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. '11 A EiL EIG NRO APPROVED FOR RELEASE 1 JULY 2015

MANNED ORBITING LABORATORY (MOL)

ORBITING VEHICLE

POWER UTILIZATION CONTROL

SAFSL EXHIBIT 30001

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The undersigned has reviewed the document and

vndersta.nds the contents to the extent necessary

• to scope subsequent proposals.

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NRO APPROVED FOR RFLEASE 1 JULY 2015-

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The undersIgncd understands. tha technical cont.c.,nt of this document and

endorses the requirents stated tharcin.

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This exhibit establishes the peak and average power allocations for each

segment of the Manned Orbiting Laboratory Orbiting Vehicle. It defines

the modes and the assumptions used in determining power utilization against

these allocations. It also establishes the minimum data requirements for

requests for changes to this exhibit.

This' document shall be upgraded as required to reflect approved changes in

. the Contents. Approved changes shall appear as Annexes to this document.'

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Ur ■,...76 VA V: A C',..1D 1 LI NRO APPROVED FOR RELEASE 1 JULY 2015

TABLE OF CONTENTS

SECTION PAGE

1.0 FORW ORD 4

2.0 APPLICABLE DOCUMENTS 6

3.0 POWER ALLOCATIONS

3.1 Peak Power Definitions 7

3.2 OV Peak & Average Power Allocations 8

3.3 Gemini B Equipment Mode Allocations 11

3.4 Photographic Payload Equipment Mode 11

Allocations

3.4.1 Simultaneity Assumptions 13

3.5 Power Calculation Assumptions 13

4.0 POWER UTILIZATION CONTROL 17

4.1 Power Reporting 17

4.2 Exhibit Change Requests 17

TABLES

3.2 OV Power Allocations

9

ANNEX I 18

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2.0 APPLICABLE DOCUMENTS

The following document of the exact issue shown form a part of this

specification to the extent specified herein.

SAFSL Exhibit 10003 Environmental Design and Test Criteria

for the MOL System Laboratory Module,

Mission Module, and Associated AGE.

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3.0 POWER ALLOCATIONS

3.1 Peak Power Definitions

•

Peak power available to each OV• segment from the LV Central Power System

Modes. These modes are defined below. These definitions constitute mandatory-

consistent with contractor power allocations.

during the various vehicle activities are allocated on the basis of OV Peak Power

requirements for the mode and do not exclude operation of additional equipments

. Mode A - Tracking Mirror Slew - During this mode the main optics tracking mirror slows and for settles. The ATEare both in operation.

Mode B - Photogra.ohic Operations - During this mode the main optics tracking mirror tracks the target and the shutter and camera-back sequence occurs for each frame taken. Both ATS operate .during this mode.

•

Mode. C - Mission Payload Checkout - This is a mode over a SGLS Station that permits complete checkout of mission payload systems including the ATS. The idea is to simulate a target pass for purposes of checkout and to deterrnjne anomolies in equipment operations in real time.

•

• -

• Mode.D - Mission Payload Activation/Preparation - This is a prepass preparation time during.which cues are viewed and mission payload equipment is activated and the visual optics magnification is adjusted,

• - • L Mode D2 - Other Mission Payload Operation - This is a mode that occurs

during target pass when main optics and A-TS are not in operation. This would occur when there are significant periods of time between targets. Certain functions that have been inhibited may be permitted during this period.

Mode E - SGLS Station - This mode covers the period preparing for, acquiring and communicating with a SGLS Station.

: Mode - Widebanci Station - This mode covers the period preparing for,

acquiring and data transmission to a wideband station.

Mode d - SGLS and 1.',rid.eband. Stations - This mode covers the simultaneous or overlapping operation required in contact with a SGLS and wideband station.

Mode H - All Other Orbital - This mode covers all orbital activities with both crew members in the Laboratory Module excluding communication or MPSS ' Operation. This mode includes all activities reqUired to support mission operations and includes such activities as film processing, cue study, food preparazicn, sleep, etc. : .

Mode I - Earl; or Late Orbit This mode covers the early and late orbit periods during which transfer of crew bc..tv.-een the Gemini B and Laboratory Vehicle sakes place. Early Orbit .::gins vi,tli severance of the Orbiting Vehicle

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from the booster and ends with the closing of the hatch after transfer of the second crew=n. Late Orbit is the reverse oteration and begins with the open-ing of•the Laboratory.hatch and ends vith the transfer from the Laboratory supolyback to Gemini B supplied power.

Mode J - Launch and Ascent - This mode covers the launch and ascent periods. It begins when the fuel cells alone supply power to the LV and ends when Gemini. B power is required frog; the LV.

3.2 OV Peak and Average P0Wer Allocations

Oil peak and average rower allocations based on the preceding mode definitions are givea in Table 1. For Mode C, EC is limited to the value corresponding to Node A if the equipment is being operated in Mode A configuration for checkout, and GE is limited to 1,480 watts with the assumption that both ATS's are not in use simultaneously. If the GE and EK equip.ment are operated in the Mode E configuration for Mode C checkout, EK is limited to the value for Mode B and GE is limited to 1,076 watts with the assu-aption that both ATS are not in use simultaneously. For special configurations used in Mode C, checkout procedures shall be designed to prevent exceeding po'ler capability. Each Segment/ Contractor shall restrict his peak power to the values shown in the Table.

Operations taking less than the maximum value are not restricted.

Gemini B and DAC power utilization for Mode I is further allocated on the basis .of threa sul.:;aodes contained in Mode I. Definitions for these submodes and the / corresponding allocations are as follows: k , i / /

/ - /

• / SIMODE • DEF1NITIOH •VAC DAC

. I1

Beginning of Early Orbit to Start 700 2765 of Crew Transfer to the LV

POWER ALLOCATIC)N

2 . Start of Crew Transfer to the LV . to end of Early Orbit

595 2900

13

Late Orbit 630 2900

The allocation for Gemini B and DAC contained in Table 1 for Mode I is the allocation for submede I3, since 13 provides the largest total peak Fever requirement of the three submodes. The total Dl phase will be split into four different oceretions which cannot be time coincident. Only one of these phasas is coincident with EK. loads of focus adjust, alignment and Visual Optics

• (v/o) Legnification Step Change. •

The D2 phase (Target Pass Standby) will be defined as the time interval be.w.?en the la:t phc•to operation 1.1p to but not including the Drive J door close ol,era-tion. The load at Drive actuation .nuts the system into the phase defined as D1-2.

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The operation for the GE-AVE during phase H (all other Orbital) will be

limited to the GE-AVE Loads of Command, Telemetry, VDP and all continuous

loads including environmental control and the low G accelerometer.

D1-1 . Coarse Warmup

This is a mode of operation during which coarse warmup heaters are energized

to ensure proper equipment operation.

D1-2 Door Cycling

This is a mode of operation in which drive electronics are in a standby and

the door is actuated.

D1-3 Adjustment Preparation

This is a mode of operation in which the tracking mirror is positioned for EK

adjustments.

D1-4 Adjustment

./ This is a mode of operation in which fpcis adjustment, alignment, and visual

optic magnification step change occur.

POWER ALLOCATIONS - (WATTS)

MODE GE WATTS EK WATTS

D1-1 Coarse Warmup 1300 Telemetry 317

DI-2 Door Cycling 1340 Standby .. 385

D1-3 Adjustment Preparation 1414 Standby 385

-D1-4 Adjustment 944 Visual Optics Mag Chg 785 \

Alignme__1. 740

Focus 430

The upper limit of LV Electrical Power System capacity potentially available

for allocation is 1.825 kw average power and 4.5 kw peak power.

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3.3

4.

Gemini B Equipment Mode Allocations.

Peak power utilized by Gemini B from the LV Central Power System is allocated

On the basis of Gemini B eeuiprnent modes. The correspondence between LV Peak Power Modes and the Gerrini B equipment modes is given in hetable below. Peak power allocations for the Gemini B equipment modes are those apearing

in Table 1 under the corresponding LV Peak Power mode and in the Gemini

C'El No. CP 58010A.

L.V. Peak Power Mode

A Tracking Mirror

B Photographic Operations

• C Mission Payload Checkout

Di Mission Payload Activation/ Prepa ration

•• D2 Other Mission Operation

E SGIS.Station

E Wideband Station

• SGLS Wideband Stations

1-1 All Other Orbital . •

I Early or Late Orbit

Launch and Ascent

-• MAC Equipment Mode

Normal

Normal

Normal

Normal

.; , •

. .

Normal

Normal Plus Telemetry

Normal . • . '

Normal Plus Telemetry

• ! Normal • -

Early Orbit or Late Orbit; See Paragraph 3.2

- NONE

•

. .

-3

3.4 Photoa”a.oh.ic Payload Ecuiornent Mode Allocations • . .' •

..Peak power utilized by the Photographic Payload is allocated on the basis of Photographic Payload Equipment Modes. The correspondence between LV Peak Power Modes and the Photographic Payload E:quipz-nent Modes is givei in the table below. Peak Power Allocations for the Photographic Paylo::,_d Equipment Modes are those .appoaring in Table 1 under the corresponding LV Peak Poser Mode except as noted in the table 1.-,elow.

-* Emergency communication allocation 100 Watts peak. Gemini B VHF' backup

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LV Peak Power Mode 5

A. Traeking Mirror Slew

B Photographic Operations . .

G Mission Payload . Checkout

Payload Eculprnent

Payload Peak Power iQGti • Allocation (Watts)

Tracking 'Mirror Slew

Photogra.phic

LV Peak Power Mode A or B Focus • .- Alignment Process

430 740 667

Mission Payload . See parezraph 3.2

Activation/Preparation

• -

Alignment Focus L

Z Other Mission Pay load Operation

SGLS. Station • Telemetry

Wideband Station Envir onrne ntal

. SC:LS & Widoband Telemetry Stations

• - H All Other Orbital

Process Unlock

• Environmental

. 430

•

167 236

Early Or Late Orbit Launch and Boost Environmental 236

3 Launch and Ascent • Launch and Boost Environmental 236 •

Different from the Corresponding LV Peak Power Mode

NOTE: Environmental Mode Power is 500 watts for the cold case, i.e., after system has been shut of for eNtende.d periods or when initially thermally stabilizing.

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3.4. 1 • Simultaneity Assumption

The subsystem bus activated for each of the photographic payload equipment

modes is given in the following table:

• Equipment

Mode ,.._,

0 F-t .F.

0 9

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Ali

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ent

Pro

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s

SG

LS

Unlo

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Vis

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Opti

cl

Mag

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Sta

nd

by

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0 0 0

13.s 0 L

Environmental X X X X X X X X X X X

LM L & B X

LM Instru. X X X X X X X X X X

Visual Optics X X X

Proc. Instru,

Focus

X X- X

X

X

X

X X X X X X

MM L & B X

MM Instru. X X X X X X X X X X

Controls & Displays X X X X X X

Unlock X

Alignment X

Processor X X X X X X X X X X X

Photographic X X X X

A continuous power switching loss is incurred in all modes.

3. 5 Power Calcula'inn Assumptions

These assumptions are no't to be considered as subsystem constraints or limitations. Their purpose is solely to provide a basis for establishing power utilization and they are not to be interpreted as design requirements.

Peak power is calculated for 25 volts at the LV main bus except for Gemini B which is based on 24.5 volts at the equipment terminals for the normal equip-ment mode and 27 volts for all other modes. Peak energies less than 10 millijoules are disregarded. Distribution losses shall be accounted for by the contractor responsible for the interface harnessing and are included in the allocations.

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Average power for DAC equipment is calculated at 28 volts at the equipment. GE and EK average power is calcula.teci for 24 volts at the respective interfaces.

All DCSG power is charged against DAC.

For ITS'S', env:iron:lent-al control power utilization is to be based on a. 0 orbit.

for the entir. clission a.nci is to be reported for a nominal tine of ye:ir of

liarch 21. Nominal fluxes as defined. in S',!:".•31, 10003 shall be used for l'oth orbit

e.Vera,s-e and instanten:-..‘ous fluxe.s for door open. conditions. A rerlresentative. sun

anile for instant.anevi.s albedo. calculations shall correspond to 500 latitude.

