-6
13-2 Chestpack Assembly (Less Housing Assembly and Control 13-9
I 13-2
Panel Assembly)
Chestpack Assembly
(Sheet 2 of 3)
(Less Housing Assembly and Control 13-I0"

Panel Assembly) (Sheet 3 of 3)
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TA BL E S
I
Table Page I
3-1 3-13
ELSS Program Events
4-1 General Environmental Conditions 4-3 I

4-2 Extravehicular Mission Conditions 4-4
4-3 Basic Test Subject Data 4-19
4-42
I
4-4 Operating Conditions
4-5
4-6
Suit Conditions
Performance Analysis Under Normal Umbilical 02 Flow

4-43
4-44
I
Conditions (Selector Valve in HIGH Position)
4-7 Performance Analysis Under AMU 02 Flow Conditions 4-45 I

(Selector Valve in MED Position)
4-8 Performance Analysis Under Emergency 02 Flow Conditions 4-46

(Selector Valve in HIGH Position)
4-9 Gemini ELSS Performance Analysis 4-53
4-I0 Preliminary Verification Tests 4-67
4-11 Operating Conditions 4-83
4-12 Evaporator-Condenser Test Data 4-90
4-15 Test Data3 Evaporator-Condenser 4-99

(Development Unit No. 2)
4-14 Representative Capacity Heat Rejection with 02 Leakage 4-102
4-15 Tensile Test Data- Umbilical Tether Strap Stitching 4-208

Pattern
5-1 Qualification Tests Performed 5-4
5-2 Administrative Data 5-5
6-1 ELSS Preliminary Organization Reports 6-2
6-2 Progress Reports 6-5
6-3 ELSS Component Acceptance Test Procedures 6-8
6-4 ELSS Component Qualification Test Procedures 6-10
6-5 ELSS Component Qualification Test Reports 6-11
6-6 ELSS Reliability and Miscellaneous Reports 6-14
9-1 Aerospace Ground Equipment 9-2
I0-1 Nonmetallic Materials Used in the ELSS 10-2
12-1 Operating Connectors_ Controls_ and Indicators 12-1
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SECTION 1
I
INTRODUCTION
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SECTION I
INTRODUCTION
I
GENERAL
I
This document is the final report of the Project Gemini Extravehicular
I Life Support System (ELSS). The program was conducted by AiResearch
Manufacturing Division of The Garrett Corporation_ Los Angeles_ California_
I under NASA Contract_ NAS9-2412.
EVENTS AND INFORMATION

I
Events are covered from the inception of the program (January 30j 196/4)
I through completion of the program (March 31_ 1967). In addition_ other useful
information is included_ such as purposej descriptionj and performar, ce of
components and the complete system.
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SECTION 2
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SUMMARY
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SECTION 2
I SUMMARY
INTRODUCTION
i The Gemini Extravehicular Life Support System (ELSS)_ Contract NAS 9-2412j
i was awarded by NASA Manned Spacecraft Centerj Houston_ Texas_ to AiResearch in
January 1964. The ELSS concept was for short-term use during the Gemini Project
I and was based on Project Mercury hardware and data. The ELSS was to be design-
ed to permit an astronaut to perform simple part-tasks making up extravehicu-

I lar activities. The original system specified an open-loop configuration
I using off-the-shelf parts. It involved the use of GFE !oxygen pressure
vessels) fitted with AiResearch regulators_ suit pressure controllers_ oxygen
quantity controllers_ and connecting hoses. The system was to support life
for 20 minutes operation with 5 minutes additional operation while sustaining
I a IO-cfm suit leak.
I SELECTION OF SEMI-OPEN-LOOP SYSTEM
Early in the program IFebruary 1964)_ concern was expressed regarding the
I metabolic heat rejection capability of the open-loop system. Prototype Apollo
extravehicular suit tests during treadmill operations indicated metabolic rates
I of 2000 Btu per hr were possible_ whereas the open-loop concept design
I was limited to 500 to 700 Btu per hr. Accordingly_ although the Apollo test
and ELSS activity were not directly related_ NASA directed AiResearch to
I study the concept of an umbilical with three type systems: open-loop_
closed-loop_ and semi-open-loop• The merits of each system were analyzed_ and
I in March 1964 the semi-open-loop system was s_lected for further development.
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REQUIRED CHANGES IN PROGRAM I
The semi-open-loop system involved design_ development_ qualification_
and production of flight hardware using spacecraft oxygen for make-up via
I
an umbilical. This concept resulted in a system utilizing three pneumatic
I
loops_ an evaporating-condensing heat exchanger_ and a complete malfunction
detector system. Original planning called for use of the open-loop system I
I
on one flight only with eight units to be supplied over II months. Because
of the change-over to the semi=open-loop system_ integration of the ELSS
with the Air Force Astronaut Maneuvering Unit ,(AMU)_ extended mission life_
I
and intended use on six flights_ the number of systems was increased to 14.
They were scheduled to be used on the GT-6_ 8_ 9_ IO_ II_ and 12 missions. I
ADDITION OF AEROSPACE GROUND EQUIPMENT
Because of the increased number and complexity of the system_ it was
determined that Aerospace Ground Equipment (AGE) would have to be utilized
to ensure consistent test results from all test locations. Therefore_ late
in 1964_ AGE was added to the contract.
MAJOR MILESTONES
The first major milestone was the on=time delivery to NASA of the
first qualification version of the ELSS in January 1965.
Accelerated fabrication and qualification efforts were made in February
through May 1965 on a special umbilical design and multiple connectors for
use on the GT-4 mission. This interrupted the normal delivery of the
chestpack program. The ELSS was initially scheduled for the GT-6 mission_
however_ NASA decided that due to time limitations and pilot training_
the ELSS would not be used until the GT-8 mission. The chestpack was
subsequently used on Gemini flights 9_ IO_ II_ and 12.
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I Wrist thrusters (AIMS) were added to the program in June of 1965.
I The
funding
hardware was
limitations_
designed
this
and
and
partially
various
fabricated
tasks in the
when_
basic
in August
contract
due
were
to
I curtailed.
Due to the increasing field support required to support the
I the chestpacks_ a field support contract was added to the program in
I October
technician_
1965.
and
As
one
a result_
engineer
as many
were
as
engaged
three test
in field
technicians_
support
one
activities
assembly
at
I one time.
Early in 1966_ NASA authorized heaters to be added to the ELSS ejector
I subassembly for GT-8 (scheduled for March 15_ 1966); the work was to be
done by McDonnell Aircraft Corp. Since Gemini flights were scheduled
throughout 1966_ ELSS repair and field support was required to support
I flight activities and permit orderly control of the program. Inspection
and repair as necessary (IRAN) was then added to the program in February
I 1966. Rework_ repair_ and all modification of ELSS were then placed in
I
AiResearch hands to achieve uniformity of repair and testing for GT-9
through GT-12; the program was extended through March 51_ 1967. Maintenance
I of schedule was critical_ and changes in the system were frequently made on an
expedited basis. The Gemini ELSS program was concluded with the successful
I flight of Gemini 12.
All qualification 3 interface_ and pre-flight checkouts were completed

I throughout the program such that the ELSS operations never necessitated slip-
I page of the spacecraft schedule. This was true_ even though mission duration
requirements almost doubled from the first qualification levels.
I
I
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°3
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SECTION 3
PROGRAM HISTORY
J
i]
i
I
I SECTION 3
I
PROGRAM HISTORY
INTRODUCTION
I Studies were conducted by NASA-CSD throughout most of 1963 on the design of
I a self-contained extravehicular life support system for use during Project
Gemini. As a result of these studies_ system requirements_ such as weight_
I volume_ mission ]ength_ and ventilating flow rate could be stated. AiResearch
submitted a proposal for a self-contained_open-loop system conforming to these
I requirements and was awarded a contract in January 964. The system
I consisted of the following components:
I , Oxygen reservoir
2. Pressure regulators (2)
,5. Oxygen fill valve
4 Oxygen shutoff valve
5 Pressure gauge
6 Pressure switch
I 7 Electrical heaters (3)
8 Manned flow control valve
I 9
I0.
Demand regulator
Suit outflow valve
I II. Battery
I The system was to be capable of providing a ventilating flow of S cfm for
a period of 25 minutes with a 20-minute reserve at this flow rate. A total of
I 8 units were ordered (2 flight units and 6 test units) to be delivered over an
I II-month period. This system was scheduled to be used on only one flight.
I
I
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I
MAJOR EVENTS (See Table 3-I at the end of this section.)
I
--System Study t Definition and Packaqinq I
Because of high metabolic loads experienced during testing of the Apollo
extravehicular suit_ NASA engineers became concerned about the low metabolic I
heat rejection (500 Btu/hr) capabilities of the proposed system. During
treadmill operation of the suit test program 3 metabolic rates of 2000 Btu/hr
I
had been observed. At about this same time_AiResearch presented to NASA the
I
results of an analysis prepared on the effects of zero-gravity environment
on heat transfer in high pressure gas storage tanks. To perform this analysis_ I
AiResearch developed a computer program for rapid assimilation of the required
equations. The model used in the program does 3 in essencej calculate the heat
transfer through the vessel_ and then calculates the mass redistribution due to
heat transfer and fluid flow. This model was based on heat transfer by the
conductive mode and mass transfer due to accompanying fluid expansion and
removal.
Using this program_ a series of computer runs were made using a tank
I
model corresponding to the 4-1b high-pressure oxygen storage tank used
I
in the Project Mercury program. Several oxygen withdrawal rates and
programmed heat input rates were investigated to determine the applica- I

bility of this type tank to the extravehicular application. Typical
results of the program are shown in Figures 3-I through 3-4.
The lines shown on the pressure-enthalpy diagrams are the locus of the
state points of the tank control volume elements as a function of time. For
this program the tank was divided into five concentric spheres or control
volumes. The line identified as (I) on the several curves is a locus of the
state points of the outermost control volume3 which is in contact with the tank
66- 1483 [_1 AIRESEARCH

MANUFACTURING
DIVISION L0S Angeles, California
Page 3-2
I
il
I
I
I fNIIIAiPY { tilU/tll)
I Figure 3-1. Zero Gravity Tank Heating

A- _.471G -A
I
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MANUFACTURING
DIVISION
66-
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3-3
Figure 3-2. Zero Gravity Tank Heating
I
I
L
I
66- 1483
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LOS Angeles California
Page 3-4
I
I
I 10,000
8,000
TANK HEATING = 50 Btu/hr

I 6,000 OXYGEN FLOW = 1.0 lb/hr
TANK IS SIDE TAPPED
I 4.000
I
I 2,000
BOO \0
CONTROL VOL. riO. I

600 CONTROL VOL. NO. 2 -!
.! CONTROL VOL. NO. 5 "I/
I ,oo _._ CONTROL

CONTROL VOL. NO. 4
f,
$ • ENTROPY (BTU/LB/OEGREE It_
DENSIrY (LB/CU FT_
! •
I I O0
OUTLET
80
I 70 .90 I10
ENTHALPY (BTU/LB)
1 _'_") I_0 110
A-,_?. 14 .
I
Figure 3-3. Zero Gravity Tank Heating
I
I
_ AIRESEARCH
MANUFACTURING
DIVISION
I Los Angeles. California

I
I
|o000
TANK HEATXNG - 6 Btu/hr

OXYGEN FLOW - O. I l b/hr
I
6,000
TANK XS SXDE TAPPED
I
I I
I
I ,000
L _00
CONTROL VOL. NO. I -

CONTROL VOL, NO, 2 I
CONTROL VOL. NO. ,5 "1_
,.
CONTROL VOL. NO. 4 -i II
I
I
I
OUTLET
" I
Figure 3-4. Zero Gravity Tank Heating I

66- 1483
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Page 3-6 [_I AIRESEARCH 11
I
I
I wall. Correspondingly, the line identified as five is the locus of state
I points of the innermost control volume. The oxygen withdrawal rates and
tank heat input rates for each of the runs is also shown on the figures.
I It will be noted that all runs which have oxygen flow rates higher than
I O.I Ib
isentropic
per hour
blowdown
are
process.
characterized
This
by
is true
tank
even
behavior
though
which
a sufficient
is essentially
quar_tity
an
I of heat is being added to the tank to make the process deviate substantially
from an isentropic path if the heat could be supplied to the entire tank
I contents. As shown by the figures, the heat added to the tank resides almost
I
entirely in the outermost control volume_with very little penetrating to any
of the inner control volumes.
This phenomenon holds true regardless of the point (control volume) from
which the tank contents are withdrawn, as shown by comparing Figures 3-I and 3-2.
I Thus, it can be seen that the attempt to heat the contents of high-pressure
I
gas storage tanks under zero-gravity conditions by the mere expedient of heating
the tank walls produces the very effect that was to be avoided_ i.e; the pro-
I duction of nonhomogeneous tank contents.
As a matter of incidental interest_ the oxygen flow rates used in Project
I Mercury were also programmed on the computer. The results are shown in Figure 3-4.
It will be noted here that even though some nonhomogeneousness is indicated, the
I locus of state points of innermost control sphere are no longer isotropic and
I that the tank contents would remain in the single-phase condition. It should
be remembered too_ of course, that the program is based on the most rigorous
I approach of absolute zero-gravity. In the actual Project Mercury programj minor
movements by the astronaut_ capsule attitude corrections_and the like would
I provide the very modest mixing required to ensure homogeneous tank contents at
I all times.
66-1483
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MANUFACTURING
DIVISION Los Angeles, California
Page 3-7
I
As a result of this analysis and the Apollo suit tests_ NASAdirected I
AiResearch to study the use of an umbilical with three types of systems: open-
I
loop_ semi-closed-loop_and closed-loop.
The ensuing investigation was based upon rules which resulted from a I
technical coordination meeting held between NASAand AiResearch personnel in
February 1964, The rules established are as follows: I
I. An
and
umbilical
electrical
line
power,
will supply normal and high flow energy oxygen
I
2. Average metabolic load for normal mission (up to one hour) is 1400 I
Btu per hr. Peak metabolic loads of 2000 Btu per hr may occur,
3. The design metabolic load under emergency conditions is 2000 Btu per hr. I
a. The condition of emergency will not exceed 20 min.
b. The system may be designed so that body heat storage
(375 Btu per hr) is permitted.

I
Another technical meeting was held at Houston between NASA and AiResearch
in March of 1964. During this meeting_the open loop concept was eliminated I
because of its prohibitive spacecraft oxygen flow requirement. The closed-loop
system was rejected because it was too complex for development and qualifica-
I
tion in the II-month schedule. The semi-closed-loop was then selected as it
I
combined desirable features of both the other systems. At this timej the
system was not completely defined. One of the major items still under dis- I
cussion was the size of the emergency oxygen tank.
The time between March 1964 and June 1964 was spent in system definition
I
and packaging.
I
Among the items that were added or defined in this time period were:
I. Chestpack and umbilical storage envelope I

2. Multiple connectors added
I
66- 1483
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Los Angeles. California
I
I
I 3. Second umbilical connection for use with the AMU added
I 4. Data monitoring requirements
a. Emergency oxygen supply flow warning light and audio signal
I b. Demand flow warning light and audio signal
I
c. Emergency oxygen pressure gauge
d. Suit inlet temperature sensing and transmission
I e. Suit outlet pressure sensing and transmission
f. Audio signal generator to incorporate manual shutoff switch
I Early in June 1964_ the emergency oxygen tank size was determined.
During this same month_ the revised program was negotiated and AiResearch was
I given a go-ahead. The number of systems in the program was still eight, and the
program duration was still II months.
In August 1964_ NASA directed AiResearch to modify the chestpack so

_r
I that it could be stowed in the spacecraft 90 o from the position for which it was
originally designed. To accomplish thisj the chestpack cross-section changed
I from a rectangular area to a trapezoidal area. The total volume of the chest-
I pack was also reduced by approximately 500 cubic inches. The already tight
packaging problem after being made more severe by the nonrectangular cross-
I section and the volume reduction was compounded by the addition of the AMU
displays. The chestpack repackaging was required to achieve better utilization
I of the stowage volume to allow space for other items used in experiments required
I to support the flight. The addition of the AMU displays was required to allow
the chestpack to be used with the AMU in addition to all the scheduled missions
I after Gemini VII, To support these added missions_ the number of systems was
increased to a total of 14.
I
I
66-1485
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MANUFACTURING
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Page 5-9
I
Mounting I
As the design progressed and the packaging became firm_ the AiResearch
method of rigidly mounting the chestpack in the spacecraft (edge mounting) was
I
challenged . Due to previous success_ the spacecraft contractor preferred to
I
hardmount the chestpack by using pins which would protrude into the chestpack.
Guide pins would have to be added to the chestpack to engage rails on the I
spacecraft to index the pack to ensure mating of the pins with the holes in
the chestpack. Because the edge mounting technique would probably require
I
more volume and because of the previous success of hardmounting_ the hardmounting
I
technique was selected; the chestpack was modified accordingly.
After this method was selected 3 a series of technical interchanges between I

the spacecraft contractor_ NASAj and AiResearch took place to resolve the
interface problems. As a result_ it was determined that master tooling would
be required to ensure the proper mating of the hardmount points. The chestpack
I
was then changed to incorporate the master tooling concept.
Addition of Aerospace Ground Equipment IAGE) I

Acceptance testing was planned to be performed using the Gemini high and
low pressure benches in conjunction with laboratory adapters. Because of the

I
increased complexity of the system_ the magnitude of the acceptance testing
I
planned by NASA and the many different test sites 3 it became apparent that
special AGE equipment would have to be built for the ELSS. The approach which I
had the most appeal was to complement the existing Gemini benches with special
adapters and modules designed specially for the ELSS. AGE was_therefore_added
I
to the contract in January 1965. To support the expanded test schedule_a
I
complete set of spares was added to the program in November 1964.
I
I
66-1483
Page 3-10
l__ AIRESEARCH
Los Angetes, California I
I
I
I Major Milestones
The first major milestone of the program was the on-time delivery
I of the first production prototype ELSS to NASA in January 1965. The fact
that this system could be designed 3 manufactured_and shipped only seven monLhs
I after the contract start with the many changes that were necessary is indicative
I of the cooperative efforts exhibited by NASA and AiResearch throughout the program.
From the middle of March 1965 until the middle of May_ an accelerated
I fabrication and qualification program on special umbil icals and multiple con-
nectors was conducted by AiResearch to support the GT-4 flight. As the ELSS
I qualification program was in progress 3 this added effort resulted in postponing
some of the tests. While maximum use was attempted to be made of qualifi-
cation by similarity to the ELSS umbilical and multiple connector_ some
I tests were repeated.
The AiResearch qualification test program began in April 1965. The first
I test to be conducted was humidity; three components of the chestpack failed to
I meet
battery.
performance
As a
after
result of
this
this
test.
failure_
The most serious
AiResearch
failure
cancelled
was
the
that of
vendor-produced
the
I battery and on a very expeditious basis produced a new design and had it qual ified
in time for the completion of the rest of the qualification test program.
I Subsequent to the AiResearch qualification test program_ problems arose with
I the
test
battery
program.
which required several design changes and another qualification
I To support the acceptance testing being performed at the different Ioca-
tions_ NASA directed AiResearch to fabricate a test bench suitable for use in
I place of the low pressure bench. In addition to the test bench_ NASA also
I
I l_ AIRESEARCH
MANUFACTURING
DIVISION LOS Angeles, California
66-
Page
1485
3- I I
I
I
added field support to the contract. This effort started with two test
technicians and then added another test technician_ one assembly technician_
I
and one engineer.
I
During this same time period_ AiResearch submitted a proposal and received
an addition to the ELSS contract to fabricate and test a wrist thruster (AIMS) I
translation and stabilization system. This system was proceeding on a highly
expeditious basis when_ due to funding l imitationsj NASA was required to limit
I
the rest of the ELSS program. Therefore_ in August 1965_ several areas of effort
I
were deleted from the program. Some of the reductions were:
I. AIMS cancelled I
2. No assembly or test of the last two chestpacks
3. Omit final assembly and test of the umbilicals
4. Reduced program documentation

I
5. Delete some AGE items
6. All overtime eliminated I

7. Spares reduced
In July_ another important milestone of the program was met with the
I
delivery of the first two flight systems.
I
During October and November of 196_ the program pace increased. By
necessity3 many of the items cancelled during the cost reduction efforts were I
reinstated_ such as increased spares and assembly and test of all flight systems
Work on the ELSS program continued on an even faster pace during 19663
I
however_
This effort
most of the
is covered
work
in
was
the
performed
IRAN section
under the
(Section
IRAN provisions
14) of this
of
report.
the contract.
I
Fundin 9
I
A funding and expenditure curve is included on Page 3-14 of this report.
I
66-1483
Page 3-12
AIRESEARCH
MANUFACTURING
DIVISION LOS Angeles. California I
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66- 148.5

LOS Angeles, California Page 3 = 14
,t
l
SECTION 4
rt
]
DESIGN AND DEVELOPMENT
.... i
i.l
!
I SECTION 4
I DESIGN AND DEVELOPMENT
I
INTRODUCTION
This section contains the following information:
I • General design requirements.
• A summary of Suit Pressurization-Ventilization Test Series_
I AiResearch Report SS-3135.
I • A description
testing_ and
of the
resulting
design_
changes
operation_
of the
major
complete
development
chestpack
I assembly.
• A description of the design_ operation or function_ major
development testing_ and resulting changes of the chestpack
" components.
I • A description of the design_ function_ major development
I testing_ and resulting changes of the umbilical system and
electrical jumper cable.
I • A description of the design_ function_ major testing_ and
I
resulting changes of the multiple connections.
I
I
I
I
I
66-1485
I _ AIRESEARCH
Page 4-1
I
GENERAL DESIGN REQUIREMENTS
I
Environmental Specifications
I
The system shall be required to operate following exposure to the
environments outlined under the prelaunch, launch, and orbital phases I

(Table 4-I and Figures 4-I through 4-4), and must remain intact during
the re-entry and post-landing phases. The system shall be required to

I
operate,
space
in both
environmental
normal and
conditions
emergency
outlined
modes_
in Table
during exposure
4-2.
to the free-
I
Reliability I
Reliability shall be assured by the implementation of NPC 250-I.
Quality Assurance
I
Quality assurance shall be in accordance with NPC 200-2.
I
I
I
I
I
1
I
I
I
66-1483
Page 4-2 AIRESEARCH MANUFACTURING DIVISION
I
I
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OI.L
I o'_,
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I i
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n_
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...... _ _ _ _" ' _.. -,3
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66= 1485
I _ AIRESEARCH MANUFACTURING DIVISION
Page 4-5
I
TABLE 4-2
I
EXTRAVEHICULAR MISSION CONDITIONS I
ENVI RONMENT EXTRAVEHICULAR I
Arabient Pressure 6 x 10 -12 psia I
Ambient
6°K
O°F
(Deep
(Earth)o
space sink)
I
Temperature
-50 to +250 F (Range from adapter to spacecraft
re-entry module, respectively)
I
Acceleration
0 to
0.68
1.64
0.25G _without AMU)
Ft/secZo(Translation,
rad/sec _ (Rotational
with AMU)
with AMU)
I
I,
M ic rometeoro id
Solar Radiation Approximates 6000°K Black Body (thermal) I

J_
o,
I
Use MSC engineering standards and criteria bulletin EC-] and Addenda.
I
I
I
I
I
I
I
66- 1483
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AIRESEARCH
MANUFACTURING
LOS Angeles_
DIVISION
Cahfornla
I
I
I 1.0
I
• TO 5 CPS
I • -+2g
I O. lO
I CURVE I
"-_--'CURVE II
I "---'--'CURVE III
=; 0.01
I Ill
u2
....1
w
-+3g
I ,,.I
o0.001
I
Ii
I
I 0.0001
\
\
I \
\
I i I i i A _ I i 1 I 1
\
_ 1 i
0.00001
I0 50 I O0 500 1000 5000
I FREQUENCY, CPS
A-2_402
I Figure 4- . Random Vibration Power Spectral Density
I
I [_1 AIRESEARCH MANUFACTURING DIVISION
66-1485
Page 4-5
I
I
I
ZOO0
I
1800
I
1600 I
1400
I
CURVE 12.6 g's RMS 0.02 I
CURVE I..... 2.0 g's RMS I
1200 CURVE II----"_.'--. 8 4 g's RMS
>2 VARIATION DUE'

Z
TO FILTERS
o,
I000 I I
800
I
t
0.09
I
I
_oo
_ , F
I
I
i,
O. 065 O. 008
I
ZOO l I
0 | i I •
O.ZO O. 16
POWER
O. 12
SPECTRAL
0.08
DENSITY,
0.04
g2/CPS
0
A-24401
I
Figure 4-2. Random Vibration. Power Spectral Density I
66- 1483
Page 4-6 j_ AIRESEARCH MANUFACTURING
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I
I
I
4800
(t,8)
I 9600
/
I 2400
4800
I 1200
I,
2400
I
L.f)
I ,_
o
600
1200 rl,28.s!
Z
500
uJ --(Iso),
600
I I'-
!
127)
_- 150
I o
z 500
I
I
t_
i, 23)
75
150
I 57.5
75
I
(Iss)
I OVER-
ALL
11v
I ,ill|ill, i,,lllll | llll|li,i ,Ill|Ill, ,,i,|li,,
140 150 120 I 0 I00 90
I SOUND PRESSURE LEVEL - DB RE: 0.0002 DYNES/CM z

A- 24400
Figure 4-5. Acoustic Environment Spectrum in Pressurized
I Cabin of Reentry Module
DIVISION 66- 1485
I
_1 AIRESEARCH MANUFACTURING
LosAngeles, California
Page 4-7
_22o ,
d
/
/
AFT /
/
/
/
Z 160.00,
/
/ \
\
/ \
/
/ 3¢ \
\
220
A-ill03
Figure 4-4.
I
Design Limit Load Factors Area II
I
(Main Cabin Section)
I
66- 1483
Page 4-8
_1 AIRESEARCHMANUFACTURING DIVISION
I
I
SUMMARY OF SUIT PRESSURIZATION-VENTILATION TEST SERIES
I Introduction
The tests described herein were conducted as a part of the Gemini

I extravehicular life-support system development program. The purposes
I of the tests were to determine (1) the oxygen flow requirements for C02
washout, (2) the ventilating flow requirements for cooling_ and (3) the
I pressure drop characteristics of the suit. This involved a series of
manned tests in the AiResearch research and development laboratory space

I suit test facility. Two test subjects were used_ both with extensive
I suit testing and military flying experience. Metabolic rate and venti-
lating flo_ rate were varied parametrically to provide the data needed
I for system design. Ventilating flow rates were varied over a range of
IO to 35 cfm; metabolic rates ranged from those obtained while the subject
was resting to 1750 Btu per hr (obtained by the subject walking 2.2 mph
I in a pressurized suit on a treadmill). The suit used in the tests was a
David Clark Company Model G2C Gemini Space Suit Assembly. The test con-
I ditions constantly maintained were a suit-to-ambient differential pressure
of 3.7 psig_ a chamber pressure equivalent altitude of 34_000 ft (3.5 psia)_
I ambient and wall temperatures of 95°F_ suit inlet ventilating gas of 45°F
I (saturated_ and IO0 percent oxygen (exclusive of water vapor). The
quantities measured during the tests include suit exit dry-bulb and dew-
I point temperatures_ rectal temperature_ electrocardiograph (ECG)_ re-
spiration rate_ suit pressure drop, and the C02 partial pressure in the
I oronasal area and at the suit outlet.
I Summary and Conclusions
I. Summary
I Under the open cycle breathing gas conditions used in the test, there
was little indication of accumulation of C02 in the oronasal area.
I
I I_ AIRESEARCH MANUFACTURING DIVISION
66-1483
Page 4-9
I
I
The ventilating flow in the helmet was adequate to sweep the C02away from
the oronasal area so that there was negligible inhalation of the respiratory I
products Application of the open-cycle test data to a semiopencycle life-
support system indicated that the inspired C02 partial pressure would be
I
approximately 5.70 mm Hg for a design ventilating flow rate of 15.0 cfm at a
I
metabolic rate of 1320 Btu per hr.
The suit outlet dry-bulb temperature is essentially a function of I

volumetric flow rate. The metabolic rate has only a secondary influence.
The outlet dry-bulb temperature decreases linearly with flow from a maximum
I
of 86°F obtained at 10 cfm (the minimum ventilating flow rate).
I
The suit outlet dew-point temperature is a function of both ventilat-
ing gas flow rate and metabolic rate_ with a fairly well defined upper
limit obtained only under conditions of heat storage. A maximum dew-point
temperature of ?9°F was obtained at a ventilating gas flow rate of I0 cfm

I
and a metabolic rate of 1370 Btu per hr3 providing a total cooling effect
I
of 960 Btu per hr. The suit outlet dew-point temperature decreases and the
total cooling effect increases with increasing ventilating rate. I

The heat balances between metabolic energy produation and heat removal
in the ventilating gas stream indicate the occurrence of heat storage in the
I
body for all ventilating flows and metabolic rates above the resting state.
I
Incidence of heat storage was verified by an increase in rectal temperatures.
After the conclusion of a work period or a reduction in the exercise rate_ I

several instances were noted in which the calculated metabolic rate was lower
than the heat removed from the suit. This observation is explained by the
I
fact that unevaporated moisture in the suit was dried out by the ventilating gas_
I
and energy stored in the body during the exercise period was transferred
back to the gas stream. I

66- 1483
Page 4- IO
_ AIRESEARCH
MANUFACTURING
DIVISION
LOS Ailgeles, Califorma
I
I
I
The test data as reported in AiResearch Report SS-31583 corrected to ELSS
I design conditions indicate that sensible cooling is 188 Btu per hr for low
flow and 206 Btu per hr for high flow. Latent cooling is 980 Btu per hr for
I
low flow and 1015 Btu per hr for the high flow.
As shown in Figure 4-5, the suit pressure drop parameter agrees well with
I
the data received from the NASA-MSC. As was the apparent case for NASA Subject
I No. 13 the suit was slightly large for the two AiResearch subjects3 leading to
lower resistance and lower suit pressure drop.

I 2. Conclusions
Achievement of a heat balance in the Gemini G2C Suit as moderate gas flow
I
rates (up to 25 cfm) is possible below total heat loads of approximately 1230
Btu per hr.
The design metabolic and external heat loads of 1650 Btu per hr and 2250
I
Btu per hr can be accommodated at the design suit flows only by storage of
heat in the astronaut.

I
The estimated maximum heat removal capability of the Gemini G2C at the
I design suit flows of 15.0 and 18.7 cfm is 1168 and 1271 Btu per hr respectively.
Carbon dioxide washout is sufficient for the presently anticipated ventilating
I gas flow rates and metabolic rates.
The suit pressure drop characteristics are valid as specified in AiResearch

I
Report SS-3135.
66- 483
I_l AIRESEARCHMANUFACTURINGDIVISION
I Los Angeles, California
Page 4-11
I
I
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66- 1485
Page 4-12
_lllluln,_..
I.
L _
..%,. "l
AIRESEARCHMANUFACTURING DIVISION
_ _ Los Angeles, California I
I
I
Test Facility and ECS
I The pressure suit ventilation tests were conducted in the AiResearch
research and development laboratory in an altitude chamber with an internal

I
volume of 750 cu ft. This chamber is equipped with a 250-cu-ft lock and with
I windows for visual observation of test subjects at simulated altitude. Com-
munications were maintained throughout each test by means of an intercom
I system. The chamber is also equipped with an oxygen supply and masks for
unsuited personnel. The mechanism used to induce various metabolic loads on

I
the test subjects is a variable-speed_ variable-inclination treadmill.
Thermocouples were located on the skin of the chamber and in the interior air
I
to measure radiant and ambient temperatures (see Figure 4-6).
The suit environmental control system used for these tests was specifically
designed to maintain the proper suit flow rates_ temperature 3 pressure_ and
I
relative humidity. Figure 4-7 is a schematic diagram of the suit ECS.
The C02 concentrations in the helmet and suit-outlet ventilating gases

I
were analyzed with Beckman IRIS-A infrared analyzers (see Figure 4-8).
I IR Cell No. I was located within the altitude chamber 3 about 18 in.
from the subject's head and was used to analyze the C02 volume percentage
I
level in the helmet. The gas sample was picked up in the helmet 3 passed
through the cell where it was analyzed_ and then returned to the suit outlet
I
duct upstream of the point at which the suit-outlet sample was extracted.
l The suit-outlet sample was pumped through a I/4-in.-OD polyflow line by a
diaphragm pump to IR Cell No. 2_ located outside of the altitude chamber.

I
The sample was analyzed and then returned to the suit outflow line upstream
of the Volo Flowmeter.

I
66-1485
I [_i
,
LOS Angeles, California Page 4-13
I
I
Q:
I-
66- 1483
i_ AIRESEARCHMANUFACTURING DIVISION
LOS Angeles, Califorma
Page 4- 14
L 0
*m C
u'_ m
0
i L.
4,4
E c
m 0
oi
o
c
u
°_
m o
u I:
I f
I t,
I
I
I !
I
I' I_1 AIRESEARCHMANUFACTURING DIVISION
LosAn.e,es,
Ca,ifomia 60-1483
Page 4 - I5
V
66= 1483
Page 4= 16 AIRESEARCH MANUFACTURING DIVISION
LOS Angeles, Cahfarnia
Calibration checks were made on the analyzers without disturbance of test
parameters. The specially designed console allowed the operator to shut off
the gas samples and to introduce the calibration gases to the IR analyzers at
the same flow rates and cell pressures as were used during an analysis. Cali-
bration gases were exhausted into the laboratory atmosphere and thus had no
effect on the closed-loop splrometry systems. Calibration checks were made at
least once every hour. The IR analyzers were connected to a Type S Dynograph
for accurate determination of the stability of sample concentrations.
Extremely reliable instrumentation was used for measuring ECS parameters_
as well as physiological parameters. Suit and ECS total and differential pres-
sures were measured with laboratory test gauges and mercury or water
manometers. All ECS temperatures were recorded on a multichannel Honeywell-
I Brown temperature recorder, Altitude chamber radiant and ambient temperatures
I were
Altitude
recorded
chamber
on a Leeds
pressures
and
were
Northrup
measured
multichannel
by mercury
temperature
manometers
recorder.
and aircraft
I altimeters at the chamber control console. ECG3 pulse3 respiration rate 3 and
C02 concentrations were recorded on an Offne_Type _eight-channel_solid-state
I dynograph. The Honeywell-Brown and Leeds and Northrup temperature and millivoit
recorders were held to an accuracy of one percent of full scale, The Offner
I dynograph was held to an accuracy of three percent of full sca|e3 with a sensi-
I tivity of one mlcrovolt per chart division.
I
I
I
I I_1 AIRESEARCH
66-1483
Page 4-17
I
I
Upon arrival at the test facility_ each subject was examined in order to
determine his physiological state and his ability to perform adequately the I
experimental program. The physician monitoring the experiment performed pre-
f]ight medica] examinations that inc]uded inspection of eyes_ nose_ throat_

I
ears_
stripped
and ]ungsj
weight of
and
each
measuring
subject
the
was
pulse
determined
rate with
on an
the subject
analytical
at
ba]ance
rest. The
having
I
an accuracy of ±1 gram. Basic test subject data are shown in Table 4-3. I
TABLE 4-3
I
BASIC TEST SUBJECT DATA
Subject Age_ yr We ight_ kgm Height_ cm

I
No. l 32 78.8 178.5
No. 2 29 76.2 176.5
I
Test Procedure
After completion of the preflight medical examination_ the test subject

I
was instrumented for ECG_ and rectal and ear canal temperatures. The test sub-
I
ject donned a full suit of underwear and socks_ and the continuity of the bio-
instrumentation was then checked before donning the full-pressure suit. Upon I
completion of this procedure_ the test subject entered the altitude chamber
and was connected to the suit ]oop and instrumentation sensors of the test
I
facility. In these tests_ which involved altitudes over 25_000 ft_ the test
I
subject_ as well as the test observer_ was required to breathe I00 percent
oxygen prior to takeoff in order to denitrogenate the blood. During ascent to I

a test altitude of 34_000 ft_ the chamber was held at 19_000 ft for approxi-
mately 30 min for calibration of the helmet C02 IR analyzer, After attaining
I
the test altitude of 34_000 ft_ the suit-outlet C02 IR analyzer was calibrated.
I
66-1485
Page 4-18
_ AIRESEARCH MANUFACTURING
LOS Angeles.
DIVISION
California
I
I
I
The subjects's suit was then pressurized to 3.7 psi above chamber pressure_
I and the exercise period commenced. 0ifferent metabolic rates were achieved
by varying treadmill speed and duration of walking period. 0uring the entire
I
period at altitude_al] important physiological parameters, pressures, tempera-
I tures, flowrates, and gas compositions were continuously monitored. Following
the completion of the exercise period, the test subject sat down and the
I altitude chamber was returned to sea level. A postflight medical examination
was then conducted and the subject was reweighed.

I
Approximately seven hours were required for instrumentation of the test
I subject, donning and doffing of the full-pressure suit, prebreathing for
denitrogenation, ascending to test altitude, gathering of test data, and descending
to sea level. .T_sts were run under_the following conditions:
I Suit Inlet Pressure, psia 7.6
Flow Rate, cfm lO, 13, 16, 20, 25

I
Inlet Dry Bulb Temperature, OF 45
Inlet Dew Point Temperature, OF 45

I
The reason for limiting the test altitude to 34_000 ft was the desirability
I of having an unpressurized observer in the chamber with the subject. Also_
this was an added safety factor in case of an ECS failure.

I
Figures 4-9_ 4-I0_ and 4-11 are photographs of the test subject and
observer inside the AiResearch altitude chamber facility.