For LVSS the worst case orbital Condition shall be used for environraentva power

utilization. In a-ddition, the folio insrelatedasstra-,-_,tions ale.to be

used: 120 min/day

1. Average processor dryer ti:r.e.

2. Alignment measurement. o. 5 min/a.ctive rev.

3. Alignment operation (One per day .10 min/day

4. Visual. Optics . 100 minidly

• .

5. Magnircat-lon Change - •

Visual Optics: Vactive rev.

3/target ATS:

6. Film Ilandlin5. (Based upon one crewrnan 100 rnin12-ay

Operation),

7. Focus monitoring. b0 rniniclay

S. Instrumentation. (On during all tines 441 rr.iniday

when payload equipment is active :.=_s VIE-11

as sampling and station contact).

9. Regulated do or ac power deur erect to payload interface will be el--,ared

to the EK budget while power rer,uired for activation of rel-ays

will be charged to GE.

10, All E7-': pc-.ver. mode values include environmental control power at rnissicn average daily cycle (r.orrnal case). Fnviro- —enta.1 power v.

--r_ich

evidenced during ascent, early orbits or during recovery from a sustain,-_ci

abnormal vDltase or power-off. neriod is denoted as the cold case and

includes all hE'.at.er cor_trollers on.

11. CsiE en.vironme_ntz.1 system is inhibited during target p ass.

12. Active target pass. .1 100 rniniday

13. Active photographic rev. 10/d2_

14. C- ed targets (traciK!c: by ATS' 1000/day

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: 185/day 15. Tracked targets (primary o;:stics). .- • ; .

16. TM pitch slew time. : 481 sec /day,

. . . !

17. TM roll sz.,:lw time. 703 sec/day

: .

•!:2405 sec/day

-18. TM tracking time. - i -

19. Photographed targets. . I 75/day • -

,--.-- .f •

- 20. Primary photographs par photo•r:-,:...phed target. 6 • i •

21. Secondary camera in-out cycles. i 1'/photographed target ; ;

t i ! 1

22. Secondary camera photographs-per •• , :

photographed tz.;_rget. , !

23. Door open time per active rev. i 390 sec i

24,, Door open cycles/clay.* - : 1 2.5/day

25; ZI, Checkbut, R&D active revs i : 2/day ' ,

: 10/day

; i • • - 20/day

Included in Item 19 above.

E,.6- , min/day

244. min/day (39 DAC; 205 C

. NRO APPROVED FOR RELEASE1 JULY 2015

•

•

-• •

a) targets tracked

b) number of targets cues

c) targets photographed

d) door open

26. Computer on-time

27. Station contacts based on contact times:

clear voice 4. /day for 12 n-.in total i at 25 percent duty cycle i on transmitter

.• ; 16/day for 90 min tc,tzl,

16/day for 93 r;-;:..n. total \

TLM. (must include c:f.p.a.5ility. to , 16/day for 90 mini total \

receive secure TRC's) • (16 with comp :_ter on I minute to accommodate computer summary data readout)

3/day for 40 min total

• ;

•

b) secure voice

c) track

el command

Includes ZI, Checkout, R&D and Photography only.

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28. SGLS time (including warmup). 120 min/day

(includes items b, c, d, and e of item 27)

29. Wideband Contacts:

a) number/mission

b) average duration

60 makimum

a.. 3 minutes

30. Door area. Based on aperture masking to the following look angle constraints:

a) 14 deg. forward l stereo b) 25 deg aft angle c) + 37 deg obliquity angle

This aperture includes the following vehicle residual motion:

a) + 5.8 deg roll b) T 3.0 deg yaw c) 7.2.6 deg pitch

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4.0 POWER. UTILIZATION CONT ROL

4.1 Power Reporting,

The allocations in this exhibit shall be utilized in all power reporting docume.ntatio to measure power requirements margins. Reported power utilization shall be based on the mode definitions and assumptions contained in this exhibit..

7.. 4.2 Exhibit Chance Requests • •

Approval is required for. all changes in the peak and average power allocations., mode definitions and assumptions. As a minimum requirement, request; for . changes must be accompanied by:

a) a detailed engineering analysis substantiating the need for a change,

b) verification that this change can be made without exceeding system allocation limits for peak and average power - capacity Znd without constraint of mission operational flexibility,

• . . c) a detailed statement of • system imPact (e.g., weight, schedule, reliab,ilit

documentation, and cost impact), with appropriate breakdown o: data zo permit SPO evaluation.

Where a change affects more than one associate contractor, the requ'est for ;e must be coordinated between all affected contractors and submitted as a.Co.-nbineci package with the above items identified for each c ontractor. .

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ANNEX 1

This Innex to SAFSL Exhibit 30001 contains the ground rules and assunptions applying to LVSS eouipn2nt and its operation and the associated LVSS pea? and average power allocations.

ECS

1. 140T., Sieve Heater and heater controllers are used for contingency only and eouipment -,tatts are not included in any peak or average.

2. Waste Managera,,nt Blower is operational. in .113d.e II only. •

3. The water heater is inhibited by crew action for 1TSS operation and will remain inhibited in nodes A, P, C, D1 and D2. It will not be turned on during mode- 12.

ELEC.-I'M:CAL - •

• 1. Contingency items do not contribute to average power (except as. noted).

2. Equipment connected to the inhibit bus is inhibited in Modes A, B, C, F'3 Fand G.

3. *-MPSS Feeder Losses are based on MPSS allocations.: MPSS Allocation Watts/2.4V z 1 volt MPSS Feeder Loss. . .

4. G/B Feeder Losses are based on 0/B allocations:: G/B Allocation Wat!...st 24V x 0.4 volt = Gill Feeder Loss.

ACTS /SCE:

1. Rotational thrustors are inhibited in Modes A, B, •C, C, J and F.

Z. Translation thrustor firing will occur in Mode H. Lower activity levels will be planned around orbit adjust. Load management will allow planned orbit adjust. •

3. Averaie., power calculations for ACTS/SCIS are based on the. following duty cycles:

51. 2% High Power 44. 6cito Low Power 4.2%. Standby

PROPULSION

The ACTS/Prop Low Thrustor heaters allocation is based on 75'n sir.ieta_neity for peak allocztions.

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BIO-INSTRUMENTATION

1. IR Spectrophotometer is considered non-operational in all modes except Modes C, E, and G.

2. Charged Particle Spectrometer is used on a contingency basis only and equipment watts are not included any peak.

3. Biological Dosimeter is included in Mode.

DISPLAY

1. Assume 1/3 of total EL Push Button Switches and EL status lights are on for all modes.

2. The EL Caution and Warning Matrices and Incandescent Push Button Switches (Lamp Test Only) are contingency items not included in peak mode allocations.

3. The EL Digital Clock is included in Mode H.

LIGHTING

/1. Main Floodlights are reported at 75% of full power for 10.5 hours per day and are off in Modes A, B, C, D2, II and J.

2. Auxiliary Floor Lights, Sleeping Area Floodlights, and Hygiene Area Floodlights are on in Mode H only.

3. EL Nomenclature Panel Lighting is on only in Modes A, B, C, and D2.

ACQUISITION

The Digital Recorder is operated in the record condition in Mode C.

DATA COMPUTATION

1. LVSS peak power allocations include full DCSG services for all modes. Computer power requirements are based upon 244 minutes of operation per day.

2. The printer is not operated in Modes A, B, and C.

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S.AFSL EXHIBIT 30002

VIOL PROGRAM EFFECTIVENESS

SECTION 3

SAFSL Exhibit 10032 consistutes the remainder of the Effectiveness Exhibit and together with this section forms the total Exhibit 30002.

6 JUNE. 1968

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3. 1. System Mission Efiectiveness

3. I 1 Definition

Mission Effectiveness is defined as the reliability of the MOL System in

completing within design performance capability all functions necessary

.from liftoff to 'retrieval to support, provide, and return 95% of the

planned primary photographic data and the flight crew for a 30-day

mission. (R, AVE)

3. 1. 2 Effectiveness Allocations

The 30-day mission effectiveness goal shall be .85 for the manned

automatic configuration and . 63 for the automatic configuration.

a. The allocations given below assume the effectiveness

of all other segments = 1.

Manned Automatic

Automatic Configuration

... PSS .AVE .96 . .86

MMSS AVE .965 ' .92

LVSS AVE .96 .90

Gemini B .986. '

Titan III .97. .95

DRV's (3 required for 30 days) ** .94

Ground Net (retrieval function)

, 995

PSA .999

.85 .63

"Design changes that are identified solely to meet the allocations specified in 3.1.2 shall not be accomplished without MOL SO approval.

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** The reliz..1)ility of each DRV shall be .98. %-•-) s • • .„, ir L.. L-0

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- 3.1.2.1• Segment Effectiveness Criteria

The deterrninatons of segment effectiveness values shall

be based on the criteria specified below.

3.1.2.1.1 Gemini B System Segment

(AVE)

The Gemini B. System Segment shall be deemed to operate .

with design performance capability provided that operation of AVE is"

in any manual or automatic, primary or automatic mode such that the

crew and transferred DRC's are safely returned to earth for recovery

at the end of the MOL 30-day mission consistent with the 95% requirement.

(AVE) 3.1.2.1.2 Mission Payload System Segment

The MPSS shall be deemed to operate within design

performance capability provided that the MPSS AVE operates in a manner

such that (1) the pointing and tracking capabilities of the main tracking

mirror are within the 3a limits of the CEI specification-, (2) adequate

thermal control is provided; and (3) attainment of 95% of the photographs

are possible.

Specific reliability design goals for the MPSS equipment are

(1) Single IVS for. M/A mode - IVS S/S mission reliability

goal 0.984.

(2) Single ATS reliability goal 0.975. (AVE)

. 3.1.2.1.3 Laboratory Module System Segment

The LMSS shall be deemed to operate within design

performance capabilit y provided that the LMSS AVE operates in such

a mariner so that:

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SPEC AL E

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(1) The crew is free to perform experiments in a

shirtsleeve environment.

(2) All displays required by the crew for performing

experiments ale available.

(3) Real time and recorded telemetry data required for

experimentation or mission scheduling are acquired

and transmitted to the ground.

(4) The subsystem operating configurations and mode

selections provide a level of performance consistent

with that prescribed for support of experimentation.

(5) Failures which result in an interruption of any of the

above criteria during a time when the degradation does

not affect experimentation are included in mission success

.if the criteria is re-established prior to the time of

need or if the interruption lasts for less than one orbit.

The above criteria are constrained by the attainment of 95% of the

photographic data. (AVE)

3.1.2.1.4 Photographic System Segment

The PSS shall be deemed to operate within design performance

capability provided that the PSS AVE operates in a manner that permits

the attainment of 95% of the photographic data. (AVE)

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3. 1. 3 System Level. Ground Rules and AssulyTtions

System level missic.-- effectiveness model.s and analyses

'shall be developed by the LVSS.contra,ctor using inputs from the segment

level mission effectiveness analyses developed by each Associate

Contractor. The system. level mission effectiveness computations shall

be based on the ground rules and assumptions below. (T, AVE)

3.1.3.1 Calculation

Details of the mathematical combinations and associated

ground rules are found in the Top Mission Effectivensss Model Report

UR. 105. (AVE)

3. 1. 3. 2 Timelines and Interval Breakdown

The most recent version of the Flight Vehicle Timeline

(U.S. 108) shall be used as the basis for establishing time intervals and

operations during those intervals. As a minimum, the following five

intervals shall be used for reliability assignment:

Ascent

Early Orbit

Orbit

Late Orbit

Reentry and Retrieval

(T, It, AVE.)

Further breakdown may be used for ease of the computations, if desired.