I
66- 1483
I _] AIRESEARCH MANUFACTURING DIVISION
LOS Anseles, California Page 4-19
1
I.
I
1
I
I
I
I
I
I,
I
1
I i
I
4
1
I
I
P
I
I J
I F i g u r e 4-9. P r e f l i g h t P r e p a r a t i o n o f Test Subject
I
AIRESEARCH MANUFACTURING DIVISION 66- I483
I Los Angeles California

Page 4-20
I.
'0
3
I
I
I
I
1
F i g u r e 4-10. Closeup o f S u b j e c t Showin L o c a t i o n o f Helmet
9
C O z Analyzer i n F r o n t o f u b j e c t ' s Head
I 66- 1483
Los Angeles California Page 4-21
I
I CHESTPACK ASSEMBLY
I General
Many significant events have occurred since the inception of this program
I on January 30_ 1964. The most significant was the evaluation of the design
I
from a simple open-]oop arrangement to a complete semi-open-loop system to
provide better conditions under emergency operation_ and the addition of an
I umbilical assembly for main life support_ tethering_ and electrical network
connections from the spacecraft. Other major changes include redesigning the
I chestpack to permit stowing it in a specific position in the center food box
(keystone) area and making the required additions to accommodate the controls
I and displays required to aI]ow the chestpack to be used in conjunction with
the AMU backpack.
FORTRAN programs were written for the AiResearch IBM 7074 digital computer
I to analyze the chestpack performance and the chestpack case temperature.
The chestpack case temperature ana|ysis was also performed to determine
I the high and low surface temperatures to be encountered during the extra-
I vehicu|ar mission. In addition_ a deve|opment chestpack was assembled and
subjected to preliminary verification tests.
I Subsequent paragraphs outline the purposej description_ and operation of
the chestpack and describe the analyses performed and verification tests
I conducted.
I
I
I
I
66-1485
I L_l AIRESEARCH
I
I
Purpose
The chestpack is the central component of an extravehicular life support

I
system, When used in conjunction with a Gemini GT4 suit and helme_ this system
I
provides a controlled environment to an astronaut functioning outside his
spacecraft, I
Description
I. General
I
The chestpack is a portable_ self-contained_ central component of a
I
lightweight environmental control system utilizing a high-pressure oxygen
source for breathing and suit circulation. (See Figures 4-12 through 4-15.) I
Provisions of the chestpack allow utilization of three different oxygen sources:
oxygen from a spacecraft system through an umbilical connector_ oxygen from eI

an astronaut maneuvering unit (AMU) backpack through a second umbilical con-
I
nector_ and oxygen from an emergency oxygen supply container within the
chestpack. The chestpack weight and dimensions are as follows: I

Dry weight_ Ib 40.0
Expendable oxygen_ Ib 2.5 I

0.7
Water_ Ib
45.2
I
Total weight_ Ib
Envelope_ in. 6 x I0 x 18 I
I
I
I
I
66- 1483
Page 4-24
_ AIRESEARCH MANUFACTURING DIVISION
I
I
.
Figure 4-12. Chestpack Assembly--Front and L e f t Side

a s Viewed by an Observer
66- 1483
Los Angeles. California Page 4 - 2 5
Figure 4-13. Chestpack Assembly--Fron t and Right Side
a s Viewed by an Observer
I Los Angcles. C a l h ~ n ~ a
Page 4-26
F i g u r e 4-14. Chestpack Assembly--Back, a s Viewed
by an Observer
66- I483
I
AIRESEARCH MANUFACTURING DlVlSlON
LO% ~ngelesCalifornia Page 4-27
1
I
I
1
1
I F i g u r e 4-15. Chestpack Assembly--Top (Control Panels) a s
I Viewed by t h e Wearer (Astronaut)
66- I483
Page 4 - 2 8
I
! The entire extravehicular life support system consists of the chestpack_
I an electrical cable_ two dual-line pneumatic connectors_ and a 25-ft umbilical
cord containing an electrical connector_ a pneumatic connector_ and a tether
I hook at each end.
When in use_ the chestpack is positioned on the astronaut's chest (occupying

I an area from above the thighs to below the chin)_ and the control panels are
I readily visible and accessible to the user. The chestpack is held in place on
the user by a self-adhering web belt on the suit. The belt ends are laid
I across strips of the same self-adhering_ web-belt material affixed to the back
of the chestpack. Electrical connection to the chestpack is made through the

I electrical jumper cable to either the spacecraft or the suit via the 25-ft
umbilical cord or the Astronaut Maneuvering Unit (AMU backpack) and suit via
a short umbilical cord. The external oxygen supply to the chestpack is
I pneumatically connected from either the spacecraft or AMU through the same
umbilical cord used for electrical connection. Controlled oxygen is routed
I between the chestpack and suit through the two dual-line pneumatic connectors.
i Operating devices on the chestpack used by the astronaut consist of four
valves_ three switches_ two meters_ six warning lamps_ and five connectors.
I
I
I
I
I
I
66-1483
I _1
MANUFACTURING
AIRESEARCH DIVISION
I
I
2. Pneumatic System (See Figure 4-16)
The pneumatic portion of the chestpack consists of a pressurization- I

ventilation subsystem_ a 7500-psig emergency oxygen supply subsystem_ and an
oxygen input subsystem allowing umbilical connection to a spacecraft and AMU

I
oxygen source. Quick-disconnect couplings for connection to the spacecraft
I
and AMU umbilical are provided on t_ chestpack. The two identical dual-line
connectors_ used to make pneumatic connection between the chestpack and the suit_ I
are provided with internal probe-to-open check valves_ and permit attachment
to the spacecraft ECS suit circuit while the chestpack is in place on the
I
astronaut's chest.
I
The pressurization-ventilation subsystem controls the temperature_ pressure_
humidity_ and gas consumption of the recirulating suit circuit oxygen. Instru-
mentation sensors are provided in this subsystem which monitor suit pressure
regulator flow_ monitor recirculating suit loop total pressure_ and control
I
recirculating circuit vent gas temperature.
I
The emergency oxygen supply subsystem consists of an oxygen supply tank_
a fill port with check valve_ a shutoff valve_ an 02 pressure gauge to indicate I
stored oxygen quantity_ a pressure reducer_ a pressure relief valve_ a heater
and controlling temperature sensor_ an emergency check valve_ and an emergency I

flow sensor to provide warning indications if the stored oxygen is flowing
I
through the emergency check valve to the pressurization-ventilation subsystem.
This subsystem functions to store sufficient high-pressure oxygen for emergency I

operation_ to regulate the stored oxygen supply during emergency operation_ and
to maintain the temperature of the oxygen from the supply tank at a nominal I
45°F during emergency operation.
I
I
66- 1483
Page 4-30 __.[ AIRESEARCH MANUFACTURING DIVISION
I
oo _-_
-- ¢I
I
! _0 m
O_ ,o _-
uO
E
4._
>.,.
I.j
°-
I'D
E
t-
13..
!
",4'
_yzisjz_-J_T--_
J
I
I
I
I
I
0 I
I
I
,J B_
_mS
_3
,j
o
-r
-1
ill
m m m Ill
N m m
m mm m m 111 mm mm 111
I
I The chestpack pneumatic system operates on a semiopen-loop principle in
which sufficient vent gas is dumped overboard during recirculation to maintain

I the inspired carbon dioxide partial pressure below the allowable maximum. This
I overboard flow also removes a portion of the heat loadj the remaining heat load
being removed by the evaporative heat exchanger in the recirculating loop. Dur-
I ing normal operation3 oxygen nominally at 70°F and 91 psig is supplied to the
chestpack pressurization-ventilation subsystem through the oxygen input sub-

i system (UMBILICAL 02 CONNECTOR) from the spacecraft oxygen supply. This oxygen
I is supplied to an ejector in the gas duct and heater assembly where its energy
is converted into work in circulating the vent gas around the suit loop. The
I heater prevents icing in the ejector.
Ejector primary oxygen flow rate selection is made by manual control (02
FLOW SELECTOR and BYPASS/NORMAL valves)_ and is dependent on the level of
I physical activity of the astronaut. The ejector primary oxygen flow rate to
the suit can be increased to compensate for excessive heat conditions by
I rotating the 02 FLOW SELECTOR valve to the HIGH position_ pressing the BYPASS/
NORMAL valve to the BYPASS position_ or changing the setting of both valves when
I maximum suit ventilation is desired.
I Recirculating vent gas from the heat exchanger passes through the ejector_
is combined with the oxygen flow from the ejector jet_ and enters the suit to
1
i
remove the carbon dioxide and moisture-laden oxygen being ezhaled by the suit
at a nominal temperature of BS°F and relative humidity of 85 percent_ and passes
I through the suit return connector to the suit-pressure outflow valve and heat
I exchanger. A portion of the carbon-dioxide and moisture-laden recirculating
vent gas is automatically dumped overboard_ and the remaining recirculating
I vent gas enters the heat exchanger to be dried and cooled. This is accomplished
by transferring heat to copper fins located in the gas stream. As the gas
i
II AIRESEARCH
MANUFACTURING
66 83
Page 4-32
l
I stream cools_ its temperature drops below the dew point and the water vapor
I picked up in the suit is condensed on a wick in the condenser section of the
evaporator-condenser. It is conducted through this wick to the steam side of
I the heat exchanger where it is used as a coolant_ thereby reducing the initial
amount of water which must be stored. Cooling is accomplished by vaporizing

I this water. A pressure control valve maintains a small back pressure which_ in
I turn; controls the boiling point of the liquid. The back pressure control valve
is regulated as a function of the evaporator-condenser outlet temperature_
I thereby providing a constant outlet temperature and dew point with variable
inlet conditions. From the evaporator-condenser_ the ventilation gas enters
I the ejector_ completing the loop.
In the event of suit failu_e_ such as a tear or rip in the fabric_ the
chestpack will maintain suit pressure through the suit-pressure regulator valve.
I If suit failure should occur_ the demand flow sensor will sense the flow through
the suit-pressure regulator valve_ light the SUIT PRESS warning lamp on the
I chestpack control panel 3 and initiate an audio warning tone to the suit helmet
I of the astronaut. The normally closed suit-pressure regulator valve senses
pressure in the recirculating loop upstream of the suit loop check valve_ and
I automatically opens and regulates when this pressure falls to 3.3 ±0. I psi
above suit ambient. The BYPASS/NORMAL valve allows the astronaut to manually
I add oxygen to the suit.
I
I
I
I
66-1483

Page 4-33
I
I
If the input oxygen source (spacecraft or AMU)pressure falls to a nominal
67 psig, the chestpack emergency oxygen supp]y will be automatica]]y initiated.

I
As the input oxygen source pressure drops, the emergency check valve opens,
I
admitting regu]ated oxygen from the chestPack emergency oxygen supp]y tank for
application to the recirculating loop. The emergency Flow sensor in the emergency I
supply line warns the astronaut when he is on his emergency supply oxygen by
lighting the EMERG 0 2 warning ]amp on the chestpack control panel and initiating
I
an audio
temperature
warning
continually
tone to the
decreases
suit helmet.
as the
Since
remaining
the emergency
oxygen expands
supply
to a
oxygen
lower
I
pressure, it is necessary to heat the oxygen before admitting it to the recir- I
cu]ating loop. This is accomp]ished by a line heater and a temperature sensor_
automatically control the temperature of the emergency supply oxygen at a nominal
45 degrees F.
I
I
I
I
I
I
I
I
I
I
66-1483 AIRESEARCH
i_ MANUFACTURING DIVISION
Page 4-34 LOS Angeles, California
I
I
5. Electrical System
I a. Purpose - The ELSS electrical system provides a means for detecting
foreseeable emergency modes and for signallin 9 the emergency modes to the
I
extravehicular astronaut and the command astronaut.
b. Description _see Figure 4-17) - The electrical system consists of

I
nine electrical subassembles. These subassembles are modularized control and
I monitoring circuit_ sensing circuits_ and a nominal 28 v d-c wet-cell battery.
An electrical jumper cable serves as a link for transmitting physiological
I
data from the extravehicular astronaut to the spacecraft. The system functions
in three modes of operation: n ormal_ test_ and emergency.

I
• Normal Mode - With the astronaut in the suit and the suit pressurized_
electrical power to the electrical system is applied by the astronaut
by means of a power on-off switch, When the power is applied_ back-
I ground lamps on the display panel illuminate. Whether the power be
I supplied by the chestpack battery or the spacecraft power system is
determined by the command astronaut in the spacecraft.
I When spacecraft power is applied_ the relay also switches ELSS ground
I reference to spacecraft ground. When spacecraft power is being used_
a spacecraft power lamp on the display panel will illuminate. The
I display panel is a multimessage unit which is panel-mounted on top
of the chestpack and is easily viewed by the astronaut in the suit.

I Simultaneous with the il]umination of the display panel_ power is
I applied to the suet pressure transducer and to the ejector heater.
I
I
I I(_l AIRESEARCH MANUFACTURING
Los Angeles,
DIVISION
California
66-
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The suit pressure transducer provides a linear d-c output which is
I ana]oguous to suit pressure. This d-c output is received by the
command astronaut in the spacecraft. An ejector heater is provided
I to prevent any ice formation in the ejector throat,
I Test Mode - With the chestpack in its norma] mode of operation_ before
leaving the spacecraft the astronaut should check to be certain the
I emergency warning display and audio system is operable. Norma]ly_
this system operates when the demand or emergency sensor switch
I c]oses (see emergency mode). To check the warning system_ a TEST-
I DIM-BRIGHT
depressed_
switch
a circuit
is depressed
is closed
to
to
the
bypass
TEST
the
position.
demand and
With the
emergency
switch
sensor switches. This results in power being applied to Gates A and
B causing the audio oscillator to emit an audib]e signa]. Simulta-
I neously_ 28 v dc is applied to the background lights_ EMERG 02_
SUIT PRESS_ and spacecraft power lights which resu]t in their

I illumination.
I The audible warning signal provides a general alarm if an emergency
I condition exists. This genera] alarm is heard by the extravehicular
astronaut and the command astronaut. The extravehicular astronaut
I has the capability of analyzing the em.=rgency visua]ly by means of
the lighted message unit on the display panel.
I Emer,cjency Mode - An emergency mode of operation could occur with the
I chestpack connected to the spacecraft or when it is connected to the
/_IU.
I
!
66-1485
[_1 AIRESEARCH MANUFACTURING DIVISION
i LOS Angeles, California Page 4-57
I
I
When connected to the spacecraft and if the pressure in the suit
drops_ which could occur as a result of a tear_ an increase in suit I

flow demand causes the demand sensor to close the demand switch.
This allows a 14-vdc input (or 28 vdc_ depending on whether the

I
TEST-DIM-BRIGHT switch is in the DIM or BRIGHT position) to the
I
logic,
The logic provides inputs to the audio warning system. In addition to

I
the audio warning_ when the demand switch closes_ the SUIT PRESS I
lamp on the display panel will illuminate. Simultaneously_ the
command astronaut will receive suit pressure readouts from the suit I
pressure transducer. If desired_ the astronaut may stop the audio-
warning signal by depressing the reset switch. Depressing the reset
switch ($2) will apply 28 vdc to a threshold; the threshold passes

I
the signal to reset the flip-flop. This removes one of Gate C's
inputs; therefore_ Gate C no longer provides an output. I

If the maximum obtainable umbilical flow is not great enough to I
maintain the required supply pressure_ the emergency oxygen supply
system is automatically activated. This action causes the emergency

I
sensor switch to close_ providing inputs to the logic in the same
I
manner as when the demand sensor switch closes. Simultaneously_
with the closing of the emergency switch sensor_ the EMERG Oz lamp I
is illuminated. Closing the emergency sensor switch also provides
inputs to the temperature control module. The module controls the

I
heater (A4)_ which maintains expanded gas from the emergency high
I
pressure tank at a comfortable temperature level. Because the
I
66- 1483
Page 4-38
,, A _, AIRESEARCH MANUFACTURING
LOS Angeles,
DIVISION
California
i
I
I
emergency sensor is in the emergency oxygen loop, it is only actuated
I when the emergency oxygen supply is being used. This is the only
time the temperature control circuitry is employed. If desired, the
I astronaut may stop the audlo-warnlng slgnal by depressing the reset
switch.
I
When connected to the AMU and if an emergency exists in the _MU, any
I one of four warning devices in the AMU causes the audio warning to
I start and the appropriate warning light on the display panel to
illuminate. Then, the audio-warning system operates in the same manner
I as when connected to the spacecraft. The AMU message units are
illuminated by AMU warning devices.
I
I
I
I
I
I
I
I
I
66-1483
AIRESEARCH
MANUFACTURING
DIVISION
I
Performance
I
I. Normal Operation
I
The normal mode of operation is for the primary oxygen to be supplied
from the Gemini spacecraft through the 25-ft umbilical to the umbilical dis- I
connect in the chestpack. From this disconnect_ the supply oxygen is diverted
through the high position of the selector valve to the ejector. This pushes
I
the ;:otal ventilating gas through the suit. Refer to Table 4-4 for normal
I
operation conditions.
I
I
I
I
I
I
I
I
I
I
I
66-1483
i_ AIRESEARCH
MANO_CTOR_NO
Page 4-40 DIVISION
LOS Ansele s California
I
I
TABLE /_-4
I
OPERATING CONDITIONS
I
02 FLOW SELECTOR Valve in HIGH Position
I Normal
Emergency Flow
Flow Through
Parameter Units from
the Umbilical
I System 02 Tank
Total Heat Rejection Rate Btu per hr 2150 1550

I Sensible Heat Rejection Rate Btu per hr 211 152
Oxygen (Primary) Pressure psig 91.0 approx 67
I Oxygen (Primary) Flow Rate lb per hr 7.8 5.6
Oxygen (Primary) Temperature oF 70 45
UMBILICAL 02 or AMU 02 Connector psig 92.5 m--
Inlet Pressure
Suit Circuit (Secondary) Flow Rate Ib per hr 18.8

I
Suit Circuit (Secondary) Pressure psig 3.7
Secondary Flow Pressure Rise in. H20 9
I Total Flow Rate lb per hr 26.6
CO2 Partial Pressure mm Hg 7.8 max 15 max

I Sui_ Return Temperature (Dry Bulb) oF 90 max 90 max
Suit Return Temperature (Dew Point) oF 80 max 80 max
I Suit Return Relative Humidity % max 70 7O

Suit Supply Temperature oF 52.5 45
Suit Supply Relative Humidity percent 53 65
I
Suit Outflow Valve Flow Rate lb per hr 7.8 5.6
DIVISION
I L_t AIRESEARCH MANUFACTURING
I
With the chestpack operating normally and the suit return and oxygen
I
conditions as indicated in Table 4-4_ the chestpack provided the conditions
I
shown in Table 4-5.
I
TABLE 4-5
SUIT CONDITIONS I
Suit Return Pressure 3.7 ±0.2 psig
I
Suit inlet Total flow (with 9 in. H20 AP) 25.6 Ib per hr
conditions
Temperature (dry bulb) 44 to 55°F I
Temperature (dew point) 34 to 42°F
I
Refer to Tables 4-6_ 4-7_ and 4-8 for parameters under normal design_ AMU
design_ and emergency oxygen design conditions.
I
I
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66- 1483
Page 4-42 I_[ AIRESEARCH MANUFACTURING
LOS Angeles,
DIVISION
California
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66-1483
I I_l AIRESEARCH MANUFACTURING DIVISION

LOs Angeles, Califorma
Page 4-43
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[_] AIRESEARCHMANUFACTURINGDIVISION
Page 4-44
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66-1483
DIVISION
[_1 AIRESEARCHMANUFACTURING
I
I
2. ,Emerqency Operation
Operation of the chestpack under emergency conditions will result in the

I
following:
• Case I. If loss of umbilical or AMU 02 supply occurs_ the emergency

I
02 supply will be automatically actuated and will supply 5.7 Ib per I
hr of 02 at 45 ±5°F to the ejector for 23 min.
• Case 2. If suit leaks 0 to 13.5 Ib per hr with the selector valve I

in the MED position and the primary oxygen pressure at 56 psia_ the
chestpack will maintain the suit return pressure at 3.3 ±O.I psig.
I
• Case 3. If suit leaks 0 to 15.5 Ib per hr with the selector valve
I
in the HIGH position and the primary oxygen at 67 psia_ the chest-
pack will maintain the suit return pressure at 3.3 ±O.I psig.
I
I
I
I
I
I
I
I
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66-1483
Page 4-46
[_ AIRESEARCH MANUFACTURING DIVISION
Los Angeles, California !
I
I
Development
I I. System Performance Analysis
A FORTRAN program was written for the AiResearch IBM 7074 digital computer
I to analyze the chestpack performance. This program allows the rapid determi-
I nation of the change in the estimated system performance due to varying input
and system ambient conditions. Generalized techniques were used in writing
I the program in order that as experimental performance data for the individual
system components became available it can be easily incorporated and the
I new system performance calculated.
I is
The
completely
suit performance
determined
(total
in a
cooling
separate
effect
subroutine
and pressure
which returns
drop
the
characteristic)
pertinent
variables to the main program. This subroutine determines the cooling effect-
iveness of the Gemini suit using experimental data obtained in the suit-test
I series performed by AiResearch.
I be
The
easily
ejector
changed
performance
as experimental
map is
data
entered
become
as input
available
data
for
and
the
can,
ejector
therefore,
under
I development at the present time. Also, the evaporator-condenser performance
is described by input data, and this can be changed as required. Pressure
I drop across the various components and in the connecting lines between them are
I described
determined
by
both
a series
analytically
of correlations
and
which
experimentally.
use input constants which have been
I The main inputs to the program which are varied in analyzing the system
performance are the ejector primary oxygen flow rate_ pressure, and temperature.
I Corresponding to every set of ejector primary conditions, there are inputs of
the estimated evaporator-condenser inlet flow rate, temperature_ vapor pressure_

I and carbon dioxide partial pressure.
I
66-1485
LoS Angeles, California Page 4-47
I
I
Other system parameters which are used as inputs and which, therefore,
can be varied to determine their effect on system performance are the I

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

I
Briefly, the operation of the program is as fo]lows: At the evaporator-
I
condenser inlet, the values of the mass flow rate, temperature, vapor pressure,
and carbon dioxide partial pressure are set equal to the estimated va]ues I
corresponding to the ejector primary conditions being investigated. Using
these values as well as the specified evaporator-condenser inlet pressure and I
outlet temperature, the pressure drop across the evaporator-condenser is ca]-
I
culated. From this pressure drop, the new outlet conditions can be calcu]ated.
Next, the evaporator-condenser-out]et-to-ejector-inlet pressure drop is

el
ca]culated. Using the calcu]ated ejector secondary inlet pressure and flow
rate and the given primary oxygen pressure and flow rate, the ejector outlet I
conditions are ca]cu]ated from the ejector performance mapwhich is in the
I
computer memory.
Progressing around the suit ventilation loop, the suit inlet conditions I
are calcuiated next. Data which are transferred to the suit subroutine includes
the inlet gas constitutent flow rates, pressures, temperature, and specific I
humidity. With this information as wel] as the suit experimental data, the
I
subroutine calcu]ates the suit cooling effect, pressure drop, and outlet con-
ditions. The subject's metabolic rate is set equal to this cooling effect in I
order that the amountof oxygen consumedand carbon dioxide produced may be
determined. The amountof water (perspiration) produced is determined in the I

empirical correlation describing the suit's effectiveness in latent heat
removal. The suit performance subroutine uses a successive-approximation
I
I
66-1483
Page 4-48
_ AIRESEARCH
I
I
I scheme in a computation loop to arrive at the suit outlet conditions. Each
I time all the computations in the loop have been completed_ the computed variables
are compared to the values of the same variables calculated in the previous
I cycle of the loop. If the percentage differences in these values are less than
I given
If the
convergence
differences
factors
are larger
(input
than
date)_ control
the convergence
is returned
factors_
to
the
the
new
main
values
program.
used
I on the loop are repeated. If convergence does not occur within a given number
of cycles (also input data)_ a message is printed giving the number of cycles
I completed and the old and new values of the variables when the final cycle
I was
and
completed.
control returns
The new
to the
values
main
are then
program.
used
The
for
two
the suit
parameters
outlet
which
conditions
are tested
in this way are the suit outlet pressure and the specific humidity. Experience
with this program has shown the computation loop to be rapidly convergent.
I Having determined the suit outlet conditions_ it is then possible to
I
calculate the suit-outlet-to-outflow-valve pressure drop. Also_ the suit out-
flow valve flow rate is determined. Since the outflow valve inlet and
I evaporator-condenser inlet are in the same location_ the new pressures and
temperature are tested against given input convergence factors as in the suit
I performance subroutine. If the differences are greater than those specified_
then the new estimates of temperature_ vapor pressure_ and carbon dioxide are
I set to those just calculated. The evaporator-condenser inlet flow rate is a
I adjusted by the ratio of the calculated inlet pressure to the given inlet pressure.
This tends to increase the inlet flow rate if the suit-loop pressure drop was
I too low_ and decrease it if the drop was too large. It has been found that the
flow rate converges to a stead'/ value very fast_ even when the initial estimate
I is considerably different from the actual value. With the new flow rate_
I
66-1485
I _ AIRESEARCH
I
temperature_ and pressure_ the entire suit-ventilating loop is retraversed.
I
Once all the parameters have converged within the given convergence factors_
I
a message is printed telling how many cycles of the loop were required. If
the parameters do not converge within a given number of cycles (input data)_ a I
message is printed giving the specified and present values of the convergence
factors. Computation then continues using the present values of the system
I
parameters.
I
In the system analysis_ an existing subroutine is used to calculate the
engineering gas constant_ constant pressure specific heat capacity_ and I

molecular weight at each point in the system.
Once the conditions in the suit loop have been fixed_ the evaporator-
I
condenser cooling effect and water storage requirement are calculated. The
final computations of the program involve the analysis _ the carbon-dioxide

el
buildup and astronaut body heat storage when the subject's metabolic rate I
exceeds the total cooling effect. This section of the program calcul, ates body
heat storage and inlet and outlet carbon dioxide partial pressure as a function
I
of metabolic rate for the same approximate suit flow rate used in the main
I
section of the program.
Printed output of the Gemini ELSS Performance Analysis Computer Program I

includes total and constituent mass flow rates and pressures_ temperatures_
and humidities at the inlet and outlet of all major components. Also included
I
are the evaporator-condenser water requirement and cooling effect_ the ejector
I
w_ight_ primary pressure_ and secondary pressure ratios_ the suit latent and
sensible cooling effect_ and a tabular listing of metabolic rate and its I
corresponding body heat storage _ inlet_ and outlet carbon dioxide partial
pressures.
I
I
66- 1483
Page 4-50
_ AIRESEARCH
MANUFACTURING
DIVISION Los Angeles. California
I
I
I
II Results of the above described program are shown in Table 4-9. The
I results
emergency
are for
oxygen
the high
supply
and
pressures
low flow
and
settings
temperatures
at both
expected
Gemini
at
spacecraft
the ejector
and
I inlet (flow selector valve outlet).
Subsequently_ new specifications were received from the spacecraft prime
I contractor regarding the range of oxygen pressures and temperatures that could
be expected at the umbilical inlet. In addition_ it was decided that the ELSS
! mission would use only one flow selector valve position; the high position.
I Only the normal mode of the AMU-ELSS mission will use the flow-selector valve
MED position.
As the new flow conditions differ slightly from those used previously_
the ELSS Performance Analysis Computer Program _as used to calculate the new
I system performance at the new positions. The new specification received from
I McDonnell Aircraft Company stated that at a nominal oxygen flow rate of 7.8 Ib
per hr_ the pressure and temperature can vary independently between 81 and
II I04 psia and between 40 o and IO0°F_ respectively. Selecting the average
umbilical inlet conditions of 92.5 psia and 70.O°F gives an ejector secondary
I inlet pressure of 90.0 psia.
II
I
II
I
I
66-1483
Los Angeles. California Page 4-51
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66- 1483
Page 4-52
__I AIRESEARCH MANUFACTURING DIVISION
LOSAnEeles.California
I
I
I
I Using ejector nozzle design conditions of 90.0 psias 70°Fs and 7.8 lb per
hr fixes the theoretical nozzle cross-sectional area. Then using this area and
I the range of possible pressures and temperatures at the umbilical inlets the
I system
4-28 show
performance
the calculated
was calculated
system
at
performance
off-design
at
conditions.
off-design
Figure
conditions.
4--!8 through
I 2. Case Operating Temperature Analysis
A digital computer program was written to determine the steady-state
I temperature achieved by an object exposed to a space environment. The program
was written so that all heat transfer to or from the outer surface of the
I
object is by radiation onlys the heat transfer across the wall of the object
is by conduction alones and the heat transfer to the interior oP the device
may be by radiation s conductions or convection.
I In order to determine the high and low temperature limits achieved by the
I chestpacks the maximum and minimum effective environmental sink temperatures
to which the chestpack will be exposed during a normal mission were determined.
I The model used for the chestpack consisted of a 1/16-in.-thick fiberglass
case surrounding a black-body heat sink or source. Because of the interior
I geometry of the chestpacks it can be assumed that radiation heat transfer occ_s
I between two black bodies. It was assumed that the interior of the pack was an
isothermal body at an average temperature of 65°F. The justification for this
1 assumption is the fact that the evaporator-condenser will operate as a constant
temperature heat sink between the extremes of 45°F and 85°F by adjusting the
I amount of water boiled. Also_ the oxygen tank and its contents represent a
I large thermal capacity and at the beginning of the mission will be at space-
craft ambient temperatures or approximately 70°F.
I
66-1483
I AIRESEARCH MANUFACTURING
Los
DIVISION
Angeles, California Page 4-53
I
I
I
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I0o
Q..
d
9O
// 'I
¢Y
/
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I.--
_ 80
/
/ I
#
B
,#
#
I
n
I
7O ill
70 B0 90
UMBILICAL INLET PRESSURE, PSIA
100
I
I
A-7916
Figure 4-18. Ejector Primary Inlet Pressure as a Function of

Umbilical Inlet Pressure and Average Temperature
I
I
I
66- 14 85
Pa ge 4- 54 AIRESEARCH
MANUFACTURING
DIVISION
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Page 4-62
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66- 1483
Page 4-64
L0s Angeles, California
I
I
i
I The thermal coating for the outer surface of the case was assumed to be
a paint consisting of aluminum powder in silicone. The emissivity and
I absorptivity of this coating are given as 0.25 and 0.24_ respectively. _
The maximum and minimum effective sink temperatures to be encountered by

I the chestpack were calculated to be 612.2°R (152.2°F) and O°R (-459.7°F)_
I respectively. Using these temperature limits_ the case outer surface steady-
state temperatures were determined to be 546.7°R (87.0°F) for the hot environ-
i ment and 495.1°R (35.4°F) for the cold environment. It is felt that this range
I of peak temperatures will cause no particular problems.
i.
I
I
I
I
I
I
I
I Neel_ Carr B._ "Research on the Stability of Thermal-Control Coatings
for Spacecraft," NASA_ Ames Research Center_ Moffett Field_ California.
I
66-1483

I
3. Verification Tests i
An assembled development chestpack was subjected to the preliminary
i
verification tests shown in Table 4-I0.
I
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66-1483
Page 4-66
___.I AIRESEARCH
MANUFACTURING
LoS
DIVISION
Angeles, California
I
I
II
TABLE 4- I0
i PRELIMINARY VERIFICATION TESTS
I Test Results and Comments
Suit loop leakage Leakage was excessive due to a poor finish on
l the inlet tubes

made to correct
of the ejector.
the problem at
No
this
attempt
time as
was
development test results would not be compromised.
l The
after
finish of
completion
the
of
gas ejector
verification
inlet
tests.
was improved
I Medium
Leakage
pressure Within specification.
I Proof pressurization
of high-pressure
Satisfactory
system
== Ejector
at sea
altitude
performance
level and
The test setup
Figures
these
schematic
4-30 through
tests.
is shown in Figure
4-34 show the results
4-29;
of
I Panel lighting and The results of these tests are discussed in the
electrical tests section covering component development testing.
I Vibration and In most cases, the test unit tended to damp out,
performance rather than amplify inputs above lO00 cps.
I (See Figure 4-35)

There was little or no amplification below lO0 cps.
I There were no structural failures.
Post-vibration performance testing indicated the
I entire
vibration
electrical
program.
circuit was undamaged by the
I Post-vibration
pressure
leakage
and suit circuit
tests
leakage
of the medium
indicated no
increase in leakage.
I Post-vibration
system indicated
leakage
no change
tests
in
of the
leakage
high pressure
except at
the pressure gauge. The pressure gauge mounting
I was found
vibration
to be unsatisfactory,
inputs to the pressure
causing
gauge.
excessive
Production
units have an improved mounting that is designed
I
DIVISION
I_ I AIRESEARCH MANUFACTURING
Los Anseles, Ca_iforma
I
I
TABLE 4-I0 (Continued)
I
Test Results and Comments
Vibration and to eliminate this problem. Previous pressure

I
performance gauge vibration tests indicate that the unit is
(See
(Cont)
Figure 4-35) satisfactory if properly mounted.
I
Nitrogen gas
proof pressure
Pressure was applied
high pressure shutoff
through
valve
the fill port.
was open,
The
permitting I
of 12,400 psig the proof pressure to be sensed on the upstream
side of the high pressure regulator. Pressure
was monitored
pressure
at
regulator
the downstream
at the
side
test port.
of the
The assembly
I
was unaffected by the test.
I
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I
I
I
I
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66- 1483
Page 4-68
,,_A,_,_...,,- AIRESEARCH
MANUFACTURING
DIVISION
LOS Angeles Califorifia
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DIVISION 66-1483
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Los Angeles Cahforma
Page 4-69
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66- 1483
Page 4-70
_:
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AIRESEARCH MANUFACTURING
Lo_ Angeles,
DIVISION
California
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66- 1483 Ft_ v
Page 4-72 I_,_n_,,--'_"_

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Los Angeles California
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F i g u r e 4-35. ELSS V i b r a t i o n T e s t

66- 1483
LOS Angeles Calllorma Page 4-75
I
I CHESTPACK COMPONENTS
I General
The following paragraphs cover the purpose_ description_ and operation
I of the components of the chestpack and the major phases of their design
I and development.
Evaporator-Condenser IHeat Exchanger) 167880
I I. Purpose
The evaporator-condenser removes heat and moisture from the suit loop
I and regulates the suit inlet and dew point temperatures with variable heat
I loads.
2.
The
Description
unit is located
(See Figures
between
4-36
the
through
suit
4-401
loop check valve and the ejector.
This unit is a sintered metal wick-type heat exchanger IFigure 4-40).
It is capable of removing a total latent-sensible heat load of 1500 Btu per
I hr from the gas stream. Water condensed on copper fins in the gas stream
I
is wicked through an air trap material into metal wicks where it is re-
evaporated and exhausted to space. The latent heat of evaporation of the
! water is provided by the sensible heat loss of the gas stream and by the
latent heat of condensation of the water vapor being removed from the gas
I s t ream.
Gas output temperature is maintained at 45 ±5°F by use of a vernatherm

I back pressure control valve. This unit uses a fusable wax element_ which is
I submerged in the gas stream in a finned casing. The differential change in
volume of this element_ which is a function of its change in temperature_
I actuates a poppet valve on the boiler side of the heat exchanger. When the
gas temperature is above 45°F_ the poppet valve opens_ lowering the steam
I back pressure. This lowers the boiling point of the water_ and more water
I
66-1485
I 1_1 AIRESEARCH
MANUFACTURING
DIVISION Los Angeles. Cahforn,a
Page 4-76
1
I
C
I
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I
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P
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1 Figure 4-36. Evapora tor-Condenser
i
I
I
66- 1483
I
LOS Angeler. California Page 4-77
I
1
I
I
1
1
Figure 4-37. Evaporator-Condenser
66- 1483
1 Page 4-78
Figure 4 - 3 8 . Evaporator-Condenser
66- 1483
ARESEARCH MANUFACTURING DIVISION
Los Angele~ California Page 4-79
F i gu r e 4 - 3 9 . Evapo r a t o r-Conden se r
66- 1483
Page 4-80
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I [_ AIRESEARCH MANUFACTURING DIVISION
66-
Page
148.3
4-8 I
I
I
is boiled to space_ thus carrying away more thermal energy. As the gas
temperature comes within the controlled range_ the poppet closes_ reducing
I
the water
constant
boiling
outlet
rate.
conditions
In this
with
method_
variable
the
inlet
evaporator-condenser
conditions.
maintains
I
3. Performance I
a. Pressure requirements:
(a) Max operating 3.9 psig

I
(b)
(c)
Proof
Burst
pressure
pressure
7.8
15.6
psig
psig
I
b. Water holdup: I
The unit shall hold 0.65 Ib of water minimum.
c. Pressure drop:
I
02 with
1.0 in.
inlet
water
conditions
maximum
5.9
pressure
psia and
drop
85°F.
at a flow of 178 lb per hr
I
d. Leakage : I
(I) External-evaporant port blocked - 0 cc per hr at 4.0 psig
(2) Gas breakthrough - with a gas side pressure of 5.7 psig 2 the I
gas
12 cc
breakthrough
per hr maximum.
through the evaporant control valve shall be
I
e. Temperature control - The outlet gas temperature shall be controlled
I
to 45 +5°F_ with the inlet conditions as stated in Table 4-II_ while
operating in two uninterrupted runs as shown in Table 4-11 for a I

total of 90 min.
I
I
I
66-
Page
1483
4-82
I_l AIRESEARCH
I
I
TABLE 4- II
i OPERATING CONDITIONS
i Run No. I
I Pa ramet er Condition
I0
A Condition B Run No. 2
Minimum Duration_ min 65 (minus time 25
I Oxygen Inlet Pressure_ psia 5.75 ±0.05

Condition
3.75 +-0.05
A)
5.75 -+0.05
I Oxygen Flow_ Ib per hr 18.2 ±0.4 18.2 +-0.4 15.2 -+0.4
Inlet Dry Bulb_ OF 85.8 -+2.0 85.8 -+2.0 87.4 -+2.0
I Inlet Dew Point_ OF 8 1.5 -+ 1.0 71. I -+I.0 74.0 -+1.0
Evaporant Outlet Pressure_ 5.0 5.0 5.0

mm Hg abs max
I
I
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I
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66- 1483
I l_ 1 AIRESEARCH MANUFACTURING
LOS Angeles,
DIVISION
California Page 4-83
I
4. Development I
a. Evaporator-Condenser Test Module--Since the primary problem
concerned with development of this unit revolved around the water trans-
I
port air block configuration_ three test modules were constructed to
I
demonstrate the conceptual design. Each test module consisted of a gas
and an evaporating section_ and_ as such_ could be considered as an I

increment of the full-sized heat transfer matrix. The primary function
of these modules was to demonstrate the operation of water removal and

I
utilization in a low pressure boiler which depends upon metabolic HzO
I
generated during operation for a portion of its evaporant.
A brief description of each module follows: I

• Module PA 48695 - sublimation type where HzO is condensed on a
porous plate which has one surface open to evaporating pressure

I
(direct H20 transport from condensing to sublimation surface).
I
• Module PA 48696 (Figures 4-41 and 4-42) - bootstrap type
utilizing sintered porous metal as the condensing wick with- I

out a separate air trap (indirect water transport from a con-
densing to evaporating surface through a wick manifold).

I
• Module PA 60215 (Figures 4-43 and 4-44) - bootstrap type
I
utilizing felt metal vaporizing wick and separate air trap.
I
I
I
I
I
66-1483
Page 4-84
[__ AIRESEARCH
I
F i g u r e 4-41. Evaporator-Condenser T e s t Module PA 48696
( S i n t e r e d Porous Metal Used as t h e
Condensing Wick)

LOS ~ n g e i e scaltfornia
Page 4-85
8 F i g u r e 4-42. Evaporator-Condenser T e s t Core-Module
PA 48696
I
66- I 4 8 3
AIRESEARCH MANUFACTURING DIVtSION Page 4-86
LOS Angeles Callloma
I
Figure 4-43. Evaporator-Condenser T e s t Module PA 60215
( F e l t Metal V a p o r i z i n g Wick, Separate
A i r Trap)
66- I483
Page 4 - 8 7
t F i g u r e 4-44. Evaporator-Condenser Test Modu e PA-60215
66- I483
Page 4-88
I Module PA 48695 was tested; data obtained from these tests are pre-
sented in Table 4-12.
I It will be noted that the test conditions contained in the data vary
I from the design conditions in both operating pressure and relative humidity.
The reasons for these variations are as follows: the sintered metal plates_
I which form the tube plates of the sublimation boi]er_ are of I_ nominal
porosity. This material is not suitable as an air trap at pressure dif-

I ferentials above 3 psi. Thereforej tests were conducted with an ambient
I pressure commensurate with the operating characteristics of the air trap.
The inlet humidity was maintained at a higher than design ]eve] so that
I the additional water required for cooling and for maintaining the air
trap would be reduced_ as this test setup did not contain a satisfactory
method of adding the supplemental water. Since air rather than 02 was
I used as a test gas_ the amount of water per pound of gas was high. All
supplemental water was added as solid water to the inlet of the unit.
I An excess of water was required to wet cornp]etely the inlet (with respect
to air flow) sublimation surfaces.
I A detail test performed on sintered metal of the I_ nominal size
I showed that the water transport capability of this material was low.
Module PA 48696 utilized the concept of sintered metal as a condensing
I wick which would transfer the condensed water through capillary action.
The sintered metal test data showed that this module would not function
I satisfactorily.
I
I
I
66-1483

LOs AnGeles, California
Page 4-89
I
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66- 1483
Page 4-90
LOS AngelesDIVISION
California
I
I
Consequently_ a third module was constructed to demonstrate the feasibility
I of a second type of boot strap concept. This componentj identified as PA 00215 I
utilizes feltmetal as the condensing wick with a separate air trap. The pres-
I
sure differential of ambient to space exerted on the air trap would then draw
the water from the gas to the evaporating side of the unit.
I
Test data obtained from this module is also included in Table 4-12. Again
I the gas side absolute pressure was limited so as not to exceed the air break
through pressure of the sintered plate.

I
With the unit charged with waterj several test runs with a duration over
90 minutes were made before the air trap dried out. At the same time_ this
I
configuration appeared quite capable of transferring the water condensed on
the air side to the evaporation side.
During the test run shown on the data sheetj the unit operated a period
I
of 90 minutes following a charge of 75 cc of water, The end of satisfactory
operation was indicated by air flow through the porous metal, Approximately
I
0.64 Ib of water was condensed and 0,45 lb of the condensation was re-evaporated,
I Comparison of the two configurations shows that the sublimation type
boiler requires a secondary water-feed system to maintain the air trap while
I
the remote air trap concept does not require any additional water beyond the
initial evaporator charge, Since the wick capacity of the sintered plate is
I
limitedj the sintered material is not capable of sustaining hot spots (such
I as the air inlet) where little or no water is being condensed on the adjacent
fin area. In addition3 the state of the art in porous metal fabrication is
I
such that maintenance of porosity is very difficult over large surface areas_
such as the tube plate in this configuration. For these two reasons_ it was
I
decided to concentrate further work on the remote air trap configuration,
66-1485
_J AIRESEARCH
I Los Angeles California Page 4-91
I
Module PA 60215 was modified to incorporate a steam discharge pan_ I
and the pan discharge was then connected to a sleeve-type contro] valve.
The discharging air was ducted over a wax-filled power element of the
I
same type proposed for use in the completed unit. The output of this
I
thermostatic element directly operated the s]eeve valve so that with high
air discharge temperatures the back pressure within the steam chamber I
decreases and with low air discharge temperatures the steam pressure in-
creases. Therefore_ the effect is to maintain the air discharge temper-

I
ature withfn the operating range of the thermostat.
I
Since the test module discharge temperature under design point con-
ditions was 60°F_ the thermostat selected was controlled between 55 and I
65°F. This provided a sufficient heat sink within the heat exchanger to
observe the control function, The test module test resu]ts are shown in
Figure 4-45 through Figure 4-47. Figure 4-48 shows the experimental test
I
setup. As indicated_ inlet air temperature was varied from 71°F to
94°F and the discharge temperature was monitored. As may be seen_ dis- I
charge air temperature was maintained at the selected control point.
These tests demonstrate that it is feasible to control discharge air

I
temperature by varying the boiling (heat sink) pressure on the evaporative
I
side of the evaporator-condenser.
g. Evaporator-Condenser 167880--A layout of a prototype develop- I

ment Evaporator-Condenser 167880 was completed and detail parts were
released for fabrication. I

Because of the unique design concept of this unit_ that of continuous
I
condenser-boiler feed_ the exact configuration at the condenser-boiler
junction is new. This joint configuration caused some manufacturing problems I

I
66- 1483
Page 4-92 I_l AIRESEARCH MANUFACTURING DIVISION
LOS Arl_{e{es, Califorrlia
I
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30 'dW31
I
I _1 AIRESEARCH MANUFACTURING DIVISION
Los A.geles, California

' 66- 1483
Page 4- 95
3o 'dW31
IIG, _ETT)I AIRESEARCH MANUFACTURING DIVISION

66-1485
_ _k Los Angeles, Catifornia
Page 4-94
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LOSAngeles,Califorma
66-
Page
1485
4-95
1
F i g u r e 4-48. Test Setup -

Evaporator-Condenser T e s t
Module PA 60215 -
U n i t Equipped w i t h
Steam Duct and Back P r e s s u r e V a l v e
66- I483
Los Angeles. Cal8Iornia Page 4-96
I
which resulted in scrapping the first core assembly fabricated.
I The second core assembly was completed so that the development tests
could be performed at the earliest possible moment. The unit was weighed
I prior to assembly of the valve; the dry weight was 7.4 lb. (Various views of
I the evaporator-condenser assembly are shown in Figures 4-36 through 4-39.)
When the evaporatOr-condenser assembly was completed_ a dry oxygen

t
:| isothermal pressure drop test was conducted. The results of the test are
shown in Figure 4-49.
I Development tests were continued on the completed development unit. These
I tests were directed primari]y toward optimizing internally stored water and
water delivery methods within the fixed geometry of the outline.
A number of performance runs at the design conditions were made to
determine the optimum material for the water storage area. The design require-
I ments are such that the water required for sensible heat cooling must be
I stored in the unit. A material must be provided which will absorb the water
and at the same time this material must be fairly dryable by capillary action
I evaporator wicks. Etched fiberglass, sintered stainless steel felt_ cellu-
lose sponge_and combination materials were tested. The pure cellulose sponge
I material had the highest absorptivity_ and it could be dried by the evaporator
I wicks
most
with
satisfactory.
reasonable
Table
effectiveness.
4-13 shows
Of the
the performance
materials
of No.
teste_ this
2 development
was the
unit
I with the pure cellulose sponge in the evaporant storage.
A method of filling and emptying the evaporator-condenser was evaluated.
I The results are an improved technique which speeds up the operation and increases
I the
unit.
reliability of a complete fill and a subsequent complete dry-out of the
I
66-1485
I _1 AIRESEARCH
Los AnIie_, _liforn_ Page 4-97
I
I
I
I
I
I •
.8 I
0
I
N
"I-
_Y
BAROMETRIC PRESS.
I
0
29.96 IN. HGA
INLET PRESS•
¢/}
Q.
6.66 IN. HGA
I
INLET TEMP.
70°F
I
20
i
50 40
I
2 3 4 5 6 78 910
OXYGEN FLOW RATE, LB PER HR I

I
A-8425
Figure 4-49. Evaporator-Condenser Dry Isothermal

Oxygen Pressure Drop Test
I
I
I
I
66- 1483
Page 4-98 _ AIRESEARCH MANUFACTURING DIVISION
I
I
TABLE 4- 13
I TEST DATA, EVAPORATOR-CONDENSER

(DEVELOPMENT UNIT NO. 2)
I Run No. 1 Run No. 2

J.,,J...,,..t_
Parameter
Cond 1 Cond 2 Cond 1 Cond 2
I
Total run time_ min I00 130
I Total heat rejection, Btu 1632 1946
Latent heat rejection, Btu IO73.5 II15.5 986.0 955.2
I
Sensible heat rejection, Btu/hr 141.5 161.5 152.8 145.2
Airflow temperature, OF 16.8 15.6 18.0 16.5

I
Air inlet temperature, OF 85.25 87.4 85.8 87.4
Ie Humidi ty,
Air discharge
gr/Ib
temperature, OF
506
47.0
440
41.2
441
47.2
430
.;-_-
,,'-"M'.
47.4
I Air out dew point, OF 47.8 46.0 45.1 45.5
I
*65 mi n
I _t_'_25min
_w_"_55 m in
_'Y,_,_,',Low
Temperature Operation Thermostat 154382-I
I
I
I
I
I
I
66- 1483
I I_ 1 AIRESEARCH MANUFACTURING Los Angeles. DIVISION
Air traps used in the evaporator-condenser were not completely effective
I
in
as
preventing
outlined
premature
below.
gas breakthrough. The problem was reviewed and solved
I
The function of the air trap is to transfer condensed water from the air I
side to the steam side, This transfer of water is to be accomplished while
restricting Oz flow. The air trap material divides the condensing from the
I
evaporating
while wet with

sections
water
with
the
a very
capillary
wettable
action
and
within
minutely
the
porous
material
surface
causes
so
the
that
minute
I
pores to pass water freely while restricting gas flow. I
The material used for air traps is a powder metallurgy material of
sintered 516L stainless steel plate with a nominal porosity rating of 0.5 I
microns.
I
I
I
I
I
I
I
I
I
66-1483
I
I
The sponge material used as water reservoir packing was selected
after a relatively extensive development program which also considered

I
felt material and fiberglass. Of the materials tested_ the cellulose
I sponge demonstrated a substantially superior water-holding capacity
coupled with the ability to transfer readily a substantial portion of

I
that water to the evaporating wicks. The sponge_ as purchased by
AiResearch_ is treated with a preservative which is soluble in water but

I
not soluble in alcohol. Upon receipt of the sponge_ the material is
I cut to size and then cleaned. The cleaning procedure is specifically
designed to remove the preservative with which the manufacturer (DuPont)

I
treats the sponge. The cleaning procedure must be adhered to or the
preservative will then contaminate the air traps. Tests have verified
that effective cleaning and analysis of the sponges before assembly
I eliminates the contamination problem.
When considering the consequences of air trap leakage_ we should

I
review the quantity of gas leakage that AiResearch has experienced and
how this quantity has affected performance of the evaporator-condenser.

I
Table 4-14 is for two evaporator-condensers and shows the gas leakage
I at 5 psi and the capacity heat rejection capabilities at both 3.75 and
5 psi. The second of these two units had a leakage of I03 cc per min at
I
a pressure differential of S psi. Nevertheless_ this unit rejected the
required amount of heat. Gas leakage added to the maximum amount of

I
steam flow begins to choke the control valve_ causing an increase in
I evaporative pressure. As can be seen from the attached data sheet_
neither of these units reached this condition.
66-1483
AIRESEARCH
I I_ MANUFACTURING
Page 4-101
._1__
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66- 148,5 AIRESEARCH MANUFACTURING DIVISION
Page 4- 102
LoS Angeles, California
I
I Suit Pressure Relief Valve 800278
I. Purpose
I
The suit pressure relief valve controls the suit loop pressure.
I 2. Description (See Figures 4-50 and 4-51)
The suit relief valve is an unbalanced poppet, spring-loaded-closed
I valve. As suit pressure, acting against the poppe t overcomes the spring
load, the poppet opens; a fail-open stop is provided to limit the

I
flow in the event the valve fails in _he open position. The unit is
I designed to allow small amounts of free water to be dumped without affect-
ing the valve's performance.
I 3. Performance
Normal flow shall be 13.S Ib per hr with an inlet pressure of 3.9
psia at a temperature of 80°F.
If valve fails in the open position, flow will be a maximum of 17 Ib

I
per hr at an inlet temperature of 80°F.
I Total leakage should not exceed 0.0081 Ib per min at an inlet pressure
of 3.5 psia and an inlet temperature of 70°F.

I
4. Development
The unit with only one guide on the poppet stem and a standard com-
I
pression spring was subjected to development testing. The unit met the
I required design flow; however, it had a very severe sticking problem.
Testing was stopped, and an additional guide was added to the poppet stem.
I
In addition, a special spring was fabricated. This spring maintains its
force vector along the centerline of the spring within a few degrees.
I
With the addition of the two changes mentioned, the valve met the
I performance requirements.
66-1483
I Los Angeles. Califorma
Page 4-103
1
I Figure 4-50. Suit Pressure Re1 i e f Valve
I
AlRESEARCH MANUFACTURING DIVISION 66- I483
1 LOI Angeles California
Page 4 - I O 4
I
I ev"
LIJ
I.l.l
r_" D
D
(/")
I I-- or, r I--
I
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I
I o_
LL
I
I
I 0
1-00
n" ,*-
I-- o0
Z
I _. Z
I
I 66- 148.3
Page 4- 105
•I
After the unit was placed in productionj several design changes were made
I
to correct performance malfunctions during unmanned and manned tests. After
I
many manned tests had been performedj it was determined that the unit would
have to be substantially redesigned. The redesign included the addition of I

I
a protective Cover over the poppet to prevent handling damage; a change in
seat material to one that was stronger and harder; removal of the upper stop; and
increasing the strength of the poppet by changing the material and the design 3
I
changing the poppet guide material_and by the addition of a cleaning procedure
to be incorporated after each manned test. I

Results of the flow-versus-pressure-drop tests are shown in Figure 4-52.
Altitude testing was performed to verify that the suit outflow valve would not
I
be subject to icing with wide ranges of gas flow and humidity (see Figures 4-5.3
and 4-54 for the test setup).

eI
No icing or malfunction was observed throughout the 3 hours and 15 minutes I
of test time. The inlet temperature was varied from 90°F to 56°F. The water
added was from 0.00?6 to 0.1652 Ib of water per lb of dry air. The flow through
I
the valve was varied from 7.5 to 13.8 lb per hour. (Normal high-flow conditions
I
for the system are 7.8 Ib per hour of oxygen flow with approximately 0.085 Ib
of water per Ib of dry oxygen.) I

I
I
I
I
I
66- 1483
Page 4- 106 _ AIRESEARCH
LOS Angeles, California I
i
8.0
I
7.9
/
..,..--
I /
/
7.8 /
I 7.7
/ /
z 7.6
/ #
o
I
Q.
7.5
V
/_ _f_--CRACK POINT
/
I 7._
/
LcJ
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O.
,
7.3
I .-'-- RESEAT 3.5 SCCM
7.2
CABIN PRESSURE = 0.5

I PSIA
7.1
7.0
I
0 I 2 5 4 5 6 7 8 9 I0 II 12 13 I_
FLOW RATE, LBS/HR

A-8804
Figure 4-52. Suit Relief Valve Pressure
I Drop
66- 1485
AtRESEARCH MANUFACTURING DIVISION
I los Angeles. California Page 4- 107
I--
l I
66- 148.3
Page 4- 108 LOSAngeles,California
I
.
II
I
I HEATER7 ~~ /INLET TEMPERATURE
u -.__ ~
1
I
E P L A S T I C DUCT / VACUUM
SOURCE
F-2066
1
F i g u r e 4-54. ELSS S u i t O u t f l o w Valve (800278)
I c i n g Test Setup

66- I483
I Los Angeler Calilornia Page 4- IO9

I An outflow valve icing test was performed on the chestpack assembly.
The object of the test was to determine if there was any change in per-
I formance of the test unit due to ice buildup on nylon supporting cords
I located in the valve exhaust. Test results indicate that chestpack per-
formance was not affected by ice or frost buildup resulting from satur-
I ated gas flows_ to the outflow valve_ as high as IO Ib per hr at a
temperature of 90°F. The test was conducted at three primary flows which
I simulate the probable operating conditions of this valve. These flows
i were 4.7 Ib per hr from the AMU_ 7.4 Ib per hr from the umbilical system_
and 10 Ib per hr from the emergency oxygen supply.
I
1o
I
I
I
I
I
I
I
I
1
66- 1483
I [_l AIRESEARCH
DIVISION
MANUFACTURING Los Angeles, Cahfomla
Page 4-1 I0
I Oxygen Tank 2 800510 (baffled) and 800512 (plain)
I I. Purpose
The emergency oxygen tank contains enough oxygen for 25 minutes of
I chestpack operation in the event of loss of primary oxygen,
2, Description (See Figure 4-55)
I The emergency oxygen tank is of cylindrical geometry and is con-
I structed
7500 psig
of [nconel
and 70°F.
718.
Internal
Capacity
fins
of
brazed
this tank
to the
is 2.48
inner wall
lb of
of
oxygen
the tank
at
I provide the necessary area for heat transfer to prevent the contents of
the tank from entering a two-phase liquid-gas state during a rapid blow-
I down of the tank.
5. Performance
I Capacity: 2.48 Ib minimum oxygen at 7500 psig and 70°F.
I Pressure Rating:
Operating 7500 psig at 70°F
I Proof 12_400 psig at 70°F
Burst
I .
Development
16_600 psig at 70°F
I Eight tanks (three plain and five baffled) were used during the
program. All tanks have been subjected to at least one hydrostatic-proof
I pressure test of 12_400 psig.
I
Two of the plain tanks and three of the baffled tanks were subjected
to a burst pressure test. The minimum burst requirement is 16_600 psig.
I The tanks burst at pressures ranging from 17_900 psig to 19_550 psig.
All tanks ruptured in the heat-affected zone of the weld. Figure 4-56 shows
I the results of the last three tanks subjected to the burst pressure test.
I
66-1485
I _l AIRESEARCH
MANUFACTURING
Page 4-111
I
co I
,=¢ N
N
I
I
I
C¢1
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0
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(J
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66- 1483 AIRESEARCH MANUFACTURING DIVISION
Page 4- I 12
I
c
0
55338
F i g u r e 4-56. Results o f t h e P/N 800310, Tank,

B u r s t Pressure T e s t
66- I 4 8 3
Page 4-113
I One of the plain tanks and one of the baffled tanks were subjected
I to
during
a hydrostatic
the 7450th
cycle
cycle_
test
and
from
the
0 to 9800
baffled
psig.
tank ruptured
The plain
during
tank
the
ruptured
16_723rd
I cycle.
One of the baffled tanks was subjected to 164 hours at 9800 psig with
i oxygen. After this oxygen age test_ the tank was cut into small sections
for material evaluation. The interior of the tank was in excellent con-
I dition; the mechanical properties met the requirements; the microscopic
I evaluation indicated no change in the brazed joints or in the tank and
there was no indication that the high pressure oxygen exposure had any
I effect on the tank.
I
I
I
I
I
I
I
I
I
_I
I AIRESEARCH
MANUFACTURING
DIVISION
66-1485
Page 4-114
I Oxygen Pressure Re_lulator and Relief Valve 800284
I. Purpose
I The pressure regulator section of this unit regulates the oxygen supplied
by the emergency oxygen bottle to a pressure below the umbilical supply pressure.
I This unit provides the shutoff feature when the umbilical supply pressure is
I within its required limits and regulates the emergency supply pressure with
variable flow demands upon loss of the umbilical supply. The relief valve portion
I protects the "medium" pressure loop against pressure surges. The unit is located
downstream from the oxygen fill and shutoff valve.
I 2. Description (See Figures 4-57 through 4-59)
I a. Regulator - The unit contains a normally open_ metal diaphragm-operated_
balanced poppet metering valve. Tank delivery pressure enters the
I reducer through a lO-micron filter and is reduced to 67 +IO psig by
the metering valve. Regulated pressure is a result of force balance or
I unbalance on this metering valve. For a given flow demand_ the inlet
I flows past the metering valve until downstream pressure builds up and
causes the metal diaphragm to stroke_ thus aIlowsing the attached metering
I valve to throttle the flow. This metering valve employs a balance area
so that variations in inlet pressure do not affect the regulated pres-
I sure. The pressure balance setting is attained by preloading the
I actuator diaphragm with a belleville spring plus a calibration compres-
sion spring.
I b. Relief Valve - The relief valve is a normally closed metal diaphragm-
operated_ unbalanced poppet metering valve. As the regulated pressure
I increases past the calibration point_ the force imbalance produced
I by the
spring.
pressure
This opens
acting
the
on the
relief
poppet
valve_
area
and
overcomes
the gas
the
is dumped
calibration
overboard.
I
66-1483
I AIRESEARCH
MANUFACTURING
Page 4-115
F i g u r e 4-57. .Oxygen P r e s s u r e R e g u l a t o r
and R e l i e f Valve
I Los Angeler California

Page 4-116
Figure 4-58. Oxygen Pressure R e g u l a t o r
and Re 1 ie f Va 1 ve
AlRESEARCH MANUFACTURING DIVISION 66- I 4 8 3

Page 4-1 17
I
I
I
I MOUNTING SENSE
PORT
SPRING
IBRATION
I
METALLIC EVILLE SPRING
I DIAPHRAGM_
UTLET
I
PORT
INLET
PORT
fA
/A RELIEF
I "_ VALVE
PORT
I
I METALLIC
SEAT_ J
FILTER
I i
i
i
i
BALANCE SEAL
I
A-2186-B
I FILTER
I
I Figure 4-59. Schematic of Oxygen Pressure and Relief Valve
I
66-1485
AIRESEARCH
Page 4-118
I 3. Performance
I
Pressure Rating:
I Max operating 7500 psig at 70°F
I P roof
Burst
12_400
16_600
psig
psig
at
at
70°F
70°F
I Regular ion: 67 +I0 psig outlet pressure with a flow capacity
of 0 to 0.225 Ib per rain at inlet pressures of
I 350 to 7500 psig and 70°F (see Figure 4-60 ).
I Internal leakage:
No flow
6 x
condition_
I0 -6 Ib per
lockup
min
pressure
max with inlet

to be 90
pressure
psig max.
of
7500 psig and 70°F and outlet pressure of 85 psig.
-7
External leakage: 5.25 x I0 Ib per min max with inlet pressure
I of 7500 psig at 70°F.
Downstream relief: The integral relief valve will limit the

I downstream pressure to 215 psig max with the regulator.
I failed open. The relief valve will reseat at 95 psig min.
I
I
I
I
I
I
66- 1483

Los Angeles, California Page 4- 119
I
I
I
I
7500 _NOMINAL OUTLET PRESSURE
67 PSIG WITH TOLERANCES
IS
I
SHOWN FOR TEMPERATURE
RANGES SHOWN
I
C9
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u_
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+160 +80 -20 -130
I
INLET TEMPERATURE, OF
I
I
Figure 4-60 Oxygen Pressure Regulator and Relief Valve 800284-1
Discharge Pressure Performance Envelope
I
A-_4614
I
I
66- 1483
Page 4- 120 I_l AIRESEARCH MANUFACTURING DIVISION
Los Angeles, California I:
I
4. Development
:1 Flow schedules were performed on this unit from lockup to 0.5 Ib
per min at inlet temperatures of -60°F_ -20°F_ +66°F_ and +I60°F. The
I results are shown in Figures 4-61 through 4-64. The unit operated
satisfactorily in all cases. The lockup pressure exceeded the required
I limit at -20°F and -60°F. This is considered no problem_ as the only
I time these temperatures are reached is during tank blowdown and the unit
is not required to lock up after this occurrence. Subsequent to this testing
I the design limits were changed from 65 to 85 psig to 57 to 77 psig.
I
Io
I
I
I
I
I
I
I
I
I
66-1485
I _1 AIRESEARCH
Los Angeles, Califorma Page 4-121
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66- 1483
Page 4- 124 AIRESEARCH MANUFACTURING DIVISION

Los Angeles, California !
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66-1483
I
Duct (Eiector) and Heater Assembly 138969
I. Purpose I
To maintain the venti]ating gas circulation in the ELSS.
2. Description (See Fi,qures 4-65 and 4-66)

I
High pressure oxygen is supplied to a converging nozzle where its
I
internal energy is converted to kinetic energy. This high velocity
gas entrains the ]ow pressure3 ]ow velocityj ventilating gas flowing coaxially I
with
static
the nozz]e.
pressure of
The
the
combined
ventilating
stream
gas,
enters
This
a diffusing
pressure
section_
differential
increasing
across the
the
I
ejector provides the potential for fluid flow through the remainder of the
I
ventilation loop. During normal operation; using the spacecraft oxygen supply 3
a primary f]ow of 7.8 ]b per hr wi]] circu]ate a total flow of 25.6 lb per hr
eI
through the Gemini suit and will provide a tota] pressure rise of 14 in. of
water. This matches the system pressure drop for the same flow rate,
I
3. Performance
I
Primary oxygen flow sha]] be 7.8 +0.4 ]b per hr at an inlet pressure of
92.5 psia and an in]et temperature of 70°F, I

Total flow shall be 25. b lb per hr of 02 with a primary f]ow of 7.8 Ib per
hr of 02 at a secondary temperature of 45°F; the gas ejector shall cause a

I
minimum pressure rise equivalent to 14 in. H20.
I
Externa] leakage shall not exceed 3.15 x 10 -4 Ib per hr 02 at 4.0 psi AP.
4. Development I
Extensive testing was done on gas ejectors to determine the optimum
configuration of the venturi section for pumping gas at the design system
I
pressure. Figure 4-67 shows the experimentally determined performance of the
I
gas ejector under development.
I
66-1483
Page 4- 126
_[ AIRESEARCH MANUFACTURING
DIVISION
I F i g u r e 4-65. Duct ( E j e c t o r ) Without Heater Assembly
E]
10s Angeles California
66- 1483
Page 4 - 1 2 7
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Los Angeles.California
66- 1485
Page 4-128
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66- 1483
I ' AIRESEARCH
LOS Angeles California Page 4- 129
I
Results of additional performance tests conducted are shown in Figures 4-68
and 4-69. The curves show how this unit is sensitive to nozzle location. I
Figure 4-68 contains data for one nozzle position and Figure 4-69 contains
data for two other nozzle positions. Because of these variations 3 the design
I
was changed to allow for angular positioning of the nozzle in the ejector.
I
This allows each unit to be set to its optimum location. Later in the pro-
gram 3 a heater was added and the bypass valve outlet location was changed. I
This effort is described in the IRAN section of this report.
I
I
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I
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66-
Page
1483
4- I,:30
_ AIRESEARCH
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66- 1483
[_1 AIRESEARCHMANUFACTURING DIVISION
LOSAngeles. California Page 4-131
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66- 1483
Los Angeles,California
Page 4- 152
I Valve Group 800282
I I. General
The valve
(see
group
Fiqures
is
4-70
comprised
through
of three
4-72)
check valves_ two flow sensors_
I one suit pressure regulator_ one bypass va]ve_ and one f]ow control va]ve
combined into one common housing. This method of fabrication was selected
I to reduce package size and weight and to reduce possib]e ]eakage paths by
I e]iminating
2. Check
many
Valves
tubes
(3)
and joints.
I a. Purpose--One check valve_ the emergency 02 check valve_ prevents
loss of primary oxygen in the event the emergency 02 pressure
I is lost. This could occur_ if the emergency Oz relief valve
failed in the open position or as a result of a broken line or
loose fitting. The other two are immediately downstream of the
I umbilical and AMU disconnects and prevent ]oss of primary Oz if
either disconnect fails whi]e open.
I b. Description (See FiQure 4-70)--The check valves are of the
flapper type_ spring-loaded-c]osed_ and are threaded into the

I main valve housing. The flapper element_ or poppet_ is meta]lic
I
I
with an e]astomer bonded to it on the sealing portion. The
poppet is guided to ensure effective seating during repeated use.
I c. Performance--Each check valve shall have a maximum pressure
drop of 0.5 psi whi]e flowing oxygen at a rate of 13.2 ]b per

I hr at an inlet pressure of 90 psia and at a temperature of 90°F.
I Maximum allowable interna] ]eakage shall be 3.15 x I0 -5 lb per hr.
I
I
I _ AIRESEARCH
MANUFACTURING
DIVISION LOS Angeles California
I
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66-1485
Page 4- 1:54
GARREI"T AIRESEARCHMANUFACTURING DIVISION
Los AngePes Cah_:r,; <_ I
-- -. J
.
Figure 4-71. Valve Group
66- I483
Los Angeks. California Page 4-135
1'
I
I
I
1
I
I
1
I,
I
I
I
1
I
I F i g u r e 4-72. Valve Group
I
I
I
AIRESEARCH MANUFACTURING DIVISION 66- 1483
I Los Angelel California

Page 4-136
I . Flow Sensors (2)
I a. Purpose--The emergency 02 flow sensor closes a circuit whenever
flow occurs from the emergency 02 supply. This operation gives
I the astronaut audio and visual indications of the flow,
I The suit pressure regulator flow sensor closes a circuit whenever
flow through the suit pressure regulator occurs_ indicating loss
I of suit pressure. This action indicates similar warning devices as
the emergency O_ flow sensor.
I b. Description (See Figure 4-70)--Each flow sensor consists of a spring-
I loaded-closed
The check valve

check
is of
valve
the
and
poppet
a pressure
type containing
switch.
an orifice. This
arrangement allows the pressure drop to be high enough to actuate
the pressure switch when the flow rate is 0.2 to 1.5 Ib per hr. With
I an increase in flow3 the poppet moves off its seat reducing the
I restriction, The maximum pressure drop with a flow rate of 13.2 lb
per hr is 2 psi.
I The pressure switch contains a pressure-activated diaphragm which
presses against a hermetically sealed micro switch.
I c, Performance--Each flow sensor closes its applicable circuit when
I oxygen
the flow
flow
rate
increases
decreases
to a maximum
to a minimum
of
of
1.5
0.2
lb per
lb per
hr
hr.
and opens when
I The maximum pressure drop is 2.0 psi when the flow rate is 13.2
lb per hr at an inlet pressure of 55 psia and at a temperature of
I 50°F.
I
I
66-1483
I L_ 1 AIRESEARCH
L0s Angeles, California Page 4-137
o
Suit Pressure Regulator
a. Purpose--The suit pressure regulator maintains the suit pressure
at 5.5 ±0. I psig in the event of a suit leak greater than the
normal primary flow.
I
b.
Description (See Figure 4-70)--The suit pressure regulator uses
a tilt valve to meter I00 psi oxygen to the suit at 5.5 ±0. I psia.
The sealing surface of the tilt valve is silicone rubber and is I

essentially leak-proof. A pressure-sensitive diaphragm_ which
has suit pressure on one side and a reference pressure on the I

other_
the
actuates
calibration
the
point_
tilt
the
valve.
reference
As suit pressure
pressure pushes
decreases
against
below
the
I
diaphragm and opens the tilt valve. The tilt valve is closed as I
the suit pressure increases above the calibration point. The
reason for using a reference pressure is to reduce the control pressure oI

spread
a large
associated
stroke_ the
with
spread
springs.
produced
Since
by
the
a spring
control
would
diaphragm
be much
must have
I
larger than that allowed. The reference pressure is maintained by
I
metering a fixed flow (IO0 scc per min) through a calibrated out-
flow valve to ambient. The housing has provisions for isolating I

or shutting off this bleed flow.
C. Performance--The suit pressure regulator allows oxygen to flow to

I
the suit loop when the suit loop pressure drops to a minimum of
I
5.2 psig and shuts off the supply when the pressure rises to a
maximum of 5.4 psig with inlet pressures of 67 to 90 psia. The I

maximum flow rate is 9.8 lb per hr with an inlet pressure of 67
psia at a temperature of 70°F. Oxygen flow through the pilot

I
valve bleed orifice does not exceed 2.95 x IO-_ Ib per min with
I
an inlet pressure of 90 psia at a temperature of 70°F. Internal
leakage does not exceed 5.15 x IO-5 Ib per hr. I

66-1483 MANUFACTURING
[_ AIRESEARCH DIVISION
Page 4-138
I .
Bypass Valve
I a. Purpose - The bypass valve allows the astronaut to add an additional
7.4 Ib per hr of oxygen gas to the suit in the event of a heat
I exchanger failure or clogging of the ejector.
b. Description (see Figure 4-?0) - The bypass valve is manually actuated by

I the astronaut by pushing on one end of an actuating lever to open the
I valve and by pushing on the other end to close the valve. Attached
to this actuating lever is a piston-like device, incorporating seals,
I that opens or seals the inlet port. The gas is metered by a calibrated
orifice as it leaves this valve.
I c. Performance - The bypass valve allows a flow of 7.4 ±0.20 Ib per hr
of oxygen into the suit loop with an inlet pressure of 67 psia at a
temperature of 70°F. The force to actuate the bypass valve is from
I 2 to 8 lb. The internal leakage does not exceed 3.15 x IO"5 Ib per
hr.
I . Flow Control Valve
I a. Purpose - The flow control valve (selector valve) is a 3-position
valve which controls the flow to the ejector nozzle. The positions
I are OFF, MED, and HIGH.
b. Description (see Fiqure 4-70) - This valve is manually actuated by the
I astronaut by rotating the handle to one of three fixed stops. The
I handle must be depressed before it can be moved to the OFF
position. As the valve is rotated from the OFF to the MED position,
I a passage in the piston-like device is positioned so that the gas
will flow through a restrictor, through the piston-like device and
I into a duct leading to the ejector nozzle. When the valve is rotated
I to the HIGH position,
66- 1483
I _i AIRESEARCH MANUFACTURING
Los Angeles,
DIVISION
California Page 4- 139
I
the gas enters through an unrestricted port and leaves through the
same duct as in the MED position. The flow control valve and the I
bypass valve are located in a common housing. This housing is flange-
mounted to the main valve group housing.

I
C. Performance - With the ejector nozzle downstreamj oxygen flows I
as fol lows:
• MED position; 4.75 to 5. 15 Ib per hr at an inlet pressure I

of 97 psia and at a temperature of O5°F.
• HIGH position; 8.0 Ib per hr at a maximum pressure drop of

I
0.5 psi with an inlet pressure of 92 psia and a temperature I
of 70°F.
Internal leakage does not exceed 3.15 x lO-5 Ib per hr. I

Development
I
.
This unit successfully completed a proof pressurization test, demand and
emergency flow sensor actuation and pressure drop tests, high and low pressure
I
leakage, check valve leakage, nozzle flow seal leakage, bypass and suit pres-
sure regulator valve leakage, constant bleed and flowrate tests, actuating I
torque tests, an altitude check, and a flow sensor calibration check. The
altitude test setup is shown in Figures 4-73 and 4-74.

I
I
I
I
I
I
66- 1483
Page 4- 140 _1 AIRESEARCH
Figure 4-73. Valve Group
F- I806
Figure 4-74. Valve Group Altitude Test Configuration
66- I483
AIRESEARCH MANUFACTURING DIVISION Page 4-141
Las Angeles. California
I
FIll and Shutoff Valve 800286
I I. Purpose
I oxygen
This
prior
valve
to
is used
use.
for filling and isolating the stored high-pressure
I 2. Description (see Figures 4-75 and 4-76)
The manifold of the oxygen fill and shutoff valve mounts directly to the
I emergency oxygen tank and has a metallic (BAR X) seal at the interface. The
I
unit contains two separate valves_ as well as a port for connecting the pressure
gauge.
I The shutoff valve contains an O-ring-sealed_ manually-operated valve with
metal-to-metal poppet seating. To open the valve fully_ it is necessary to
rotate the handle counterclockwise approximately one and three quarters turns.
Clockwise rotation of the handle causes the poppet to seat. A maximum 40 in.-Ib of
I torque is required to provide zero leakage. The poppet is antirotational_ thus
I assuring effective sealing even after repeated use.
The fill valve utilizes a metallic ball for the sealing poppet. The ball
I seals on a sharp-edged seat machined into the housing. The ball is spring-
loaded-closed to ensure rapid seating. The valve contains a redundant sealing

I super-pressure cap at its inlet to ensure zero leakage capability.
I 3. Performance
Leakage:
I Internal: 6 x I0-8 lb per min (max) at inlet pressure of 7500 psig
External: 5.25 x 10-7 Ib per rain (max) at inlet pressure of 7500
I psig
I
I
66-1485
Page 4-142
I Figure 4 - 7 5 . F i l l and Shutoff Valve
I
1
8
66- I 4 8 3
I Page 4- 143
I
I
I CLOSE
I
MANUALLY OPERATED
SHUTOFF-VALVE HANDLE
I
I FILL PORT
(PLUGGED) FOR
EMERGENCY
TANK Oa
I
I
*,_g)
Io /p
/#*
,,r/
_Fl_
I
I
I TO SUIT
LOOP
I /f
//
Lz
I
I FROM
EMERGENCY 02
TO
EMERGENCY Oz A-26589
TANK TANK
I
I Figure 4-76. Schematic of Fill and Shutoff Valve
AIRESEARCHMANUFACTURINGDIVISION 66- 1483
I Los Angeles, Cahforma

Page 4- 144
I Pressure rating:
I Operating 7_500 psig
P roof 12_400 psig
I Burst 16_600 psig
Operation:
I
Torque required 40 in.-Ib(max)
I 4. Development
I Tests performed on this unit include proof pressurization to 12_400 psig_
cycling-actuating torque tests_ temperature-actuating torque tests_ cycling
I test with over]oad torque prior to beginning of test_ fill test to check
]eakage through check valve and functional test of R&E va]ve. A]] tests were
successfully completed.
I
I
I
I
I
ii
I
I
I
66-1485

LOS Angeles. California Page 4-145
Suit Loop Check Valve 850040 I
I. Purpose
The suit loop check valve prevents reverse flow in the event the manual
I
bypass valve or the suit pressure regulator is actuated.
I
2. Description (see Fi.cjures 4-77 throuclh 4-79)
The valve consists of a circular rubber sheet retained by the valve I

housing at its outer periphery. The sheet is cross-cut in the center to
form four hinged flappers 3 which are backed up by a perforated metal disc.
I
When pressure is applied in the flow direction 3 the flappers are forced
I
away from the perforated disc 3 allowing gas to pass through the perforation.
If pressure is applied in the reverse direction_ the flappers are forced I

against the perforated disc_ preventing flow through the perforations.
I
I
. Pe rformance
Leakage: I
External 3.15 x I0 -s lb per hr max 0 2 at 3.9 psig
Internal a) 0.5 lb per hr oxygen max at 3.5 psig check

I
pressure
I
b) 1.0 per hr oxygen max at I0 in. H20 check
pressure I
Pressure Rating:
Operating 3.9 psig

I
Proof 7.8 psig
Burst
I
15.6 psig
Pressure Drop: I
I. I0 in. H20 max at 16. I lb per hr
66-
Page
1483
4-146
Oxygen
temperature
with
of
an inlet
45°F
pressure of 3.47 psia
_
and an inlet
AIRESEARCHMANUFACTURINGDIVISION
,
I
1
1
I
I Figure 4-77. S u i t Loop Check V a l v e
(Upstream Side)
I
66- I483
I
LOS nngeler California
Page 4- 147
F i g u r e 4-78. S u i t Loop Check Va ve
(Down Stream Side)
I tor Angeler Caltfornn

Page 4- 48
I
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66- 1485
I [_ AIRESEARCHMANUFACTURING DIVISION
LOSAngeles, Cahfornia
Page 41 149
I
4. Development
Initial development tests of this item consisted of external and internal I

leakage _ proof and burst pressure_ and flow.
Excessive swelling and curling of the elastomer flapper material in the

I
suit loop check valve were encountered during the qualification humidity test
I
of chestpack_ P/N 800308, S/N 102. AiResearch Process and Materia]s Laboratory
then made a study of potentia] materials, which might e]iminate the condition. I
Results showed that AiResearch material EMS 364_ ethylene propylene rubber
(EPR), could solve the problem, and several flappers were constructed and
I
tested. It was found that EPR withstands the conditions of the humidity test
I
and_ therefore_ it was incorporated into chestpack S/N 102 and subsequent units.
Figure 4-80 shows the condition of both the origina] and new material after
eI
component humidity testing.
I
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66-
Page
1485
4- 150
_ AtRESEARCH MANUFACTURING DIVISION
I
P
I
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1
1
1
I
8 0
03
I
u
I z
3
.-
(31
LL
I
8
P
I
66- I 4 8 3
I
I Pressure Gauge 800300
I. Purpose
I The pressure gauge is used to monitor the oxygen pressure in the emergency
I oxygen tank both before and during extravehicular activity.
2. Description (see Ficjure 4-81)
I The gauge is connected to the system by a port on the oxygen fill and
shutoff valve. The gauge has only one moving part: a helically wound_
I beryllium-copper bourdon tube_ which is directly connected to the pressure
I source. Internal pressures in this tube cause it to unwind_ sweeping the
pointer_ at the free end_ across the dial face.
I . Performance
Leakage:
External 3.15 x I0"5 Ib per hr max with inlet pressure of
I 7500 psig
Pressure Rating:
I Operating 7_500 psig
Proof 12_400 psig
I Burst 16_600 psig
I Accuracy: ±5 percent of full scale
Pressure Range of Dial: 0 to IO_O00 psig
I 4. Development
Pressure Gauge P/N 800300 was proof-pressurized to 12s400 psig and

I subsequently leak-checked. A leak of 9 cc per min of standard air was discovered
I in the high pressure ports and the part was returned to the vendor for repair.
A second pressure gauge was subjected to a sinuoidal vibration test. A reso-
I nance was found at about 1350 cps and a crack in the case developed after about
3 min of dwell at this frequency. The crack was not in the high pressure area_
I and a remedy was not difficult to find. 66-1483
Page
I _AIRESEARCH MANUFACTURING
Los Angeles
DIVISION
California
4-152
I
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' A-2&$O8
I
I Figure 4-81. Pressure Gauge
I
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i
I [_l AIRESEARCH MANUFACTURING

LOS Angeles,
DIVISION
California
I
Housing Assemblies
During March 1965_ a development program extended the state of the art in I
close
housing
tolerance
assemblies
fiberglass
of Chestpack
construction
S/N I01
techniques.
was formed in
The
the
upper
original
and lower
mold and
I
had variations in wall thickness and hole sizes. S/N 102 incorporated an
I
improved technique from the same mold. S/N 103 is also from the same mold_
but the process and methods were improved still further. S/N 104 and subse- I
quent units are from new mo]ds_ with the techniques and machining methods used
for S/N 103. Figures 4-82 and 4-83 show two steps in the process of making
I
the fiberglass mold. I
I
I
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66-1485
Page 4-154
_I AIRESEARCH MANUFACTURING DIVISION
1
Figure 4-82. Chestpack Lower Case

Mold f o r P l a s t e r Plug
Figure 4-83. Chestpack Lower Case

Plaster Plug f o r
F i b e r g l a s s Lay-Up
AIRESEARCH MANUFACTURING DIVISION 66- I 4 8 3

Lo$ Angeles California
Page 4 - 1 5 5
i Electrical Components (see Figure 4-84)
I I. Harness (AI) 138723
a. Purpose - To provide all electrical connections between subassemblies
I A2 through A9.
b, Description - The harness is comprised of insulated and shielded
i (where needed) conductors attached to connectors which mate with appropriate
module or electrical device.