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3. 1 . 4 Segment Level G-...o!nid Pules and Assumptions

The segment eilectvenss models and analyses, are to be

developed by each Associate Contractor for his segment and shall be

based on a methodology consistent. \-,71h system level effective'ness

, methodology. Each Contractor shall determine the equipment that is

required, to operate for the completion of each function, and develop

the necessary numerics. The segment level effectiveness model shall

be capable of providing the inputs required by the system level effectiveness

model. (T, AVE)

3. 1.5

Data

All input and output data, calculations, a.ssemptions, models,

and computer programs shall be available for review by MOI, SPO. (T, AVE)

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3. 2.2 PhOT Allocations

For the manned-autc-)matic configuration, the one-day PLOT

requirement is .68 and the any one of three-day PLOT requirement is

.89. For the automatic configuratio, the one-day PLOT requirement

is . 68 and the any one of three-day PLOT requirement is .88. These

numerics do not include delays resulting from adverse meteorological

conditions or local rail traffic control. Contractor allocations against

these requirements are as follows: • (R, AVE)

1 DAY

MANNED AUTOMATIC

CONFIGURATION

1 of 3 DAYS

AUTOMATIC CONFIGURATION .

1 DAY 1 of 3 DAYS

PSS .964 .99 .945 .98

MMSS .964 .99 .96 .99

LVSS .95 .935 .94 .975

Gemini B .95 .985 .1. ...00

T-III .90 .97 .90 .97

PSA .999 .9999

MISSION SUPPORT 90 . .97 .90 .97

DRV's .99 .99

TOTAL .68 .89 .68 .88

All allocations include AGE as well as AVE and are for the last

six (6) hours of countdown.

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3.2.3 System Level Grou

•

and Assumptions

(U) System Level PLOT modc:1 and analyses shall be developed by DXC.

using inputs from segment level PLOT analyses developed by each :\ssociate

Contractor. The system level PLOT model shall be based on the ground

rules and assumptions below. (T, AVE)

3.2.3.1 Success Criteria

(U) A launch attempt shall be deemed to be successful if ignition occurs

during the one hour window. It shall be assumed that ignition will be withheld

if there is any known unco rrected failure of AVE equipment andior if the

ground/air communication operational requirements for ascent and early

orbit are not being met. (AVE)

3.2.3.2 Availability

(U) The 2-week-in-advance-specification shall be interpreted to imply that

activities prior to countdown can be planned so that the system is ready to

start countdown on time. In other words, it is to be assumed that the system

is available at the start of countdown. (AVE)

3.2.3.3 Countdown Timeline and Interval Breakdown

(U) The most recent version of the Launch Operation Flow Subgroup Base-

line Flow Sequence (LOFS) shall be used as the basis for establishing time

intervals for PLOT calculations. The timeline for the PLOT calculation shall

be divided into no more than 9 sub-intervals. The sub-intervals shall reflect

at least 1) the start and stop times of radio frequency silence, 2) time of

insertion of flight crew and 3) the retraction of the mobile service tower.

3.2.4 Segment Level Ground Rules and Assumptions (T, R, AVE)

(U) The segment PLOT models and analyses are to be developed by each

Associate Contractor for his segment and shall be based on a methodology

consistent with the System Level PLOT methodology. The segment level

PLOT model shall be capable of providing the inputs required by the System

Level PLOT Model. • (T, AVE)

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3. 2. 5 Coml-ionent Guidel racf; Sec rnent

(u) For each sub--interval, those components which meet

one of more of the following criteria shall be included in the segment

PLOT analysis.

a All AVE components shall he considered.

. b. When the 6,-.pected failures of an operating ground equipment component divided by the expected failures of the total segment operating ground equipment is greater than 0.01.

c. The total corrective action time is expected to be greater than 2.1 hours.

d. The corrective action requires segment disarming, deviating or refueling.

e. Failure requires revalidation of any AVE.

f. The failure of the operating ground equipment component has an effect which crosses a segment interface and. induces a, secondary dependent failure in that interfacing segment and/or requires changes in the nominal count-down procedures of that interfacing segment. Situations requiring recycling on the second segment or requiring that the second segment wait until corrective action is completed are covered here.

g. A Class III or Class IV hazard to the prime flight crew is involved.

h. The operating ground equipment component is "critical" according to the criteria set forth in the discussion of Reliability Critical. Items, RCI (See Paragraph 5. 3. 1).

i. The component is life limited. (See Paragraph 5. 3. 2). (T, R, AVE)

3. 2. 6 Data

(U) The input and output data, calculations, assumptions,

models, and computer programs used for Segment Level PLOT

assesment shall be available at the contractor's facility for review by

the MOL Systems Office. (T, AVE)

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•• 3.3 Y ANALYSIS •

(U) The analysis requirements for the MOL Safety Program are specified

in this section. Safety analyses shall be used to evaluate the hazardous -

conditions that may exist during the MOL mission and the resultant impact

on safety. An acceptable level of flight crew fatality risk is specified in

3.1.3.7 of SS-MOL-1B. The hazardous conditions to be considered are

specified. in MIL-S-38130A. The goals for the maximum probability of .•

occurrence of Class III and.IV hazards is specified 3.3.8 herein and

allocated to the affected segments. '(T, AVE)

(U) Safety analyses are required by MIL-S-38130A for all phases of MOL

system segment, and subsystem design and development. There exist a

number of analytical techniques that can satisfy this requirement. It is

intended that. the most effective of these approaches be applied to MOL design

to the extent necessary to verify that an acceptable level of safety has been

obtained. ' To achieve this goal within the MOL Associate Contractor structure,

each contractor must conduct a safety analysis effort compatible with the

programs of all other contractors. Requirements of. this section are designed

to provide compatibility by assuring uniform and timely application of

appropriate techniques at the integration level and apply•to those AVE, AGE

and facility equipments that support the prelaunch through retrieval phases of the

MOL mission. (T, AVE)

3. 3. 1 Analysis Methods

(U) Four safety analysis methods may be used to satisfy the requirements of

this exhibit for system level analysis: Gross Hazards Analysis, Fault Hazard

Analysis, Fault Tree Analysis, and Operating Safety Analyses. The extent

to which each analytical method is - applied, including schedules and milestones,

will be specified by the Contractor in his System Safety Plan (SSP), 5.3.'11.

The program for incorporating various Associate Contractor safety analyses into

integrated safety analyses of the overall system will be defined by the phase

integrating contractor in his SSP and in coordination with the supporting

Associate Contractors.

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(T, P, AVE)

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(U)For safety analysis of hazards cenfi.ned to an individk.al segment, alternative .

techniques may be utilized, providing (1) the data, supplied to the integrator is

in a form that can be utilized aeld (2) the Contractor in the SSP provides -

justification that the techniques being utilized accomplish the end result.

3.3.2 Responsibility. alvsis Integration

.(U) The Aerospace Corporation, systems level integration contractor, is

responsible for conducting•a gross hazards study, fault tree analyses and

operational analyses at the system level. The responsibilities for integration

of system safety for each mission phase shall be delegated to the associate

contractors specified below.

Prelaunch and Launch Phase Titan HIM S/S Contractor

Ascent. Phase Gemini B S/S Contractor

On-Orbit Phase Laboratory Vehicle S/S Contractor

Reentry and Retrieval Phase Gemini B S/S Contractor

The contractor responsible for the design a.nd development of a segment shall

meet the intent of MIL--S-38130A by conducting the analysis defined below, as

required, relative to his segment and supply the analyses data in a form that.

supports the integrated analyses defined above to the criteria provided below.

(T, AVE)

3. 3. 3 Gross Hazard Analysis

3.3. 3. 1 Scope of Study.

(U) A system level Gross Hazard Analysis (GHA) shall be performed to

provide a qualitative safety evaluation of the MOL design. This effort will be

performed by the system level integration contractor. (T, AVE)

3. 3. 3. 2 Environmental Hazards

(U) Hazards associated with the design operational environment will be identified

• by the Gross Hazard Analysis. The impact of changes in the operational

environment will be investigated to establish the degree to which each mission

phase should be evaluated for sensitivity to environmental conditions.

(T, AVE)

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3.3.3.3 Source:

(U) Particular attention shall be ,2iven to sources, control and diStribution

of energy, such as ordnance devicc.'.s, fuels and propellants, and electrical

systenis. (T, AVE)

3.3.3.4

Other Hazards

(U) Other areas to be considered include, but are not limited to, the

following: •

a. Compatibility of materials

b. Electrical transients an d RF energy

c. Pressurized systems

d. Atmospheric Contamination

e. Human interface • (T, .AVE )

3.3.4 Fault Hazard Analysis

(U) A qualitative Fault Hazard Analysis (FHA) shall. be conducted to identify

potential hazards associated with each contractor's AVE and the OGE and

facility equipments required for the launch phase subsequent to prime

flight even-insertion into Gemini B and is performed by documenting all

identifiable component failure modes and defining their resultant effects.

(T, AVE')

3.3.4.1 Classification

(U) The hazard associated with each failure mode shall be classified in

conformity with the criteria listed in Paragraph 3.2.3 of MIL-S-38130.A..

Failures resulting in safe (Class I) or marginal (Class II) conditions or events.

required no further analysis. Failures resulting in critical (Class III) or

catastrophic (Class IV) conditions or events shall be reported to the procuring

agency and to the designers with recommendations for remedial action. (T, AVE)

3.3.5. Fault Tree Analysis

Fault tree analyses shall apply to the same time periods and equipment as the FI-Ln..

3.3.5.1 Scope

(C)

All. critical and catastrophic events shall be analyzed to deterrni:--,J:

nature of the hazard. Fault tree analyses (FTA) shall be used to identify events

or likely groups of events which will produce the defined undesired Class III or IV L-599.8_

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ha z -ard, with a pctential t e predicted prime flight crew fatality,

or, in the case of the backup :•ecele qualitative Leult tree type of assessment

for equipment damage. AV E)

3. 3. 5. 2

(U) Each segment contractor :.:.all lye a quantitative risk assessment for

identifiable.hazardous conditions, within his segment. Each segment

'contractor shall derive a quantitative risk assessment of hazards which may

propogate across segment interfaces. This interface information shall be of

sufficient detail and in such a format as to allow both mission phase and system

level integration. Each phase integration contractor shall specify the data

requirements such that a quantitative estimate of the probability of flight crew

fatality can be established and evaluated against the requirements of

SS-MOL-113. (T, AVE)

3. 3. 6 Operatincf Safety Analysis

(U) Each Associate Contractor shall perform operating safety analyses to

determine the safety requirements for personnel, procedures and equipment

which he provides and which are used in maintenance, support, testing,

operation and flight crew training during all phases as specified in the system

requirements. Phase integrators (3.3.2) shall perform integrated Operational

analyses. The analyses shall be used to verify that the equipment is safe to

use or to identify additional procedural requirements necessary to assure

safe usage. The analyses to be performed by the Contractor shall be described

in the Contractor's SSP (5.3.0). (T, R, AVE)

= 3. 3. 6. 1 Procedures.

(U) The results of the operating safety analyses shall provide the basis for

the preparation of procedures, including handbooks for:

a. Rendering the subsystem/system safe under normal and emergency conditions.

b. Emergency escape or egress and rescue operations.

c. Ground handling and transportation operations.

d. Operating and maintenance operations, including warning and caution notes.

(T, AVE)

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3.3.7 Analysis Schedule

" . The analysis schedule provided belr.)v,- shall be used as a guide in establishinz,

formal revievis and data submittal resuircudents to he shown in the associate

Contractor's SSP.

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• Submittal of gross hazard study and list, of identified critical

and catastrophic events inherent in system design.

Fault hazard analysis submitted prior to CDR so that integrating

contractor can prepare system FTA in tin for CDR, Su'onlit t 1

dates established by contract

Fault tree analysis presented at CDR

Updated safety analyses, including FTA and FHA of eciuipment

if design changes after CDR.

Final safety analysis of CEI submitted for incorporation in

s y stem documentation (5. 3. 11 (AYE)

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3.3.8 Numericz.11 atior;s

(U) Seernent allocations or the pi.obability of occurrence of Class III and

Class IV hazards and oth- "Decision-Conditional" abort conditions which

impact prime flight crew sa:Cety given in Tables 3-1 and 3-2. These

allocations shall be used s design goals in assessing system safety as a

result of equipment: failure, human. error, or other system conditions.