I
c. Performance - In addition to providing electrical connections_ the
I harness restrains electromagnetic interference to acceptable limits.
d. Development - The original switch of the Wiring Harness_ 138527_ had
I an excessive delivery lead-time. Because of this availability problem_ the
wiring harness was modified and redesignated 138723. While the modification
was taking place_ the system wiring was simplified resulting in fewer wires_
I which_ in turn_ improved reliability and made the assembly of the system
easier.
I 2. Indicatin 9 Panels (Control Pane] Assembly_ A2 / 138594 and 138793
I emergency
a. Purpose
conditions.
- To provide visual indications of chestpack and AMU backpack
I b. Description - The indicating panels are designed to include all the
warning lights and panel lighting in a unified panel of acrylic with imbedded
I lamps and electric circuits. This appoach offers buried lighting elements_
I maximum
each message
protection
area_
of
and
circuitry_
elimination
the
of
possibility
a loose wiring
of dual
harness
lighting
section.
elements
The
for
I panels are mounted on top of the chestpack_ easily viewed by the extravehicular
astronaut. Each panel contains background light to indicate chestpack power
I application. Panel 138594 indicates the name and position of the bypass valve
I
66-1483
Los Angeles.
DIVISION
i
l
i
I -
I
i TO/FROM
SUIT
I
I
I
L
( .-
I I
I
I
33 i7 14 I 36 35 20 37 18 28 29 30 15 16 11 25 24 23 22 21 I0 3t 32 27 t3
,JUMPER
I ,"_.?ii'
I c_ c_
dd
I
Z Z
0 0 w
oo_ z_ o _-
o __
I
'Z Z
0 0
4 R
w
I
I UMBILICAL
3433
,4-
17
'ii!
- +
36
-
35
"1-
20
"
37
+
'_B 28
+
29
-
30 1S
-
S
+
16 10 24 23 11 25 B 7
TO/FROM" SPACECRAFT
I
,9/_- 15")
I
A3 A, 1 A5 TEMPERATURE CONTROL & OSCILLATOR
TEMPERATURE j A6
J TRANSDUCER
r HEATER 1 J
SENSOR
OSCILLATOR ]
TRIG
T I
TRIG
2 3 I 6 7 8 5 2 1
E L P2 ---
P2 J3
'AUDIO WARNING r_! I
AUDIO WARNING
BATTERY RETURN i _ 1_
SUET PRESSURE t'_ HARNESS

ASSEMBLY
.202
GAGE [tl
H202 GAGE i & !
MMU TEST +28 VDC i' LI
H20 2 (+14-28 VDC) I
I _!
0 2 PRESSURE (+14-28 VDC)-,_
.FUEL PRESS (+14-28 VDC)_
RCS (+14-28 VDC) J 'H
RESET _ -J-
_T.__ _ __. _ -91_ _ __ALARM TR,GGE R 'm

I,L_
_
CASE GRD
tl
C
26 9 12 3 7 2 6
4 f 4 ÷ ÷ - 4
• t
J
MMU "ONLY
2 5 11 19 15 16 6 7 17 18 1 3
J TRIG
OUTPUT
TRIG TRIG 28V 14V + RESET
[
DSI
"S/C POWER"
J
VOLTAGE
REG
DEMA
OR' GATE FLIP-FLOP
A8
OSCILLATOR CONTROL AND
ELECTRICAL VOLTAGE REGULATOR
NOT USED SPARES
31 27 26 19 9 13 12 22 21 6 3 2"_ P2
I --CHEST PACK
V-- e_
A7
BATTERY ]
•- o-,,_ _a_4
- , J
.°___ I {_,-
---_' I J $1 --
4
.20 WATT
-..__, .__
J iF'- [ J
•)
'.a
i I
II, ,._,t
,-,/ M,\
I
,,Lp 11:'""._o,_
p -......._-,,
_ _, "TEST",--'_-----_ C> cI _'

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_ _ _.-- _ _-_
, i
DS9 )SI,
DS10 )$2
I _DSll, ptES_S, DSS,

I DS12 DS6
C'
°° '"I A2A I
C_
I i D.. :'_"EMERG
DS8 Lr_J 02 -:
0
-I LEFT-HAND PANEL
J1 P1
L.,-_.) BACKGROUND LIGHTS
DS13-DS17
"SUIT f 1 DS3,
"._ B
PRESS"
m ClP4
+ ¢ASqj1
ID
FLOW
A9
SENSORS
J
EMERGENCY
I I
BACKGROUND LIGHTS
I DSI-DS5
A2 I_ AZ_2 J
CONTROL PANEL
ASSEMBLY
B- 12530
Figure 4-8z_. Schematic of Electrical System

I and the oxygen flow selector valve; all other displays and controls are incorpor-
ated in Pane] 138793. These include emergency oxygen_ suit pressure_ space craft
I power light 3 and four AMU warning lights. The diodes are provided to permit test-
I ing
rent
the
flow-back
EMERG Oz3 SUIT
through
PRESS_
the test
and the
circuitry
background
when the
lights.
background
The diodes
lights
prevent
are
cur-
illuminated
I normally. The six emergency lights_ diodes_ and conductors are encapsulated
in the panel. Mounted on this panel is a button switch. When this switch is
I depressed_ 28 vdc is applied to the flip-flop in Module 800374 and turns off
I the
power
audio-warning
is employed
tone.
as the
A 28-vdc
chestpack
lamp
power
is provided
source.
to indicate
A hydrogen
when
peroxide
spacecraft
quantity
I gauge is included in the panel. This gauge is a 1,0 milliampere full scale
deflection meter_ with both leads going to the AMU,
Each AMU warning light will illuminate when the proper AMU warning device
I directs
A
it to
three-position
ground.
(TEST_ DIM_ BRIGHT) switch is mounted on the panel, The
I TEST position provides 28 vdc to the EMERG 02 light_ the SUIT PRESS light_ both
background lights_ the spacecraft power light_ and to _he logic of module
I 8700374 (bypassing the demand switch and turning on the audio oscillator).
I positions
The DIM position
provides 28
provides
vdc.
an input of 14 vdc to the chestpack; the BRIGHT
I c. Performance - The lights on the indicator panel illuminate under the
following operating conditions:
I The SUIT PRESS light illuminates when the demand switch closes.
I
The EMERG 02 light illuminates when the emergency switch closes.
The spacecraft pawer light illuminates when spacecraft power is
I being used,
I 66-1485
Page 4-158
I
AIRESEARCH
l_I MANUFACTURING DIVISION
I
The AMU warning lights and the H202 _JANTITY gauge receive their
I inputs from the AMU.
d. Development - Indicator Panel 138793 was initially designated
I 138595. Because of modifications which took place during development,
I Indicator Panel 138595 was redesignated 138793. The results of the development
tests are outlined in the following paragraphs.
I • All lamps operated when their design circuits were energized, indicating
that circuits, including lamps and diodes, are correct.
I • A shield was found to be in contact with a conductor within the
I potting on Panel 138595; precautions were taken to prevent a
recurrence. Subsequent electrical tests were made with this shield
isolated electrically from other conductors.
• Relative brightness of lights on Panel 138594 was very good; no one
character was preceptibly brighter than the others. On one area of
I Panel
balance
138595
of the
the
panel.
lighting
This
was a
condition
little less
was
intense
remedied
than
by
that
relocating
on
the
I lamps.
• The thermal distortion test consisted of applying 28 v to the
I' background lights and two adjacent warning lights simultaneously for
95 min while panels were in an evacuated bell jar. Surface tempera-
tures were monitored at know_ hot spots by means of thermocouples.
I The maximum temperature experienced by Panel 138594 was 130°F. The
maximum temperature experienced by Panel 138595 was 220°F at a
I location immediately over a warning light. In the area of the warning
I lights,
for this
Panel
panel
138595
has been
showed
changed
temperature
to Lexan,
distortion.
made by General
The material
Electric
I
I [_J AIRESEARCH
66-1483
Page 4-159
I
Company. Subsequent testing was performed on Panel 138594 and a
Lexan mode] of Pane] 138595° The test consisted of heat-soaking I

the
4 hr.
panels
No heat
in a 230°F
distortion
hot air
of the
oven with
panels
all
occurred.
lights operating for
I
Hz02 Quantity Gauge 800386 I
!. Pu rpo.s.e
The HzOz quantity gauge indicates bulk quantity (in percent of full tank)
I
of hydrogen perioxide liquid propellant remaining in the AHU.
I
2. Description/see Figure 4-85)
This unit is a 0 to I milliammeter of the Weston_ moving-coil type. The I

pointer and numbers are white. The background is nonreflecting black.
3. Performance eI
The gauge is calibrated to read zero percent when there is no current
I
flow through the meter and I00 percent when the flow through the gauge is
0.001 ampere. Between these points_ the reading of percent vs current varies I
1 inearly.
The accuracy of this gauge is +5 percent of full scale for all current
I
levels between
Electrical
0 and
resistance
0.001 ampere.
is 500 +-5 ohms at a temperature of 70°F.

I
4. Development I
The development phase of this component consisted primarily of vibration
of different types of gauges until one was found that was acceptable. After
I
that_ testing was performed to verify accuracy.
I
I
I
66- 1485
Page 4- 160 __1 AIRESEARCH
Los Angeles, California I,
I
I
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66-. 1483
I [_ AIRESEARCH MANUFACTURING DIVISION
Page 4-161
.
Temperature Sensor IA3) 800294
J
(see Figure 4-86)

I
a. Purpose - This unit senses temperature of oxygen from chestpack
I
emergency oxygen supply tank at the heater outlet_ and controls
operation of heater (A4) through temperature control circuit in I

module (A5).
b. Description - The element is a thermistor. The sensor resistance

I
equals 920 ±92 ohms at a temperature of 45 ° ±O.I°F.
I
c. Performance - The sensor constitutes one leg of a _eatstone I
bridge in the temperature control module.
d. Development - The sensor was subjected to development tests in

I
conjunction with heater (A4).
I
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66-1483
P_ge 4-162 I_ IAIRESEARCHMANUFACTURINGDIVISION
Los AnKeles, California
I
I
ID
I
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I C30
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I I'--UJ
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66- 148.3
Los Angeles, California Page 4- 16,3
I
4. OxyRen Heater {A4) 800290
a. Purpose - The heater is used to heat the oxygen which has been I
cooled by the expansion and throttling process as it is delivered from the
emergency oxygen tank.

I
b. Description - The heating element is a Cal-Rod electrical resistance
I
heater (see Figures 4-87 and 4-88). The element is submersed in the gas
stream and supported inside the delivery tube by the heating fins brazed to I
the element. The gas temperature is sensed by a temperature sensor (A3)
located at the heater outlet and controlled by a temperature control and

I
oscillator
c.
module
Performance
(A5).
- Performance characteristics are shown below.

I
Gas temperature range: Inlet_ +80 o to -IlO°F; outlet_ +40 to +50°F
when inlet is less than 40°F
Heat input: 160 w ,nin at 24-v dc

I
Pressure drop: I psi
57 psia
max
and
at rated
-llO°F
flow with inlet conditions of
!
Rated flow 1.0 to 13.2 lb per hr oxygen I
Element resistance: 3.2 ±0. I ohms at 70°F
d. Development - A preliminary test was performed on a design for the

I
I
electrically powered oxygen heater. The main concern was that the response
time of the heater might be too large. It was found, however_ that the response
time was small enough to maintain allowable outlet temperatures adequately.

I
The tests were performed using nitrogen with an inlet temperature of -llO°F
and a flow rate of 13.2 Ib per hr. Outlet control temperature was 45°F. One I
hundred and sixty watts of power were alternately applied at l°F below control
temperature and switched off at l°F above control temperature. The rate of
I
change of outlet temperature with respect to time was found to be O.8°F per sec.
I
66-1483
Page 4-164
I_IAIRESEARCH
_
L_An_eles,_lifornia
I
L
F i g u r e 4-87. Oxygen Heater and Temperature Sensor
66- I483
Page 4-165
..tJ
QJ
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66- 1485
I 1_1 A'RESEARCH
MANOFACTOR,NO
O,V,S,ON
LOSAngeles, Cahfornla
Page 4- 166
P
I 5. Temperature Control and Oscillator Module (A5) 800518
a. Purpose - To control heater (A4) and provide audio warning tone.
I b. Description (see Figure 4-89) - Contains a temperature control
circuit and an oscillator circuit. Temperature control circuit turns on and
I turns off heater (A4)_ as dictated by temperature sensor (AS). Oscillator
I circuit provides audio warning tone to suit helmet and spacecraft when triggered
by logic in oscillator control and voltage regulator module (A8).
I c. Performance - When logic in module (A8) discerns an emergency_ Gate
C output from module (A8) is circuited to the input of Gate D. A continuous
I input is also received by Gate D from the 1700 Hz oscillator; therefore_ the
I output of Gate C is effectively a trigger to enable passage of the 1700 Hz
oscillator to one input of the modulator. The modulator's other input_ the
I_Hz oscillator_ results in a modulated output of a 1700-Hz tone modulating
at I Hz, the audio-warning tone.
I When the temperature control circuitry is idle_the continuously operating
I 1700-Hz
The hold
oscillator
off bias
output
voltage
is amplified
applies reverse
and directed
bias to the
to hold: off
output
bias
amplifier_
circuitry.
thus
I eliminating leakage and thermal runaway problems. The oscillator output is
directed into another amplifier. This amplifier output is used to drive the
I temperature bridge. The bridge is a Wheatstone type with the temperature
I sensor (AS) and a variable resistance constituting two legs. The variable
resistance is an external adjustment and is used to null the bridge when the
I sensor temperature equals 45 ±l°F. When the sensor temperature drops below
this value_its delta resistance causes a bridge imbalance. The bridge output
I is ampl if led and fed into a synchronous demodulator (SD). _See Figure 4-90.)
I The SD samples the bridge input with its amplified output. When the sensor
temperature is above 45 ±I°F_ the bridge is imbalanced also but a 180 ° phase
I
66- 1483
Los Angeles DIVISION
Californla
Page 4- 167
1
I
I
1
1
I
I
Figure 4 - 8 9 . Temperature Control and O s c i 1 l a t o r Module

66- I483
10s Angeles California Page 4 - 168
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I
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I
I
I
I
I I
I I
I I
I I
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I I
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I L i I i m m m I i i i i i m i m i m I m m I m I J
l
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change occurs when the sensor temperature passes through the 45 ±I°F temperature
point. The SD rejects that phase which represents a temperature point above
45 ±I°F. The result is an output from the synchronous demodulator when the
sensor temperature is below 45 ±I°F. This output is directed to an error
signal circuit which provides an input to the base of a pulse width modulator
(PWM). A sawtooth ramp generator output is applied to the PWM emitter. As
the error signal becomes greater_ the PWM output (square wave) increases its
average power output (the width of the square wave becomes wider). The PWM
output is ultimately capable of attaining a"full on"d-c level. The PWM output
is applied to a driver. The driver output drives the darlington amplifier which
is in series with the emergency 02 heater (A4_ Figure 4-84). Note that the
PWM and the driver obtain power only when the emergency switch is closed.
Because the emergency flow sensor is in the emergency oxygen loop_ it is only
I actuated when the emergency oxygen supply is being used_ which is the only
time the temperature control circuitry is employed.
I d. Development - All the required performance parameters were tested
I during development at the required temperature extremes and overvoltage levels.
I
I
I
I
I
I
66-1485
I _j AIRESEARCH MANUFACTURING
Los Angeles
DIVISION
California
Page 4-170
I 6. Pressure Transducer (A6) 800298
I pressure
I.
to
Purpose
spacecraft
- To provide
for monitoring
an indication
purposes.
of recirculating suit loop total
I b. Description (see Figure 4-917 - The pressure-sensitive-transducer
diaphragm is mounted between two coils. These coils are energized by an 8-kc
I sinusoidal carrier generated in the solid-state circuit. Matched electrically
I and
circuit.
magneticallys
Pressure
each
displaces
winding
the
serves
diaphragm_
as one leg
moving
of
it
a four-leg-balanced
closer to one coil

bridge
and
I away from the other. Since minute changes in an air gap of a magnetic circuit
produce wide variations in reluctance s diaphragm displacement of thousandths of
I an inch produce variations in total reluctance of up to ±7.5 percent. These
variationss in turn s control the inductance and_ thereby_ the amplitude of the
carrier. The bridge circuit provides ready means for introducing temperature
I compensation for zero drift and sensitivity changes. Resultant signal levelss
after rectifying and filtering s provide linear EC output within I percent of
I theoretical absolute accuracy for the overall system.
I c.
•
Performance
Linear d-c
-
outputs
Performance
2.5 to
characteristics
5.0 v dc
are described below.
I • Pressure 0 to 5.0 psig
d. Development - Tests conducted on this unit include linearity-
I temperature checks_ cycling-linearity checkss proof-pressure and ]inearity tests
I burst-pressure
tests were
and
successfully
linearity
completed.
tests and
Figures
an insulation
4-92 and
resistance
4-93 show
check.
the cycling
All
and
I linearity test setups.
I
I
66-1485
I _[ AIRESEARCH MANUFACTURING
Los Angeles.
DIVISION
Califorma Page 4-171
585 I 1-3
Figure 4-91. Pressure Transducer
AI RESEARCH MANUFACTURING DIVISION 66- I 4 8 3

Los Angeler. California
Page 4-172
I
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F i g u r e 4-92. Pressure Transducer Cycl i n g T e s t Setup
I
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66- I 4 8 3
AI RESEARCH MANUFACTURING DlVlSlON Page 4-173
i
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I Figure 4-93. Pressure Transducer L i n e a r i t y Test C o n f i g u r a t i o n
I 66- 1483
Page 4-174
8 Lo6 Angelel. Cal8lornla
I
I .
Battery (A7) 800670
a. Purpose - The battery #rovides all primary power required for the
I chestpack.
I b. Description (see Figures 4-94 and 4-95) - This unit is a zinc-silver_
peroxide-alkaline secondary storage battery. The battery cells are contained
I in a nickel-plated_ aluminum case. The electrical output is through wires potted
into a self-sealing cover. The wires terminate in an electrical connector.
I The battery is comprised of 24 individual cells. Fourteen cells are
I connected in series. Two banks of five cells_ connected in series_are paralleled
and_in turn, are connected in series with the 14 cells. The inner connections
I of the five series cells are brought to a terminal strip. This provides a
means for connecting all 24 cells in series during the charging cycle. The
individual cells are housed in a plastic case and are rated at 1.5 amp-hour
I capacity
38.8 watt-hours.
each. The minimum energy requirement of the completed battery is
I When in the charged condition_ the cells have a metallic zinc positive
plate and a silver peroxide negative plate. The positive plate is wrapped
I in a single layer of cloth material and is then enclosed in four layers of
I cellulosic
hydroxide
material.
solution. The
The electrolyte
chemical reaction
is an aqueous
which describes
40 percent
the
potassium
reversible
I discharge-charge cyclic is:
Agz Oz + H20 + 2Z
n discharge 2Ag + Z 0 + Z (OH)2
I charge
n n
I The silver oxides are soluble in the electrolyte. The cellulose acts as a
barrier and prevents the silver ions from reaching the zinc plate_ thus
I preventing short circuiting.
I
I _] AIRESEARCH
MANUFACTURING
DIVISION los Angeles. Cahfornla 66-1485
Page 4-175
D ’
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F i g u r e 4-94. Battery
I
I tas ~ngeiesCalifornia Page 4-176

I
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66- 148.3
! _i AIRESEARCH
MANUFACTURING
DIVISION
Page 4- 177
I
After assembly 3 the cells are activated with electrolyte. It then
I
undergoes two discharge-charge cycles. A cell is judged to meet the specified
I
requirements if it will supply rated power during these discharge cycles and
will return to full charge, I

c. Performance - Performance characteristics are shown below.
• Leakage
I
External : 5.15 x I0 "6 lb/hr Oz (max) at 20 psig
I
• Relief pressure
Crack: 30 psig (max) I

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

I
• Power output
38.8 watt-hr between 24 and 32 v dc
Life I
Dry charge: 36 months
Wet charge: 20 days or 6 charge-discharge cycles

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

closed circuit is 24 v (min)
I
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66-1483
Page 4-178 I_l AIRESEARCH MANUFACTURING DIVISION
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I
d. Development--Considerable development testing was performed on the
I initial version of the battery. This testing covered such areas as high
I temperature discharge_ low temperature discharge_ discharge after standby_
discharge in vacuum_ discharge after inverted standby acceleration_ vibration s
I short circuit test and burst test. The performance was adequate_but marginal.
After completion of development_ the battery was subjected to humidity qualifica-
I tion testing. This test brought out deficiencies that the development tests
I did not. This_ coupled with the vendorTs poor production rate_ necessitated
AiResearch to manufacture the battery. Because of the critical schedule and the
I experience gained with the first battery design_ qualification testing of the
new battery was started without development testing of the completed unit.
Development testing was limited to testing cells and groups of cells. The
I qualification testing performed is covered in the qualification section (Section
5) of this report.
I
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66-1485
I _1 AIRESEARCH
MANUFACTURING
DIVISION
Page 4-179
I
8. Oscillator Control and Voltage Regulator Module (A8) 800374
I
a. Purpose - This module provides logic that discerns emergency modes
I
and provides output triggering to warning oscillator.
b. .Description (see Figures 4-90 and 4-96) - The module contains two three- I
input
circuit
OR gates_
generates
a flip-flop
a voltage
circuit_
to trigger
and a voltage
oscillator
regulator
circuit in
circuit,
temperature
Flip-flop
control
I
and oscillator module (A5) when input signal from both OR gates are received.
I
The ac OR gate supplies an output to the flip-flop circuit if an input is
received through the switch of either the demand or emergency flow sensor (A9) I
or from _MU back through harness (AI),
c, Performance - Gates A and B provide an output when a fast rising d-c

I
level is applied to their inputs. Each gate provides an input to a threshold,
The thresholds are provided to stop nongenuine signals. The signal from Gates
A passes the threshold and sets the flip-flop; the flip-flop_ in turn_ provides I
an input to Gate C. The signal from Gate B passes the threshold and also pro-
vides an input to Gate C, Gate C output is directed to Gate D of the tempera-

I
ture control and oscillator module_ finally causing an audio oscillator output.
I
A means of turning off the audio warning tone is provided. Pressing the
reset switch ($2) will apply 28 v dc to a threshold; the threshold passes the I
signal to reset the flip-flop. This removes one input to Gate C_ therefore_
Gate C will not provide an output.

I
d. Development - A complete development test program was conducted on
I
this unit without problems.
I
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66-1483
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8 - *
8
8
8
8
8
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la
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8 ~ - , g u r e4-96. O s c i l l a t o r Control and V o l t a g e R e g u l a t o r Module
6 6 - I483
Page 4-181
I
I 9. Flow Sensors (A9)
I a. Purpose - The demand flow sensor is provided to monitor flow of
oxygen through suit, The emergency flow sensor is provided to monitor flow
I of oxygen from the emergency oxygen supply tank.
b. Description - A demand flow sensor and an emergency flow sensor are

I provided. Both flow sensors are of the pressure-differential_ diaphragm-switch
I type with a single-pole_ double-throw contact. Contacts close in the demand
flow sensor_ if suit pressure drops to 3.3 ±0. I psig_ and oxygen flow is
I initiated through suit-pressure regulator valve.
c. Performance - Closing of demand flow sensor contacts provide an

I input to the OR gate in module (A8)_ thereby causing the oscillator circuit
in module (A5) to initiate an audio warning tone to suit helmet and space-
craft. Closing of contacts also causes the SUIT PRESS warning lamp in
I indicator panel (A2) to light.
Contacts close in emergency flow sensor_ if oxygen in chestpack emergency

I oxygen supply tank flows through the emergency check valve to the recirculating
I suit loop. Closing of emergency flow sensor contacts provide an input to the
OR gate in module (A8)_ thereby causing the oscillator circuit in module (A5)
I to initiate an audio warning tone to the suit helmet and spacecraft. Closing of
contacts causes the EMERG Oz warning lamp in indicating panel (A2) to light.
I
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66- 1483
I _] AIRESEARCH MANUFACTURING
Los Angeles,
DIVISION
I
I
UMBILICAL ASSEMBLY 800326
I General
For many months_ the umbilical problem statement was continually refined
I and redefined. Fortunately_ most of the changes eased the severity of the
I thermal protection requirements. The following paragraphs outline the purpose_
description_ and operation of the umbilical assembly_ in addition to the thermal
I analyses which were conducted_ as well as other phases_ of the design and
development.
I Purpose
I The umbilical assembly provides for flow of primary oxygen from the
Gemini spacecraft to the chestpack_ communications_ biomedical and system
status readouts, and mechanical tethering of the astronaut to the spacecraft.
Desc_[ription (See Fiqure 4-97)
I The umbilical assembly is comprised of an oxygen hose_ electrical conductors_
I a tether
around the
strap_
outside
and
of
a sheath.
the oxygen
The electrical
hose. The nylon

conductors
tether
are
strap
wrapped
carries
spirally
all
I tension loads on the umbilical and is placed over the electrical conductors.
I The entire assembly is then covered with multilayers of aluminized mylar. This
I is then placed in a protective nylon sheath.
I Performance
Leakage (with or without mating gas connector) shall not exceed 3.15 x IO-s
I Ib per hr at an inlet pressure of 120 psia. Pressure drop of the completed
assembly shall not exceed that shown in Figure 4-98. Force to engage 649257 with
I the umbilical pneumatic socket did not exceed 15 lb. Force to release 649257
I from the umbilical pneumatic socket did not exceed 5 lb.
I
66-1485
I I_1 AIRESEARCH MANUFACTURING
Los Angeles,
DIVISION
I
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66- 1483
Page 4- 184
I
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I00
9O
i 8O
i _ P_
tlt
7O
I 60
5O 11:
I !!:! .,
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I 50
25
]i] tii
I 20
tl ttt
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I th
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FLOW, LB/HR OXYGEN A-26212
I
Figure 4- 98. Umbilical Assembly Pressure Drop
I
66- 1485
LoS Angeles,
DIVISION
California
Page 4- 185
I
I
Maximumstatic operating load shall be 373 lb; elongation at operating
load was 12 percent maximum. Static design load is 600 lb; elongation at design
I
load was 16 percent (max).
I
Breaking load was I000 lb (min).
The electrical resistance between connecting pins was 0.70 ohms (max). I
Development
I. Thermal Analyses
I
A steady-state analysis of the conditions to which the umbilical would be
I
subjected was performed. The purpose of the steady-staR analysis was to define
the worst operating conditions and then to design as though the hose would I
reach steady-state operation at this one point. In this manner_ it was reasoned
the umbilical would meet its objectives (of minimal heat transfer from the hose)
at all operating points. However_ after a thorough analysis_ it was concluded

I
that a steady-state analysis would not produce a design guide which would lead
to a practical solution to the problem. It was decided to conduct a more I

difficult and time-consuming transient-performance analysis. This decision was
not based so much on the difficulty of building an umbilical to the requirements

I
of
hose
the
thus
steady-state
constructed
analysis
would be
as it
grossly
was on the
overdesigned
recognition
for
of
the
the
actual
fact
problem_
that a
which_
I
in this case3 would require a high degree of sophistication. I
In order to obtain sufficiently accurate results_ it was necessary to
write a comprehensive numerical computer program using finite-difference I

I
procedures. The program allows arbitrary initial conditions and arbitrary
I
I
66-1485
L0s Angeles, Calif0rma I
I
I variation of both fluid-inlet and sink temperatures. The hose may have as
I many as 12 different layers; it may be divided lengthwise into as many as 40
different elements giving a total of 480 possible different elements.
I For the analysis_ two hose models were used. Initially_ the hose was
assumed to be 0.5 in. overall diameter with an insulation thickness of O.L in.
I For the analysis_ only two layers were assumed: the basic rubber hose and
I the
thick
insulation.
layer of
Later_
insulation)
the
was
overall
increased
diameter
to
(including
0.625 in.
an
To
assumed
account
O.I
for the
in.
I metal wire wrap used to strengthen the basic hose_ a layer of steel was assumed
between the basic rubber hose and the insulation. The addition of the steel
I increases the thermal capacitance of the hose and thereby slightly delays its
transient response.
Upon completion of the transient-performance thermal analysis_ it was
I concluded that due to the low oxygen mass flow rates invo]ved and the consequent
effect on the capacity rate (approximately I Btu per hr OR at the 5.11b per
I hr flow rate) the temperature change of the oxygen in the umbilical is sensi-
I
tive to even minor variations in the environmental conditions.
Variations in the mechanical (conduction_ mass_ specific heat) and
I spectral (emittance) properties of the umbilical can also have an appreciable
effect on the oxygen temperature drop or rise through the umbilical.
I The fluctuation of the umbilical outlet temperature is further aggravated
I
by the stated variation in the spacecraft supply temperature_ although this
could be converted into an advantage if the temperature change could be con-
I trolled or scheduled_ as_ for example_ in Figures 4-99 through 4-101.
I
I
66-1483
I _ AIRESEARCH
MANUFACTURING
Page 4-187
I
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Page 4- 188 _ AIRESEARCHMANUFACTURING DIVISION

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66- 1483
_ AIRESEARCHMANUFACTURING DIVISION Page 4- 189

LoS Angeles, California
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66-1483
Page 4-190
[__ AIRESEARCH
I
I
Steady-state analysis does not sufficiently define the problem_ resulting
I in the generation of an overdesign requirement dictating the use of sophisti-
cated and_ from an intended use standpoint_ impractical insulating and
I reflective materials.
I Btu per
An umbilical
hr ft°R and
design
emissivities
with conductivities
in the range
in
of
the
0.5
range
to 0.2
of 0.05
properly
to 0.112
combined
I will result in a practical_ satisfactory solution to the problem provided
that oxygen temperature is contolled at the umbilical inlet_ at least during
I Case I operation. The temperature during this time should be maintained at
75 to 90°F.
I 2. Complete Umbilical Assembly
The complete umbilical assembly consists of the oxygen hose_ electrical
cable_ a tether a strap_ and a sheath. During the early stages of development_ the
I components were placed together by polyurethane retainers spaced at 6-in. intervals.
I These
retaining
retainers
qualities
replaced
of the
the teflon
teflon.
retainers
The retainers
used on
were
the mockup
stretched
due
like
to the
rubbe#
poor
! bands during fabrication and then released to clamp the oxygen hose and elec-
trical cable together. The nylon tether rope was free to slide through the
I retainers and was secured at the middle of the umbilical.
I
Figure 4-I02 shows a photograph of the umbilical mockup. Then an overall
external sheath was placed around the umbilical to prevent accidental snagging
I of the various parts of the three-member system. The sheath_ however_ defeated
all reasons for the triad configuration. The flexibility of the umbilical
I would be reduced greatly. Therefore_ a coaxial configuration was investigated_
I
I
I
66-1483
_l AIRESEARCH
F i g u r e 4-102. O r i g n i a l Umbilical Assembly Mockup
AIRESEARCH MANUFACTURING DIVISION 66-I 4 83

Los Angeler. Cal!tornla Page 4-192
I
with the oxygen hose serving as a core and electrical conductors wrapped
I spirally around the outside. The electrical conductors would not be molded
to the oxygen hose as in normal combination coaxial hosess but wou]d be merely
I encased by a nylon outer sheath. A nylon tether strap placed on top of the
I electrical conductors and underneath the nylon sheath would carry the required
lo_d. This configuration was finally determi_d to be the most flexible and
I compact design for the umbilical system.
A model of this coaxial umbilical system was shown to NASA. It was
I pointed out that the overall umbilical flexibility was almost as good as the
I oxygen
The
hose by
umbilical
itself.
assembly subsequently underwant a major configuration change.
These changes occurred in two steps from 800326-I-I to 800326-4-I and finally
to 800326-5-I. The basic differences between the various configurations
I fabricated is summarized in the following paragraphs.
I outer
The
surface
most
of
significant
the umbilical
change
and
was
the
the removal
substitution
of the
of a
gold
Nomex
plating
(HT
on
nylon)
the
braid
I for the nylon outer sleeve (covering) of the umbilical assembly. This was the
result of a test to which AiResearch subjected several umbilical assemblies.
I During the insulation resistance portion of this tests it was determined
that there was insufficient resistance between some of the wires and their
I shields. An evaluation was performed to determine the cause of this low
I resistance and to determine a process technique which would prevent recurrence
of this condition. The first step of the evaluation was to examine visually
I the exterior of the umbilical assembly. There were a few bumps which indicated
possible problem areas. Nexts the assembly was photographed with X-rays. The
I
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I I_ AIRESEARCH
MANUFACTURING
LOS Angeles,
DIVISION
California
66-1485
Page 4-195
I
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arrow in Figure 4-103 points out the kinks under one of the bumps. The gold
coated covering of the assembly was removed_ exposing a kink in the double- I
wound teflon covering over the shielding as illustrated in Figure 4-I04. The
teflon covering was removed_ exposing the same kink in the shielding over the
I
pair of wires as illustrated in Figure 4-I05. Nexts the shielding was removeds
I
and it was seen that one of the wires was protruding through its insulation as
illustrated in Figure 4-I06s causing the wire to short directly to the shield. I
It was concluded that the kinking was caused during the temperature-curing
cycle of the umbilical assembly gold coating. The curing cycle was performed
I
at about 320°F and caused shrinking of the short sections of the nylon cord
I
used as spacers of the wires around the umbilical assembly. The shrinking
was caused because the nylon had not been pretemperature stabilized. As the
shrinking occurred_ the wires were caused to compress and in a few isolated
cases the compression forces caused a kink in the shielded pair of wires. I
The kinking_ in turn3 caused the rupture of the insulation on the wires. It
was also concluded that the type of failure noted would always be ascertained
I
during the insulation resistance or dielectric strength tests.
I
Subsequently_ NASA suggested that several layers of aluminized mylar be
placed under the outer Nomex sheath to provide the required thermal protection. I
Umbilical system thermal tests conducted in a solar simulation chamber at NASA
verified the acceptability of aluminized mylar insulation.

I
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66-1483
Page 4-194
__[ AIRESEARCH MANUFACTURING DIVISION
Los Angeles, California i
F-2309
Figure 4-103. Umbilical System Insulation Resistance

F a i lure Evaluation (X-Ray Showing Kinked
Wi res 1

66- I483
Lo5 Aogeles. California Page 4-195
w
c
8
1
I
i
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I
t
1
1.
1
I
T
4
E
1 Umbilical System Insulation Resistance Failure
Figure 4-104.
8 Evaluation (Kink in Teflon Covering Over Shields)
1
66-I 4 8 3
LOS Angeles. Calilornia
Page 4- I96
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1
t
8
8 F i g u r e 4-105. U m b i l i c a l System I n s u l a t i o n Resistance F a i l u r e
E v a l u a t i o n (Kink i n S h i e l d Over a F a i r o f W i r e s )
8
Page 4-197
I
E0
Figure 4-106. Umbilical System Insulation Resistance Failure Evaluation

(Wire Showing Through Ruptured Insulation)
66- I483
AIRESEARCH MANUFACTURING DlVlSlON Page 4- I98
LOS Angeles. Calltornla
I
I The oxygen hose and electrical cable breakouts were changed considerably.
I On the spacecraft end_ the oxygen hose_ the electrical cable_ and the tether line
all break out at the same place. On the chestpack end_ the electrical lead comes
I out at a 20 deg angle and is longer than the previous configuration.
I weight
The polyvinyl
dacron sheath
chloride
with
(PVC)
a nylon
protective
zipper. The
sheath
PVC
was
sheath
replaced
was not
by a
suitable
light
for
I use in a vacuum chamber due to its outgassing properties. The dacron sheath
provides an odorless flexible cover for the umbilical system during vacuum
I chamber tests. See Figure 4-I07 for a view of the current umbilical assembly.
UMBILICAL ASSEMBLY COMPONENTS

I General
The following paragraphs cover the major phases of the design and
development of the components of the umbilical assembly.
I Oxyqen Supply Hose 158441
I
The oxygen supply hose is a composite of a basic modified military
breathing oxygen hose_ an insulation layer_ and an outer_ low emittance_
I micrometeroite protection sheath. The basic hose is based on Specification
MIL-H-22489_ Type I_ Low Pressure Breathing Oxygen Hose_ with modification to
I reduce weight and size_ increase flexibility_ and operate at lower temperatures.
I
I
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66- 1483

LOS Angeles,
DIVISION
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I Figure 4-107. Current Umbi 1 ical Assembly
I
I
1 Los Angcles Callfornla
Page 4-200
I
I The major modifications of the Mil Spec hose are as follows:
I a. Corrosion resistant spiral reinforcing wire size is decreased
to approximately 0.35 in., as determined by actual test to meet
I 150-1b static load.
I b. Substitution
of -lO0°F as may
of a
be
low temperature
anticipated
silicone
in the AMU
to meet
mission
a
with
low
no
temperature
flow.
I c. Modification of the end fitting to decrease the pressure drop caused
by the hose inserts.
I Two prototype oxygen hoses were subjected to development tests. The
I first
fittings.
prototype
The
hose
second
was
prototype
identical
hose
to the
was
production
identical to
hose_
the
except
production
for the
hose,
end
except that one end fitting was aluminum whereas the production fitting is
made of stainless steel.
I Pressure drop tests were conducted on the first prototype oxygen hose
I
(less the quick disconnects) in a straight extended position and a coiled
position. The results of this test are presented in Figure 4-108. Figure
I 4-I09 illustrates the hose in the straight position as tested. The hose was
then coiled in a figure 8 position as shown in Figure 4-110 for a second
I' pressure drop measurement.
Oxyqen Hose Quick Disconnects

I The oxygen hose quick disconnect is a trigger-operated coupling designed
I for operation with the pressurized glove. The operation of the connector is
as follows: (I) a simple push to connect and (2) a depressing of the push
I trigger to disconnect.
I
I
I I__ AIRESEARCH
MANUFACTURING
DIVISION LOS Angeles California
66-1485
Page 4-201
I
40.0
I
30. I
I
I
I
I
STRAIGHT
I
e,J
nr_
...J
!
eI
0.,
<3
t_
I
I.¢
PROTOTYPE
LENGTH = 524
158441-1
IN.
R&E NO. I
I
o = L
p =
Po
STD AIR AT 14,7 PSIA
I
o AND 70°F
I
I
I
0.1
5 4 6 7 8 9 I0 15 20
I
FLOW - LB/HR AIR
A-8088
I
Figure 4- 108. Umbilical Pressure-Drop Test Results
I
66- 1483
Page 4-202 I_l AIRESEARCHMANUFACTURING DIVIS)ON
1
I
I F i g u r e 4-109. Umbi 1 i c a l
Pressure Drop
Test-Coi l e d
(Figure 8 )
1 Position
1
1
1
I
I.
1
F i g u r e 4-1 IO. U m b i l i c a l Pressure
Drop Test - Straight
Position
F-1541
66- 1483
I Page 4-203
I
I
The connector system allows the bulk of the connector to be recessed into
I the pack providing minimum protrusion that could interfere with the astronaut
I
operations. The flush trigger will prevent accidental swagging which could
cause unintentional disconnect.
I The oxygen supply disconnect was changed early in the program. This
change resulted from development tests conducted to compare the performance
I of each unit. Also, the basic design was taken into consideration: (1) The
first unit was constructed from aluminum and weighed 0.37 Ib_ whereas (2) the
I final unit was constructed from stainless steel and weighed 0.17 lb.
I Each disconnect was submitted to a cycle test under pressure until a
failure occurred. The first unit failed at 435 cycles with a broken lever
spring and an excessive connect and disconnect force. The final unit leaked
slightly after 6300 cycles as a result of an O-ring failure. There was no
I evident increase in coupling or uncoupling force during the final unit cycle
I test.
Tether Line
I The tether line consists of a 3/16-in.-diameter nylon rope with a safety
hook at each end. The rope has an IIO0-1b breaking strength with a 20-percent
I elongation. The tether line_ when assembled to the umbilical_ is shorter than
I
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66-1485
I _ AIRESEARCH
MANUFACTURING
DIVISION
I
I
the electrical cable and oxygen hose to allow for the elongation under load.
I A common eye splice is used to secure the safety hooks to the rope.
A survey of the commercial and marine hardware revealed no acceptable
I safety hook for this particular application. The safety hook must be easily"
i connected and disconnected by the pressurized gloved astronaut_ must prevent
accidental connection and/or disconnection_ and must withstand the load to
I the breaking strength of the rope.
A single point attachment of the tether at the upper left chest to the
I parachute harness appears to be the most feasible attachment location. The
! astronaut could easily reach the rope in this position if he lost his grip
on the spacecraft. Multiple attachment points would cause interference with
other umbilical connections and_ due to the short length of the multiple
lines required to prevent visor contact with main tether fitting_ only small
I angles of alternation bracketing the CG would be attained.
I A major change was made in the tether line when the coaxial configuration
was adopted. The tether line is now a strap instead of a 3/16-in.-diameter
I rope. This change resulted in a slimmer_ more compact umbilical system. The
tether line is fabricated from natural nylon webbing procured per
I Specification MIL-W-5625 D. The webbing is I/2 in. wide and has a breaking
I strength
place
of
according
IO00
to
lb. The
Specification
ends are loopad
FED-STD-751_
over the
Type
tether
301.
hooks and stitched in
I Tests were conducted to determine the strongest stitching pattern for the
tether hook connection. A series of tensile test samples were fabricated using
I several possible sewing patterns and are shown in Figures 4-III and 4-I12.
I Samples
an overlap
I through
of 6 in.
6 were
Samples
approximately
7 to 9 ware
14 in.
also
long between
approximately
the loops
14 in. long_
and had
I
LOS Angeles,
DIVISION
California
66- 1483
Page 4-205
F i g u r e 4-111. T e t h e r L i n e Test Figure 4-112. Tether L i n e Test
Samples I Samples 7
through 6 through 9
F i g u r e 4-1 13. I n s t r o n T e n s i l e Test

Mach i ne

I
i
except that the stitching overlap was only 3 in. on each end. Each sample
I was tested on the Instron tensile test machine pictured in Figure 4-I13.
The graph on the left side of the machine records the elongation vs load of the
I tensile test sample. Each end of the sample straps was secured to the cross-
I heads
sample
by
was
an 0.25-in.-diameter
loaded until failure

pin_
which_
similar
in each
to the
test_
pin in the
was greater
tether
than
hook.
the
Each
design
I break load of the webbing. Each sample failed in the center section of the
webbing and not in the stitching pattern. Table 4-15 lists the stitch pattern
I vs the breaking load and the elongation at break. Since the stitch pattern
I was
was
not
selected
the weak
for
point
the
of
production
the junction_
stitching
the simplest
pattern.
patt3rn (sample No. 8)
A tensile test was conducted on 24 tether samples to determine the
ultimate strength at elevated temperatures. The increase in temperature
I causes a definite decrease in strength_ but the required strength level is
I maintained
test data
at temperatures
is presented in Table
below 300OF
k-IS.
as illustrated in Figure 4-I14. The
I The test sample ends were sewn identically to the umbilical tether and
had a distance of 6 in. between the stitching. The samples were pulled at
I' a rate of IO in. per min on an Instron tensile test machine.
Tether Hook t 138642

I Figure 4-115 shows the R and E hook assembled and disassembled.
I
I
I
I
66- 1483
I _I AIRESEARCH MANUFACTURING DIVISION

Page 4-207
I
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66- 1483
Page 4-208 Los Angeles, California
I
I
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1400
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I
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I I--
Z
w
I-- IlOO
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.J
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0 I00 2OO 500 400
I TEMPERATURE, OF
A-13798
I Figure 4-114. Ultimate

Temperature
Tether Strength MS
66- 1485
I _____ AIRESEARCH MANUFACTURING DIVISION

Los Angeles.California
Page 4-209
Figure 4-115. Tether Hook-Assemb ed and Disassembled Views
66- I483
Los AngeCs. California Page 4-2 0
I
I
Tether Line and Tether Hook m 138642
I Development tests were conducted using the tether hook and tether line
to determine the breaking strength of the combination restraint. The break-

I ing load of the nylon tether strap occurred at 1340 lb. The test specimen is
I shown in Figure 4-116 after the conclusion of the test. Figure 4-117 shows
a disassembled view of the production tether hook P/N 138642.
I
I
I
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I
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I
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I
I
66- 1483
I _1 AIRESEARCH
MANUFACTURING
DIVISION Los Angeles Cahf0rnia Page 4-2 II
F i g u r e 4-116. Tether Test Specimen A f t e r
Conclusion o f T e s t
J
I
I
I
I
I
I
II F i g u r e 4-117. P r o d u c t i o n T e t h e r Hook-
Disassembled View
C
I 66- 1483
Page 4-2 I 3
I
I
ELECTRICAL JUMPER CABLE 800372
I Purpose
The electrical jumper cable allows a transfer from the umbilical electri-
I cal system to the AMU electrical system with uninterrupted electrical continu-
I ity between astronaut and chestpack.
Description (See Figures 4-I18 and 4-I19)
I The umbilical electrical jumper cable consists of six twisted pairs of
shielded conductors 3 one triple conductor twisted shielded cable 3 and their
I electrical connectors. The conductors are wound spirally to permit a flexi-
I ble cable that will not kink and will return to its original shape after
flexing or being coiled. One connector plugs into the chestpack; one is
mounted on the chestpack case and receives either the umbilical or AMU con-
nector; the remaining connector is attached to the suit.
I Performance
I The cable was wired as shown in Figure 4-84. The resistance between two
connecting pins was 0. I0 ohms (max). The key withstood a pull of 150 lb.
I Deve Iopme n t
Teflon-insulated wire in accordance with Specification MIL-W-I6878_ Type
I ET_ was initially used in order to maintain minimum weight and size and to
I obtain the greatest degree of flexibility. The electrical wire has been
changed from MIL-W-168780_ Type ET3 to MIL-W-16878D_ Type E. The difference
I between the two types is
I
I
1
66- 1483
I _____ AIRESEARCH
MANUFACTURING
DIVISION
J
F i g u r e 4-1 18. Electrical Jumper Cable
66- I483
AIRESEARCH MANUFACTURING DIVISION Page 4-215
1
LOS ~ n g e l e sCalifornia
I
I
I
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..o.,,,
q .--I0
t.LI I--
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66- 148.5
Page 4-216
I
I
I that
the
the
E wire
ET wire
has
has
a wall
a nominal
thickness
insulation
of 0.010
wall
in.
thickness
The terminal
of 0.006
connectors
in. whereas
were
I Deutsch Company components to mate with the existing spacecraft and spacesuit
plugs, The electrical connectors were subsequently changed from Deutsch con-
I nectors to the Microdot Marc 53 connectors in order to match the configuration
I of the latest space suit, In addition_ the following changes were incorporated:
I. Change in location of the key-hole slot in the chestpack.
I 2. The key attachment to the jumper was strengthened.
3. The wiring was changed to allow spacecraft power to be utilized by
I the chestpack.
I
I
I
I
I
I
I
I
I
66- 1483
I _l AIRESEARCH
I
MULTIPLE CONNECTOR 800566 I
Purpose
The multiple connector permits connection of a space suit either to the

I
spacecraft life support system or to the ELSS_ or to both life support systems
I
at the same time. The prime purpose is to allow a change-over from the ELSS
to the spacecraft ECS with a decompressed cabin. I

Description (See Figure 4-120)
The multiple connector is a quick-disconnect type of a T configuration

I
which has one male port and two female ports. A check valve located in each
I
of the female ports moves to the open position whenever a connecting nipple
is inserted. The nipple is automatically locked in place by six balls equally I

spaced around the internal diameter of the female port. The balls are locked
in the closed position by the location of an outer race. This race is located
in the closed position by a shoulder on the nipple that is inserted. To un-

I
lock the connection_ two independently operated tabs must be pulled and
rotated. I
Pe rfo rma nce
External or internal leakage did not exceed 3.15 x I0-s Ib per hr at an

!
inlet pressure of 3.9 psig.
I
Pressure drop did not exceed 2.0 in. of water at an oxygen flow of 25.6
Ib per hr with an inlet pressure of 3.7 psia and an inlet temperature of I

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

I
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66- 1483
Page 4-218 j__ AIRESEARCH
I
I
_o
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L)
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(..)
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o_
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0 o_
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LU
-r"
(-I
I
I
66- 1483
I
_[ AIRESEARCH MANUFACTURING DIVISION
Page 4-219
I
Development
I
The initial prototype units were subjected to a complete qualification
I
test program without prior development tests because of prior experience of
similar units on ali Gemini suits. A11 tests in the program were completed I
successfully. (Refer to Section V, Qualification Tests 3 for detailed infor-
mation.)
I
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I
66-1483
I_l AIRESEARCH MANUFACTURING DIVISION
I
..... t
SECTION 5
QUALIFICATION TEST PROGRAM

o ii
_J
I
I SECTION 5
I QUALIFICATION TEST PROGRAM
I INTRODUCTION
I the
This
chestpack
section contains
assembly and
a summary
its components
of the
were
qualification
subjected.
tests
The
to which
quantity of
I units tested and the results of the tests are included.
All tests were directed by the ELSS Program Office of AiResearch
I Manufacturing Company.
I
I
I
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I
I
I
I
I
I _1 AIRESEARCHMANUFACTURING DIVISION
66-
Page
1485
5- I
I
GENERAL QUALIFICATION TEST PLAN

I
AiResearch Document SS-3207 defines the scope of the qualification test I
plans for the ELSS. This general test plan satisfied the requirement of the
NASA Statement of Work_dated 19 June 1963. The Program Test Plan was confined I
to the overall scope of the test program. Detailed test instructions and test
I
procedures were prepared to define the applicable tests and test parameters
for specific items. I

The environmental test conditions were as described in Table II 3 General
Environmental Conditions_ of the Statement of Work_ with minor exceptions. I

The testing was performed at the Garrett Corporation_ AiResearch Manufacturing
I
Division_ Los Angeles, California_and at other Government-approved laboratories
in the Los Angeles area.
I
I
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I
I
66- 1483
Page 5-2 I_l AIRESEARCHMANUFACTURINGDIVISION
Los AngeJes. Cahfornia
I
I
I QUALIFICATION TESTS
Introduct ion
I The tests performed on the ELSS chestpack and its components are shown
I in Table
administrative
5-I and
data_
are discussed
including
in subsequent
test dates_ test

paragraphs.
agency_ and
Table
report
5-2 presents
document
I references.
Test Requirements
I The test requirements for most of the tests were defined in Qualification
I Test
were
Procedure_
issued as
AiResearch
necessary for
Report
certain
No. SS-3500.
tests.
Revisions
Separate test
and change
documents
notices
were
I produced for specific test items requiring special procedures or instructions.
Test Procedures and Results
Io A brief description of the test procedures for each test performed on the
I
chestpack or components is given. The descriptions are general in nature;
detailed procedures were varied for specific applications as outlined in
I appropriate documents listed in Table 5-I. The results of the tests are given
briefly after the procedures.
I I. Hum id ity
The specimens were exposed for four 24-hr cycles of humidity as follows:
I • At the start_ humidity was uncontrolled; temperature was 68 to lO0°F.
I • During the next 2-hr period_ humidity was raised to 95 (+5_ -0)
percent; temperature was raised to 120°F.
I • During the next 6-hr period_ humidity was maintained at 95 (+5_ -0)
percent_ and temperature at 120°F.
I
I
I
66- 1483
I L_______j AIRESEARCH MANUFACTURING

LOS Angeles, DIVISION
C_lifornia Page 5-3
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66-1483
Page 5-4
_1 AIRESEARCH MANUFACTURINGLos Angeles,
DIVISION
California
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I
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66- 1485
Page 5-7
v
I
I
• Finally, during the next 16-hr period, with humidity at 95 (+5, -0)
percent, temperature was decreased to between 68 and IO0°F. This I

constitutes one 24-hr cycle.
The chestpack successfully satisfied the requirement of the performance

I
record test prior to and after the rerun humidity test. (Problems arose in
I
the first chestpack humidity test which required some redesign and rework.)
After four 24-hr cycles of the rerun test, no detrimental effects were evi- I
denced. Figure 5-1 shows the test setup.
All components exposed to humidity successfully completed the test.

I
Small spots of corrosion were observed on the electrical jumper cable, but
I
operation was not impaired.
2. Pressure-Temperature
The specimens were subjected to a pressure-temperature test for three

lI
mission profiles (70 o , 160 o , and -60°F) of five phases each.
I
Phase I was preparatory steps to put the system into operation at
I
the required conditions.
Phase 2 was a 60-minute period at a pressure of 2.5 mm Hg abs (max) I

which is normal when oxygen is supplied through the umbilical to the
chestpack. A metabolic simulator supplied 2150 Btu per hr heat load.

I
C02
Phase
was
3 was
added
a
at 0.44
20-minute
lb per
period
hr.
under Phase 2 conditions, except that

I
a suit leak was simulated. The leak causes the regulator to operate
I
to maintain the suit pressure of 3.3 psig.
I
I
I
66- 1485
Page 5-8 __l AIRESEARCH MANUFACTURING DIVISION
-1 1- Report NO. 65 -47
Page No.. 10
PHOTOGRAPH ## 2
C H E S T PACK Date June 14, 1965
I
AT COMPLETION OF HUMIDITY T E S T Revision
F-2781
DYNAMICS TECHNOLOGY LABORATORlES

16304 South Main Street, Gardena, California
F i g u r e 5-1. Chestpack a t Completion of
Form 120
Humidity Test

Lo$ Angeles Calilornia
Page 5-9
I
I Phase 4 was a 15-minute period under Phase 2 conditions, except
I the flow to the umbilical was stopped and the heat loads and CO z
supply were changed resulting in flow from the emergency oxygen
I system. The metabolic simulator supplied 1550 Btu per hr heat
load. C02 was added at 0.32 Ib per hr.
i Phase 5 was of an uncertain duration to determine additional capa-
I bilities of the ELSS. When the emergency oxygen tank was depleted,
the Phase 2 conditions were_-established and maintained until the
I reservoir capacity of the evaporator-condenser was depleted.
The initial test and retest of the chestpack at 70°F failed. The
I specimen was disassembled and evaluated; a regulator and a valve were repaired.
A retest indicated the operation time and heat rejection capabilities of the
evaporator-condenser were less than required. The evaporator-condenser was
I refurbished_ retested, and reassembled. (Figure 5-2 shows the test setup.) The
final tests were successfully performed for the 70°_ -60°_ and 160°F missions.
I The outlet dew point was high, but the total heat rejection was acceptable.
I No deterioration to the restraint pad, battery, electrical cable, and
multiple connector resulted from the pressure-temperature tests. Umbilical
I System 800326-I-I was qualified by means of similarity to chamber umbilical
system 80058Z-I-I. Pressure-temperature tests were conducted on the ELSS_of
I which 800326-I-I was an integral component. This test was not construed as a
I qualification requirement of 8003c6-I-I. The criteria for the temperature-
pressure test were contingent on the insulation resistance test that followed
I each mission test on the chamber umbilical. The requirements of these tests
were satisfied.
I
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66-1483
I L_] AIRESEARCH MANUFACTURING

LOS Angeles
DIVISION
California
Page 5-10
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Figure 5-2. Pressure-Temperature Test Setup

Page 5-1 I
I
I 3. Temperature
I The specimen was subjected to a 9-day temperature test. The first seven
days were at ambient atmospheric conditions. The last two days were in an
I oxygen atmosphere at 5 +0.5 psia. Each temperature cycle was of a IO-hr dura-
tion. The specimen was exposed to 32°F for 4 hr and to 120°F for 4 hr with an
I hour transition period between soaks. The cycling was continued for seven days
I at ambient atmospheric conditions and then temperature-cycled in an oxygen
atmosphere at 5 +0.5 psia for two days. An evaporator-condenser performance
I test was performed after the 9-day test.
The initial chestpack test was successful_ however_ during the subsequent
I pressure-temperature tests_ the evaporator-condenser did not reject the required
heat load. (Figure 5-3 shows the test setup.) The final temperature test was
performed on the reworked evaporator-condenser which lost 0.25 Ib of water.
I The evaporator-condenser gas breakthrough test was performed_ but the leakage
rate exceeded the required limit because of the lost water due to insufficient
I sponge depth resulting from the rework of the evaporator-condenser.
I There were no visible signs of deterioration of the restraint pad from the
temperature test. After the temperature test_ a shear and peel test proved the
I restraint pads to be satisfactory. The electrical jumper cable_ multiple con-
I nector_
passed
umbilical
the temperature
system_ battery_
tests.
and chamber umbilical system satisfactorily
I 4. Explosive Decompression
A nonoperational specimen was pressurized to 6.6 psig. The pressure was
I rapidly reduced for explosive decompression of 6.6 psi (min) within 0.40 sec
or less. The type and amount of deformation resulting from decompression was
I determined. The emergency oxygen tank was pressurized to 7500 psig. At least
I three sides were measured for deformation.
Los Angeles,
DIVISION
CaFifornla
66-1483
Page 5- I 2
F i g u r e 5-3. Temperature C y c l e T e s t Setup Showing
Chestpack i n P r e s s u r e Chamber

Los Angeles C a l h r n i a
Page 5-13
I
I Figure 5-4 shows the setup. Photographs were taken of a dial indicator
I located on the chestpack. The film confirmed the dial indications that the
case movement was insignificant. Pertinent frames of the film are shown in
I Figure 5-5. There were no visible indications of damage to the specimen. No
Trouble Reports were issued for the explosive decompression test.

I The battery was exposed to explosive decompression with no visible damage.
I Following the test_ an energy test was performed. The available energy and
open circuit voltage after recharge showed no significant change from the
I initial servicing values. (A typical setup is seen in Figure 5-6.)
No damage or deterioration resulted from the explosive decompression tests

I of the chamber umbilical system_ electrical jumper cable_ or multiple connector.
Umbilical System 800326-I-I was qualified by means of similarity to chamber
Umbilical System 800582-I-I.
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Los Angeles Califorma
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r i y u r e 3-4. txpiosive uecornpression l e s t L o c a t i o n O t u i a i l n d i c a t o r
t on T h i r d Side o f Chestpack Assembly 800308
I
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Page 5-15
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I Figure 5-5. Explosive Decompression Sequence
F-2855
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I Los Angeles California Page 5-16

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I F i g u r e 5-6. B a t t e r y 800670-1-1, S e r i a l No. 65-102
i n Explos i ve Decompress ion Test Setup
I
1 AI RESEARCH MANUFACTURING DIVISION
66- I483
Page 5-17
I
I 5. Evaporator-Condenser Performance
Chestpack S/N 35-I03 satisfactorily passed the evaporator-condenser
I performance tests (simulated mission)_ after both the acceleration test and
I the shock test.
Chestpack S/N 124-I02 was unable to meet the heat rejection performance
I for the required time of 90 minutes during the pressure-temperature test_ due
to the water lost during the previous temperature test. A rerun test verified
I the evaporator-condenser would perform satisfactorily_ if it contained the
I required 0.5 Ib of water. The evaporator-condenser was reworked to correct
the cavity size_ and was retested as a separate component as described in
I SS-3863. A simulated mission (same parameters as the ambient temperature
mission of the pressure-temperature test) was performed on the evaporator-
condenser of chestpack 124-I02 within 24 to 36 hr after the acceptance test.
I The
three
days; the water loss

was
was
refilled
measured
and
at
placed
24-hr
in a vertical
intervals. The
position
test
for
I specimen was subjected to an acceleration test immediately after the 3-day
period. The water loss due to the acceleration test was determined. A
I simulated mission test of the evaporator-condenser was performed within 12 hr
I after
component
the acceleration
of chestpack
test.
S/N 124-I02,
Evaporator-condenser
failed to meet
167880-2,
simulated
S/N
mission
124-I04,
require-
a
I ments of SS-3500. Further testing of this unit was discontinued.
I Substitute
requirements.
The results of an
S/N
acceptance
75-I16
test
was used
were
to comply
satisfactory_and
with testing
the
I evaporator-condenser met the requirements for a simulated mission. The 3-day
standby and acceleration tests were completed satisfactorily. In the simulated
I mission test after acceleration, the unit performed 3 min. over the 140-minute
requirement before the outlet temperature increased above 55°F.
I
66- 1483
I I_i AIRESEARCH MANUFACTURING DIVISION
LOS Angeles, California Page 5- 18
Y
I
I Interim Report 66-0887 presented the results of tests conducted on 12 other
evaporator-condensers P/N 167880 and contained recommendations for the configura-
I tion to be used in the GT-12 extravehicular mission. The need for these tests
was because the metabolic loads evidenced in Astronaut Gene Cernan's GT-9
I extravehicular mission exceeded the design loads constructed for the ELSS.
I These
tax
higher
the capacity
metabolic
of the
rates_
evaporator-condenser.
when coupled with over
Tests
2
were
hours
conducted
in mission
to
lengths_
determine
I the operating limits and characteristics of the evaporator-condenser under time-
load conditions outlined above. Based on tests_ conclusions were reached
I regarding the extension of the capabilities of the exchanger.
6. Burst
I The specimen was subjected to several burst pressure tests and was visually
examined during disassembly. The proof pressure of 7.8 psig was applied to the
low pressure (suit circuit) for a period of IO min_ then pressure was increased
I at a rate of 2 psi per min (max) until rupture occurred. The medium pressure
system was tested at a proof pressure of 240 psig for a period of IO min. The
I pressure was increased at a rate of 50 psi per min (max) until well above specified
I minimum rupture pressure. The emergency oxygen tank was pressurized at a proof
pressure of 12_400 psig for a period of IO min_ then pressure was increased at
I a rate of IO00 psi per min (max) until rupture occurred.
The results of the burst test were satisfactory for all systems tested.
I The low pressure system ruptured at 43.3 psig_ well above the 15.6 psig required_
I in the oxygen outlet hose. Figures 5-7 through 5-I0 show various parts that
were tested. The medium pressure system was pressurized to 240 psig and then
I increased above the required value of 480 psig. At 960 psig_ no rupture was
evidenced; therefore_ the test was discontinued. The high pressure system was
I
I
66- 1483
I I_ AIRESEARCH MANUFACTURING
Los Angeles,
DIVISION
California
Page 5- 19
+ + I D E N T I F I C A T I O N AND W I T N E S S STAMPS
AS APPEAR ON BACKSIDE O F PHOTOGRAPH
I F-2844
I F i g u r e 5-7. Emergency Oxygen Tank w i t h F i l l and
1 S h u t o f f V a l v e Assembly B u r s t T e s t Setup

Lo5 Angeles California
Page 5-20
I
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1
I 4 + I D E N T I F I C A T I O N AND WITNESS STAMPS
AS APPEAR ON B A C K S I D E O F PHOTOGRAPH
i F-2848
I Figure 5-8. Pressure Regulator Burst Test Setup
I
AI RESEARCH MANUFACTURING DIVISION 66-I 4 8 3
I LOS ~ n g d eCahfornia
~.
Page 5-21
Figure 5-9. S u i t C i r c u i t System Burst Test Results (Closeup)

66- I483
Lon Angelen California Page 5-22
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I F i g u r e 5-10. Burst
Top :
Lower
T e s t Results
Oxygen Tank w i t h F i l l and Shutoff Valve
L e f t : Oxygen Pressure Gauge
Lower Right: Pressure Regulator
1
I 66- I483
I
I tested
ruptured
independently
at 17_800 psig_
in three
which
parts.
exceeded
The
the
Pressure
16_600
Gauge
psig
800300-I_
requirement.
S/N CA5648_
Pressure
I Regulator 800284-I-I_ S/N 8_ ruptured at 24_400 psig_ exceeding the 16_600 psig
requirement. Emergency Oxygen Tank 800310-3-I_ S/N 45-I03_ ruptured after a
I hydrostatic pressure of 18_800 psig had been applied. The rupture was typical
I
of previous burst tests on development tanks. No trouble reports were initiated
as a result of the burst program.
I The battery ruptured at a pressure of 58.8 psig; pressure was increased at
a rate of 2 psi per min. A voltage of 3&.77 volts was obtained across the buss
I bars of the battery 24 hours after the burst test. The multiple connector
remained intact at 7.8 psig and also at the burst pressure of 15.6 psig. There
I was no damage to the unit after it had been subjected to pressures six times
greater (IO0 psig) than the nominal burst pressure (15.6 psig). The umbilical
system ruptured at I I20 psig which was well above the required 330 psig. Tests
I are shown in Figure 5-II.
7. Elect romaqnet ic Interference

I The test specimen electrical system was subjected to the EMI test specified
I in AiResearch Report No. SS-3500_ Rev. 2_ amended by Proposed EMI Test Plan and
Deviations for the ELSS_ submitted to NASA/MCS/CSD on June 3_ 1965_ and approved
I by NASA TWX BG-63-1284_ July 29_ 1965. The EMI test plan was in accordance with
the Class IA requirements of MIL-I-26600. The test specimen electrical system

I includes the chestpack assembly_ electrical jumper cable_ and the umbilical
I system assembly. The test instrumentation techniques and EMI measurements
comply with MIL-I-26600. The chestpack was subjected to broadband radiated
I EMI measurements with the test specimen bonded to_ and isolated from_ the
groundplane. Test results of all EMI tests were summarized in AiResearch Report
I No. SS-3797. (A typical setup is shown in Figure 5-12.) The chestpack with
I
66- 1483
I I_ AIRESEARCH
MANUFACTURING
DIVISION LOs Angeles, California
Page 5- 24
Figure 5-11. Burst Test S e t u p s f o r Umbilical System Assembly
F-2817
800326-1-1, Serial NO. 45-106

Los Angeles. Calilornla
Page 5-25
I F i g u r e 5-12. Test Setup f o r Broadband Radiated EM1 Test w i t h
Chestpack Assembly Bonded t o Groudplane (Chestpack)
o n l y ) , Frequency Range 0.15 t o 25 rnc
1
1
66- I483
1 Los Angeles. California Page 5-26
I
I electrical jumper cable was subjected to broadband radiated_ broadband conducted_
I and susceptibility EMI measurements. Conducted and radiated susceptibility
measurements were performed on the chestpack and electrical jumper cable. A
I specimen of the chestpack with electrical jumper cable and umbilical system
was subjected to broadband radiated and broadband conducted EMI measurements.
I The recorded EMI graphs indicated that interference did not exceed the inter-
I ference level requirements of MIL-I-26600 on any test. Current probe measure-
ments not within specification were subjected to further analysis and EMI test
I measurements and were found to be completely satisfactory.
Battery 800670-I-I was used as the power supply for Chestpack 800308 during
I the EMI test. This was an added test for the battery. The battery_ as a compo-
nent of the chestpack_ displayed satisfactory performance.
The chamber umbilical system EMI specimen was subjected to the radiated
I and conducted susceptibility tests at frequencies up to 920 and at 5000
megacycles. There was no change of signals throughout this test. Each imposed
I signal was evaluated with and without other transmitted signals before and after
I the
8.
EMI
Random
test. There
Vibration
was no indication that these signals had any cross-coupling.
I AiResearch Document VTI No. 132-EDJ was prepared for use by an outside test
facility in conducting the random vibration test (and the acceleration test).
I This document further amplified the requirements as applicable to the vibration
I test as
performance
specified
test
in AiResearch
indicated the
Report
chestpack
No.
was
SS-3500_
capable
Rev. 2.
of withstanding
The results
the
of
forces
the
I of the random vibration test_ except for the hydrogen peroxide quantity meter
and its background light. (Figure 5-13 shows the setup.) The revibration
I program corrected the trouble with the quantity meter and the background light.
I
I AIRESEARCH
MANUFACTURING
DIVISION
Page 5-27
66- 1483
Im
F-2075
F i g u r e 5-13. Chestpack Random V i b r a t i o n Test
I
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66 1 4 8 3
I AIRESEARCH MANUFACTURING DlVlSlON
Page 5-28
I
I The suit relief valve test was performed in accordance with requirements;
see Figure 5-14 for setup. Excessive poppet leakage was noted during the
I performance test following random vibration. A rerun vibration test was
I
performed. Acceptability of the performance test following random vibration
(rerun) was authorized if the poppet leakage did not exceed 0.005 Ib per min
I difference from the leakage of the performance test after the first vibration
test. However_ the leakage did return to within the original leakage require-
I ments; this was a change greater than allowed_ but this condition was accepted.
The random vibration tests were conducted successfully on the fill and shutoff
I valve. The internal and external leakage tests following each vibration test
I showed no leakage. There was no damage to the battery in the random vibration
test. The performance test (battery discharge)_ following the random vibration
test_ indicated 65.54 watt-hours supplied above 24 v dc. The umbilical unit
showed no damage in the random vibration test. The performance test results
I were satisfactory. (Figure 5-15 shows the vibration test setup.) However_
I the electrical continuity and insulation resistance test revealed an insulation
resistance failure. The cable between Connectors PI and P2 was found to have
I split teflon insulation revealing the bare wire. This split in the insulation
allowed a low resistance path to the metallic sheathing surrounding the cable.
I Figure 5-16 shows the split insulation which was analyzed in Reliability Failure
I Analysis_ AiResearch Report No. RC-89-MR.
The chamber umbilical random vibration specimen showed no damage. The
I performance tests were completed satisfactorily. (Figure 5-17 shows the test
setup.) The electrical jumper cable and multiple connector also passed the
I random vibration test satisfactorily.
I
I
66- 1485
I _1 AIRESEARCH
MANUFACTURING
DIVISION
LOS Angeles, Ca[iforma
Page 5-29
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1 F-3772
1 Figure 5-14. Random V i b r a t i o n T e s t Setups
I
I LOS Angeles California
Page 5-30
I F i g u r e 5-15. Random V i b r a t i o n Test Setup w i t h Top Cover
o f Test F i x t u r e Removed
8
LO^ ~ ~ g e i e California
s.
Page 5-31
F i g u r e 5-16. View o f S p l i t T e f l o n I n s u l a t i o n Cover
Surrounding a Conductor Cable (Stranded
Wire)
AIRESEARCH MANUFACTURING DlVlSlON 66- I 4 8 3

LOS ~ngeler.California
Page 5-32
F i g u r e 5-17. C,,amber UrrUk c a l rrsserr,, j
I F-2770
Random V i b r a t i o n Test Setups
66- I483
Las Angeles California Page 5-33
I
I 9. Accelerat ion
I The acceleration qual ification test requirements were detailed in
AiResearch Report VTI No. 132-EDJ. This report was furnished to the vendor
I that performed the acceleration tests. The specimens were subjected to the
I acceleration loads shown in Figure 18 of AiResearch Report No. SS-3500, Rev. 2.
The load increase was linear from 1.0 to 7.3 g in 333 seconds. The rotation
I was decreased to zero g in a manner which would produce uniform lateral
deceleration forces of I g. (See Figure 5-18 for test setup.l There was no
I evidence of damage or deterioration forces. The performance tests following
I acceleration were satisfactory.
The electrical jumper cable, multiple connector, suit relief valve
battery, evaporator-condenser, umbilical System, and chamber umbilical system
exhibited no damage or nonoperation from the acceleration test.
I IO. Shock
I (30
The
g) and
test
two
specimens
shocks
were
in accordance
subjected
with
to two
Curve
shocks
B (40
in accordance
g) of Figure
with
19 of
Curve A
I AiResearch Report No. SS-3500, Rev. 2. The shock profile is a half-sine wave
of II +4 milliseconds duration in the direction as sensed by the spacecraft
I' during landing. One shock of each curve was applied with the specimen rotated
I 22 degrees off the spacecraft longitudinal axis in one direction and another
was applied with the specimen rotated 22 degrees off the spacecraft longitudinal
I axis in the other direction. The test specimen was nonoperational. The chest-
pack evaporator-condenser was filled and the battery was installed and fully
I charged. (See Figure 5-19 for test setup.) No external structural or mech-
anical damage was noted after the 30 g and 40 g shock tests. A dimensional
I
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66- 148.3

Los Angeles, DIVISION
California
Page 5-34
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1 F i g u r e 5-18. Chestpack A c c e l e r a t i o n Test
I
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8 Los Angeles. Calilorn8a Page 5-35

F -2 806
Figure 5-19. Chestpack Mounted t o Shock Simulator, 30 G Test
AIRESEARCH MANUFACTURING DIVISION 66-I483

Los Angcks. Caltlornia
Page 5-36
I
RD
I
inspection was performed on the case to compare with data after the 40 g
I shock test. The original data compared very closely with data after the
40 g test.
I The original battery 800292 was included in the chestpack only for weight
I purposes. The Battery 800670 (latest configuration) was subjected to the test
as a component. No damage to the battery was noted in the shock test. The
I post-shock specimen was subjected to a discharge and recharge cycle. The
specimen satisfactorily completed the test as the energy supplied above 24 vdc
I was 65.098 watt-hours. Recharge was satisfactory as indicated by an open
I circuit voltage of 35.32 volts (35.0 volts min required). The electrical
jumper cable_ multiple connectors, umbilical system_ and chamber umbilical
system performed satisfactorily after the Shock test.
II. Additional Tests
I A salt spray test was performed on the suit relief valve. The valve was
I operated at sea level ambient conditions under cyclic flow to simulate various
flows. A salt spray solution was injected into the nitrogen flow upstream of
I the valve inlet for a period of I0 hr. The valve was regulated within 3.5 to
3.9 psig during the salt spray test. Figure 5-20 shows the test setup. The
I test results were satisfactory.
I maximum
The battery
mission
discharge
requirements_
rates
which
during
are
battery
9 watts
tests
for
were
the first
similar
72 min_
to expected
70 watts
I for the next 24 min_ and then discharge through a SO-ohm resistor until the
voltage is 24 v dc. The test specimen was returned to ambient conditions_
I discharged to IO v dc_ then recharged. A gas evolution test was performed on
the battery. Also the battery was subjected to life tests conducted in
I accordance with the charging and discharging procedures in AiResearch Report
I
66- 1483
Los Angeles,
DIVISION
California
Page 5-37
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I F i g u r e 5-20. Salt Spray Test Setup for Suit Relief Valve
I
1 Lor Angeles California Page 5-38
I
I SS-3769. In addition_ pressure relief valve and leakage tests were performed.
I In one test_ the volume of gas after the 96th minute of battery discharge was
IO std cc. The gas was 90 percent oxygen and IO percent hydrogen. After dis-
I charge cycle to 24 v dc_ the total gas evolved was 40 std cc of 72 percent
I oxygen and 28 percent hydrogen content. All of the life test requirements were
satisfied. All results for the discharge-recharge cycles exceeded the required
I 38.8 watt-hour output above 24 vdc discharge voltage. The leakage values for
the pressure relief valve and leakage tests were excessive. After cleaning_
I the retest was successful. The battery was subjected to a direct short-circuit
I test. The internal fuse functioned after 0.83 second during which period the
current flow was approximately 74 amperes on this test. The amount of gas
evolved during this period was not measurable.
The multiple connector was subjected to a performance test (flow vs AP)
I at approximately 18.4_ 8.2_ and 3.7 psia pressure_ and flow rates of 5 to 35 Ib
per hr of nitrogen. The data obtained from these tests were plotted to create
I a performance map. The adapter AP values were deducted from the gross values
I to obtain the net /_P values which were plotted against flow. Due to the
problems in the setup_ the test was rerun. The unit was found to have O-ring
I leakage during the performance (flow vs AP) test and was subjected to a
IO0-cycle life-test to verify that the leakage was a result of a test setup
I problem. During the IO0 cycles_ another O-ring became inoperative due to an
I improper test adapter. The test unit O-ring and the test adapter were
replaced_ and the test was continued. Additional cycles were performed to
I verify that normal operation did not affect either O-ring. The multiple
connector was subjected to the additional extreme temperatures test.
I
I
66- 148,3
LOS Angeles,
DIVISION
I
The operational forces before exposure_ during the high and the low tempera-
I
ture tests_ and at laboratory conditions indicated insignificant variation in I
values. The leakage through the specimen was within tolerance. (The unit
is shown under test in Figure 5-21.) I

The umbilical assembly was subjected to insulation resistance and dielec-
tric strength tests with the sameresults as outlined under vibration. Then_
I
a burst test and a tether pull test were performed. The burst test was I
performed by internally pressurizing the specimen to 220 psig for IO min.
The pressure was then increased at a rate of 50 psi per min_ until rupture I
occurred. Rupture occurred at I I20 psig_ which is well above the minimum
allowable of 330 psig. The tether pull test was performed by applying a
I
tensile force to the tether (while still in the system assembly] of 600 -+20 lb
for approximately 30 sec. Then_ the force was increased at a rate of IO0 -+50
Ib per rain until rupture occurred. The tether ruptured at a force of I050 lb. I
The allowable minimum rupture force is IO00 lb. (Figure 5-22 shows the test
setup.)
I
The chamber umbilical assembly was subjected to a low temperature leakage
I
and flexure test. The specimen was subjected to a flexure test by bending it
around a 2.5 to 4.5 in. diameter rod while at a temperature of -60OF. Leakage i
was determined during this operation; maximum allowable rate is I I std cc per
min. The maximum bending moment required to wrap and unwrap the umbilical
I
around the form was 21 in. lb. The leakage rate was found to be 5 std cc per
I
minute.
The chamber umbilical assembly was subjected to low temperature impact I

loading tests. This test was performed on samples of tether at -60OF and
ambient temperature. The impact load was applied at a rate of 1200 pounds
I
until rupture occurred.
I
66- 1485
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Extreme Temp Leakage and O p e r a t i o n

T e s t Setup ( M u l t i p l e Connector i n
I Temp Chamber and Pneumatic Setup. )
Extreme Temp Leakage and O p e r a t i o n A
Test Setup ( E x t e r n a l View o f Temp .c

LX *
Chamber W i t h Pneumatic Setup. )
--
l
a
-
---9
. --. -
--
#
7- Extreme Temp Leakage and O p e r a t i o n

Test Setup. ( PushiPu 1 1 Sca le,
Torque Wrench and P l u g f o r T e s t i n g
M u l t i p l e Connector Performance).
F-2777
F i g u r e 5-21. M u l t i p l e Connector T e s t s

Lor Angeles California
Page 5-41
I
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1
I Figure 5-22. Tether Pull Test Setup for Umbilical System
F-2816
Assembly 800326-1-1, Serial No. 45-106

Page 5-42
I
I
A sample was stressed at a slow rate to determine elongation at 375- and
I 600-1b loads and then stressed until rupture occurred. Samples were impact
tested and elongation tested at room temperature. The insulation resistance

I test was performed after the shock_ explosive decompression, and low temper-
I ature tests. The requirements were met satisfactorily in all cases.
Low temperature impact loading tests indicated all ruptures occurred at
I the same load_ between IIO0 and 1290 Ib_ whether the load was applied abruptly
or at a slow rate and whether the sample temperature was -60OF or +70°F. The
I elongation requirements at 375 and 600 Ib were within required limits on a
I sample at low temperature and on samples at ambient temperature. It was con-
cluded 3 therefore, the tether material was satisfactory for the purpose intended
and to the extent of the loading anticipated.
The fill and shutoff valve was tested for internal and external leakage.
I The pressure cycling was conducted after the random vibration test. Nitrogen
I was authorized as the pressurizing medium in place of oxygen after the first
150 pressure cycles to complete the required 500 cycles. Initial leakage
! tests on the valve were successful. However, during the subsequent pressure
test_ the valve seat became damaged. (See Figure 5-23.) A leakage test
1' after rework was within requirements_ but after a few cycles_ excessive
I leakage was noted. After rework, the specimen was successfully tested.
During the preceding tests_ the breakup of the line filter allowed the seat
I of the unit to become irregular after cycling.
I
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66- 1483
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1
8 SEAT, F I L L VALVE 138983
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SECTION 6
DOCUMENTATION
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I DOCUMENTATION
I INTRODUCTION
The following tables give a summary of the documents pertinent to the
l design_ development_ testing_ qualification_ and delivery of the ELSS.
I Program
and
plans_
preliminary
preliminary
organization
test
reports
plans_
are
guide
given
standards
in Table
and
6-1.
specifications_
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I the monthly and quarterly progress reports generated during the program.
Table 6-3 presents the Acceptance Test Procedure reports for the LLSS
I components, Table 6-4 lists the corresponding qualification test procedures
for ELSS components. The ELSS Qa]ification Test Reports containing test data
for the components are given in Table 6-5. Reliability and miscellaneous
I reports generated for the project or related to a phase of the program are
tabulated in Table 6-6.
I All of the documents were prepared for NASA-MSC_ Houston_ except Mil
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66- 1483 AIRESEARCHMANUFACTURING DIVISION

Page 6- 14
H
SECTION 7
QUALITY CONTROL
j ,
I
I
SECTION 7
I QUALITY CONTROL
I INTRODUCTION
I for
At
the
the outset
collection
of
and
the ELSS
transmittal
program_
of data
a Quality
as
Control
required by
Directive
NASA quality
was issued
require-
I ments Specification NPC-200-2 and NASA rel iabi]ity requirements Specification
NPC-250- I.
I This procedure translated the data requirements into individual responsi-
I bilities
system
for each
implementation.
participating department and provided direction for the data
DATA FILE
A complete end-item and component data file was maintained through the
I course of the program_ providing ready information regarding test results_
I inspection
and cycles_
performed_
component
rejection
removal and
and rework
replacement
history_
records_
accumulated
and end-item
running
weight.
time
I EQUIPMENT LOG
Consistent with NPC-200-2 data requirements_ an equipment log book accom-
I panied each delivered unit. The log principally consisted of configuration
I record_
trouble
modification
reports_ trouble
record_
report
systems
forms_
and
(for
component
NASA use)
log_
and
acceptance
log book
test
check
data_
list.
I CONFIGURATION CHANGE CONTROL
Genera l
I During the course of the program_ a significant configuration change was
I
introduced under the IRAN provisions of the contract. This change necessi-
tated the return of end-items for upgrading. In order to maintain control of
I previously generated data returned with the hardware and new data to be
I __1 AIRESEARCH MANUFACTURING DIVISION

g6-1483
Page 7- I
I
I
generated during the course of the upgrading process_ a quality control direc-
tive was issued. The procedure defines organizational responsibility for such I
items as configuration maintenance_ assembly operation and inspection records_
and retest data. A flow chart was prepared dividing the upgrading program into
I
five phases.
I
Accountability - Phase I
This phase provided for the transfer of Government property accounta- I

bility into our GFP inventory control and provided for the generation of
shipping documents for the equipment reshipment.