The equipment to be considered shall. include all AVE and that OGE and

facility equipment required for the launch phase subsequent to prime

flight crew insertion into Gemini B. (T, R, AVE)

3. 3. 8. 1 Definitions

(U) The following categories are defined for the purpose of interpreting

MIL-S-38130A Class III and Class IV hazards allocated in Tables 3-1

and 3-2.

Class IV: Catastrophic Hazards - Conditions which result in crew

fatality because corrective action is impossible.

Class III: Critical Hazards Conditions which require corrective action

(including escape/abort) for crew survival.

Decision-Conditional Hazards - Conditions whereby a single

subsequent failure of backup equipment or alternate procedures

would result in a crew fatality. (AVE)

3.3.8.2 Distribution of Hazards

(U) Tables 3-1 and 3-2 provide the distribution of hazard allocations

such that those hazards of primary importance are allocated in Table 3-1.

Those hazards which generally are less critical, but do significantly

impact on flight crew risk, are allocated in Table 3-2. Of those hazards

balocated in Table 3-1 no more than 1% of the individual values shall be

Class IV catastrophic, except during the reentry phase where an escape

capability does not exist. For the Reentry Phase of the mission, the

Class IV hazard allocations shall not exceed 10% of the value in Table 3-1.

Of those hazards allocated in Table 3-2, no more than 10% of the individual

allocations distributed in each phase shall be "Decision-Conditional. "

Figure 3-1 provides a descriptive interpretation of the Class III (T, R, AVE

and IV hazards distribution.

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APPENDIX

EK DEVIATJONS

TO

SAYS", 30002

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EK's current contract baseline calls for a reliability goal of at least

91. 4:,,7.0 for the probability of successfully exposing 14, 000 ft. of primary

reco:ed at an acceptable quality level in the manned-automatic mode.

This requirement is lower than the goal allocation given in paragraphs

• 3.1.1, 3,1.2, & 3.2,2.

Therfore a SAFSI, deviation to retain the contractual baseline is granted

until a study can .be performed to determine the capability of the PSS to

meet the SAE'S', 30002 requirements.

• Included in the study will be identification of changes required to approach

the SAFSI, effectiveness goal allocation.

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L-5996 Copy 2 Zol Pa c, e

NRO APPROVED FOR RELEASE- 1 JULY 2015 .

& L.

ce :01 .k/A

SAFSL EXHIBIT 30005

ELECTROMAGNETIC COMPATIBILITY REQUIREMENTS,

ORBITING VEHICLE, GENERAL SPECIFICATION

FOR THE

MANNED ORBITING LABORATORY

PROGRAM

"-Jui46-- —3-171rr. 1968

p- lnL

c L - 6 0 0 6 • I,

Copy of Page I f//?--O

e.,1

(Signed) ,

• (Signed )

(Signed)

(Signed)

NRO APPROVED FOR RELEASE 1 JULY 2015 SPECIAL HANDLING

5Mb'- c.)e 51".


understands the contents to the extent necessary

to scope subsequent proposals.

(Signed)_

(Signed)

(Si.gned)

(Signed)

(Signed)

SPECIAL HANDLING

u w7


r •

r

FORE1A'ORD

Electromagnetic Compatibility Desigii and Test Philosophy

Every precaution should be taken in.a Manned Spacecraft program to ensure the safety

of the astronauts. It is vitally important that all significant equipment involved

in the flight operate properly. One factor in ensuring such operation is the

control of Electromagnetic Compatibility (EMC), with the associated control of

Electromagnetic Interference (EMI). EMI generation and susceptibility must be

kept within limits to ensure that the composite system and its component vehicle

system, Aerospace ground equipment system, and their respective subsystems

and equipments are compatible within themselves and that they have a high

probability of operating within acceptable tolerances in conjunction with other

subsystems.

Experience with other space programs has pointed up the need for thorough EMC

testing and prompt application of necessary corrective measures, from preliminary

design through testing on the pad in or.der to minimize costly delays due to

last minute EMC "fixes."

EMC control can be most expeditiously, effectively, efficiently, and economically

applied during the engineering design development phase. For this reason, this

speCification discusses and stresses the design phases of EMC control and

establishes the EMC design and testrequirements for the composite system, its

component systems, and their respective subsystems and equipments.

The intent of this specification is not to impose arbitrary and unreasonable

requirements upon contractors,• but rather to assist them in engineering a

compatible composite system. For this reason, the various EMC control

plans and test plans, discussed herein, are highly important and significant

documents.

This specification utilizes the applicable portions of the governmental documents

noted in section 2. O. It further supplements this consolidation with additional

technical and management requirements to establish a MANNED SPACECRAFT

SPECIFICATION. This specification was derived from SSD Exhibit 64-4 and

the deviations granted to the MOL Associate Contractors. It applies only to the

segments comprising the Orbiting Vehicle and a different specification applies

to the T-IIIM. SAFSL Exhibit 10005 is identical to this document except EK

deviations have been deleted. Page 2 of 106

rs, '73 •-• .3 171 r--, r

;Page :;‹ of /,/ •••,-..

!! rtt, q t •.j NRO APPROVED FOR

F1ELEASE 1 JULY 2015

L aeopm,■•••••

L-, 77i en.r ps

t.

. L- 6 0 0 6 .

Copy.TV). of 4/C

: 'Pa cre _9 of i i' 7,--

CONTENTS

•

). SCOPE 1

. •1.1 Use 1

1. 1. 1 EMC Control Program 1 •

1:1.2 Application to Specifications 1

1.2 Classification 2

2. APPLICABLE DOCUMENTS 5

3. REQUIREMENTS 7

3. 1 Electromagnetic Compatibility Control Program 7

3. 1. 1 Composite System

7 3. 1. 1. 1 JIG. Control Board 7

3. 1. 1. 2 EMC Design Control Plan 8

3. 1 . 2 Subsystems and Equipment 9

3. 1. 2. 1 EMC Control Group 9

3. 1. 2. 2 EMC Design Control Plan 10

3. 1. 3 Short Duration Interference 11

3. 1. 4 Electromagnetic Interference Safety Margin 11

3. 1. 5 Electroexplosive Actuated Systems 12 •

•

3. 1.6 Government Fuihished Equipment 12 •

3.2 Design 13 3.2. 1 Interference Free Design 13 3. 2. 2 Susceptibility 13

3. 2. 3 Case Shielding 14

3. 2. 4 Bonding 14

Page 3 of 106

•

r • •,-7S F 1 11' F . Gas--1 L \,)

1,1• .1 0,

NRO APPROVED FOR RELEASE 1 JULY 2015 . II

..paie 4 of 106

•

C", 7', rs' P., ?? v c

_ L - 6 0 0 6

Copy? of Zt- of if 7-

L CONTENTS (Continued) •

3. 2. 5 Design Criteria 18

3.0. 5. 1 Wire Design 18

3. 2. 5. 2 Interconnecting Wires 21

3, 2. 5, 3 Grounding and Isolation 22

3. 2. 5. 4. EED Firing Circuits 23

3. 3 Interference Control Requirements 24

3. 3. 1 Subsystems and Equipment . 24

3. 3. 1. 1 Interference Generation Lii-nitt, 24

3.3. 1. 2 Sus c 25

3. 3. 1. 3 Electroexplonive Devices 27

3. 3. 2 Space Vehicle System 29

3. 3. 2. 1 Electrical/Electronic Compatibility Test • • • 29

3. 3. 2. 2 Improper Response 29

3. 3. 3 Validation of EED and EED Initiator Circuit 30

3. 3. 3. 1 Syntez-n Sensitivity 31

3. 3. 3. 2 Free entation of Data 31

4. QUALITY ASSURANCE PROVISIONS 33

4.1 Electromagnetic Compatibility Tent Plano 33

4. 1. 1 Compcieite System 33

4. 1. 1. 1 Schedule 33

1. 1. 1. 2 Content 33

4. 1. 2 Subsystems and Equipments 34

4. 1. 2. 1 Schedule 34

4.1. 2. 2 Content • 34

4. 1. 3 Teat Plan.tiched.ule ; 36

' EA f' e E [7: NRO APPROVED FOR RELEASE 1 JULY 2015 417) ■■,,

CONTENTS (Continued)

4. 2 Interference Measuring Instruments

4. 2. 1 Vehicle a.nd AGE Subsystem and System Test

• Equipment

4. 2. 2 Subsystem and Equipment

4.2.2. 1 Catcgory.A

• .4. 2. 2. 2 Category B

4. 2; 2. 3 Category C

4. 2. 2. 4 Broadband Spectrum Analyzers

4. 2. 2. 5 Automatic/Semiautomatic Test

37

37

37

37

39

39

39

Instrumentation 39 •

4. 3 Opernion of Measuring Instruments 40

4. 3. 1 Calibration 40

4. 3.2 Generator Accuracy 40

4. 3. 3 Broadband Interference Measurements 40

4. 3. 4 CW Interference Measurements 41

4. 3. 5 Pulsed CIV Interference Measurements 41

4. 3. 6 Monitoring 41

4. 3. 7 Bonding of Measuring Instruments 41

4. 3. 7. 1 Rod Antennas 41

4. 3. 7. 2 Instrument Grounding 42

4. 4 Test Frequencies 43

4.5 Tuning 44

4.6 Test Conditions 45

4. 6. 1 System 45

4.6. 2 Subsystems and Equipments 45

4.6. 2. 1 Ambient Interference Level 45

4. 6. 2. 2 Ground Plane 46

4.6. 2. 3 Bonding 46

4. 6. 2. 4 Power Supply Voltage 47

4. 6. 2. 5 Arrangement and Operating Conditions 47

Page 5 of 106

fm.

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r ' " Pale ,`.5 of

5.

6.

J

c". • • Oz:

• f7") • g L s:2 • NRO APPROVED FOR

RELEASE 1 JULY 2015 .

CONTENTS (Continued)

•

4. 6. 2. 6 Antenna Orientation and Positioning in Shielded Enclosures

4. 6-. 2. 7 Antenna Orientation and Positioning (Free Space)

4. 6. 2. S Loads

49

49 50

4. 7 Test Methods 51 4.7. 1 Composite System 51 • 4. 7. 1. 1 Implementation 51

4. 7. 1. 2 Improper Response ,: 51 4. 7. 1. 3 Test Approaches 52

4. 7. 2 Equipment''Tesi Methods 52 •

4. 7. 2. 1 Conducted Interference 53

4. 7. 2. 2 Radiated Interference 53

4. 7. 2. 3 Transmitter (Key- down) 53

4. 7. 2. 4 Transmitter Crossmodulation 54

4. 7. 2. 5 Susceptibility 54

4 . 7. 2. 6 Intermodula.tion 58

4. 7. 2. 7 • Receiver Front End Rejection 58 4. 7. 2. 8 Isolation Resistance Measurement

PREPARATION FOR DELIVERY 61

NOTES 63

'6. 1 Intended Use 63 6. 2 Definitions 63

6.3 Referenced Figures and Tables 76

Page 6 of .106

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( L 6006 Copy 22,,ef

Pa cre 1-- °// ?-- /

•

T,1 A r r:- j r c, NRO APPROVED FOR

RELEASE 1 JULY 2015 •

FIGURES .

1

1.

Z.

3.

Interference Control Requirements

.Peak Detector Conducted Limits, 30 CPS to 15 KC

Peak Detector Conducted Limits, 15 KC to 100 MC

77

78

79

4. Broadband and Pulsed CW Radiated Interference 1 Limits 80 i

5. Broadband and Pulsed CW Radiated Interference I

Limits 81 1

6. Narrowband CW Radiated Interference Limits 82. ! t

7. Narrowband CW Radiated Interference Limits 83 t

8. Receiver Front, End. Rejection v-1 - 84

9. Typical Simple Test Setup 85 I

10. Typical Test Setup Using More Than Two Power Lines . 86 1 11. Typical Test Setup for Conducted Interference

Measurements 87 12. Typical Test Setup for Radiated Measurements, Rod I :

Antenna . 88

13. Typical Test Setup for Radiated Measurements, Dipole Antenna 89 i

14. Typical Test Setup fo? Radiated Measurements, Log Spiral 90

I i

i 15. Conducted Susceptibility Limits, 30 CPS to 150 KC 91

16. Susceptibility Test Setup, 30 CPS to 150.1‹C - 92 I

17. Spike Characteristics 93 18. Spike Generator, DC Lines

.. 94

t 19.

20.

Spike Generator, AC Lines

Pulse Transformer Specifications

95

96 i 1

21. Typical Cable Induction Test Setup 97 i

22. Typical Radiated Field Susceptibility Test Setup Using Long Wire Antenna 98

23. Power Delivered to a Tuned Dipole Antenna versus Radiated Field Intensity in Volts/Meter for One

Foot Distance 99

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FIGURES (Continued)

Radiated Volts/Meter vs Line current in the Radiated Line 100

Comtersion Chart - Microvolts/kc to db/MC 101

Conversion Chart - Microvolts to d.b above One Microvolt 102

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25.

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1.0 SCOPE

p This specification provides the requirements of an electromagnetic compatibility

(EMC) control program for each manned spacecraft composite system procured

by the Manned Orbiting Laboratory Systems Program Office (MOL.SPO). The

EMC control program for each such system shall be used by MOL SPO to establish

and maintain "engineered-in" EMC control from issuance of contractual go-ahead

of the program definition phase through the life of the affected system so that the

confidence .level and degree of probability of system performance in its operational

environment will be before the fact. All deliverable data and/or documentation specified in this Exhibit shall be in accordance with the respective contractor CDRL

1.1 USE (Dli142.3 or equiv.) as detailed by Forms 9.

For MCASTRO, SAFSL Exhibit 10005 shall be applicable to: new equipment,

extensively modified equipment, and equipment interfaces between associate F r

contractor segments.

R-AVE (a)

The contractor shall comply with the conducted and radiated

interference requirements imposed by the interface specifi-

cation as measured at the interface.

(b) SAFSL Exhibit 10005 shall apply to relays, solenoids,

swtiches, and EED Firing Circuits, but need not apply

to other passive equipment.

(c) The test requirements of SAFSL Exhibit 10005 shall not

apply to launch complex AGE not associated with vehicle

testing or that is not normally used in the vicinity of the

launch pad, LCC, or CSA. EMC for this AGE shall be

verified by successful functional utilization of this AGE

and inspection of the EMC design provisions.

EMC Control Program

T This specification shall be used by the integration contractor assigend such

responsibility by MOL SPO to establish and maintain the EMC control program

subject to the approval of MOL SPO for the affected composite system and to

establish and maintain the application of such a program to the component

systems and their respective subsystems and equipments, as formulated in

the applicable EMC design control plans, as verified by the applicable EMC

test plans, and as documented in the applicable EMC test reports.

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1. 1 . 2 Application to Specifications

R-AVE The. applicable and intent of this specification shall be implemented in every

contractual specification, whatever its kind,• class, or sub-class, which

defines and describes any item of the composite system, the individual

systems, when that item may affect the electrical or electronic- functioning

of the composite, regardless of whether an aural, electrical, mechanical

or video input or output is involved.

1.2 CLASSIFICATION

This specification covers the EMC control of the Orbiting Vehicle Segments.

As a composite system, it will consist of all or part of:

(a) the vehicle which will consist of one or more stages and er:Vpsules or modules each of which may comprise all or part of the©e subsystems:

R-AVE 1 . spaceframe, including environment control, separation and joining mechanisms, observation and access areas and provisions therefore

2. propulsion, including primary, secondary, tertiary

3. electrical power, including primary and secondary power sources, such as batteries, solar arrays, fuel cells, and inverters

4. guidance and control, including attitude control and stabilization, orbital adjustment

5. communications, including telemetry, data link

6. life support which will comprise those devices, plumbing, wiring, scaling, seating, etc. which are installed in the life support compartments, bays, or other areas of the appropriate capsule(s) or module(s)

7. experimentation and observation equipments, self-contained power therefore, and the various accessories attendant thereon.

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(b) The astronaut subsystem which will incluf.ie those equipments, materials, and items worn or carried by the individual men, such as radio transmitters and receivers, light sources, body functions, psychophysiological equipments, etc.

(c) The aerospace ground equipment system (AGE) consisting of:

1. the operational ground equipment (OGE) subsystem which includes the instrumentation, control and checkout consoles, cabling, wiring, communications, ground electrical power., fluid loading (whether liquid or gas), handling, including erecting, mating, demoting, adjusting, calibrating, command loading, and all other material. required to conduct precountdown tests, countdown, and launch

2. the maintenance ground equipment (MGE) subsystem which includes those items and material of the types noted in (1) above, (OGE), which are used to maintain the vehicle system in, or restore it to, a state of readiness for launch, countdown, and precountdown tests. For EK Only: Although support equipment not associated with the vehicle system in its final launch configuration is not considered part of the composite system and thus excluded from the requirements of this specification, factory checkout equipment used for EMC testing shall be designed such that its operation does not degrade the EMC or EMI test results or the operation of the AVE equipment under test.Dr other Associate Contractors, this EK deviation applies to non-CEI equipment.

3. exchange hardware used for electrical tests with the EDCTU, qualification, acceptance, and readiness tests shall meet the OGE EMC requirements or the allowable EMI limits specified in the appropriate interface specification.

For purposes of this specification, the operational environment shall be

understood to be that of the launch environment, including precountdown tests,

countdown, and launch, as encompassing the worst environment to be encountered

by the composite system, its component systems, and their respective sub-

systems and equipments. The ambient EMC environment surrounding the launch

vehicle is not included in the conditions stated in this specification. The

contractors shall inform the SPO when the ambient conditions (data to be furnished

by the SPO and analyzed by the EMC integrator) do not allow the contractor to

meet the requirements of this specification.

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3 Li t r i

. 0 APPLICABLE DOCUMENTS

1 he following documents

f,,rm a part of this specification to the extent specified herein. In case of

conflict with this specification, the requirements of this specification shall

covern.

(a)

MIL-STD-831 - Test Report, Preparation of, dated

28 August 1963

(b)- MIL-B-5087B - Bonding, Electrical, and Lightning

Protection, for Aerospace Systems, dated 15 October 1964

(c)

MIL-STD-202C - Test Methods for Electronic and Electrical

(c1)

SAFSL 30034-EMC Control Plan Composite System 6 June 1968 Component Parts 12 September 1963

It is to be acknowledgd, that the documents listed below provided source

material for this specification, although their particular requirements are

not specified herein.

AFMTCP 80-2, 'Vol I Appendix A

MIL-STD-826(USAF)

MIL-E-6051

MIL-I-6181

MIL-I-26600

AF/BSD Exhibit 62-87

General Range Safety Plan, Air Force Missile Test Center, Patrick Air Force Base, Florida

Electromagnetic Interference Test Requirements and Test Methods

Electrical-Electronic System Compatibility and Interference Control Requirements for Aeronautical Weapon Systems, Aircraft Subsystems, and Aircraft (Cf. Aerospace Industries Association- proposed "D" revision thereto)

Interference Control Requirements, •Aircraft Equipment

Interference Control Requirements, Aeronautical Equipment

Electro-Interference Control Require-ments for Minuteman (WS-133B)

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REQUIREMENTS

ELECTROMAGNETIC COMPATIBILITY CONTROL PROGRAM

Composite System

It is intent of this specification to provide the requirements of an

Electr magnetic Compatibility (EMC) Control Program for each ..

spacec:- aft composite system procured by the Manned Orbiting Laboratory

Syster Program Office (MOL SPO). Such a Program shall be used by MOL

SPO establish "engineered-in" electromagnetic compatibility control

from ?. ::proval of go-ahead orthe Program Definition Phase through

the lif-a of the affected composite system. The implementation of the EMC

Contrc,r Program requirements shall be accomplished by the EMC Control

Board ::irough thdeoinposite system EMC Design Control Plan and the

=r11 and equipment EMC Design Control Plans and through the EMC subsyr,•.

Test associated with each. The Test Plan Reports will document the

activk; and shall function as the formal record of contractual compliance

with

Electrr,fnagnetic compatibility shall be engineered-in by before-the-fact

de •sign •if the composite system components in accordance with the require-

ments -,f. this specification so as to preclude the existence of any potential

interference(s) in or between the components, i. e. , the vehicle

syster:, and the AGE system, regardless of where their electrical, aural,

video 2;:.d mechanical inputs and outputs fall within the. overall frequency

spectr.in of the composite system.

3. 1. 1. EMC Control Board

The E'LC Control Board shall be established by MOL SPO on the initiation

of go-:;head of the Program Definition Phase of a manned spacecraft .

composite system procurement program and shall function through comple-

tion of ..he Development Phase. The Board shall exercise technical control

of the composite system EMC Control Program, of the composite system

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r'I A 7 NRO APPROVED FOR RELEASE 1 JULY 2015

EMC Design Control Plan which is established and maintained to implement

the Program, and of the EMC Test Plan which is established to verify the

composite system EMC Design Control Plan within the constraints of the

Control Program.

The VlvfC Control Board shall function as specified in the EMC Board Charter

contained in SAFSL 30035.

3.1 . 1. 2 EMC Design Control Plan

3.1 . 1 . 2.1 Schedule

The composite system EMC Design Control Plan shall be established by the

integration contractor, in coordination with the associate contractors, and

shall be submitted to MOL SPO for approval within ninety (90) calendar

days after contractual notice of go-ahead for the Program Definition Phase

from the procuring activity. At its descretion, MOL SPO shall convene the

EMC Control Board to resolve any problem areas arising from lack of complete

approval of the submitted Design Control Plan and to establish any schedule(s)

necessary for accomplishment of complete approval by MOL SPO.

Maintenance of the composite system EMC Design Control Plan shall be

the responsibility of the integration contractor who shall revise or supplement

it with the approval of lviOL SPO. This maintenance of the composite

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system EMC Design Control Plan shat be directly related to the

EMC Design Control Plans for the individual subsystems and equipments

of the vehicle and AGE systems, as noted below.

3. 1. 1. 2. 2 Content

P The composite system EMC Design Control Plan shall delineate the methods

that shall be used by the EMC Integrator to ensure the electromagnetic

compatibility of the combined system segments, in a composite MOL system.

3. 1. 2 Subsystems and Equipments

3. 1 . 2. 1 EMC Control Group

T Each associate db'iLtiacto'r (this includes the integration contractor in his

function as a direct contractor for one or more of the vehicle and AGE

subsystems or equipments) shall establish an EMC Design Control Group

which shall function for the affected subsystems/equipments.

The EMC Design Control Group shall meet as required through the life

of the composite system program.

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EMC Design Control Pin

3.1:?. 2. 1 Schedule

Each associate contractor establish an EMC Des in Control Plan for

the individual subsystem(s) or equipment(s) for which he has contracted witu

the procuring activity and shall submit it(s) to the integration contractor

within forty-five .(45) days of contractual go-ahead of the Program Definition

Phase. Such a Plan shall ho maintained through the life of the composite

systsrn program and sh-r:11 r,2 su'lin-litt,26 in accordance with the schedule(s)

established by the integration contractor. Such a design control plan shall

include the constraints placed on subcontractors and suppliers to assure

1 EMC.

3.1.2. 2. 2 Content

Interference shall be controlled to eliminate undesired interaction and

malfunctioning of the respective electronic and electrical subsystems and . - equipments, regardless of whethei: the affected inputs and outputs of the

systems are electrical, aural, video, or mechanical. This requirement

applies to the entire frequency range of such subsystems and equipments,

and those for which "provisions for" have been incorporated,•when per-

forming their intended functions. There shall be no improper response,

whether unacceptable or inadvertent, from the output of any vehicle or AGE

subsystem or equipment because of electromagnetic interference produced

by any or all of the electrical, electronic, and other devices of the sub-

systems or equipments when tested in accordance with the applicable EMC

Test Plan (see section 4. 1).

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This requires that .suc.:). subsystems and equipments not be adversely affected

by interference voltages and fields reaching them from external sources and

also requires that such equipment and subsystems not be sources of inter:-

ference which might adversely affect the operation of other equipments or

subsystems.