I
Investi.clation - Phase II
I
This phase provided for the receiving inspection of the returned equip-
mentj
tests
a
to
review
determine
of the original
the extent of
data returned
refurbishment
wl th the
required;
hardware_
with
functional
this informa-
.i
tion cost estimates and delivery schedules were prepared.
I
Pro.clram PIannin.cI - Phase III
I
After customer approva] of cost and delivery information_ Contract
Administration releases task sa]es order which approved release of other I

internal work authorizations and authority to procure parts and rnaterials.
Repair and Upqradin.q - Phase IV

I
This phase provides for the physical repair and upgrading of the equip-
I
ment_ in process and fina] inspections_ tests_ and documentation.
At the completion of final inspection and test_ the original log book I
data were updated reflecting the final configuration and accumulated running
time 3 etc. New data were added to the log book as required.
I
Delivery
Shipping
- Phase V
instructions were provided_ accountability transfer documents

I
I
60- 1483
Page 7-2
I_1 AIRESEARCH
I
I
I
were prepared_ copies of all upgraded and new data were introduced into the com-
ponent and systems data file_ and the end item narrative report was prepared.
Under the IRAN program_ this end-item narrative report was issued for
I each ELSS delivered providing NASA information peculiar to that specific
system_ such as component serial number record_ component test history_ origi-
I
nal configuration_ accumulated component operating tiem_ component rejection
I report numbers_ trouble report numbers_ etc. Also included in the report is
a discussion relative to test anomalies and action taken to render the equip-
I ment operable within specified limits, The tare weight was also given3as was
the equipment configuration at the time of weighing.

I
Shakedown inspection support at KSC was provided on several occasions,
This support consisted mainly of hardware review with McDonnell and KSC
quality assurance personnel_ discrepancy disposition_ and implementation of
I corrective action for future units.
66- 1483
Page 7-3
!
SECTION 8
J
RELIABILITY
,!
)
' i
.... J
L,J
1
SECTION 8
RELIABI LITY
INTRODUCTION
The reliability effort on the Gemini ELSS chestpack program commenced
with the engineering feasibility studies and continued until the program
was completed. The first task was the preparation of a fairly comprehensive
Reliability Program Plan_ which ultimately went through several revisions
from June through December of 1954. Other reliability tasks performed dur-
ing this period were Failure Modes and Effects Analyses_ Quantitative
Reliability Analysis_ and the beginning of reporting trouble analysis_
followed successively by definition_ initiation_ implementation_ completion_
and assessment of required corrective action. Since upwards of 90 percent of
all reliability funding was employed for the various facets of trouble
reporting_ emphasis will be placed upon narration of how trouble reporting
was conducted and upon what precisely were its objectives.
First_ it is important to emphasize the objectives of any first class
quality program. It is cIear that reliability's function should_ to the great-
est degree possible_ avoid duplication of either the engineering or the
quality function_ but should serve to fill the voids that always exist in
these functions_ as well as serve in a liaison capacity. Since the relia-
I bility engineer will ordinarily be far more conversant with both factory
I areas and shop personnel_ he is far less dependent upon inspection and other
quality control personnel and thus serves as a continuous audit of quality
I procedures. The same is true of all test facilities and_ therefore_ the
base of reliable information upon which engineering decisions and changes can
I be made is strengthened. Thus_ every discrepancy discovered in a finished
article was automatically and routinely reported to reliability by means of

I the plant-wide trouble reporting system_ which is described in detail in
I Appendix A.
LOS Angeles DIVISION
Cahfornla
66- 1483
Page 8- I
I
FLEXIBILITY OF PROGRAM
I
The reliability program practiced by AiResearch on the Gemini ELSS pro-
I
gram was very flexible_with various reliability people involved in details of
design and with individual trouble reports. The reliability effort fluctuated I
with the program. For example_ during the months of May and June 1965_ no
fewer than four trouble analysts_ formed into a coherent team under the guid-
I
ance of a senior reliability analyst_ were involved in the analysis of 189
I
open trouble reports. Many of these involved trivial in-process discrepancies
which had to be investigated until their nature was determined. Each such I
reported or alleged trouble had to be investigated to ensure that they were
either corrected or found to be mere incidents discovered in an entirely proper

I
fashion at inspection stations designed to function in that precise capacity.
The trouble analyst_ being familiar with every facet of the design and
construction of the chestpack_ was pressed into service on several occasions I

preceding flights as the AiResearch representative at Cape Kennedy and Houston.
His presence proved invaluable in resolving problems that arose in the field.
I
DATA PROCESSING SYSTEM
I
A new system of IBM EDP tabulation of trouble reports_ symptoms_ analyses_
actions required_ actions taken and assessments_ was introduced into the I
Gemini ELSS program in November 1965_ and the first printout was transmitted
to NASA Manned Spacecraft Center Reliability on December 12_ 1965. The system
I
was devised to handle a huge mass of detail for the Apollo Environmental Con-
I
trol System (ECS)_ and since NASA funds had been employed for Apollo_ it seemed
fitting to apply the system to GEMINI. The system was an instant success and I
has since been applied to other U. S. Government programs at Garrett/AiResearch_
I
I
66- 1483 _ AIRESEARCH
MANUFACTURING
DIVISION
Page 8-2
I
I
I including TITAN III_ all of which have benefited immediately and directly. A
I unique
language
feature
abstract
of the
that
system
permits
is that
even a
every
stranger
line of
to
printout
a program
has
to
an
be
English
instructed
I in using the printout. A variant type of printout was instituted on the
Gemi-nj ELSS program in mid-1966; this variant was identical to the first_
I except that all closed trouble reports were suppressed and only open reports
I
were tabulated. I_a particular part number had had troubles in the past but
all troubles were closed out_ the part number only appeared in the printout.
I Both types of printout continue to be run;but the analyst ordinarly will
employ the variant_ identified as "LIMITED DATA--ONLY THE OPEN TROUBLE REPORTS
i ARE LISTED_" while the record-keeping function in the program office depends
upon the complete history_ which is always available to the analyst.
CONCLUSIONS
I In conclusion_ it can be stated that many facets of the Gemini ELSS
program benefited from the complete reliability engineering coverage_ includ-
I ing design engineering_ test engineering_ quality control_ and program manage-
ment_ both at Garrett/AiResearch and NASA Manned Spacecraft Center.
I
I
I
I
I
I
I
I AIRESEARCH
MANUFACTURING
DIVISIONLos Angeles, California
66-
Page
1485
8-_
,i
1
SECTION 9
AEROSPACE GROUND EQUIPMENT

"i
.)
,i
I
I
SECTION 9
I AEROSPACE GROUND EQUIPMENT
I INTRODUCTION
Table 9-I shows all major Aerospace Ground Equipment required to test the
I ELSS chestpack. This equipment could also be used for component testing_ with
I the proper adapters.
I
I
I
I
I
I
I
I
l
I
I
66- 1483
I I_J AIRESEARCH MANUFACTURING
California Page 9- I
I
I
I
I
I
I
I
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eq
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66- 148.3
Page 9-2
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66- 1483

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66- 1483
Page 9-4
_1 AIRESEARCH MANUFACTURING DIVISION
LosAngeles, Califorma
I
I
I FREQUENCY
ELECTRICAL CC METER
I PANEL ASSE :OPE
IITAL
I VOLTMETER
I :TRICAL
PANEL
I POWER SUPPLY
I HEAT TRANSFER SURFACE
:L ASSEMBLY
'
I _BELL JAR
SINK
I BRAKE
I A-27794
I
Figure 9-I. Low-Pressure Bench
I
66- 1485
Los Angeles,
DIVISION
California
Page 9-5
I
I
GAGE PANEL ASSEMBLY POWER SUPPLY
I
ELECTRICAL CONNECTIONS
GAGE PANEL ASSEMBLY I

DIGITAL MULTIMETER I
ELECTRICAL METER ASSEMBLY
I
: ELECTRICAL PANEL ASSEMBLY
I
I
I
J_CONTROL PANEL
ASSEMBLY (RH) I
I
_CONTROL PANEL ASSEMBLY (LH)
HIGH PRESSURETEST CHAMBER ASSEMBLY

CABINET
I
A-27793
I
I
I
Figure 9-2. High Pressure Bench
I
I
66-
Page
1483
9-6
LosAngeles,
California
I
I
I
0
/
I
Figure 9-3. ELSS PDA Pneumatic Adapter 649204

I
I
66- 1483
I LOS Angeles, California Page 9-7
I
I
I
I
I
I
I
I
I
@
I
I
I
I
Figure 9-4. ELSS PDA Electrica] Adapter 649205-X I
I
I
I
66-1483
Page 9-8 I_ AIRESEARCH MANUFACTURING DIVISION
I
I
I
I /
/, .....
i "X';": " :.:_.=,
I PNEUMATIC
INLET
OUTLET
INTERFACE
OR
ADAPTER
P/N 649212-X
I
I
I
/</_// PNEUMATIC OUTLET OR
I _" ....
:-_.//""-""_'_ INLET INTERFACE ADAPTER
!/i i ',/ r ]
I • ,j-
I .,,_._..
//_I./>,. - ,.
,.,. ..-"
l.f --_.
_'_
l!,/ -// \
I I II_ I I .'.. ".f]
"--_--:_: i t,"_' 4' i_ BENCH CONNECTOR
-:.:<i/i ( ,.' ,_J
I ADAPTER P/N 6492!5-X
-,_.. _,_
I
Figure 9-5. Pneumatic Outlet or Inlet Interface Adapter
I
I
I
!
Los Angeles.
DIVISION
California
66-
Page
1483
9-9
I
I
I
I
I
\
\ I
I
I
I
I
I
I
I
I
I
Figure 9-6. Suit Outflow Valve Adapter 649213-X
I
66- 1483
Page 9-10 _ AIRESEARCH MANUFACTURING DIVISION
I.
3
....t
SECTION 10
MATERIALS
i1
I
I SECTION I0
I MATERIALS
I INTRODUCTION
This section presents the results of materials selection studies. Two
I areas arecovemd; nonmetallic materials and metals for the oxygen tank. The
I materials approved for use were selected on the basis of the design requirements
from the list of NASA-AiResearch approved materials for the Gemini and Apollo
I programs. All materials studies_ evaluations_ and selections are the respon-
sibility of the Materials and Process Engineering Department at AiResearch.
I NONMETALLIC SELECTIONS
All nonmetal materials u_ed in the Gemini ELSS are listed in Table I0-I.
Included in the tabulation are the material designation_ application_ test
1 history_ approval status_ and applicable specification. AiResearch Report
No. SS-2108 MR (referenced in Table IO-I and included in Appendix B) describes
I the procedure AiResearch uses to select nonmetallic materials.
METAL SELECTION FOR OXYGEN TANK
i General
I
The materials used for construction of the high pressure gaseous oxygen
I tank were to have the following properties:
• High strength
I • Corrosion resistance
I • Immunity to stress corrosion and cracking
• Low notch sensitivity
I • Commercial availability
• Ability to be shaped_ machinedj welded_ and heat treated by
I conventional methods.
66-1485

California Page I0-1
I
TABLE IO- I
NONMETALLIC MATERIALS USED IN THE ELSS

I
Part Name and Number Material Approval Status Specification
I
Material Application Vendor Designation and Test History MIL or AiResearch
Pack Assembly I
800308 System Assy Silicone Elastomer Tested SS-2lO8 MR-Gemini EMS-342
O-Ring
138563 and 138564

AiResearch
Ethylene Propylene
Use
Tested SS-2108 MR EMS-664

I
Inlet and Outlet Rubber
Hoses EPR
I
138594, 138595 Polycarbonate Resin Approved MAC 6792 MIL-LP-393
Display Panels "LEXAN" E. I. DuPont to 160°F
138625 Grommet Polyurethane Tested SS-2108 EMS-363

I
Gemini Use
138638 Cushion Silicone

Elastomer
Tested
Gemini
SS-2108
Use
MR EMS-342 I
S8157AG Washer Polytet rafluoro- Approved SS-2108 MR S-8157-AG
ethylene MAC-6792
"TEFLON" DuPont
I17-001-9002
Adhesive
Silicone Adhesive
Dow Corning A-400
Approved MAC-6792
I
Insulation Sleeving Ethylene Propylene Tested SS-2108 MR EMS-364
S-9051 Rubber
"EPR"
I
Sealant Silicone Adhesive Approved MAC-6792
219-016-9002 Dow Cornlng RTV-731 I
Cable Strap Nylon 101 Approved MAC-6792
Potting Boot
E. I.
Nylon
DuPont Item Tested
Approved
SS-2108
MAC-6792
MR
I
M9600-3-25 - Various -
Potting Compound Epoxy Approved MAC-6792 RS- 129 I

Various Parts Epoxylite Corp. No. 801
Case Assembly Epoxy-Anhydrlde

Epon 828 Shell Chem.
Resin Cured wlth
Tested
DETA
Per SS-2108 MR
MIL-R-9300
I
Approved MAC-6792 EMS-729 Type I
Nameplates,
Adhesive
Various
I
Sealant Silicone Elastomer Approved MAC-6792
219-050-9002
Lubricant, Methyl-Phenyl Chemically Similar DC-200 L-9

I
Assembly 473,-035- Polysiloxane is approved MAC-6792,
9001 Dow Cornln9 DC-510 Extensive Gemini Use
I
66-1485
Page 10-2
_ AIRESEARCH
I
I
!
! TABLE I0-I (Continued)
I Material
Valve
Application
Group, Life Support

Vendor
800282-3
Designation and Test History MIL-or AiResearch
I 800283,
Adhesive
Valve Assy Epoxy
Armstrong
Adhesive
Prod. A-2
Approved MAC-6792 RS-13
Diaphragm Silicone Elastomer Tested SS-2108 MR
I
EMS-345
138489 G.E. SE-550 Extensive Gemini Use
Diaphragm Silicone Elastomer Tested SS-2108 MR EMS-345
I 138489
Insulation Sleeve
AiResearch
Silicone
Mfg.
Impregnated
Extensive
Tested
Gemini
SS-2108 MR
Use
S 9046-16 Fiberglass - Com'l Extensive Gemini Use
I Thread Locking Locktite,

Sealants
American
Grade-A
Approved MAC-6792 MIL-S-22473
and Grade-H
138504 Diaphragm Fluoroloy, Inorganic Approved as Teflon

Stop Fluorocarbon Corp. MAC-6792
Filled Teflon
I Packing (O-Ring) FI uoro Elastomer Tested SS-2108 MR EMS-338

$8057 BF E. I. DuPont, Vi ton A Extensive Gemini Use
I Fluid Heater, 800296-I-I
Wire 58935JgSW Polytetrafluoro- Approved MAC-6792
I Electrical Insulation ethylene Teflon,

E. I. DuPont
Insulation Sleeving Fluoroi nated Approved MAC-6792
I $9051-2 ethylene
Teflon
propy
FEP E.
lane
I. DuPont
I
Potting Compound Epoxy Approved MAC-6792 RS-129
Seals Electrical Epoxylite Corp. 801
Connectors
I
I
I
I
I l_ AIRESEARCHMANUFACTURING DIVISION
Los Angeles, Cahfornia
66-
Page
1483
10-3
I
I
TABLE IO-I (Continued)
I
Material Application Vendor Designation and Test History MIL or AiRes rch
Lubricant 473-042-9002 Grease, Oxygen Approved

Assembly and Anti Gall Compatible Drilube MAC-6792
Aid Corp.
NAS 1081C, Screw Nylon Approved

Thread Locking Insert I. Eo DuPont MAC-6792
Gage, Quantity, H2O 2
Gage 800386 Hermetic Sealed Tested as Assembly

Indicates H202, AMU Weston Instruments SS-2108 MR
Adhesive I17-003-9002 Epoxy Approved MAC-6792

Bonds Support Ring Armstrong Prod. A-2
Potting Compound Epoxy Approved MAC-6792 RS-129

Pots Lead Wires Epoxylite Corp. No. 801
Cable S8929FOgW Polytetrafluoro- Approved MAC-6792

Insulation Electrical ethylene E. I. DuPont
Conductor Teflon
Valve Check 850040-I-I
850201-I Valve Chlorosulfonated- Tested SS-2108 MR EMS-352

Flapper polyethylene Extensive Gemini Use
Hypalon, AiResearch
Seal S8520-7B Silicone Elastomer Used on 95% Gemini EMS-342

Molded Groove Seal AiResearch Components Tested
SS-2108
NAS I189C0GP3 Nylon Approved MAC-6792

Self Locking Insert E. I. DuPont
Valve 850205 Ethylene Propylene Tested SS-2108 MR EMS-364

Molded Flapper EPR AIResearch
Heat Exchanger 67880-2-2
Adhesive Epoxy - Anhydride Tested SS-2108 MR

Furane Plastics Epibond - 123W/931 Extensive Gemini Use
167882-55
Wick
Fine Pore Cellulose Tested SS-2108 MR
E
Sponge, E. I. DuPont at 160°F 100% 02
1007 R.H.
Packing Fluoro Elastomer Tested SS-2108 MR EMS-338

58057 BU E. I. DuPont Viton A. Extensive Gemini Use
I
66-1483
Page 10-4
_'_,_R_TT
_1
Los Angeles Cahfornla
I
I
I
I TABLE I0-1 (Continued)
I Material
Valve, Relief,
Application
Low Pressure
Vendor
800278-I-I
Designation and Test History MIL or AiResearch
I
I Adhesive I17-004-9002 Epoxy Approved MAC-6792
Bonds Sleeve Armstrong Prod. A-2
I Molded
On 138513
Seat Silicone
Mod. SE-525-G.E.
Elastomer Tested
Gemini
SS-2108
Use
MR EMS-348
I Packing
O-Ring
9026
Seal
E Silicone
Aire
Elastomer Tested
Used on
SS-2108
95/, Gemini
MR
Parts
EMS-_"i2
Lubricant 473-O51-9001 Methyl Phenyl Po!y- Tes_d*_ SS-2!08 ....

MR L-"_
Assembly Aid siloxane Used on _rv
;_! Gemini Parts
Dow Corning DC-510
Sealant 219-001 .... i

-_uu Locktite A and D _pproveu ,,AC-6/_=
I
_1 L-- _oi,nv
Thread Locking American Sealants

Compound
I Nut Insert 525-573- Nylon Approved MAC-6792

9005 Locking Insert DuPont IOl
Multiple "Y" Connector (SCD)
I O-Ring
Dynamic
- Static
Seals
and Silicone/TFE
6071 (GE.
Modified
LS-53+TFE)
Tested SS-2108 MR
I Detent Acetal
Delerin
Resin
G.E,
Approved MAC-6792
Seal/Guide Tetrafluoroethylene Approved MAC-6792
I Anti-Friction
Adhesive
Seat Teflon
Epoxy
E. I. DuPont Used on Suit
I Bonds, Seat and Body Pittsburgh Plate Present Gemini

M-777 Connector
Umbilical Assembly and Electrical Cable
I Hose Assy
Oxygen Line
Silicone
W/Dacron
Elastomer
Wrap
Tested SS-2108 MIL-H-22489
R. E. Darling and Co.
I Electrical
Insulation
Conductor Polytet raf luoro- MAC-6792 MI L-C-16878
ethylene, Teflon
Hi-Temp Wire Co.
I
,I [_ AIRESEARCHMANUFACTURINGDIVISION
66-1483
Page 10-5
TABLE I0-1 (Continued)
I
I
Material Application Vendor Designation and Test History MIL or AiResearch
Overbraid
(800326-4-I & -5-I)
Polyimid
"Nomex"
Yarn
E. I. DuPont
Tested Per SS-2108 MR
I
I
Tether Line Nylon Type 66 MAC-6792 MI L-W-5625D
Chemstrand As Nylon
Potting Compound Polyurethane Tested SS-2108 MR

Pot Electric
Connectors
Products
1527
Research
I
Thread Nylon SS-2108 MR MI L-T-7807
Tether Sewing E. I. DuPont
I
I
Thermal Insulation Aluminized Mylar Tested SS-2108 MR
(800326-5-I) Dacron Scrim
I
I
I
I
I
I
I
I
I
66- 1483
Page I 0-6
l_I AIRESEARCHMANUFACTURING DIVISION
LOS AnEeles, California
I
I
I
Subsequent paragraphs discuss the materials considered for this application.
I Candidate Materials
I I. Titanium Alloys
Titanium alloys were considered_ but were almost immediately eliminated.
I Bare titanium is not compatible with high pressure oxygen. Barrier coatings or
a bladder would be required for a titanium tank. Neither approach in the present
I state of the art offered the required degree of safety and reliability.
I 2. Heat Treatable Steels
There are several low alloy steels which could be heat-treated to high
I strength ]evels_ e.g._ 4335 modified_ D6AC_ 4340_ 300 M_ etc. The disadvantages
common to all are poor corrosion reslstance_ low temperature brittleness_ and
susceptibility to stress corrosion. Although the heat treatable steels have
I several
difficulty
advantages_
in providing
they are
adequate
considered
and
unsuitabie
reliable corrosion
primarily because
protection.
of the
I 3. Hardenable Stainless Steels
Only two were considered_ AM 355 and AFC 77. AFC 77 is a new alloy now
I in the development stage. Development problems_ particularly in the area of
I welding appear to be formidable. Considerable development work would be
required_ particularly in the area of forming and welding_ before serious
I consideration could be given to AFC 77. AM 355 heat-treated to high strength
levels_ e.g._ 190 - 200 ksi displays susceptibility to stress corrosion
I cracking. Further_ AM 355 becomes quite notch-sensitive at subzero temperatures.
4. Ma ragi nq Steels
I These steels offer a very attractive strength-to-weight ratio. They have
I the disadvantage of requiring corrosion protection_ and recent published data
show considerable variation in resistance to stress corrosion. Some heats
I
66- 1485
I I_[ AIRESEARCH
MANUFACTURING
DIVISION Los Angeles. California Page 10-7
I
display remarkable resistance to stress corrosion, while other heats show
I
very poor resistance to stress corrosion. The implication is obvious. Ha- I
raging steels at present would require thorough screening tests before release
to production. I
5. Nickel
Several
Base
age
Alloys
hardenable nickel base alloys were considered. These alloys

I
have several advantages over steels, maraging steels_ and the hardenable I
stainless steels_ such as:
• Exceptionally good corrosion resistance I

•
•
Immunity
Good toughness
to stress
at
corrosion
subzero
cracking
temperatures
I
Some of these alloys, Ren_. 41, Inconel X 750_ for examplej present rather
difficult manufacturing problems, particularly in welding and heat treating.
Inconel 718 and Ren_ 62, however, present no serious manufacturing problems. I
Ren_
reason
62 is
cannot
a comparatively
be given serious
new allQy
consideration
of limited
at
availability
present.
and
Therefore_
for this
Inconel
I
718 was selected for the oxygen tank.
I
Material Selected
The material selected for the ELSS emergency oxygen tank was Inconel 718 I
having the following
Ftu
guaranteed minimum properties
190,000
at
psi
room temperature.
I
Fry 1653000 psi I
Elong. (percent in 2 in.) 12.0
To obtain these properties, it was necessary to select heats of Inconel 718 I

and
to supply
to control
Incone]
heat
718
treatment.
to the above
Three suppliers
requirements.
were contacted, and all agreed
I
I
66-1483
Page I0-8
I_l AIRESEARCH MANUFACTURING
Los Angllles,
DIVISION
California
I
,!
-.]
SECTION 11
J
FLIGHT HISTORY
....
_J

LO_ Angeles [_ahforma
I
II SECTION II
FLIGHT HISTORY
I FLIGHT HISTORY
I GT-8 (Launch Date)_ 3-16-66
The first intended use of the ELSS was on Gemini VIII. However_ due to
I a thruster malfunction on the spacecraft_ the mission was terminated early_
I therefore,
GT-9 (Launch
the extravehicular
Date]_ 6-3-66
activity was not performed.
I The ELSS was first used during Gemini IX. The primary objectives of the
extravehicular activity were:
I • To evaluate the astronaut maneuvering unit (AMU) (Experiment D-12)
• To evaluate the dynamics and limitations -,f extravehicular tethers
After the tether dynamics evaluation_ Astronaut Cernan moved to the
I adapter to prepare for the AMU experiment. It was during this preparation
that his visor fogged. Because of this foggingj the extravehicular mission
I was terminated at this time. The fogging has been attributed to an unusually
high metabolic load (in excess of 3000 Btu per hr) 3 which is in excess of the
I capabilities of the suit-ELSS
I Total extravehicular time was 2 hr_ 9 min.
GT-IO (Launch Date) 7-18-66
I The primary objectives of the extravehicular activities on Gemini X were:
To evaluate the operation of the extravehicular life support system
I (ELSS)
I • To evaluate the Hand Held Maneuvering Unit (HHMU)
Because of depletion of the fuel supply on the spacecraft_ neither objec-
I tive was completely achieved. Astronaut Collins terminated his extravehicular
activity prior to the planned completion time.
I Total extravehicular time was 36 min.
I F_
AIRESEARCH
LosAo_e,esC,,f0rn,_ Pagel_83 I I- I
66-
I
I
GT-II [.Launch Date, 9-12-66)
The primary objectives of the extravehicular activities on Gemini X1 were:

I
•
•
To
To
evaluate
evaluate
the
the
operation
HHMU for
of the
maneuvering
extravehicular
in space.
life support system.
I
• To attach a tether between spacecraft and Agena. I
Astronaut Gordon attached the tether between the spacecraft and the Agena.
In doing this 3 he became so exhausted that the extravehicular activity had to

I
be terminated before the HHMU could be evaluated. The ELSS operated satis-
I
factorily; however3 the metabolic heat loads were again much higher than anti-
cipated. I
Total extravehicular time was 37 min.
GT-12 (Launch Date_ 11-11-66_
The primary objectives of the extravehicular activity on Gemini XII were:
• To attach a tether from spacecraft to Agena.

I
• To evaluate the ELSS operation.
I
• To evaluate the use of waist tethers.
• To evaluate adapter work station tasks. I

• To evaluate antitorque wrench.
The entire extravehicular mission was accomplished without problems.

I
Astronaut Aldrin encountered none of the problems noted in previous extravehicu-
I
lar flightsj such as float-out tendencies or high metabolic rates with
resultant overheating.
I
Total extravehicular time was 2 hr 9 min.
I
I
I
66-1483
Page 11-2
_ AIRESF_ARCH MANUFACTURING DIVISION
I
i]
-]
SECTION 12
OPERATING INSTRUCTIONS
oi
• J
'AJ
I
I
I SECTION 12
OPERATING INSTRUCTIONS
I INTRODUCTION
I of
All connectors_
the chest
controls_
pack are identified
and indicators involved
and functionally
in the manual
described in Table
operation
12-I and
shown in Figure 12-1.
I OPERATING CONNECTORS,
TABLE 12-1
CONTROLS, AND INDICATORS
I Index
(Figure
No. Connector, Control,
or Indicator
Function
I Suit Return Connector Routes

moisture
expelled, carbon
laden oxygen
dioxide
through
and
dual-
line connector from suit to chestpack
suit pressure outflow valve and heat
exchanger.
I Suit Supply Connector Provides regulated oxygen supply

from chest pack ejector and recircula-
ring vent gas for application to suit
through dual-line connector.
I AMU 0 2 CONNECTOR Provides chest pack with oxygen

supply through an umbilical cord from
I astronaut maneuvering
pack) when astronaut
unit (AMU back
desires to func-
tion independent of spacecraft oxygen
I 4 UMBILICAL 02 CONNECTOR
source.
Provides chestpack with oxygen supply

from spacecraft through an umbilical
I cord.
5 ELECTRICAL CONNECTOR Electrically connects chestpack to
I either spacecraft
suit, depending
and suit or AMU and
upon source of input
oxygen supply (spacecraft or AMU).
I 6 H202 LIGHT Lights

peroxide
to indicate
supply
that hydrogen
in AMU is low.
I 02 PRESS LIGHT Indicates

supply
that breathing oxygen
in AMU is low when lighted.
I
Los Angeles,
DIVISION
Cahforma
66-
Page
1483
12-I
I
TABLE 12-1. OPERATING CONNECTORS CONTROLS, AND INDICATORS (Continued)

I
Index
(Figure
No,
12-1
Connector, Control
or Indicator
Function I
Gives indication that high-pressure
EMERG 02 LIGHT
oxygen reserve contained in chest pack I
emergency oxygen supply tank is being
used to supply suit oxygen. Lights
when
or AMU)
external
pressure
air source
falls below
(spacecraft
67 psig.
I
RCS LIGHT Lights
reactance
to indicate
control
malfunction
system,
in AMU I
lO FUEL PRESS LIGHT Indicates
low.
that fuel supply in AMU is
I
ll Controls amount of oxygen added to
02 FLOW SELECTOR Valve
recirculating
normal operation.
vent gas
This
supply
valve
during
can be
I
set for normal operating conditions
(MEDIUM position), excessive heat or
other high oxygen consumption condi-
tions (HIGH position), or can be used
to stop chestpack
supply
ejector
to suit (OFF position)
oxygen
when
I
BYPASS/NORMAL valve is in NORMAL
12 BYPASS/NORMAL Valve
position.
BYPASS position provides additional

I
quantities of oxygen to suit for rapid
cooling
or any
under excessive
other condition
heat condition
requiring a
I
greater suit oxygen input than is
obtainable
valve
with 02 FLOW
in HIGH position.
SELECTOR
NORMAL I
position closes valve.
13 TEST/DIM/BRIGHT Switch Selects illumination

hand and left-hand
level
control
of right-
panel I
background and warning lamps. Also
provides
six warning
mobile test capability
lamps on left-hand control
for
I
panel and audio warning circuits in
I
chestpack. DIM position provides 14
vdc to lamps, and BRIGHT position
provides 28 vdc to lamps. TEST posi-
tion provides 28 vdc directly to
EMERG O_ and SUIT PRESS
28 vdc _o AMU to complete
warning lamps,
a ground
I
path to H202, FUEL PRESS, RCS, and
I
66-1483
Page 12-2
i_ AIRESEARCH MANUFACTURING DIVISION
I
I
I TABLE 12-I. OPERATING CONNECTORS, CONTROLS, AND INDICATORS (Continued)
Index No.
I (Figure 12-I
Connector, Control,
or Indicator
Function
13 TEST/DIM/BRIGHT Switch O^ PRESS warning lamps, and 28 vdc
I (cont) dfrectly
in chestpack.
to audio warning circuits
14 Indicates pressurization level (in
I 02 PRESSURE Gauge
psig)
chestpack
of oxygen
emergency
reserve
oxygen
contained
supply
in
tank.
I 15 AUDIO Reset Switch When depressed, resets audio warning

signal generated by chestpack when-
I ever suit pressure

mately 3.3
falls
psig,
to approxi-
external oxygen
source (spacecraft or AMU) pressure
I falls
oxygen
below
reserve
67 psi% and
in chestpack
high
emergency
pressure
oxygen supply tank begins to flow to

suit, an alarm trigger generated by
AMU is supplied to the chest pack, or
TEST/DIM/BRIGHT switch is placed in
TEST position. Simultaneously_resets
I alarm trigger circuit in AMU.
16 SUIT PRESS Light Gives indication that suit pressure
I is too
sure
low.
falls
Lights
to approximately
when suit
3.3
pres-
psig.
I 17 S/C POWER Lights

applied
when
to
spacecraft
chestpack
power is being
I 18
H202 QUANTITY Gauge Indicates bulk quantity
full tank) of hydrogen
(in percent
peroxide
of
liquid
propellant remaining in AMU.
I 19 EVAPORANT CONTROL Valve Allows chestpack

automatically
heat
maintain
exchanger
proper
to
moisture
content of recirculating vent gas when
I placed
placed
in ON position.
in ON position
This valve
before
is
chest pack
is used as extravehicular life support
I 2O BATTERY SWITCH
system.
Applies 28 vdc to chest pack elec-

tronic control and monitoring cir-
I cuits when
Right-hand
placed in ON
and left-hand
position.
control
panel background lamps light when
I
66-1483
Los Angeles
DIVISION
Califorma Page 12-3
I
TABLE 12-1. OPERATING CONNECTORS CONTROLS, AND INDICATORS (Continued) I
Index No, Connector, Control,
(Figure 12-1) or Indicator
Function
I
20 switch is placed in ON position. With
(cont) BATTERY SWITCH
K1 automatically
in ON position,
applies battery
relay
power
I
to chestpack if sPacecraft power is
discontinued.
in ON positio_
This
before
switch
chest
is placed
pack is
I
strapped to astronaut.
21 SHUT OFF VALVE Allows high pressure oxygen reserve

I
contained in chestpack emergency
oxygen supply tank to automatically
be used if external oxygen source I
(spacecraft or AMU) pressure falls
below 67 psig.
before chestpack
astronaut.
This valve
is strapped
is opened
to I
Right-Hand and Left-Hand Provides background lighting for
Control Panel Background right-hand and left-hand control panels
Lights Lamps light when BATTERY SWITCH is
placed
pack
in ON position,
is electrically
indicating chest
activated. I
I
I
I
I
I
I
I
I
66- 148.3
Page 12-4
_1 AIRESEARCH MANUFACTURING DIVISION
I
I
6 7 8 9 10
I =_ __
I ._
II o_ _*\_ ____'_
,, _, .:.--/"//" EJ_)
' ®
19
I A-27769
Figure 12-I. Chestpack Operating Connectors_
I Controls and Indicators
66- 1483
I _ AIRESEARCH
LOS Angeles Caqforma Page 12-5
I
SECTION 13
i
PARTS LIST
• ii
• i
I
I
Fig. & Units
Description
I Index
No. Part No. l 2 3 4 5 6 7
per
Assy
CHESTPACK ASSEMBLY (LESS HOUSING ASSEMBLY AND CONTROL PANEL ASSEMBLY)

I (SHEET I OF 3)
13-2 No Numbe r CHESTPACK ASSEMBLY (Less housing assembly .....
I and control
Figure 13-1)
pane] assembly) (35,
-l $9026E022 • PACKING, PREFORMED ..........................
I
-2 800282-5 • VALVE GROUP, LIFE SUPPORT SYSTEM ............
(ATTACHING PARTS)
NAS679C3M • NUT .........................................
NAS620ClOL • WASHER ......................................
I -3 NAS1352C06-6 SCREW .......................................

-4 AN960C6L • WASHER ......................................
I -5
-6
138635-I
800300-I
• SHIM, CLAMP .................................
GAGE, PRESSURE ..............................
(ATTACHING PARTS)
MS2i044C04
I AN960C4L
NAS1352C04-6
NUT eI.,,•le•oee.°o°o°°°ee*eee°oeooe,eaooeooI
WASHER ......................................
SCREW .......................................
I -7 800284-I REGULATOR, OXYGEN PRESSURE

(ATTACHING PARTS)
..................
MS21044C08 NUT .........................................
I -8
AN960C8L WASHER ......................................
138603-I TUBE ASSEMBLY, METAL ........................ l

-9
I
138597-I • BRACKET ASSEMBLY, REGULATOR MOUNTING ........ l
-0 138604-I • TUBE ASSEMBLY, METAL ........................ l
800294-I SENSOR ASSEMBLY, THERMAL ..................... l
-- 2 AN507C440R6 SCREW ....................................... 12
I --3
--4
AN960C4L
MS21044C04
•
•
WASHER ......................................
NUT .........................................
12
12
- 5 138500-I BRACKET ASSEMBLY, NON REPAIRABLE ............ I
I 138609-I • CLAMP ASSEMBLY,

(ATTACHING
MULTIPLE
PARTS)
TUBE ............... l
NAS1352C06-4 • SCREW .......................................

AN960C6L WASHER ......................................
I -17 138606 TUBE ASSEMBLY, METAL ........................
-18 $9028E904 PACKING, PREFORMED ..........................
I -19
-20
S9026EOll
57195
•
•
PACKING,
NIPPLE
PREFORMED ..........................
(11362) ..............................
(ATTACHING PARTS)
I NAS1352CO8LL6
S8157N182-O32K •
SCREW
WASHER,
.......................................
SPECIAL, 0.032 in. thick ............
6
6
I
66-1483
I I_[ AIRESEARCH MANUFACTURING DIVISION

8
I
D
I
I
I
I
I
F-6657
Figure 13-2. Chestpack Assembly (Less Housing Assembly and

Control Panel Assembly) (Sheet I o f 3 )

LOI ~ n g e k sCahfornia
Page 13-6
I
I
Fig. & Units
Desc ri pt ion
I Index
No. Part No. | 2 3 4 5 6 7
per
Assy
FIGURE 13-2 (SHEET I OF 3)

i 13-2-21 138591-I HOUSING ASSEMBLY, NIPPLE ....................
-22 138564-I HOSE, PREFORMED OUTLET ......................
-23 2721JI.125 CLAMP ASSEMBLY (94581) ......................
I
-24 138969-I DUCT AND HEATER ASSEMBLY, GAS ...............
-25 138607 TUBE ASSEMBLY, METAL ........................
I -26
-27
S9026E024
800278-6
PACKING,
VALVE,
PREFORMED ..........................
SUIT LOW PRESSURE RELIEF .............
(ATTACHING PARTS)
NAS1352CO8LL6 SCREW ....................................... 4
I AN960C8L WASHER ...................................... 4
-28 138966-I BRACKET, RELAY MOUNTING ......................
I -29 800298-2 TRANSDUCER,

(ATTACH ING PARTS)
SUIT OXYGEN PRESSURE ............
MS35233-41 SCREW ....................................... 4
-30 800318-2 MODULE, CONTROL AND OSCILLATOR ..............

TEMPERATURE
(ATTACHING PARTS)
I MS35233-26 SCREW ....................................... 4
-31 167880-2 EXCHANGER, CHEST PACK HEAT .................. 1
I NAS1352C08-10 •
(ATTACH ING PARTS)
SCREW ....................................... 2
AN960C8 WASHER ...................................... 2
I -32 138965-I BRACKET, FUSE MOUNTING ......................

AR
1
-33 138634-I SHIM, BRACKET ...............................
-34 850040-2 VALVE, CHEST PACK SUIT LOOP CHECK ........... 1
I
I
I
I
I
I
I_l
[ os AnRe_es
DIVISION
Cahto_nla
u
I
Fig. & Units
Description
Index
per I
No. Part No. l 2 3 4 5 6 7 Assy
CHESTPACK ASSEMBLY (LESS HOUSING ASSEMBLY AND CONTROL

(SHEET 2 OF 3)
PANEL ASSEMBLY)
I
13-2-35 NAS1352C06-8 • SCREW ....................................... l
-36
-37
AN960C6
$8154-139C010
•
.
WASHER ........
WASHER, :.:::.:: ..
;;E_iI'_÷EEZ';_iA,'G:6i6 AR
'I
in. thick
-38
-39
138964-1
138622-I
•
•
WIRING HARNESS, NON REPAIRABLE BRANCHED .....
BRACKET, SENSOR CONNECTOR ...................
'I
l
(ATTACH I NG PARTS)
• SCREW ....................................... 2
NAS1352C06-4
NAS620C6L • WASHER ......................................
mn_mm
2I
-4O 138620-I • BRACKET, HEATER CONNECTOR ...................
(ATTACHING PARTS)
NASI352C06-4 • SCREW .......................................
NAS620C6L • WASHER ...................................... 2
-41 138605 • TUBE ASSEMBLY, METAL ........................

-42 S9028E904 • PACKING PREFORMED ...........................
-43 138567- l . UNION, TUBE .................................
CHESTPACK ASSEMBLY (LESS HOUSING ASSEMBLY AND CONTROL PANEL ASSEMBLY)

(SHEET 3 OF 3) I
138618 • TUBE ASSEMBLY, METAL ........................
800374-I • MODULE, OSCILLATOR CONTROL AND VOLTAGE ......
REGU LATO R 'l
(ATTACHING PARTS)
SCREW .......................................
AN526C632R4
AN960C6L
.
, WASHER ...................................... 4I
-46 138563- l • HOSE, INLET ................................. 1
-47
-48
138663-4
No Number
•
•
TANK ASSEMBLY, HIGH PRESSURE STORAGE ........
CLAMP ASSEMBLY ..............................
'I
1
138636- l • . PAD, CUSHIONING ..........................
-49
138555-2
800296-1
•
•
.
.
CLAMP ASSEMBLY, OXYGEN BOTTLE ............
HEATER, FLUID ............................ ,I
1
(ATTACHING PARTS)
NAS1352CO8LL4 • . SCREW .................................... 2
AN960C8L • . WASHER ................................... 2I
I
I
66-1483
Page 13-8
[_1 AIRESEARCH MANUFACTURING
Los
DIVISION
Angeles, California
I
F-6659
Figure 13-2. Chestpack Assembly (Less Housing Assembly and

Control Panel Assembly) (Sheet 2 o f 3)

~ngeiesc a i h r n i a
LOS
Page 13-9
I Figure 13-2. Chestpack Assembly (Less Housing Assembly and
F-6658
II Control Panel Assembly) (Sheet 3 o f 3)

Los Angeles C a l h n l a
Page 13-10
I
I VENDOR CODES
I vendor
The following
parts.
vendor
When a vendor
code numbers are used in the parts
has not been assigned
list
a code number,
to indicate
the full
name and address of the vendor is included in the parts list.
I Code Vendor Name and Address
03838 ...... Long-Lok Corp

I1362 ...... Symet rics Inc
I 2919 Nebraska
Santa Monica, California
90404
I 78189 ...... Shakeproof Div

of Illinois Tool Works
Elgin, Illinois
I 94581 ...... National Utilities Corp
!35 East Railroad Ave
Monrovia, California
91016
I 97375 ...... Ai r-Lock

Milford,
Inc
Connecticut
I
I
I
I
I
I
I
I
66-1483
i I_ AIRESEARCH MANUFACTURING
Los Angeles.
DIVISION
Califc_rm,i
Page 13-II
J
!r" i
7
SECTION 14
INSPECTION AND REPAIR AS NECESSARY (IRAN)

J
I
J
i
J
_J
t
I
I SECTION 14
I INSPECTION AND REPAIR AS NECESSARY (IRAN)
INTRODUCTION
I This section contains the final report of the Project Gemini Extravehicular
I Life Support System (ELSS) Inspection and Repair as Necessary (IRAN). The
program was conducted by AiResearch Manufacturing Division of The Garrett
I Corporation under NASA Contract NAS 9-2412.
SUMMARY
I The ELSS IRAN program was started in February 1966 and continued through
I February 1967. The primary purpose was to repair returned hardware 3 however_
as the Gemini flight program progressed_ design changes and modifications which
were required as a result of this activity were also covered under the IRAN
provi s ions.
I The chestpacks that were repaired and modified under this contract were
I serial
suit
numbers
pressure
I05
relief
through
valve_
II4.
wiring
Modifications
harness 3 bypass
were made
valve_
to the
gas
fill
ejectorj
valve_
battery
I and the chestpack assembly.
OPERATION AND HISTORY
I At the start of the IRAN program_ the quality control department issued a
I directive
procedure
covering
is shown
the
in Appendix
data acquisition
C.
procedure for chestpack IRAN. This
I Design Modifications
After the IRAN phase of the program was started_ design modifications
I were required because of a change in mission requirements_ human factors inputs_
I flight
cations
history
required
inputs_and
were as
manned
follows:
and unmanned test inputs. The design modifi-
I
66-1483
I AIRESEARCH
MANUFACTURING
Page 14-I
I
1. Emergency Oxygen FIll Port Check Valve
The fill port check valve poppet was of an elastomer design compounded
from a special Nitron formula. Because of two fires in the check valve area,
it was decided to replace the elastomer design with one of all metal. While
this compound is approved for use in high pressure oxygen, it will ignite more I
readily than metal when exposed to a flame or to hydrocarbon impurities. At the
same time,it was believed best to delete a thread locking compound that was I
being used. This was accomplished by controlling the installation torque.
AiResearch performed a qualification test on the new change to verify its I
integrity. I
2. Addition of an Ejector Heater and Bypass Valve Modification
During a series of tests performed at NASA in their altitude chamber using J
a liquid nitrogen cooled enclosure, the chestpack ejector was subject to
freezing during certain off-design conditions. Because of the potential I

hazard to an extravehicular crewma_ NASA elected to add an ejector heater I
and to place the bypass valve outlet downstream of the ejector. Due to the
added power required to operate these heaters, a relay also was added to allow I
the chestpack to use power supplied by the spacecraft during part of the
I
extravehicular mission. Since this modification was to be incorporated for I

use on GT.8 and. since time wase×tremely critical, MSC rnade this first ejector modi]i
I
fication at Cape Kennedy and AiResearch made the bypass modification at Los Angeles..
After the GT-8 flight, it was decided that the program could best be served if I
I
all modifications and controls were placed under one jurisdiction. As a result_
I
AiResearch was directed to make this modification on all chestpacks_in addition I

I
to several others that were in process. NASA-MSC performed a partial qualifi-
cation test on a chestpack ncorporating this design modification.
I
b6- 1483
Page 14-2
I_ I AIRESEARCH MANUFACTURING DIVISION
LOS Angeles+ California
I
I
I 3. Addition of Evaporator-Condenser Seals
The GT-9 flight plan called for a stand-up EVA before the umbilical EVA.
I As this would expose the evaporator-condenser to an hour of hard vacuum_ a seal
I was thought to be required for the unit. Because enough time was not available
to perform the required testing to determine if the seal was required before
I manufacturing the seals_ the design had to be started before the tests were
completed. Two designs were made of the A and B port plugs and a seal was
I designed for the steam exhaust. The hardware was built_ tested, and shipped
I to the
chestpack
Cape.
could
The test
stand one
results
hour
were
exposure
then complete,
to hard vacuum
and it was
and still
determined
perform
the
within
I specification. Therefore, the seal hardware was never used.
4. Design Change of the Chestpack Battery
I Because of continued problems with the battery 3 an investigation was
I initiated.
between the
This
potting
investigation
and the cell

showed
cases
that
was
the primer
attacking
used
the
to assure
case_ causing
a good bond
electrolyte
I to leak out. This provided an electrical contact between cells and between the
case and cells. The result was short circuits and unpredictable battery life.
I An acceptable primer was located_and two redesigned batteries were subjected to
I a qualification
S. Redesign of
test
the
to
Suit
verify
Relief
the
Valve
new design integrity.
I The suit relief valve underwent a complete redesign as a result of
malfunctions in the field. To verify the redesign_ the relief valve was sub-
I jected to a qualification test program.
I
6. Evaporator-Condenser Modification
As test time was accumulating on the chestpacks_ it was noticed that the
I performance of the evaporator-condenser was deteriorating. An investigative
program was undertaken to determine the reason and to find a method to restore
I
66-1483
Page 14-3
I
I
the units. The results showeda combination of effects for the performance
deterioration, and a method of refurbishing was implemented. A series of tests I

followed to verify this and to determine maximum heat rejection capabilities
which were in excess of the design requirements. In addition_ AiResearch

I
was directed to investigate the possibility of adding a water injection
I
mechanism. A prototype unit was manufactured and tested. This modification
was never incorporated because the mission duration did not warrant the risk I
of adding a new system to the chestpack.
7. GT-12 Modification
I
Because there were no provisions for monitoring the pressure _ransducer
I
output it was removed from the GT-12 chestpacks.
Actual Modification and Refurbishment

I
Chestpack serial numbem I05 through I14 were all sent to AiResearch for
refurbishment at least once. During the refurbishment processj all or part of

I
the design modifications covered in the foregoing paragraphs were incorporated.
I
In addition, several external chestpack modifications previously made by
NASA-MSC were also incorporated. I

I
I
I
I
I
I
66- 1483
I
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.i
7
APPENDIX A
t
AIRESEARCH RELIABILITY PHILOSOPHY ORGANIZATION, AND
DATA SYSTEM SECTION 5: TROUBLE REPORTING SYSTEM
AIRESEARrCH REPORT NO. RC-56-R
....
I
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I
I
I
I
I
I
APPENDIX A
AIRESEARCH RELIABILITY PHILOSOPHY ORGAN IZATION_ AND

DATA SYSTEM SECTION 5: TROUBLE REPORTING SYSTEM
I AIRESEARCH REPORT NO. RC- 56 - R
I
I
I
I
I
I
I
I
66- 148,5
i_l AIRESEARCH MANUFACTURING DIVISION
I
Los Angeles Cahtorma
Page A I
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I ¢ORP_ORATBOH
_i_esearch ManuFacturing Division

LOS ANGELES 45, CALIFORNIA
I
I REPORT NO. .RC-Sb-R_ Rev. I
I
I AIRESEARCH
ORGANIZATION_
RELIABILITY
AND DATA
PHILOSOPHY_
SYSTEM
I
RC-56-R_, Rev. I ,_u_u_.
A ...... a. 7y )o,_
av_. |
I
I Revised By G. A. Burfless (8-7-62)
I NO.OF PAGES 23 PREPARED BY

F. K. Greene
July 21_ ]962 W. I. McAulIffe
I DATE EDITED BY
APPROVED BY
I W. I. McAuilffe
I i
RE¥ISIONS ADDITIONS
I PAGE DATE PAGE DATE PAGE DATE PAGE DATE
I
I
I
I
I AIRESEARCH RELIABILITY PHILOSOPHY
ORGANIZATION_ AND DATA SYSTEM
I TABLE OF CONTENTS
I REPORT SECTION PAGE
I INTRODUCTION AND SCOPE I
TROUBLE REPORTING SYSTEMS I
I RELIABILITY PHILOSOPHY 2
EDUCATION AND TRAINING 4
I UNIVERSAL TROUBLE REPORTING SYSTEM 6
I MATHEMATICAL MODELS AND METHODOLOGY 12
THE AIRESEARCH RELIABILITY ORGANIZATION 20
FIGURES I-I AND I-2: TYPICAL UTRS IBM TABULATION 24
FIGURE 2: OVERLAY FOR UTRS TABULATION 26
I FIGURES 3-I AND 3-2: UTRS TROUBLE REPORT FORMS 27
I FIGURE 4: TYPICAL FIELD SERVICE REPORT 29
I
I
I
I
I
I
I
Los
DIVISION
An£.e]es California
I
I AIRESEARCH RELIABILITY PHILOSOPHY.,
ORGANIZATION, AND DATA SYSTEM
I INTRODUCTION AND SCOPE
I The reliability
of AiResearch
program
experience
outlined
in reliability
herein reflects
engineering.
approximately
This experience
five years
has been
obtained from a wide range of products., and has resulted in increased emphasis
I in the areas
sis upon purely
of system design
predictive
and trouble
techniques.
reporting.,
This allocation
and somewhat
of emphases
less empha-
has re-
sulted from the desire to have rel lability participate in hardware programs
I rather than serve only in a staff or technical service function.
AiResearch has at present several contracts requiring formal rel iabil ity
support and/or rel iabil ity demonstration. Among these are components or sub-
I systems for the Project
ICBM Inertial Guidance
Mercury
Cooling
Capsule
(AC Spark
Life Support
Plug)., Polaris
System (McDonneIl).,
FBM Spin Generator.,
Titan
and Vector Steering (Lockheed)_ B-70 Central Air Data System (North American)_
I Dyna-Soar Re-entry
Auxil iary Power
GI ider Cool ing (Boeing).,
Supply (NOL-Goodyear).
and SUBROC ASW Missile Control and
TROUBLE REPORTING SYSTEMS
AiResearch has recently designed a major modification of the trouble re-

porting system which had been used since February 1957. The earl ier system
I was oriented
Auxiliary
heavily
Power Units
toward
supplied
production_
to Douglas
and did yeomen service
for the Nike-Hercules
for the 4.,946
Missile. The
older system made inadequate provision for coping with the early development
I and qualification
Trouble Reporting
phases
System
of a program. The new system., called
(UTRS)., is implemented at the inception
the Universal
of a develop-
ment program3 and is not terminated until the hardware has been obsoleted;
I AiResearch
system.
Field Service Engineering reports are an integral part of this
This new system first went into effect in February 1961 in the USN
I SUBROC
programs
ASW Missile
(Polaris
program., and is being
FBM., Nike Zeus_ Dyna-Soar.,
placed into effect
and Saint).
on four other
In all new proposals
by AiResearch3 this data system is being proposed for rel iabil ity programs for
I weapon and space systems where MIL-R-275/_2 is spelled out as applicable.
The primary purpose of the system is the earl lest possible disclosure of
I each and every

remedied
confine itself
deficiency.,
by the start
to hardware
in order that most or all of these will
of qualification
deficiencies_
testing. The system
but also covers
reporting
such things
have been
does not
as en-
gineering assembly and test instructions., test equipment., test calibration and
I instrumentation.,
quality control
and final
procedures
assembly operations.
only to the extent
It overlaps
of major
the existing
subassembly and assem-
bly_ and functional test., and is not concerned with items rejected by Inspec-
I tion but only with

under the cognizance
items accepted
of rel lability
by Inspection.
engineering.,
The reporting
not quality
system is
control., and is
intended to achieve its major contribution to rel iabil ity prior to series
I
product ion.
RC -56-R
I [_ AIRESEARCH
MANUFACTURING
DIVISION
Lo Alf_ele,s Cahlorr, la Page I
I
I RELIABILITY PHILOSOPHY
I in a
AiResearch_
position
bil ity organizations
to
as a vendor
evaluate
to the aircraft
the modus operandi
of its many customers. AiResearch has benefited
and
and
missile industry_
effectiveness
greatly
of
has been
the re] ia-
from this exposure to a multipl icity of philosophies and organizations_ and
I has formulated
desirable
its own philosophy
facets_ and incorporate
in a conscious
the more desirable
attempt to avoid the less
ones of its customers.
I Found on Page
is a discussion of
9 of USAF Bulletin
such organization.
510: Guides
A!Research
For Reliability
concurs
Or_anization_
with both the general
and specific points raised with respect to in-l _ne authority and function_ and
I has placed
organization
signing
its primary
(projects)
reliable hardware
rel iability
where,
emphasis
incidentally_
and subsystems
in the existing
always
engineering
the real responslbil
has resided. When
line
ity for de-
this route
is followed, there immediately occurs the quest'on where and how can the
I technical reliabil ity staff

rel iabil ity staff
functlon
in its Prel imlnary
best?
Design
A;Research
Department
has placed
in engineering,
its technical
where
the technical reliability function first was exercised in 1954 (by one man_
I part-time).
it accords
Since all proposal activity
the rel iabil ity technical
its inception.
staff
is centered
greater
in pre] imlnary
scope to affect
design_
design at
It is frequently difficult to make specific recommendations to experienced

component designers_ but it is relatively easy to make specific recommendations
as to the orientation of components in a subsystem. For example_ most skill-
I ful designers
to proceed to
of components
improve
are, upon investigation_
components of their own design.
quite
Faults
well aware of how
of design gener-
ally speaking_ require some testing to discover and evaluate. The selection
I of suitable
example.
ball bearings
AiResearch
for a particular
reliability believes
appllcat_on
it best to
are
allow
a good illustrative
the project people
and the Bearing Coordination Group to make such selections, and the very suc-
I
cessful experience of AiResearch in high speed rotating machinery (nominal
speed ratings of up to I00,000 rprn) justifies this approach. In mechanical
design, the proper function of rel iabil ity seems to be not to attempt to dupli-
cate what a] ready is being accomplished, but to discover areas where a rel ia-
I bil ity
trouble
function can
and failure
fill an existing
reporting early
bona fide need.
in development
Such areas
programs, and
exist_ in
in system
design and analysis.
I AiResearch
fertile
rel iabll ity has found system
area for rel iabll ity assistance.
and subsystem
For example,
design
a reliable
to be a
life support
system for a manned spacecraft can be defined as a system .vlth a large toler-
I ance for component
This philosophy
failure_ the opposite being
has paid off in the life support
true for an unrel iable system.
system al ready delivered to
McDonnell for their Project Mercury capsule. This llfe support system has an
I astonishingly
component
good resistance
is essential and is
to chance type failures_
not a static device_
since where a system
:t has been made redundant.
Even the method of activating such redundant elements ;s made redundant. For
I example,
of fresh
function
the astronauts
air through
fail,
space
the suit,
the orbital
su_t compressor_
is electrlc-motor-drlven.
mission would of necessity
wh'ch assures the circulation
have
Should the compressor
to be aborted within
I
RC-56-R
I E_l
.
AIRESEARCH MANUFACTURING
Los A',gele=
DIVISION
Cahfornia
Page 2
I
I minutes.
placed
McDonnell
a second
and AiResearch
compressor in the
engineering
space suit
(and reliability)
circuit_ but also
not only
backed up the
pressure loss sensing switch required to cut in the standby compressor by a
I manual override
have been developed
toggle switch that selects
as a logical solution
between compressors.
to very real problems
Such concepts
of the space
age.
I A distinction is made between safety of flight and the abllity to complete

the intended mission. This is an important dlstinction_ and_ in a narrow
I sense_
success.
rel iabil ity is concerned
In actual
self with safety
fact_
and human
however_
primarily
factors_ since
with
rel iabil ity
most
the probability
at AiResearch
problem
does
statements
of mission
concern
do not
it-
se-
parate these in any clear-cut manner_ and all three impinge upon one another.
I EDUCATION AND TRAINING
I AiResearch
orientation
has
and training
since
lectures
the
on company
early
premises
summer
during
of
working
1958
hours.
conducted rel iability
The emphasis of these lectures (they are a continuing series) has changed
I
from time to time, to fit existing needs as interpreted by the rel iabil ity
technical staff. The lectures in 1958 and 1959 concerned themselves with the
concept of constant hazard (chance failure) and reliabil ity prediction as it
.... l led both to electronic o,,u ,o non-electronic ,-Ha; ..... Th ..... phil,<
currently is how to employ PERT {Program Evaiuation _ev.ew Technique,'.' to
further the objectives of the reliability program, and thus_ a series of
I-hour weekly lectures on this subject is being given by a member of the re-
I l iabil ity staff.
From time to time_ authorities in related fields have been brought in to

give lectures in their fields of specialty. Thus, in 1959_ Dr. Mario Juncosa
I of the Rand Corporation
in his field
presented
of probability theory.
a series
Members
of 20 lectures
of prel iminary
on a graduate
design_
levei
rel iabi-
l ity_ and qual ity control engineering attended_ with text books suppl led by
I the company. In 1960_ Dr. Alexander

ing at the University of California
Boldyreff, Professor
in Los Angeles,
of Systems
presented
Engineer-
lectures to top
Division and Corporate management_ and to the senior engineering staff_ on the
I importance
For the past
the AiResearch
of rel lability
18 months_
Los Angeles
in the design
Professor
Division
of future
Boldyreff
weapon
has been a senior
in the fields
and space systems.
consultant
of rel _abll ityj systems
to
en-
glneering_ and operations research.
I AiResearch has continued to encourage and sponsor engineers with rel labi-
lity assignments to enroll for courses at local universities ;n the areas of
I rel iabil ity, stochastic processes_ statistlcs_ and probabil ;ty theory.
The qual ificatlons of personnel with rel iabil ity assignments are those of
I engineers_
bility
assigned
plus additional
theory_ stochastic
to rel iability
training
processes,
tasks
(company sponsored)
and statistics.
have had a minimum
in rel iabil ity_ proba-
All project
of five years
engineers
hardware (design_
development_ or testing) experience in one special ized area of product.
I AiResearch
theory
has never considered a grasp
to qual ify a man to contribute
of mathematical
to or to determine
and other
detail
rel iability
or component
I
RC -56-R
I AIRESEARCH
MANUFACTURING
DIVISION
Los A_ei_s (_al,fornta
Page 5
I
I
design. Therefore; AiResearch considers it to be mandatory that everyone with
I
tel iabil ity assignments be thoroughly knowledgeable in the basic engineering
details of his assignment.
UNIVERSAL TROUBLE REPORTING SYSTEM
I This section is intended to describe the AiResearch Universal Trouble

Reporting System in sufficient detail so as to constitute a useful and in-
I structive guide
of the casual
to those
reader
from an explanation
people
the minimum
who will implement
of effort_
of the objectives
it.
the system
In order
is described
of the IBM 407 print-out_
to require
in reverse,
the print-out
itself_ the over-lay to read the print-out; to the precise details of the
I failure
them out.
reporting forms 3113A and 3113-1A_ and how to assign personnel to fill
I Objectives of the System
The Universal Trouble Reporting System permits cognizant engineering
I management
and progress.
which trouble
and project
It generates
engineers
is encountered,
to monitor
its own documentation
and the effort
a development
being
of trouble_
program's
made to rectify
the area
health
in
the trouble.
Every *_rouble pnrn,,nter_d
.......... ;s r_u_rte,J _,,c; ] ,,UL,_u
..... in I o th i5 repo_
, ......... ;_q Sysi _m
j . , L ,It . _ _.,.i
this includes not only product defects but "

deficiencies of test m_
_ hod_ and
equipment; calibration_ instrumentation; assembly techniques_ etc. While the
emphasis of the system is very heavy during development and qualification test-
I ing, provision
by inclusion
has
of Field
been made for
Service
coverage
Engineering
throughout
Reports into
a product's
the system.
service life
I rcadily
tion of
In order
available
corrective
to be able
upon short
action_
to
notice;
individual
cope with a
every
large
report
and collective
of
amount of data,
trouble;
acts of
and
analysis;
correction_
to make
defini-
and
it
confirmation of correction_ generates an IBM punch card. Thus; IBM tabulations
I or summaries
on the shortest
of troubles;
possible
and the status
notice.
of c_rrective actions; are obtainable
I those
It is perfectly
activities
apparent
included
that any properly
in the Universal Trouble
managed program
Reporting
should
System.
perform
All the
system can do is to make it difficult to conceal from view troubles which;
I sooner
failure
or later_
and primarily_
depends
must be rectified.
as a working
primarily
The reporting
tool for the project
upon the support he gives
system
engineer.
is intended_
Its success
to the system.
first
or
The occur-
rence of an increasingly large difference between number of reports of trouble,
I their
itself.
analysis_ and acts of correction_
The effort required to analyze
is a sure sign of trouble;
each trouble_ and to define
in and of
in precise
terms what must be done to correct it_ must be made sooner or later if the
I trouble
track
is to
of such analysis
be corrected.
and definition of corrective
The UTRS
action. In addition_ in-
is a very convenient medium for keeping
creasingly of late_ D.O.D._ the armed services; and NASA_ are requi ring docu-
I
mentation of everything accomplished; and the UTRS performs this documentation
automatically and in sufficient detail to satisfy the requirements of MIL-R-
27542 and other appl icable military specifications and bulletins on rel iabil ity.
I
I AIRESEARCH
MANUFACTURING
DIVISION [0s Angeles CaJifcrma
RC-56-R
Page 4
I
I
Description of the System
I IBM
The
punched
new
card
Universal
system
Trouble
which
Reporting
permits routine
System
(,and
is_ in
special)
brief_
sorts
a fully
and
automated
tabula-
tions of reports of troubles encountered during any development program. The
I system
through
is
the
intended
shipping
to provide
(and rece;pt_
monitoring
of prototype
from the
and
inception
early
of
production
development
hardware.
The system is intended to enhance competent and prompt engineering analysis
I of
action,
and
each
finally,
trouble
including
test
reported,
the various
confirmation
the clear
areas
of
definition
(engineering_
successful
of
correction.
the
test_
required
QC)
The
of
corrective
required
system does
actlon_
not
do any of these th!ngs_ but me_eIy provides the medium for the orderly and
I systematic
of the rel lability
reporting of
engineer
troubles
assigned
and their
to a
correction.
program to keep
It
the
is the
project
primary
engineer
duty
informed and current on the amount of time lag between any trouble report and
I analysis
correct lye
of the
act ion.
trouble, and between analysis and completion of indicated
I ]93-II_
the
If
UTRS
the
he
in
reader
will
operation
see
will
two
for
refer
successive
a
to
complex
Figures
pages
equipment
l-I
of
and
an actual
]-2
currently
(Reports
IBM
in
407
158-]
print-o_t
development
through
for
from
a
,:_a_ifi_d ..........
w_pf_n _.y_rn..
..... ;-,gure __ ShO_S the trar,.SE,_FenL ,_,,_lay_._..
_:_H_,._
,_n._
rea,4 the prinL-out_ and FTg-res 3-i and 3-Z show the Trouble Report Forms 3i13A
and 31]3-IA. Those who use the system routinely find the overlay a convenient
reference_ but those unfamil iar with the system, or who read the print-outs
I weekly, find the overlay indispenslble.
There are no Field Service Reports, as such_ contained in this print-out.
I When
on
oF
Lhe
the
this
Field
will
weapon
Service
follow
system
the
enters
Engineering
same
service,
format.
Form
troubles
7030 shown
in
in
the
Figure
field
4,
will
and
be reported
print-outs
I number
Referring
appears
to
to
Figure
the extreme
l-l, it
left,
can be
followed
seen that
by
an
a dash
orlglnal
number
trouble
suff:x.
report
There
are lO possible report suff;_es, ,anglng from zero _-0) for the original
I unexpanded
Lhat the
report
corrective
of trouble
action taken
s_mptom,
has
through
proved
nine
successful
(-9), for
confirmed
the final
by
report
testing).
The IBM system is designed so that_ whenever dash zero _-0_ report number
I
has been printed_ and there happen to be additlonal cards in the deck which
represent reports of later phases of correction related to this particular
trouble report, the cards are stacked and therefore pr:nted in suffix numerical
order. Thus. the elapsed time ,equired to complete each phase of correction
I is
appear
immediately
in the
apparent
column to
from
the
the
right
respective
the lear
dates
is shown
of the
as one
report
digit;
suffix,
I =
which
1961),
I A tabulation of each suffix _ith explanatory comment ;s presented belo_
I
I
RC-56-R
AIRESEARCH MANUFACTURINGDIVISION
I Page 5
I
I
Surf ix Generated By_ Description
I -0 Any authorized dept. Original report of trouble symptom.
-I
I Any authorized engineer Analysis_ plus definition of required
corrective action.
-2 Reliability Engineer Report of completion of correction in
I one area.
-3 Rel lability Engineer Report of completion of correction in
I one _ area.
-4 Reliability Engineer Report of completion of correction in

one _ area.
I -5 Reliability Engineer Report of completion of correction in

one area.
I -6 Reliability Engineer Report of completion of all defined

action.
-7 Any authorized engineer Report o¢ additional analysis and

action required.
I -8 Reliability Engineer Report of

corrective
completion
action.
of additional
I -9 Reliability Engineer Report of confirmation of correction.
Continuing the reading of the tabulation from left to right in Figure !-I for
I the dash zero (-0) suffix

agency reporting the trouble
reports_
symptom
there is the date_ an abbreviation
(it can be and sometimes is other
of the
than
AiResearch)_ and the single digit indicating the level of hardware tested_
which is in accordance with the following code.
I Code Hardware Level :*:Examples of Nard_are Level
I 0 Detail Part Fastener_ dlode_ transistor_ ball bearing.
I One Subassembly Any incomplete assemblage of detail parts.
I 2 [ncomplete Component An electrically driven pump, less motor.
5 Complete Component An electrically driven pump_ with motor.

I
I NOTE There are also ten possible areas of required corrective action as
shown in Form 5113A.
I NOTF These distinctions are merely convenient; each program can make its own.
RC-56-R
I AIRESEARCH
MANUFACTURING
DIVISION
Page 6
I
I Code Hardware Level Examples of Hardware Level
I 4 Two or More Components Any unit assembly, replaceable as such.
5 One Package A logical and deliverable end item.
I 6 One Subsystem Two or more packages that are used together.
7
I 8
System
System
(Test
(Service
Only)
Trial)
Complete AiResearch manufactured system.
I System (Service Use)
* NOTE: These distinctions are merely convenient; each program can make its own.
I Continuing the reading of the tabulation from left to right for dash zero
(-0) suffix reports_ there is the AiResearch End Item or System Outline Number
I and Serial Number.

is at a lower
by the component
level.
and its serial
If no serial
Following
number
is the package
number. There
appears_ it signifies
and its serial
then appears
number_
that the hardware
a four digit
followed
space
which_ in the IBM tabulation included in this report, is the test run number.
In most programs_ fewer test runs can be expected on any one build-up, and the
first two of the four digits can represent assembly or build-up number_ and the
second two digits can then represent test run number for the indicated build-
I up number.
the unit of
The last entry is
time (s = seconds,
the elapsed
m = minutes_
time of the test
h = hours).
run (3 digits) plus
I The dash one (-I) suffix

port the number_
(3 digits),
data_ total
the unit of time
reports shown
time accumulated
(I digit)_
(reading from
on the failed
component
left to right)
name (noun
or faulty
re-
component
plus modifier),
I
detail or subassembly name (noun plus modifier)_ detail or subassembly number_
manufacturer_ a trouble verb, and_ most important_ the areas of corrective ac-
tion in engineering_ testing_ and quality control.
I AiResearch
corrective action.
has found
The first
it
four
significant
are engineering's
to categorize
responsibility_
I0 distinct areas
the next
of
three are the laboratories'_ and the last three are quality control's respon-
I sibility.
(Flgure
These areas are
3-I) and on the IBM tabulation
shown both on the basic
overlay
trouble
(Figure 2).
report_ Form 3113A
Each phase (suffix -0 through -9) of a report is punched on just one IBM
I card. Only
The tabulation
the -0 and -I
shown (Figures
reports
I-I
use all
and I-2)
of the space
has dispensed
available
with
on one card.
separate reports
of each act of correction in each area of corrective action; thus_ there are
I no -2 through
It will be noted
-5 reports.
that there
The newer programs
is considerable
at AiResearch
room for explanatory
will report
English
these.
text
on all -2 through -9 reports.
I
I
RC-SO-R
[o Area'he
DIVISION
' Ii'_Ifonla
Page 7
I
I MATHEMATICAL MODELS AND METHODOLOGY
I Abstract
The basic premises of reliability analysis and prediction are summarized.
I Reliability_
derived
hazard_
and hazard
failure rate and
is shown to be the
mean time
reciprocal
to failure (MTF) are defined
of mean time to failure
or
for the
case of complete randomness of failure. Some cumulative probability distributions
I and probability density functions are shown in order to expand upon basic ideas.
Assumptions
I The following premises of reliability analysis are considered self-evident:
I .
The procurement specification and other applicable documents
I must be assumed
use_ maintenance_
to have defined
qualification_
adequately
the required
the conditions
function and
of
mission time in precise terms with sufficient margin of safety
I for the intended application.
°
The validity of any chance failure analysis applies only to
developed designs capable of being qualified to the specified
test conditions.
.
The analysis presupposes only random failures. Failures
I which
when
repeat
encountered
themselves
in
are considered
the development
to be correctable
phase of any program.
I The quality
system
control
is presumed
exercised
to be fully
for all components
equal to or better
and the sub-
than the
levels achieved for the qualification test samples.
I Definitions
Reliability is defined as the mathematical probability that an equipment
I will successfully
conditions
complete
of maintenance_
a mission
operation
of specified duration_
and environment. Thus_
under specified
R(t) = Q-'- where l_(t)

I Qo
= probability
to time t
of survival
Q surviving quantity of
I equipments at time t
R(t) = I - F(t) Q = starting quantity of

o
I Qo-Q
equipments at time t = 0
F(t) : Q F(t) = probability of failure to
I o time t
I
RC-S6-R
L _':: ,i
DIVIS!ON
, r _h ....
Page 8
I
I
Hazard IX) is the ratio of the time rate of change in the number of sur-
I vivors
be viewed
severity
at time t compared
as the generating
of the conditions
to the number
force
of use.
of survivors
to failure,
Thus_
at time t.
and reflects
Nazard
the collective
may
I k =
Q
I -dQ
dt
Hazard, for any probability distribution of lifetimes_ is equal to the
I lifetime
In the
hazard
probability
case of maximum
is constant with
entropy
time.
densiLy function, divided
{completely random
by the probability
occurrence
of
of Failure)_
success.
I of
Failure
survivors
rate (X') is the ratio of
at time t compared to the
the time
quantity
rate of
at time
change
t = O.
in the number
_.hus_
I Q
I
0
-dQ
dt
I the
_ailure
constant
rate is not constant
hazard (chance
with
failurei
time,
period_
but
and
decreases
_mcreases
with time throughout
as it enters the
wearout period. Note that X is the failure probability density function which
in turn is the first derivative of the probabilitg cumulative distribution of
failure. This latter distribution is the distribution function _(t) of llfe-
times, a cumulative probability of failure to time t, and is always the comple-
ment of the cumulative probability of success _reliability) to time t. Since
I failure
derivatives
and success
,time
probabilities
rate of change)
are complementary
are equal
expressions,
but of opposite slgn
their
The
first
distribution function is the integral of the density Function, and F(t) = I R(t)o
I The
divided
lifetime density
by the original
function ¢ (t)
or starting
is the
quantity
time
at
rate
time
at which
- O.
failures occur
I always
In writing
surviving quantity
the equations
be understood thaL the

for this section_
{Q) hove not been further
starting
defined.
quantity
However.
starting
(Q) and
it s_ould
quantity is always set equal to I
(the population of equipments), and the number of survivors then becomes some
fraction of the starting quantity. This surviving fraction is_ by definltlon_
the reliability, and the Q_s reduce to the various vaIJes of the reliability.
Thus, failure rate becomes the time rate of change, or the rate of decrease_
I in rellability_
is that reliability
since Qo = I.
is at all times equal
An interesting
to the failure
result of these relationships
rate divided by the
constant hazard, as demonstrated in the next section.
I Mathematical Models
The three mathematical quantities of reliability_ Cailure rate and
I hazard are
1 -d_
I Qo dt
R = X /h - 1_ _ - Q/Qo
Q dt
I
RC-56-R
Lo_ _r,_eles. Cah_c,rma
I _] AIRESEARCH
MANUFACTURING DIVISION Page 9
l -dq -dR
X' - Qo dt dt
l -d_ l -dR
- Q dt - R dt
d__: -XR = -X
R
dt
Integrating the last equation we have,
"t
r
-_ Xdt
o
-Xt
R = e = e
It is generally assumed that for complex systems the haza-d_ or force

to failure, is constant (uniformly distr!buted in time • Wear-out failure
generally is assumed to be normally_ and not uniformly, dist-ibuted in time,
in accordance with the followin 9 Gauss;an p-ubability-density Function:
where F(t_ = probability of failure

to time t
-it-l_i
2 F i t) = probability density of
I F _t) - dF(t)
dt
_ _1
oF e
2 ,j
I_
fa I lure
= mean time to failure
I c = standard deviation
the distribution
of
I Mean time to failure

of failure with respect
c_ irrespective
to time (or cycles_
of the probability
starts_ etc.)_
distribJtion
is the summation
of the time to failure of each equipment_ divided by the number of such equip-
I ment • Thus_
where n = number of equipments

tested to failure
I n i=1
n t
t.
I
= time r.o failure of i th
samp l e
I It can be shown that, provided the particula r form of the distribution

is determined by nothing but a constant hazard_ the probabili_.y distribution
I.
of time to chance failure_ and hence its centroid, the mean _ime to Failure,
is defined. Since the reliability function itself is the applicable prob-
ability distributionj it represents the p_obability that any life time, x,
is greater than some mission time t. This may be expressed
I
I
RC-S6-R
l es Angeles
DIVISION
California Pa9e I0
I
I
P(x > t) = F'(x) dx = R(t)
I
thus where P = probability that x > t
I F(x) = frequency
of life
distribution
times
_-_
dR = _"
d _t °° F'(x) dx = -F'(t)
I and
R(t) = reliability at time t
I F'(t) - -dR(t)
dt
= ke-Xt
I Therefore, the centroid_ or mean time to failure_ may be expressed:
I =
L tF'(t) dt = R(t) dt =
L- e -X dt = IIX
For any series system, where the failure of any one component causes
failure of the system_ the reliability is expressed:
where r. = component reliability
I n
-tT.
i_l
n
X.
I "ks
t
-t/{
X.
I
i
= component hazard
R= x r, = e = e = e
I i=! I X
S
= series system hazard
= series system MTF
I For a system which incorporates redundancy_ special techniques are

required that are available from well-established theorems from probability
theory. To employ such theory_ it is necessary to stipulate that redundancy_
I as it
ponents,
is employed in reliability
or a collection of
theory_
components (not
requires that
necessarily
two (or
identical)
more) com-
be so
arranged functionally that the failure of one does not and can not result in
I a degradation
the success or
or other
failure
failure
of
of
redundant
the system
elements
performance.
in a system are
In other words_
independent of
one another. In general_ entire systems are not made redundant_ but only
certain critical elements are made so. Thus_ a series system possessing
I redundant elements and the required failure detection and isolation com-
ponents (in series)_ has a reliability:
I
I
I
RC-5b-R

Los An_,elesCaHforn,a Page I I
I
I whe re R = reliability of series
S.
elements
I k n
R = joint reliability of
Pj paralleled elements
R _ R
l
R _
i=1 si j=k+l Pj .th

= hazard of i element
I
! R = e
-£ X.t
i=l
!
= e
-X
S
t
Xs = collective
series
hazard
el ement s
of
S, k = number of elements in
I
I n
series
th
m
r. = reliability of i series
Rpj I x
j=k+l (]-rj)
l
l element
th
Rn = I - (I-rl)n r. = reliability of j
J paralleled element
l R
n
= e'Xn t
R = collective reliability
n
of n identical elements
in parallel_ each with
reliability of r I
I X = collective
identical
parallel
hazard
elements
of
in
n
!
I
I
I
I
I
I
I
RC-56-R
Los Angeies
DIVISION
California Page 12
References
I . AGREE Commlttee_ Reliabili'ty of Hilltary Electronic Equipment, Office

of the Asst. Secty of Defense_ 4 June 1957.
. Flehinger_ B. J,_ and Lewis_ P. A._ Two Parameter Lifetime Distributions

for Reliability Studies of Renewal Processes_ IBM Journal of Resea,ch
and Development_ January ]959.
II . Henney_
Ground
Lopatin_
Electronlc
Zimme%
Equipme_t_
Adler and
(Rome
Maresky_
ADC)_
Reliability
McGraw-Hi]l,
Factors
1956.
fo_
II L#,o U. S. Dept
(NAVSHIPS
of Commerce
900-193)_
Office
Reliabi]ity
of Technical
Stress
Services
Analysis for
Bulletin
Electronic
PS 131678
E_uipment,
This document is a reprint of RCA Report TR 1100_ dated 28 November
II 1958.
JI
I
I
I
I
I
I
I
I
I
RC-56-R
DIVISION
I _] AIRESEARCH
MANUFACTURING Los Angees Cal:fornla Page 13
I
1 Met hodol o_ty
The application of the mathematical model to reliability prediction is

based upon one theory of the incidence of failure in complex equipments.
This theory assumes that the hazard of failure of any one component part is
II sma11j
of any one
that there
is sufficient
is a very
to
large
induce
number
failure
of
of
such components
some specified
and the
system
failure
function.
Degradation of performance in excess of that specified as allowable toler-
II ance
intended
is considered
to reflect
a failure_
both
so that
catastrophic
the hazard
and degradation
assigned each
hazards.
component
The hazard
is
also is intended to reflect the environmental conditions and their cumulative
II effects.,
It is
which
implicit
always
in the
increase
preceding section
the degree
that the
of
computed
hazard.
reliability
of a system requires the summation of the hazards of all contributing com-
II ponents.
its known
This summation
contributors.
represents
Tile assumption
the cumulative
is that
constant
survival
hazard
probability
for
for
all
any
_jiven mission duration is independent of the age of the components. This
PI assumption results in the diminishing exponential expression for reliability.
It is interesting to observe that the entire basis for this theory is

one of chance failures. This concept presupposes that no design or quality
control deficiency exists_ since such deficiencies result in failures which
tend to repeat. Thus., it is deemed to be a primary objective of reliability
engineering not only to predict a realizable mean time to failure_ but also
I to ensure
objectives
that
are
the objective
the inception
of
of
the various
remedial
test
action
programs
whenever
is
such
realized.
deficiencies
These
are disclosed by test. Included in this is the reliability review of all
I proposed
as to what
in the
engineering
success
testing.,
of
{f
changes
prediction
any_ is
in already
required
techniques
qualified
to qualify
has led
components
to the
the change.
inclusion
and the
The belief
decision
of MTF among
the detail design and test requirements for both components and entire systems.
I The primary
cognizant design
responsibility
team is kept informed
of
of
reliability engineering
the
is to ensure
magnitude of
that
system
the
hazard that
is implied by the summation of individual component hazards_ in order to
I keep the inherent hazard within allowable bounds.
THE AIRESEARCH RELIABILITY ORGANIZATION
I at
The Reliability
Los Angeles
Organization
has evolved into its
within
present
the AiResearch
configuration
Manufacturing
through the
Company
con-
tinuing investigation and incorporation of those concepts best suited to the
I company's
to that
activities.
outlined in Part
The Reliability
II of U.S. Air
Organization
Force
conforms
Specification
in all
Bulletin
respects
No. 510:
Guides For Reliabili_ Oy___OE_Eization_ although this bulletin was not the only
I criteria utilized in defining the AiResearch organization.
The structure of the AiResearch Reliability Organization is illustrated
I on
to
the included
and under
reliability
chart.
the overall
The entire
direction
activity
Reliability
of the Division
is under
Organization
Manager.
the control of and reports
is responsible
to the
All engineering
Chief Engineer_
I
RC-56-R
Los
DIVISION
Amgeres California
Page I Z_
I
I through the Chief of Reliability. The following discussion outlines the
functions and responsibilities allocated to and performed by each major group
I of
The
the
Reliability
Rellablllty Organization.
Council
I Engineering_
The Reliability
O.uality Control_
Council
Purchaslng_ Support
is
Servlcej
comprised
and Sales
of the managers of the Hanufacturlng_
Departments.
This council is convened for major policy decisions by the Division Hanager_
I who Is the
functions
chairman_
and
or at
responslbilitles
the request of
of the council
the Rellabllity
are'
Committee. The
I I . To administer
pollcles and
the dlvlslonal
procedures
rellablllty
establlshed by
program
dlvislon
and Implement
management.
the
To coordinate interdlvlslon rellabllity problems through the