The design aspects of the composite system operational environment, utili-

zation of the inherent shielding characteristics of the vehicle or installation,

antenna location, shielding and bonding techniques, cable routing, the design

and location of interference control components, and alil other pertinent

design and control factors shall be included in the affected subsystem/equipment

Control plans.

Each Design Control Plan shall consider frequency management of all

equipments as a prime factor in controlling the operational electromagnetic

environment. Freqtfericy management shall consist of: control of all

assigned primary radiating bands and requencies, strict conservation of

spectrum bandwidths; control of all local oscillator frequencies and rise

times; gain bandwidth products, harmonic and sideband control, and time

duty cycle operation of equipment.

3.1.3 Short Duration Interference

RAVE Exemptions shall not be granted for short duration. or transient interference

in any EMC Design Control Plan, unless such interference occurs at such a

time sequence as to not affect the operation of the MOL System and with the

approval of MOL SPO (MCASTRO system segment single event switching

transients are not required to meet SAFSL 10005 interference requirements

provided they do not cause Flight Vehicle system interference. All Gemini B

System Segment switches and relays (except hand controller switches) will

be considered single event switching devices).

3.1.4 Electromagnetic Interference Safety Margin

R-AVE The Electromagnetic Interference Safety Margin (E/vIISM) shall be determined

for critical leads under operating conditions, including switching equipments

or subsystems ON and OFF manually by the astronauts or as programmed.

Operating conditions shall be defined as the launch environment for FV

system test, factory environment for segment testing and screen room or

factory environment for subsystem and equipment testing. The susceptibility

threshold shall be determined at the subsystem and equipment level within _

the constraints of this specification. The reference for system an.-L - 6 0 0 6 • t 1'. actu-.1 o7eratirc:, noise. Copy of 1

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3.2.5.2 3.2.5.4 3.3.1.3.1 3.3.1.3.2 3.3.1.3.2.1 3.3.1.3.2.2 3.3.1.3.2.3 3.3.1.3.2.4 3.3.1.3.2.5 3.3.1.3.2.6 3.3.1.3.2.7 3.3.3

3.3.3.1 3.1.4

- 3.3.3.2.1

■Ir•i :;"

NRO APPROVED FOR RELEASE 1 JULY 2015 I i•

3.1. 5 Electroexplosive Actuated. Systems

R-AVE This specification prescribes the minimum acceptable ordnance EMC

characteristics to enhance the safety of personnel, the space vehicle system,

and the vehicle launch facilities during ordnance operations in existing and

planned vehicle electromagnetic radiation environments. The following

paragraphs of SAFSL Exhibit 30005, with identified deviations or

interpretations, shall apply to the design and verification of design of

EED's and firing circuits. Subparagraphs of an applicable paragraph are

not applicable unless specifically identified. The remaining paragraphs of

SAFSL 30005 apply for design only..*

3. 1 . 6 Government Fur n ished Equipment

T

It shall be the res'p.cinSibilfty of each affected associate contractor and sub-

contractor which uses. government-furnished equipment (GFE) as part of its

subsystem(s) and equipment(s) to ensure that such equipment meets the

requirements of this specification and of the affected EMC design control

plan. In the event that such compliance necessitates testor modification

of the GFE, which is out of scope of the affected segment contract such

tasks shall be subject to separate negotiation.

*The following paragraphs of SAFSL Exhibit 30005, with identified

deviations or interpretations, shall apply to the design and verification of

design of EED's and firing circuits. Subparagraphs of an applicable paragraph

are not applicable unless specifically identified. The remaining paragraphs

of SAFSL 30005 apply for design only.

SAFSL Exhibit 10005 Paragraph Title

Interconnecting Wires EED Firing Circuits RF Susceptibility

EED Validation

Validation of EEED and EED Initiator Circuit System Sensitivity EMISM RF Susceptibility,- Data L+- 6 0 0 6

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3.2 DESIGN

3. 2. 1 Interference-Free Desi ,7, n

R-AVE Interference control shall be considered in the basic design of all electronic

and electrical equipment and subsystems. The design shall be such that,

before any interference control components are applied, the amount of

interference inherently generated and propagated is the minimum achievable

consistent with good design practices. The api)lication of interference control

components that must be used, such as filtering, shielding and bonding,

shall conform to good aerospace engineering practice and should be an

integral part of the system. Any interference control components must

be of minimal weight and volume consistent with maximal reliability,

vehicle weight constraints and associated tradeoffs.

Separately installed and

external components shall not be used Unless specifically authorized by

the procuring activity.

R-AVE

3.2.2 Susceptibility

All equipment shall be designed to minimize susceptibility to interference

from other sources. Any enclosing case construction shall be designed

not only to minimize interference propagation but also to minimize

interference pick-up from external sources. Where conducted energy on

the power or other external leads might cause interference, these leads

shall be isolated from others to avoid coupling and where necessary and

feasible, shall have line filters at thieir entry - into the enclosing case.

Receiving antenna inputs or other low-level signal circuits shall be of

low impedance or of balanced design so that coaxial or other shielded

transmission lines can be used to ensure an interference-free installation.

Routing of such circuits within the equipment shall minimize circuit coupling

with power and control leads. There shall be no common impedance paths incompatible

or sharing of/grounn returns between different classifications such as or

signal, power, control or ordnance circuits/ within the same classifications .

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3.2. 3 Case Shielding •

R-AVE

R-AVE

Mechanical discontinuities in the case of those enclosures intended to provide

EMI Shielding, (such as covers, inspection plates, and joints) shall be kept

to a minimum. All necessary discontinuities shall be electrically continuous

across the interface of the discontinuity so. as to provide a low-impedance

current path. Multiple-point spring-loaded contacts are suggested as a

desirable method of obtaining this low impedance continuity. Ventilation

openings shall be designed not to degrade the required case shielding

effectiveness. Electrical bonding shall be provided where access doors

or cover plates form a part of the shielding; hinges, in themselves, are

not considered satisfactory conductive paths.

3. 2. 4 Bonding

The provisions'of :\,111.2:-13-5087 with regard to characteristics, application

and testing of electrical bonding shall be applicable. The appropriate

MIL-B-5087B bonding class shall be used. The use of BE/CU or aluminum

bonding straps of L/W ratio 5 and a minimum thickness of 005 inches

is permitted. The requirements of paragraph 3.1-3.1. 3 of MILB 5087B

may be met through the use of contractors preferred parts list.

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3. 2. 5 Design Criteria

3. 2. 5. 1 Interconnecting, Wire Design

A-AVE Line shielding shall not be used when equivalent interference reduction control

or containment can effectively he accomplished inside an equipment. It shall

not be used intentionally as a current carrying conductor, except for coaxial

conductors in rf circuits. Equipment requiring antennas, but not employing

wave guides, shall be designed to utilize coaxial cable as lead-in. When it

has been determined that a single braid shield is not adequate, a double or

triple braid, or a solid shield, shall be used as required. The following

criteria shall be used to determine signal line and shield configuration.

3. 2. 5. 1. 1 DC Supplies

To minimize the possibilitr of DC supply lines coupling interference to other

circuits and to protect them from receiving interference from other lines,

the best procedure is to use twisted-pair for the supply line and its return.

Shielding should not be used on power wires.

3.2. 5. 1 2 AC Power

Alternating current of comparatively high amperage, characteristic of most

AVE AC power lines, makes them potential sources of interference through

coup1;ing to adjacent lines. Transposed or twisted lines shall be used for all

AC power circuits. The routing of these lines shall be away from susceptible

lines. Shielding should not be' used on power wires.

3. 2. 5. I 3 Low Level Signals of Low Impedance (<1001vIV and ...1000;)

For runs internal to the equipment, the use of a twisted-pair alone may prove

adequate. For runs external to the equipment, twisted-pair shielded wire

shall be used. When shielded wire passes through a connector, three pins

shoUld be made available on the connector to provide insulated passage of the

two signal leads and the shield. Shields must be grounded at least at one

end. For signal wires external to equipments, balanced circuitry shall be

used. Low level RF circuits may use coaxial cable and need not be balanced.

Circuit impedance represents either the source or load impedance, whichever

is higher.

*The following design criteria are for wiring external to equipment, however

the criteria may be used as design guides for wiring internal to equipment.

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3.2.5. 1. 4 Low Level Signals of 1-iiah Impedance (:.--_1001VIV >10002)

_-AVE Where signals from high impedance output devices must be transmitted over

any appreciable distance, an impedance transforming device such as a

transformer, cathode follower or transistor Should be used to lower the

transmission circuit impedance to 1000 ohms or lower. However, the use

of high impedance signals for transmission of information should, in general,

be scrupulously avoided, whether high or low level. Where the use of such

signals cannot be avoided, the interconnecting lead must be shielded and

the shield grounded. In some cases, the use of a double or triple shielded

cable grounded at each end may be required if the cable is in an intense

electrostatic environment. Circuits not meeting the impedance criteria of

z 1000 S-2 of 3.2.5. 1. 3 are defined as high impedance.

R VE

3.2.5. 1. 5 High Level Signals ( >1001vIV)

Signal circuits of high level will, in general, not be susceptible to EMI.

Rather, they may be a source of interference to lower level signal lines

For this reason, and dependent on other characteristics of the signal,

either a twisted-pair or a shielded lead should be used. Multiple shielding Shield

may be required if the signal is of sufficient level. / Grounding should be at

both ends of the shield to prevent electrostatic radiation from the cable.

3.2.5. 1. 6 Reference Voltages

The transmission of reference voltages should be avoided. If this is not

possible, care should be taken to minimize the possibility of introducing

interference as well as AC voltages. Grounding, where required, should

be only at one point. Treat the reference voltage•as a circuit, always

including its return lead either in the form of a twisted-pair or a shielded

or coaxial lead.

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The use of twisted-pair and/or shiolding for the reference voltage lead and

its return will minimize the• pickup from sources of electromagnetic radiation.

In the case of AC reference voltages this treatment will aiso minimize the

interference effect that the reference voltage might have on other circuits.

Shielding of the twisted-pair may be helpful, especially when the circuit

impedance is not held to a. low value; hovvever, filtering of the reference

voltage inside the using equipment is to be preferred over the use of shield-

ing. The source impedance of the voltage should be maintained as low as

possible in .order to minimize electrostatic pickup. In any case, the using

element should see only the reference voltages, and not the reference voltage

plus small components of other signal and power voltages.

3. 2. 5. 1. 7 Control Voltages

The control of various functions is usually accomplished with the use of

voltages of either AC or DC which are switched on or off in a step manner.

Lines carrying such voltages are potential interference generators; they

should be of a nature that will hold coupling to other circuits at a minimum.

Separation and shielding are thus applicable.

3. 2. 5. 1.8 RF Signals (>150KHZor5l0 u sec rise/fall time signals)

R-AVE RF signals within a unit should be routed in such a way that cross coupling

between input and output circuits is held to a minimum. Outside the unit,

shielding should be used if necessary to prevent excessive radiation from

the wire or excessive pickup on the wire. Grounding of such shields shall

be multi-point and continuous for rf signals.

3. 2.5.1.9 Shield Continuity

R-AVE The electrical continuity and isolation of signal circuit electrical shields

shall be maintained through connectors, equipment, and/or junction boxes

intermediate between the signal source and the signal load. Any intermediate

terminal strip or block shall be shielded by a metallic enclosure which is

bonded to the structure. Where the number of connector

pins is limited, shields may be grouped on a selective basis and. carried

through on a single pin. Individual shield segment may be separately

grounded.

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C f. NRO APPROVED FOR RELEASE 1 JULY 2015

3. 2. 5. 1. 10 Shic.,Id . rezLkouts

Only the following methods of shield termination are acceptable.

(a) On the electrical connector, provided the connector

has a conductive finish and is provided with a con-

ductive path to structure.

(b) Direct to structure, provided the length of shield

-pigtail is 6 inches or less.

(c) Terminate inside of the equipment by means of a

pin in the electrical connector. The combined

length of the ground wire and pigtail shall be 6

inches or less.

It is preferred that the shield extend inside the connector shell. In the event

that this is not feasible, the shield breakout shall be so positioned that it is

as close as possible..with not more than1.5inch of unshielded, insulated wire

showing in back of the connector.