I
.
Division Manager.
3. To review and evaluate the progress of all rellablllty activities.
I To assure compllance wlth reliabllity commltments by the asslgn-

ment of speclflc rellabllity actlvltles to the varlous departments.
o
To revlew rellabllity commltments wlth speclflc emphasls on con-
tractural obllgatlons and cost conslderatlons.
I , To
by
resolve
Rellablllty
items of
Commlttee
controverslal
actlon.
nature which cannot be settled
I The Rellabillty Committee
The Reliability Committee is comprised of personnel designated by the
I managers
cludes
of each
those
department
personnel
represented
most closely allied
on the
with
Reliability
the general
Councll_
problem
and in-
areas
under consideration. This committee Is chaired by each of the Rellabllity
Council members in turn on a slx-months-rotatlon basis_ and meets whenever
I an Interdepartmental
Reliability. The Chief
problem
of
arises
Reliability
which
is
cannot be resolved
a non-voting member
by the
of this
Chief
com-
of
mittee. The functions and responsibllitles of the committee are:
I I . To assure proper Implementation of declsions and rulings established

by the Reliability Council.
I 2. To coordinate and resolve Interdepartmental rellabillty problems.
I 4 To
for
establish
review by
and coordinate
the Reliability
periodlc
Council
reports of
and Corporate
reliability
Management.
progress
To advise the Rellablllty Council of unresolved problems and to
I request thelr resolution,
I
RC-56-R
I [_ AIRESEARCH
MANUFACTURING
DIVISION Los AnReles California
Page 15
I
I The Reliability Staff
I The
Preliminary
Reliability
Design Department
Staff
and reports
is made
technically to
up of engineers from key groups in the
the Chief of Reliability.
The staff members perform reliability tasks within their own Preliminary Design
I group_
projects.
and also provide
These
assistance
engineers_
in reliability matters
in addition to being competent
to all engineering
in their reliability
functions_ are experienced in tile many phases of equipment testing.
I Enqineerinq Project Reliability Enqineers
The Engineering Project Reliability Engineers consist of experienced

I hardware
either
specialists
specific
who are assigned
contractual reliability
the responsibility
requirements
of accomplishing
or the routine duties
necessary to achieving reliability in equipment. These engineers report
I directly
Chief
to their
of Reliability
project leaders and are technically
for all reliability activities.
responsible to the
I The Chief
The
of
Chief
Reliability
of Reliability reports directly to the Chief Engineer_ and acts

in an advisory capacity to divisional management with respect to all reliability
matters. The major duties and responsibilities of the Chief of Reliability are:
I , To establish divisional reliability policy_ in concert with the
I Division
matters
Manager_ Chief Engineer_
that pertain to AiResearch
and all department
reliability
heads_
activities.
in all
I To assist all engineering project teams in their early design

.
activities in order to ensure that AiResearch design leadership

in reliability is maintained.
I . To
of
establish
AiResearch
and maintain
customers
contact
and vendors.
with the reliability departments
I To conceive_
systems
plan_ design
for engineering_
and place
field
into effect
service and other
failure-reporting
departments re-
quiring such systems.
I . To initiate
reports
and
intended
supervise the preparation
for AiResearch customers
of divisional
and vendors.
reliability
I .
To provide
liability
guidance_
Council
counsel and
and Reliability
continuity
Committee.
to the Division Re-
I .
To assist
vendors
Quality Control
in Reliability
in the
matters.
maintenance of cognizance over
I To exercise technical supervision of the Reliability staff and

.
Engineering Project Reliability Engineers.
I
RC-56-R
I _ AIRESEARCH
MANUFACTURING
DIVISION
Los Angeles. California Page 16
I
+_ _
t_
li'l
--]
! Ill '
I
I
I I:
J
I
I
I
I
I
I RC-56-R_ Rev. I
Page 17
I
I
I
j--
,,
_
.,
j--
_, _ o
_
_
_
. o_
b9
0
4
N
I
nf, DE t-- QE
I%1 O N N
I o-_o o_ o_ _ _ :
,,, _. ,,, _, ,, o _ _. o o_
N
0
N
•r o' o _ g g
d"
0
I_1 l%1 I_ N N _%1 Q.
• N t_
T T T T T T T T T T T T T T T T T T T T T T T T T T T T T T
I "wl
I
W
/
_"°
I
O
I
_ O
I
N
I
A
I
_ O
I
O
I
N
I
0
I
N
I
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_'w_
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NON
I I I I
N
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ffl_
I
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I
_'_ m
I
_,_ O
I
M
|
,T_ooo oo _o
I , , , ? , , T , , ? _
I Figure
RC-56-R
I'1
DIVISION Page 18
I I_ AIRESEARCH
MANUFACTURING
I Figure
RC-Sb-R
I-2
Page I9
I [_ NRESEARCH
Los Arlgeles Califorma
I
I *
I 'i
3
I : +-,_L_
I <
•* _ uu¢_ a:,-
m_+.. i,,. _ o _i -- ii
c _ u I.+ i,.,i iP +i_ iI.
I_ Ill Ill
I,,. O,.P.+ L..
++.+.._ _O.+ll-- II- I,.
SIT
ml IP-
_ W It_
0 _ C
m II
W aO'q m II
O,IA G
< g ,,..< ,._,.. ,.. ,,_,,. :+:,,.

• I II II I II II I I II
_ N ii11 ,,,I+ i11 ,ll IP_ ol 0, 0
z z k- r
• I'- *1" m, i-- 0 lb.
o P ,+ o . _ '+
o "; , _ _- _ =
, ,. o , __ - 8_.
4_ Ill ! 4_ I-I IL
++,_ +-+m... +I+_+I++

i
n
++ ' + °,0 - ; :l
Ill _+.! _ _.
-I+O?o
"8,.,+
II II o...,...
I.,_ I.L. 0111
li o.'; ,+,";
ilDO
,,,,
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•
+ +_, _ _ = ,: .-,II + ,=_ _P...+

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I '+'+
I_I I
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I RC-Sb-R
Page 20
Los Angeles, Cahfornla
(_il_esearc_ Manufacturing Company UNIVERSAL TROUBLE TROUBLE REPORT NO ...........
x_¢,_,.o! /"-'_ _ REPORTING SYSTEM
DATE .............................
CONTRACT NAME__ *AGENCY REPORTING ............... '__
TASK OBJECTIVE_ EWO
**TEST OR ASSY, LEVEL ........................
SYSTEM NO .......................... "
TROUBLE SYMPTOM SIN
SUBSYS NO ..
S/N
COMPONENT NO.
DISPOSITION_ S/N
BUILD UP NO
ORIGINATOR DEPT. NO. DATE
RUN NUMBER.
TROUBLE ANALYSIS TEST DATA NO,
RUN DURATION
TOTAL TIME
-- DO NOT WRITE BELOW THIB LINE --
***NOMENCLATURE:
COMPONENT
DETAIL NAME.
I DETAIL P/N ( )
TROUBLE
I ANALYST DEPT. NO. DATE AREAS OF ACTION REQUIRED
ACTION REQUIRED DESIGN/DRAWING 1
I PROCESS SPECIFICATION
ASSEMBLY INSTRUCTION
2
TEST INSTRUCTION 4
I TEST METHOD/CONDITION 5
TEST EQUIPMENT 6
I TEST CALIB/INSTRUMENT
PROCESS/MANUFACTURE
'7
I ANALYST DATE PROJECT ENGINEER DATE

INSPECTION
VENDOR
(QC) 9
AREAS OF ACTION TAKEN
I ACTION TAKEN
I NOTES:
ENGINEER DATE *WRITE LAB, MFG, INS, OR ENG
I CORRECTION CONFIRMED
**SYSTEM, SUBSYS, OR COMPONENT
***USE GENERIC NOUNS ONLY, SUCH
AS VALVE, DIODE, ETC., FOLLOWED
PROJECT ENGINEER DATE BY DESCRIPTIVE ADJECTIVE
FORM 3113 10M 2-62 LC
I RC-Sb-Rj Page ZI
I
I (hl_esearch Manufacturing Compang UNIVERSAL TROUBLE TROUBLE REPORT NO ..........
REPORTING SYSTEM
'mmuq
I CONTRACT NAME.
DATE
*AGENCY REPORTING ....................

TASK OBJECTIVE EWO__
I **TEST OR ASSY. LEVEL .............
SYSTEM NO.
I TROUBLE SYMPTOM.
SUBSYS NO.
SIN
S/N
I COMPONENT NO,
DISPOSITION S/N
I ORIGINATOR DEPT. NO. DATE

BUILD UP NO..
RUN NUMBER,
TEST DATA NO.

I AS THE TROUBLE IS ISOLATED TO SUCCESSIVELY LOWER LEVELS OF
THE ASSEMBLY, TRANSFER THIS FORM TO THE SUSPECTED ARTICLE
RUN DURATION
IN TURN UNTIL THE BASIC CAUSE OF TROUBLE IS ISOLATED. AFTER TOTAL TIME
COMPLETING THE LOWER PART OF THIS FORM, FORWARD IT TO THE
PROGRAM RELIABILITY ENGINEER,
RESULTS OF DISASSEMBLY INVESTIGATION OR TESTS TO DETERMINE CAUSE OF TROUBLE:
I 1. FAULTY PART OR COMPONENT:

(IF APPLICABLE)
PART NO., S/N
PART NAME
I 2. FAULTY CONDITION: .......
I
I 3. CAUSE (IF POSSIBLE TO DETERMINE): .......................................................................
I
I 4. COMMENTS:
I
I
I ORIGINATOR DEPT. NO. DATE
I RC-Sb-R
Page 22
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I ...... "-_._ _l'li_[llti_; i.i.i.i_'__fO__4
uoolt _ SERiALI_I.__KIIO.
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Bit sEll'IS NO. --M-_I_I_N OR SERIES NO. --; "M_IFI'CAI'ION'OR'IERIE| NO. -_ ..... _71
i I I I I HRS i OIECEiVlNG INSPECT/TEll , , i.,

7. , I l. I-"l ROUTINE INSPECTION I, _] AI)IUII
|. OI_IIJITINO lie l" 9. IAILUR[ NOT P DURIN_ --_ i-_. I-M_Mi6TATE ACTION ll."i'_i_OtLOWS
12, ACIIOitiANSWIR _ ::
I_Q;O _; _- r:].'JJ;IH
i_ ,
_: I. , * ,.L C'-
CYCS 3 ROUBLE
4._TARTIttG litOOTiNG 3.'O.EPAI,
4. EIHOLD foil DISPOSITION _ /l_iNO_O._, ii
I iiI,, iI ,I ,I II ,,,ir,l!l.l-,
IIi_tRS , B.r'iTAKE
S. ElGItOUetO OFFRUN.Or
II.
It.
[] RETURN TO SureLY
I_]R[TURNTOAIRESEARCH I II
li. '1 lUMMA-II-V_I}E
I l t.l ..... I t li I
•l IB
$'N1£, 0 NO
AVAILAILE D AI_P |,
,, []
(":_ LAHI)II_I
OlliilUil i Off / R. ,GilT I. m 'J.I I_' _
- SPICIAL EQUIP. AVAILABLE S, (_ TEAR DOWN
I
I
I
I
TYPICAL FIELD SERVICE REPORT
FIGURE 4
I
RC--56-R
Los Arlgeres
DIVISION
California Page 23
oi
APPENDIX B
PROCEDURES FOR QUALIFYING NONMETALLIC

MATERIALS FOR USE IN OXYGEN BREATHING SYSTEMS _
AIRESERCH REPORT NO. SS-2108-MR
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APPENDIX B
PROCEDURES FOR QUALIFYING NONMETALLIC MATERIALS FOR USE
I IN OXYGEN BREATHING SYSTEMS

SS-2108-MR
AIRESEARCH REPORT NO.
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66- 1483
I _] AIRESEARCH MANUFACTURING
Los Angeles.
DIVISION
California Page BI
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I THE coRpORATION
i_il_esearch Manu_'acturincj Divisions
I LOS ANGIEtES 45, CALIFORNIA
I It£PORT NO. SS-2108-MR _,ev
I
I PROCEDURES
NONMETALLIC
FOR QUALIFYING
MATERIALS
FOR USE IN OXYGEN BREATHING SYSTEMS
I
SS-2108-MR _ev
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This
inform
used,
document
or
Buyer
disclosed
of
is
the
the
for
property
status
any
of
of The
Seller's
other
Garrett
purpose
Corporation.
performance
without
and
the
is
prior
not
It
written
to
is furnished
be duplicate_
permission
to
I
of Tile Garrett Corporation.
I
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I
I
I _Jl L _,_ A,,ge_e,, ( al,h_',,=,_
I
I
I PROCEDURES FOR QUALIFYING
NONMETALLIC MATERIALS
I FOR USE IN OXYGEN BREATHING SYSTEMS
SS-2108-MR, Rev_ ,
I I. OBJECT
A_gult 2_ 1965
I I.I This report

nonmetallic
prescribes
materials for
a procedure
use in
for
oxygen
the qualification
breathing systems.
of
I 1o2 The
for
intent is to
the selection
establish mutually
of elastomers_
acceptable
lubricants
methods
3 and plastics
and criteria
for use
in oxygen breathing systems at pressures not to exceed 20 psig.
I 2. TEST CONDITIONS
2.1 The exposure conditions are as follows:
I 2.1.1 Atmosphere: I00 percent oxygen at 5.0 psia
2.1.2 Time: 48 hr
2.1.3 Temperatures: 160°F, 200°F_ 250°F_ 300°F
I 3. ACCEPTANCE CRITERIA
The acceptability of a material shall be determined by tests_ described
I herein_
toxicity.
for odor characteristics,
The criteria for
susceptibility
acceptability shall
to oxidation,
be as fo]lows"
and
I 3.1 Odor
3.1.1 A material exhibiting an objectionable odor at a particular

temperature level shall be considered as unacceptable for
I use at that and higher temperatures.
3.1.2 The material may be established suitable for use by tests at
I temperatures
was discerned.
below that at which the objectionable odor
3.1.3
I The
material
2o!.3_
level
tested_
of acceptability
at the
or at temperature
shall
temperatures
conditions
be established
established
required by
for
a
each
in paragraph
particular
component or system.
I
I
I
SS-2108-HR,Rc_v
DIVISION
I _ A_,gele_ Cahforn,a Page I of 6
I
I 3°2 Oxidation
I The physical
after
oxidation
exposure
shall
properties
to the test
be based
of materia!s
conditions°
on the
shall
Following
be compared
Acceptability
criteria:
before
relative
and
to
I 3.2.1 Elastomers
3.2.1.1 No cracking_ blistering_ or charring of the surface.
I 3.2ol.2 Tensile strength shall not change more than

20 percent.
I 3.2.1.3 Elongation shall not change more than 20 percent.
3.2.1.4 Weight shall not change more than _0 percent°
I 3.2. n.5 Shore hardness shall not change more than I0 points
I 3.2.2 Lubricants
3.2.2._ No evidence of fire or coking.
5.2.2.2 For oils_ viscosity shall not change more than

I0 percent°
I 5.2.2.5 For greases_ change in dropping

than :±6°F_ if applicable.
point shall be less
I 5.2.2.4 For oils, the

i_O percent°
weight shall not change more than
I
5.2.2.5 For greases the weight shall not change more than
5.0 percent_ unless the grease is designed with a
volatile fluid_ in which case weight loss shall
not apply.
I 3.2.3 Plastics
I 3.2.3.
3.2.3.2
I No cracking_ blistering_ or charring of the surface.
Plastics shall not lose more than 5°0 percent by

weight.
I 3.2.3.3 Where applicable, hardness shall not change more
than ±I0 points as determined by Barco] hardness
I tester°
3.2.3.4 Tensile strength shall not change more than
I PO percent.
I
SS-2108-MR Revo i
AIRESEARCH
I I_l MANUFACTURING
t os Angeles
DIVISION
California Page 2 of 6
I
3°3 Toxicity
I 3.3.1 A material as intended for use shall not contain unreacted_

known noxious or toxic compounds; nor shall it produce any
I
noxious or toxic gasses at the extremes of its operating
temperature.
3.3.2 When possible, materials utilized are those whose basic
I 3.3.3
formulation
An acceptable
is controlled
odor shall
by
be a necessary
specification;
but not sufficient

condition of qualiflcation for nontoxic properties,
I TEST PROCEDURE
Methods to determine the acceptability of e!astomers, lubricants_ and

I plastics are separately descrlbed herein_
4.1 Elastomers
I 4.I.I Elastomers Oxidation Test Procedure
4.1oi.I Conduct tensile and hardness 'tests; per ASTM D.&I2.64T

I and ASTM D-676-59_
Three determ!nations
respectively
for the
s For
control
control
and for
purposes.
each
exposure test condition are required.
4.!.I.2 Place the samples for exposure in a desiccator of 2.5

to 2_7 l!ters vo!ume. Evacuate and fill with gaseous
oxygen_ per MIL-O-27210, a minimum of three times.
I The final fill shall be to the desired test pressure.
4.1.1.3 Place the desiccator in an oven_ at the desired test
I temperaturey for 48 hours_
4.1.1.4 Upon completion of the exposurej examine the specimens

at fOX magnification for visual evidence of surface
I damage s and reevaluate
described in paragraph
the physical
4.! !,!o
properties as
I 4.1.2 Elastomers Odor Test Procedure
4.1.2.1 Prepare a material specimen of IO to 12 cm 2 surface

area weighing approximately one (I) gm. Weigh the
I specimen
watch
to
glass.
the nearest mg and place on a 2-in_
I 4.1o2.2 Expose
described
the sample
in paragraph
to
4 1oI.2_
a gaseous oxygen
using
atmosphere
a separate
as
desiccator for the odor evaluation°
I 4.1.2.3 Place the desiccator in an oven at the desired test

temperature for 48 ho, s,
I 4.1.2,4 Upon completion

desiccator
of
to atmosphe
th_ exposure
ic pressure
period
with
bring
oven-
the
temperature air, and "emove from the oven immediately.
I SS-2!08-MR Revo
_ AIRESEARCH MANUFACTURING DIVISION Page 3 of 6
I LOS Angeles Cal,fornla
I
I 4.1.2.5 In an odor-freej draft-free room, open desiccator
containing odor test sample while it is still at
I temperature.
dently quickly
Each of four subjects
smell the desiccator
shall indepen-
atmosphere and
record their finding as: "not detectable_"
I "detectabie_
able." Report
but not objectionable3"
the consensus.
or "objection-
4.1.2.6
I Following
from the
whole mg.
odor evaluationj
desiccator
Record
remove
and reweigh
the
the watch glass
to the nearest
percent change in weight.
I 4.2 Lubricants
4.2.1 Lubricants Oxidation Test Procedure
I 4.2.1.1 For greases_ determine the "dropping point" per

ASTM D-566--4_ and prepare a second "cup" for oxygen
exposure° Oxidation resistance of oils shall be
I evaluated by
ASTM D--445-6_
determination
before and after
of viscosity
exposure
per
to oxygen at
! the desired test ,temperature.
4.2.1.2 For sample containment_ use a standard dropping cup

I
for greases_ and a watch glass for oils (About
I0 m} of oil is required for viscosity testing.)
4.2.1.3 Expose the samples to oxygen in the manner described

in paragraph 4.1.1o2o
I 4.2.1.4 Place the desiccator in an oven at the desired test
temperature for 48 hr.
I 4.2.1.5 Upon completion of the exposure period remove the

samples and reevaluate the appropriate physical
I 4.2.2 Lubricants
property.
Odor Test Procedure
I 4o2.2'. I For grease

sample
odor test,
to the nearest
weigh
whole
approximately I gram
mg on a 2-in, watch glass.
Spread the grease evenly over the glass to a uniform
I thickness°
4°2.2.2 For oil odor tests weigh approximately a l-gm
I sample
glass°
to the nearest whole mg on a 2-ino watch
4.2.2.3 Place samples in separate desiccator_ of 2.5 to 2.7
I liters by volume
per MIL-O-272!O_a
and evacuate
minimum of
and fil!
3 times.
with gaseous
Final fill
oxygen_
shall be to the desired test pressure°
I
SS-2108-MRo Rev I
I t_1 AIRESEARCH MANUFACTURING

Los Al_geles
DIVISION
California Page 4 of 6
I
I
I
I 4.2.2.4 Place desiccators in an oven at the desired test

temperature for 48 hr.
I 4.2.2.5 At the completion of the exposure period, bring the

desiccator to atmospheric pressure with oven tempera-
I 4.2.2.6
ture air I and
In an odor-free_
immediately
draft-free room_
remove the desiccators.
open desiccator
containing odor test sample while it is still at
I temperature.
dently quickly
Each of
smell
four subjects
the desiccator
shall
atmosphere
indepen-
and
record their finding as: "not detectable_"
I "detectable_
able." Report
but
the
not objectionables"
consensus.
or "obJection-
4.2.2.7 Fol_owingodor evaluation_ remove the watch glass

i with
the
the samples
nearest whole
from the desiccator
mg and record percent
and reweigh
change in
to
weight. Examine samples at fOX magnification for
I evidence of charring.
/+.3 Plastics
I, 4.3.1 Plastics
4.3.1.I
Oxidation
Conduct
Test
tensile
Procedure
strength and hardness determinations
I according
(Barcol
to ASTM D-638-64T
hardness testor)_
and ASTM D-1706-61
respectively. Three
determinations for the control and for each exposure
I test condition are required.
4.3.1.2 Place the samples for exposure in a desiccator of
I
2.5 to 2°7 liters volume. Evacuate and fill with
gaseous oxygen, per MIL-O-27210_ a minimum of 3 times.
The final fill shall be to the desired test pressure.
I 4.3. I.3 Place

temperature
the desiccator
for 48 hr.
in an oven at the desired test
I 4.3.1.4 Upon completion

at fOX magnification
of the exposure
for visual
examine
evidence
the specimens
of surface
damage_ and reevaluate the physical properties as
I 4.3.2 Plastics
described
Odo_ l Test
in paragraph
Procedure
4.3oi. Io
I 4.3.2ol For
sample
odor evaluation,
to the nearest
weigh
whole
approximately
mg on a 2-in.
one gm
watch glass.
The sample shall expose I0 to 12 cm 2 of surface area.
I
I
SS-2108-MR, Revo i
[_I AIRESEARCH
MANUFACTURING
DIVISION
I los Angeles Caldomla Page 5 of 6
I
I 4.3.2.2 Place the sample in a desiccator of 2.5 to 2.7 liters
by volume and evacuate and fill with gaseous oxygen
I per MIL-O-27210
shall
a minimum
be to the desired
of 3 times.
testpressure.
Final fill
Place desiccator in an oven at the desired test
i 4.3.2.3 temperature for 48 hr.
4.3.2.4 At the completion of the exposure period bring the
I desiccator
temperature
to atmospheric
air and remove
pressure with oven
the desiccator immediately.
In an odor-free, draft-free room_ open desiccator

I 4.3.2.5 containing odor test sample while it is still at
temperature. Each of four subjects shall indepen-
dently quickly smell the desiccator atmosphere and
I record their
"detectable
finding as: "not detectable,"
but not objectionable_ or "objection-
,l
able. " Report the consensus.
4..3.2.6 Follc
Following odor evaluation, remove the desiccator
and
and rreweigh to the nearest whole mg. Record the
percent change in weight.
5. REPORTING
i_ perc(
5.1 A material shall be reported
v as satisfactory (S) or unsatisfactory
(U) at each of the
the test conditions.
t(
is found unsatisfactory at a particular temperature

I 5.2 When
level,a material
further is f(
testing at higher temperatures shall not be performed.
testir
I W. A. Lyons
Materials and Process
I APP 0W ,I
APPROVED.: .__J , / .
_'T'_.
Iles
I f_.___P_rogr_3m.Engineer, EVLSS Project
APPROVED
V. K. C rawf_'rd
I A PPROVED : _J'_ ._qr.(__
APPROVED :R ._C. ('_e_
Program Manager, Project

"
................
Gemini
K. Jackson ' I
I Chief
Project
Program
Gemini
Engineer_ APPROVED: L/_),'_.
W. J. _eilly
_'__,.
Program Manager_ EVLSS Project
I
I
SS-2108-MR., RleVo I
Page 6 of 6
lo_ AngeqesDIVISION
Cahlomla
I
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I
APPENDIX C
DATA ACQUISITION PROCEDURE 210-A7

I
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I LOS Angeles, California

I
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APPENDIX C
DATA ACQUISITION PROCEDURE 210-A7

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66-1483
I LOS Angeles, California Page CI

I.
210-A7
LOS ANGELES
DATA ACQUISITION PROCEDURE
i
QUALITY CONTROL DIRECTIVE
i ELSS - CHESTPACK
IRAN
i
I Page I
! I , GENERAL
I A. This
documents
procedure
may be acquired
provides
and/or
a means
maintained during
by which
the "Inspect
selected AiResearch
and Repair as Necessary" (IRAN) activity and the upgrading and
I
refurbishment of the Extravehicular Life Support System (ELSS)
B. The acquisition, retention, and transmittal of this data will

satisfy the requirements for Aerospace Equipment Contractor
1 Historical Process
by NASA Reliability
and Performance
Document
information,
NPC-250-1 and NASA
as defined
Quality
Assurance Document NPC-200-2.
I II. SCOPE
A. Departments affected
I. Manufacturing
I ao
b
Furnish
Upgrade
Interim
Interim
AOIR
AOIR,
for
as
each unit.
required.
I 2.
ao
inspection
Accumulate data, as noted and forwarded to Quality

Control.
I b. Assemble deliverable data to accompany unit.
3. Quality Control
I a.
b.
Prepare
Accumulate
Narrative End Item report.
all data and maintain fileo
I 4. Contract/Sales Administration
ao Direct repair and/or upgrading, as required by
I issuance of task sales order.
5o Engineering Laboratory
I a.
b.
Provide
Provide
copies of test
instrumentation
data sheets.
records.
co Maintain existing system and component logs returned
! with unit.
I CONT:
I FORM 2674-B EFFECTIVE: 3-7 -66

2;0-A7
I
DATAACQU
I SUTIONPROCEDURE
ELSS- CHESTPACK
i RAN QUALITY LOS ANGIr Lit $
CONTROL DIRECTIVE I
Page 2,
I
Ill. COMPONENT DATA FiLE !
A. Documents
I • Sys_-em and Component Log (Form No. 3139).

I
2. T_ouDie Report
at _unctional
Forms (initiated
acceptance test.
against the component
I
o AI
de
data
ivery
generation, acquisition,
will be limited to the
retention
items listed
and
below. I
Va ve 850040
Nipple
Nipple
800562
800562
I
Gage 800386
J
Modu _e 800374
Module 800318
Press Trans o 800298
Heater 800296
Sensor 800294
Battery 800670
Regu !ator 800284
Vaive Group 800282
Vaive Relief 800278
Heat Exchanger 167880
Panel 138594
Pane i 138793
Duct Assembly 138541
Tank Assembly 138663
Multi Connector 800562
Electrical Jumper 800600
Umbilical Ass'y• 800362
4. Interim Assembly Operation and Inspection Record
5. inspection Transfer and Rejection Record
6o Functional Test Data Sheets.
7o instrumentation Record
CONT:
'EFFECTIVE: 3-7-66 FORM 2674-1B

21 O-A7
QUALITY
..No
ANo,
O'V"'O"
cT,.,,
IL, s ,NOtos
CONTROL D_RECTIVE
DATA ACQUISITION
IRAN
PROCEDURE
ELSS - CHESTPACK
Page 3_
B° Procedure
I. System and Component Log
ao The Laboratory, when performing a test, either

acceptance or investigation, will enter, on the SACL
returned with the equipment, the time in hours and
minutes expended in performing such test.
2. Trouble Reports
a. Laboratory, Manufacturing, and/or Inspection personnel

will initiate T/R's when malfunctions or discrepancies
I are detected
cycle.
during the repair, test, or modification
bo Reliability wil_ process T/R.'s in the same fashion,

as occurred during ¢he production program and will
maintain T/R file.
3. Interim Assembly Operation and Inspection Record

,
al Manufacturing will prepare, in coordination with
I Engineering
necessary
and Quality
each unit received.
instruction
Control,
This document
an interim
shall
to refurbish,
AOIR
contain
repair or upgrade
for
the
the specific unit to satisfy customer requirements.

I bl The final inspector shall review each AOIR for
completeness of entry, including evidence of Govern-
I ment Inspection
AOIR shall
witness
be placed
when required. The completed
in the data book accompanying
the unit.
i 4. Inspection Transfer and Rejection Report (ITRR)
a. Materials Review shall prepare a copy of each
I completed
in paragraph
ITRR written
III. A. 3.
against
and
the components
forward to Quality
listed
Control.
!
i
I CONT:
I FORM 2674-B EFFECTIVE: 3-7-66

210-A7
I
ELSS - CHESTPACK
JRAN
i AIRESEARCH
LOS
QUALITY MANUFACTURING
CONTROL
ANGELES
DIVISION
DIRECTIVE I
I
Page 4.
o Functional Test Data Sheets (IDS)
ao The Laboratory
data sheet
will
prepared
reproduce
against
one copy of each
the items listed in I
paragraph Ill. A. 3.
bo The
will
Laboratory
review the
Quality
data
Control
sheets for
representative
completeness of
I
entries, government witness, etc., and insert
the data into the data book.
I
o instrumentation Record
a. The Laboratory shall initiate the instrumentation I

record prior to performing each test, recording
each instrument type, registry number and cali-
bration due date. The completed instrumentation
record shall be placed in the component data book.
IV. SYSTEMS DATA FI LE
A. Documents
I. Systems Data Folder I

2. Modification Record
3. System and Component Log

I
4. Functional Test Data Sheets
I
5. Acceptance Test Data Sheets
6. Trouble Report Forms I

7. Trouble Report Forms Instruction
8. Configuration Record
I
9. Instrumentation Record
t
i
CONT:
4
I
• EFFECTIVE: 3-7-66 FORM 2674-1B
I
210-A7
! QUALITY CONTROL °'v"'oN

DIRECTIVE I DATA ACQUISITION PROCEDURE
ELSS - CHESTPACK
IRAN
I Page 5.
11 I0o Interim AOIR
I Iio
12o
Trouble
Rejection
Reports
Reports (ITRR's)
! 13. Test Data Sheets (iDS)
14. Component Data Package
! B. Procedure
I
I. Systems Data Fo_der
ao Quality Control will furnish a supply of Data

folders to final inspection°
bo Fina_ _nspection will identify the folder with
the part number, name, and serial number.
I 2. Modification
ao The final
Record
inspector will make the required

entries in the existing m,d. record, indicating
I the component
and serial
removed
number.
by part name, part number,
II Entries will be made for new components installed.
3. Configuration Record
I a. The final
existing
inspector
configuration record,
will make entries
indicating
on the
the
components changed by order of change as listed
I in the mod° record°
4. System and Component Log
I a.
The Laboratory
returned with
shall make entry
the equipment°
on existing
These entries
SACL's
shall
!
indicate the actual time accumulated during tests
or any other running time of the equipment. The
time shall be expressed in minutes and/or hours
and minutes. The SACL (original) shal_ remain in
I the data book.
I CONT:
I
FORM 2674-B EFFECTIVE: 3-7-66
21O-A7
DATAACQUISITIONPROCEDURE LOS ANGELES
ELSS- CHESTPACK AIRESEARCH

QUALITY MANUFACTURING
CONTROL DIVISION
DIRECTIVE
IRAN
Page 6.
. Functional Test Data Sheets
ao The Laboratory will record T.I. test results on

Internal Data Sheets (IDS) and provide two
additional copies.
bo The Laboratory Quality Control Representative
will review the ATP data sheets for completeness
of entries, government witness, etc., and place
the data in the data folder.
,. Acceptance Test Data
a. The Laboratory will perform the acceptance test

per the ATP, record and retain in the data folder.
b. Laboratory Quality Control representative will
review the ATP data sheets for completeness of entry,...
Government witness, etc., and retain in the data
folder.
. Trouble Reports
a. The salmon copy of trouble reports generated

during any phase of testing will be retained in
the data folder.
to Reliability
Vellum copies
93-3 via the normal
will be forwarded
Laboratory
I
method.
Reliability will retain all completed trouble reports. I

The final inspector will review each TR for completeness
l
b.
and clarity of entry and inclusion of the TR data

on the interim AOIR.
. Instrumentation Record
I
a. The Laboratory shall initiate the instrumentation
record
date.
prior
instrument
to performing
type,
The completed
registry
form
tests,
number,
shall
recording each
and calibration
remain in the data
due I
folder.
l
I
CONT:
I
I
EFFECTIVE: 3-7-66 FORM 2674-1B
I,
210-A7
I
QUALITY
"ANU'CTO''N°LO,
AN.ELE,
i
CONTROL DIRECTIVE
ELSS - CHESTPACK
IRAN
I Page 7.
I . interim Assembly Operation and Inspection Record
I a. Manufacturing will prepare an interim AOIR in

coordination with Engineering and Quality Control
for each ELSS end item to be processed.
bo The final inspector shall make entries as required
I during the IRAN process and acquire government
witness evidence as directed. Inspection evidence
shall also be provided.
I I0. System and Component Data Folders
I a.
b.
The final inspector shall prepare the system data
folder, as instructed in paragraph V.
The final inspector shall verify that the systems
data folder contains a copy of each of the following
documents.
i. Configuration Record
I Original and one copy
2. ATP Data Sheets
I 3.
Original
instrumentation
and two copies
Record
Original and two copies
I 4. System and Component Log
Original and one copy
I 5. Trouble Reports (system and components)

Original (salmon) and one copy
I . Inspection Transfer and Rejection Report

One copy of each ITRR which has an MRB
disposition only.
I 7. Test Instruction Data Sheets (IDS)

Original and one copy
I C. The final inspector shall verify that there is

a complete component data folder for each component
listed in the modification record.
I
I CONT:
I
FORM 2674-B EFFECTIVE: 3-7-66
i
210-A7
ELSS - CHESTPACK
I RAN
LOS ANGELES

QUALITY CONTROL DiRECTiVE
I
Page 8o I
Vo System Travel Data (to be shipped with the equipment)
I
A. Documents
I
i . Configuration Record
o
Upgrading
Modificat;on
existing
Record
record and one copy
I
Upgrade existing record and one copy
o AoToPo data sheets

I
One blue I_ne copy
o Instrumentation Record I
One blue line copy
5_ SoA.CoLo
Upgrade exist;ng SACL (original)
o TrouDIe
B_ue
Reports
line copy of all TR's generated during
I
processing of unit, including components.
o I oToRoRo I
One copy of al iTRRVs which have an MRB disposition
0 Trouble
onlyo
Report Forms
I
Ten blank forms
o Trouble Report Forms instruction

I
One copy of instruction
B. Procedure I
The finaO inspector will initiate two copies of the
I
I •
Travel folder check _ist and remove one copy of each

of the documents noted thereon from the systems data
folder.
o When all documents on the check list have been assembled,

I
the final inspector shall place them together with one
copy of the check
forward to shipping
list, into the travel
with the equipmeni.
folder and
I
CONT:
I
EFFECTIVE: 3-7-66 FORM 2674-1B
.
210-A7
I QUALITY
LOS ANGELES
CONTROL DIRECTIVE
DATA ACQUI S I T I ON PROCEDURE
ELSS - CHESTPACK
I RAN
I Page 9.
I . The remaining copy of the document check list shell

be placed in the data package for the quality control
I file.
. Quality Control, in coordinatlon with project engl-
I neerlng will prepare an End Item Narrative Report

in accordance wlth the requirements and format set
forth by NPC-200-2.
I This report shall be completed and transmitted to

Contracts Administration wlthln four working days
from time of equipment shipment, fifteen (15) copies
I required plus file coples.
L. C. Harrlson
I
I
!
M. WI [bur
I Project Superi ntendent
I L.,,J
- 0 'r')
W. J.'-e_Reilly
''
Program Manager - ELSS
I Prepared by :
I _eorge Roberts
Quality Control Engineer
I
I -END-
I
FORM2674-B EFFECTIVE:3-7-66

Project Gemini - Extravehicular Life Support System ELSS Final Report, 30 Jan. 1964 - 31 Mar. 1967

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Project Gemini - Extravehicular Life Support System ELSS Final Report, 30 Jan. 1964 - 31 Mar. 1967

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I _AsA e_

I NASA (:ONTRA(iT NAS-9-2il2

I Events and Information I-I

Selection of Semi-Open-Loop System 2-1

I Required Changes in Program 2-2

Addition of Aerospace Ground Equipment 2-2

I Major Milestones 2-2

3 PROGRAM HISTORY 3-1

System Study3 Definition and Packaging .3-2

Major Milestones .3-11

DESIGN AND DEVELOPMENT 4-1

General Design Requirements 4-2

I Environmental Specifications 4-2

Quality Assurance 4-2

I Summary and Conclusions

Test Facility and ECS 4-13

Evaporator-Condensor (Heat Exchanger) 167880 4-76

Suit Pressure Relief Valve 800278 4-105

Oxygen Pressure Regulator and Relief Valve 4-115

Duct (Ejector) and Heater Assembly 138969 4-126 I

Fill and Shutoff Valve 800286 4-142

H202 Quantity Gauge 800386 4-160 I

Description (See Figure 4-97) 4-1 83 I

I Umbilical Assembly 4-199

I Oxygen Supply Hose 138441 4-199

Oxygen Hose Quick Disconnects 4-201

Multiple Connector 800566 4-218

QUALIFICATION TEST PROGRAM 5-1

General Qualification Test Plan 5-2

I Qualification Tests 5-3

Procedures and Results

Data File 7-1

Configuration Change Control 7-I

Accountability - Phase I 7-2

Flexibility of Program 8-2

Nonmetallic Selections I0-1 I

Candidate Materials 10-7 I

II FLIGHT HISTORY I1-1 I

Date) 3 6-3-66 II-I !

I GT-I I (Launch Date_ 9-12-66) II-2

GT-12 (Launch Date) II-11-66) I I-2

I 12 OPERATING INSTRUCTIONS 12-1

I 13 PARTS LIST 13-I

I 14 INSPECTION AND REPAIR AS NECESSARY (IRAN) 14-I

Operation and History 14-I

Design Modifications 14-I

Actual Modification and Refurbishment 14-4

AIRESEARCH REPORT NO. RC-S6-R

I APPENDIX B PROCEDURES FOR QUALIFYING

I APPENDIX C DATA ACQUISITION PROCEDURE 210-A7 C-I

3-I Zero Gravity Tank Heating 3-.3 I

3-3 Zero Gravity Tank Heating 3-5 I

Power Spectral Density

4-3 Acoustic Environment Spectrum in Pressurized Cabin 4-7

4-5 Mass Flow vs AP for Gemini Astronaut Extravehicular Suit 4-12

4-6 Sectioned View of AiResearch Altitude Chamber Facility 4-14

4-7 Schematic Diagram - AiResearch Altitude Chamber 4-15

4-8 Schematic Diagram Showing Location of the Suit Parameter 4-16

4-9 Preflight Preparation of Test Subject 4-20 I

Exercise Period on Treadmill 4-22

4-14 Chestpack Assembly--Back_ as Viewed by an Observer 4-27

Primary Inlet Pressure as a Function of Umbilical

I 4-21 Total Cooling