3. 2. 5. 2 Interconnecting Wires Categorization and Seperation

In order to reduce interactions between the different subsystems, inter-

connecting wiring shall be isolated in accordance with the following criteria.

A minimum of 4 inches shall be maintained between wires or wire bundles including ground umbilicals

of the different categories. Separation during constrained passages/may be

less than 4 inches but shall be resumed as soon as practical after passing

constrained area. (For EK: If cable separation is required to reduce inter-

actions between wires of different signal types, 4 inch separation, consistent

with space allocation factors, should be maintained between wires ) (For the

Gemini B Segment: In the re-entry module and at the interface between it

and the adapter, in order to reduce interaction between the different subsystems,

interconnecting wiring shall be isolated where feasible in accordance with

following criteria. A minimum of 4 inches shall be maintained between wires

or wire bundles of the different categories, except when different categories

use the same connector, or where space and/or weight constraints make such

separation impracticable. In such a .case, pin assignment and layout shall

stress isolation between different categories, and grounded spare pins shall

be utilized when available to provide isolation for sensitive circuits.

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NRO APPROVED FOR

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RELEASE 1 JULY 2015

In the adapter moclule, interconnecting wiring s7-..F.11 ne separted using the

same criteria applied in the re-entry module except:

(a)

Wires crossing the interface between Gemini B and

associate contractor segments shall be classified

into categories I, II or III, as applicable. A

minimum of four (4) inches shall be maintained between

interface wires or wire bundles of these three (3)

categories. However, interface wires need not be

separated where they pass through guillotines.

Gemini B wires not crossing the interface may be

bundled with interface wires providing the interface

wire categorization is not violated).

The classifications clf- he following wire categoric:, are design requirements

to assure compatibility. Further subcategorization may be required to

achieve compatibility because of complexity of design cr in the cas-e of a

circuit filling the criteria for two categories and are not precluded by this specification

Category I

1. Three phase power distribution wiring (twisted)

2. Single phase power distribution (twisted with return wire)

3. Other wirinecarrying 115 volts ac

4. DC circuit wiring carrying currents (transients and

steady state) above 5 amps

5. Low voltage power circuits (ac)

6. Low voltage lighting circuits (ac)

Category II

Wiring carrying less than 36 V peak and current between •

100 ma and 5 amps.

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Cate o ry

1.. Lou' level circuits

2. Low voltage circuits •

3. Receiving antenna coaxial cables

Category TV

All ordnance firing circuits.

Category

(Not for GE

RE transmitting coaxial transmission lines and wave guides and EK)

(150 kc and above).

3. 2. 5. 3 Groundin2, and Isolation

A single-point grounding system shall be the design baseline. A deviation

to use multipoint ground will be granted when such is proven to be electro- ,.;

magnetically compatible. Each electrical component shall have the primary

power terminals isolated from its own case by a minimum DC resistance

of 1 MEGDEIM when all of its external harnesses are completely disconnected.

(For IVICASTRO a separate guidance and control ground may be used. Resulting

structure return shall not jeopardize system compatibility.)

3. Z. 5. 3. 1 Power. System Ground

-AVE The negative lead of individual power sources that are separated from each

other by 5 feet or more or are located in separate vehicle compartments

shall have its own Structure Ground Point (SGP) connected to the vehicle

frame adjacent to the power source. The length of the lead from the power

source to the SG? shall not exceed 16 feet and shall not extend through any

vehicle interface. All ground return leads for any one load shall be grounded

to the SGP for the power source of that load. All DC ground power supplies

shall be grounded at the SGP for that particular load. If more than one load

or SGP is involved, separate ground power supplies shall be used. There

shall be no sharing of ground return leads between separate subsystems. Any

deviation from this requirement shall be approved by MOL SPO. (For

MCASTRO, the negative lead of individual power sources, within the Gemini B

shall terminate at a negative bus which in turn is connected to one (I) structural

ground point on the spacecraft vehicle frame. The length of leads from power

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sources to the negative bus shall as short as practicable. All groul-ld power

supplies shall be grounded at the SGP for that particular load. If mo:ce than one

load or. SGP is involved, separate ground power supplies shall be used. There

shall be no sharing of ground return leads. Any deviation to this requirement

must be approved by the MOL SPO).

3. 2. 5. 3. 2 Sensitive Circuit Groundinc

R-AVE Grounding connections for signal circuits shall be made to the SGP of the

power source supplying the signal source or load.

3.2. 5. 3. 3 Aerospace Ground Equipment (AGE)

R The low or neutral sides of AGE power supplies and operational, calibration,

and test circuitry associated with the vehicle shall, except for rf circuits,

be isolated from each ground potential and shall be terminated at the vehicle.

When the circuit isliseonnbcted from the vehicle, a switched safety ground

may be used to preclude personnel hazard.

3. 2. 5. 3. 4 Radio Frequency Sensitive Circuits

R-AVE Equipment intentionally operated in frequency ranges above 150 1:c or rise or

fall.times loss than 10 micro seconds may have secondary power supply

circuit ties exist, the following ground and isolation requirements are

mandatory. Excluding primary input power (which is covered in Paragraph

3. 2. 5.; 3).

(a) A minimum dc resistance of 10, 000 ohms shall exist

between all audio frequency (0-150 KHZ) input or output

terminals or leads and the RF circuits with both audio

frequency and RF frequency circuits having a common

ground reference at the unit case.

(b) Wire shields, including coaxial cable outer conductors,

shall be multiple grounded; they must be continuous

and tied to the unit case(s) at both ends.

R-AVE 3.2.5.4 EED Firing Circuits

Firing circuit conductors, shall be twisted pairs to maintain electrical

balance and reduce induction. EED firing circuits shall be isolated from

other electrical circuits and each other by means of individual shields

before and after installation of the EED. Shielded 'ZED circuits may be

routed together in a common secondary shield. There shall be no electrical

discontinuity or gans in the shields. No EED circuit shall s=are L - 6 0 0 6

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Firing circuits to EED's shall be balanced to, and isolated from, the FED

cas.e and other con_dAmtinp: parts of the vehicle. If a circuit must be grounded. for sLaLic oiscnarge pa.o,ection, it be grounded with a static discharge resistor of 100,000 ohms or more.

3.3 INTERFERENCE CONTROL REQUIREMENTS

3.3.1 Subsystems and Equipments

Requirements for interference control for subsystems and equipments are

R-AVE included in the table of Figure 1. The limits defined in the various sections

noted in Figure 1 are relaxed for AGE only as follows: Radiated interference

for Operational Ground Equipment (OGE) shall be measured at a distance of

three feet. An increase of 10 db in the limits for conducted interference for

OGE is allowed for wirinp- that does not directly interface with AVE, Only

requirements A and B of Figure 1 are applicable to I\./aintenance Ground

Equipment (MGE).-Ra.diated interference for MGE shall be measured at_a

distance of three feet, with an increase of 20 db allowed in the limits for

radiated interference and 10 db in the limits for conducted interference. No

relaxation of these •requirements shall be permitted for carry-on equipment.

3. 3.1.1 Interference Generation Limits

3. 3.1.1. 1 Conducted Interference

R- A VE Interference voltages or currents in the frequency range of 30 cps to 100 Mc,

generated by an equipment or subsystem in excess of the values indicated

in Figures 2 and 3, shall not appear on any conductor which may conduct

interference to other equipments or subsystems. A description of the test

setup is found in Paragraph 4.7.2 - and Figures 9, 10 and 11.

Interference limits of Figures 2 and 3 shall not be applied to those leads

carrying the intentional signals within the frequency passbands specified

in individual equipment performance specifications).

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3.3. 1. 1. 1. 1 30 cps to 15 1:c

Narrowband c,,v conducted interference shall not exceed the value shown in

YE Figure 2 when the meter is used with a 60-cps or less banch,vi;i:h. 3: e.oz.-;..in'ai-13.

and pulsed cw conducted interference shall not exceed the values shown in

Figure 2, when measured in a '.videband pea:'_: mode of the meter as shown in of the powerline measured in the

Paragraph 4.7.2.1. The fundamental an,_: •i,ainnonics (2-5)/shall be exempt poweriine

from meeting this requirement, however, the measurements shall be made

and 6 db EIvIISM.S for all critical circuits shall be maintained.

3. 3. 1. 1. 1. 2 15 kc to 100 Mc

R-AVE In the frequenCy range of 15 kc to 100 Mc the interference values shall not

exceed those shown in Figure 3 when tested as required by Paragraph 4.7.2.1.

3. 3. 1. 1. 2 Radiated Interference

R-AVE Radiated interference fields in excess of the values shown in Figures 4

through 7 shall not radiate from any unit, cable (including control, pulse,

IF, video, antenna transmission, and power cables), or interconnecting wiri tr

over the frequency range of 15 kc to 400 Mc for broadband irnpulsivd inter-

ferences and 15 k.c to 10 Cc for cw and pulsed cw interference. (EK: "For

testing purposes, the upper frequency limit shall be 1 Gc, or the twentieth

harmonic of the highest fundamental frequency being purposely generated,

whichever is higher, for Cu' and pulsed cw interference. '') This requirement

includes transmitter fundamental spurious radiation, oscillator radiation,

other spurious radia-tions, and broadband interference, but does not include

radiation emanating from antennas. A description of the test is included in

Paragraph 4. 7. 2. 2.

R-AVE

3. 3. 1. 1. 3 Antenna-Conducted Spurious Emanations

3. 3. 1. 1.3. 1 Transmitter (Kcyup) or Receiver

The rf output of any transmitter (keyup) or receiver shall not exceed 40 db

above I microvolt for cw or 60 db above I microvolt per Mc for impulse

interference at any frequency between 0.15 and 10,000 Mc. Actual measure-

ments above 1,000 Mc will not be required, if the contractor can show that

such measurements would not result in significant data.

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3. 3.1.1. 3. 2 Transmitter (I.eyee-N,..n)

AVE Spurious emanations shall not exceed a level of -25 dbm , when teste d as

described in Paragraph 4.7.2.3. Actual measurements above 1,000 Mc

will not be required, if the contractor can show that such measurements

would not result in significant data.

3. 3.1. 1. 3. 3 Transmitter Cros,imodulation

R-A.VE The transmitter shall meet the requirements of Paragraph 3. 3.1.1, 3.2

above while being subjected to the test described in Paragraph 4.7.2.4.

3. 3.1. Z

Susceptibility

R-AVE Equipment deemed by the procuring activity to be incapable of being affected

by applied extraneous signals will be exempt from the susceptibility

requirements noted..below.

3. 3.1_.2.1 Conducted Susceptibility

R-AVE

3. 3.1. 2.1.1 Conducted - 30 cps to 150 1:c

No undesirable response, malfunction, or degradation of performance shall

be produced in any equipment when a sine wave voltage of the level shown

in Figure 15 is applied in series (for AGE, the conducted susceptibility

test requirement shall be per Figure 15 or 3 volts rrns, whichever is

smaller) with each power of the test sample.

The test setup will he as described in Paragraph 4.7.2.5.1.1.

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3. 3.1. 2.1. 2 Conducted - '150 1:.c. and Above

R-A

No undesirable response, malfunction, or degradation of perforrnance shall

be produced in a.ny equipment when anyf signal of +13 dbm, developed across

a 50 ohn-i load, is applied across. the pc.--Jier input terminals of the test

samples. The test description is found in Paragraph 4.7.2-5.1.2.

3. 3.1. 2.1. 3 Condncted -,Transient

R-AVE No undesirable response, malfunction, or degradation of performance shall

be produced. in any equipment when a pulse. or transient is induced in or

across the power line and between each power line and case in each polarity

using the test setup and transient description found in Paragraph 4.7.2.5.1.3.

(EK Deviation.: No undesirable response, malfunction, or degradation of

performance shall be produced in any equipment when. a pulse or transient is

induced into it in accordance with section 4.7.2.5.1.3. This is not a

requirement for equipment internal to the system (i.e., non-interface)

where it has been shown by analysis or test that the. equipment will not

be subjected to a transient of this magnitude. However, for internal

equipment, an appropriately reduced test level shall be used).

3. 3.1. 2. 2 Induced into Cable

R-AVE Interconnecting cables shall withstand, without evidence of equipment

performance degradation, the application of a magnetic field caused by a

wire carrying 20 amperes rms at the fundamental power frequency. The

test description is found in Paragraph 4.7.2.5.2.1.

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3. 3.1.2. 3 Induced into Eovioment

R-AVE No undesirable response, malfunction, 01 degradation of performance shall

be produced in any equipment when it is subjected to an ambient magnetic

field as described in Paragraph 4. 7. 2.5. 2.2.

3. 3.1. 2. 4 Radiated Field

No undesirable response, malfunction, or degradation of performance

shall be produced in any equipment when it is subjected to the following

radiated fields:

R-AVE Frequency Field Strenth

0.015 to 35 Mc

10 vim

35 to'1000-Mc

5 vim

1 to 10 Cc

5 vim

R-AVE

R-AVE

The test setup and equipment are described in Paragraph 4.7.2.5.3. The

test shall be carried out to the level of equipment malfunction or a 6 db

higher field intensity, whichever is lower. However, if analysis or prior

test data indicates that equipment damage above the normal susceptibility

test limits will result, these malfunction threshold level tests need not

be performed and the susceptibility threshold shall be the susceptibility

test limits.

3. 3.1. 2. 5 Intermodulation

Receivers, preamplifiers, or antenna couplers shall not produce an output

indication when two sine wave signals, representing undesired signals, are

connected to the input terminals of the test sample. The test frequency

selection and levels are given in Paragraph 4.7.2.6.

3. 3.1.2. 6 Receiver Front End Rejection

Front end rejection of receivers shall be equal to or greater than the limit

shown in Figure 8, except that image rejection outside the tuning range of

the receiver shall be 60 db. This requirement shall apply to each tuning

unit on receivers with plug-in or separate tuning units. Dimension (a) in Figure

8 shall not be greater than 20 percent of(fc). A description of the test and the

method of calculating the front end rejection ratio are given in Paragraph 4.7.2.7.

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3. 3. . 2.7 Su s

1-3..:AVE A susceptibility threshold curve shall be determined experimentally with

suppOrting analysis for each critical test point (See Paragraph 6. 2). This

data will be used during full system tctin to establish the EMISM. (See

Section 6).

II.- A V E

3. 3. 1.3 Electroexolosive Dt- vice-(EED's) Class A

MCASTRO: Applies to new EED's only. (NASA Gemini/EED's, analysis

and tests shall be conducted as reported in MAC Report B078 dated 21

February 1966, title, ''Analysis of Electromagnetic Radiation Hazard in

Gemini and Augmented Target Docking Adapter Pyrotechnic System.")

(For GE: The EEI)'s used on the D.RV are exempt from this requirement)

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R-AVE 3. 3. 1. 3. 1 Susceptibility

The susceptibility of each EED to RI' energy shall be determined over the

frequency range of 0.150 to 10, 000 l'...41.1Z with the following as a minimum number

of frequency points:

Test Frequency. Range (MHZ) Conditions

5 -10 CW

25 - 450 CW

900 1350 CW

• 1750 - 1850 CW

2200 - 2290 CW

5000 - 6000 CW-

8500 - 10, 000 CW

1750 -=.1850 Pulsed

2200 - 2290 Pulsed

500d - 6000 Pulsed

8500 - 10, 000 Pulsed

Susceptibility shall be determined for the following modes:

a. Pin-to-Pin (P-P),

b. Pin-to-Case (P-C),

c. Briclge.-wire-to-Briclgewire (B-B) (then requirement only applies to initiators with two or more bridgewires).

It-AVE 3. 3. 1. 3.2 EED Validation

The validation of compliance with 3.3.1.3.1 shall include the following:

R -AVE 3. 3. 1. 3. 2. 1 DC Constant Current Sensitivity Test (45 initiators)

A Bruceton test (Pin-to-Pin mode) using a group of 45 initiators using each

bridgewire shall be conducted in which the pulse time will be held constant and

the current will be variable. The pulse time in this test shall be 10 seconds or

longer. Five of the initiators may be used to find the proper starting level for

the test.

The DC constant current sensitivity Bruceton test data obtained for SAFSL Exhibit

10030 may be used in lieu of this testing.

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R- AVE 3.3.1.3.2.2 Impeciance i'vleasurernent (10 Initiators)

The dc resistance and RF impedance for all freouencies (and all -nodes) of

3.3.1.3.1 shall be. determined for a of 10 initiators.

R-AVE 3.3.1.3.2.3 RP Comparison Tests le bridge. - 135 initiators, Dual

bridge - 225 initiators)

The RF power exposure level for all of the RE' comparison tests shall be the

mean firing level determined in the 3.3.1.3.2.1 dc constant current test converted

to power. For this conversion to power, the RI- resistance shall be taken into

account. This calculated power will be delivered to the EED's at each test

frequency and in each mode, i. e. , pin-to-Din, pin-to-core, and bridgewire -to-

bridgewire. Non-fires from the pin-to-pin and bridgewire-to-bridgewire modes

may be revised for the pin-to-case mode testing.

Ten EED's shall be exposed to the test power at each condition for a duration of

10 seconds or greater (note: it is only necessary to size the pin-to-case test

sample to 5 since some no-fires should be obtained from the pin-to-pin tests).

If 8 or more of the 10 initiator samples fire, it shall be considered that the FED

at the particular frequency and mode is more sensitive than the dc level. Other-

wise it shall be assumed that initiator has a sensitivity equal to or less than the

dc level for the particular frequency and mode.

R-AVE RE' Bruceton Tests (80 initiators)

Following the probing tests of 3.3.1.3.2.3, two RE' Bruceton tests shall be

conducted at the most sensitive conditions.. In the event more than two conditions

have sensitivities greater than the dc level, RF Bruceton tests shall be run for

all these conditions.

R_AvE 3.3.1.3.2.5 EED Sensitivity

For the conditions having the 3.3.1.3.2.4 test, the RF Bruceton test data shall

be used to determine 0.001 probability of initiation with 95% confidence. For

those conditions where it is determined by 3.3.1.3.2.3 that the RF sensitivity is

less than the dc level (and where 3.3.1.3.2.4 tests were not made) it shall be

assumed that RF 0.001 probability of initiation with 95 confidence is the same

as the dc value.

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3. 3. 1. 3. 2. 6 Determination aini reporiing of the smallest field intensity

capable of producing in the EED, in its noral respective configuration, the

power determined in paragraph 3.3. I. 3. 2.4 above. The determination shall

be based on the most favorable conditions for induced power during routine

handling, processing, transport- and storage. Data shall be presented as

described in paragraph 3. 3. 3. 2 below.

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R-AVE 3. 3. 1. 3. Z. 7 Evaluation of tlie EED as a receiver of RE ener;;y dun, installation.

The evaluation consist of determining and reporting the minimum RE

field intensity or field strength required to produce in the EED the power

determined according to paragraph 3.3.1.3.2.6 above. The evaluation shall

include the most favorable conditions for induced power, including unshorted,

uninstalled conditions. Data will be presented as described in paragraph

3. 3. 3. 2 below.

T

3. 3. 2

Space Vehicle System

3. 3. a. 1

Electrical/Electronic Compatibility Test

The first spacecraft's complete electrical/electronic system shall be sub-

jected to a complete functional compatibility test. The vehicle shall be

tested in accordalice with paragraph 4.7. 1 of this specification to demon-

strate compliance with its requirements. As.-iy modification or relocation of

the electrical or electronic subsystems or equipments, resulting from the

elimination of an unacceptable or inadvertent response as defined in para-

graphs 3.3.2.2 and 3.3.2.3 below, shall require a re-test unless such

specifically waived by the procuring activity.

3. 3. 2. 2 Improper Response

The requirement for improper response shall beconsidered to have been

met when the sum of all energy coupled into the most critical point of each

subsystem by extraneous. electromagnetic or electrostatic fields or by direct

conduction is at least 6 db below that input, which would produce or prevent

operation, actuation, or functioning. Detailed test methods, instrument-a.,

tion, monitored points, interference tolerance limits, and test procedures

applicable to the functional usage of the particular subsystem or component

shall be outlined in the test plan specified herein.

3.3. 2. 2. 1 Unacceptable Response

Output responses from any subsystem which are the result of operation of .

any planned combination of subsystems shall be unacceptable when these

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outputs cause the space system per fee.. .-nce to be degraded in excess of the

required performance limits. This unacceptable response for other than

aural outputs shall be determined in terms of .the degree that performance"

limits are degraded at the subsystem output. This degradation shall be

related, if applicable, to the signal plus noise to noise ratio (S N/N) at the

most critical point of the subsystem exhibiting the unacceptable response.

Unacceptable response for equipment providing aural outputs shall be

determined in terms of the electrical power equivalent, measured in the

audio line, .of the threshold of hearing in the system operating environment.

3.3.2.2.2

Inadvertent Response

Criteria. to prevent inadvertent response shall be defined interms of the

margin (EMISM) between interference levels and circuit thresholds of

operation at critical points within each subsystem. This 'margin, or

separation, shall be a minimum of 6 db but may be greater than 6 db

depending upon the characteristics of the particular subsystem. If the

criteria for inadvertent response at critical subsystem points cannot be

determined prior to test for inclusion in the test plan, these criteria may

be determined as part of the test. In such cases, the integration contractor

shall specify the test approach to be used in demonstrating that a 6 db

minimum EMISM exists at these critical points.

R 3.3.3 Validation of FED and EED Initiator Circuit

(MCASTRO Only: For NASA Gemini Class A EED's, analyses

and tests shall be conducted as reported in MAC Report B-078,

dated 21 February 1966, entitled, "Analysis of Electromagnetic

Radiation Hazard in Gemini and Augmented Target Docking

Adapter Pyrotechnic System.) (For GE: Existing EED's on

the DRV's are exempt) The EED's shall survive before, during and after installation when exposed

to the following electromagnetic fields:

Frequency Range

150 kc to 50 Mc

above 50 Mc

Field Intensity .

2 watts per square meter (28 volts per meter)

100 watts per square meter (194 volts per meter)

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System Sens:it - I

The evaluation shall consist of determining analytically and/or experimentally

and reporting the minimum RE field intensity or field strength required to

produce in the EED the power determined in paragraph 3. 3. 1.3. 2. 4 above after

ordnance installation but with access ports open. Data will be presented as

des& ribed in. paragraph 3.3. 3.2 below.

3. 3. 3.7, Presentation of Data

3. 3. 3. 2. 1 Suscentibility

The RT.' susceptibility of each device shall be presented in graphical form.

The ordinate scale will be in relative db above or below a 0 db reference

level. The 0 db reference will be applicable ordnance survival level, as

defined in paragraph 3.3.3, and as noted below: P I db = 10 log -p--

db 20 log E l

Above .5(i Mc:

or

db = 10 log 100

db = 20 log 194

3. 3. 3. 2. 2 Positive Di3 Values

Positive db values will indicate EED susceptibility to RF fields of larger

magnitude than the survival levels contained in paragraph 3.3. 3 and, there-

fore, represent Safer conditions than negative db values. Data shall be pre-

sented on standard serni-logarithmic paper 8-1/2. by 10-1/2 inches with a

linear 'db scale and a logarithmic frequency scale. Graphical data will be

limited to the following frequency ranges per graph maximum:

0.100 to 100 Mc

100 to 10, 000 Mc

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3. 3. 3. Z. 3 Graphical Data .1 . .

'Graphical data depicting the RI'. susceptibility of each F,ZD within each

frequency range for the four conditions describe:6 in paragraphs 3. 3. 1. 3. 3(a),

(b), and-(c) and 3. 3. 3. 1 are required. Where no sacrifice in clarity will I

result, the four conditions may be plotted as four curves on one graph for 1

each frequency range.

A description of the test equipment and test procedures used to obtain the 1 !

data shall be provided. I

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3. 3. 3. 2. 3 Graphical Data

Graphical data depicting the RE' susceptibility of each EED within each

frequency range for the conditi.c: ns described in paragraphs 3.3. 1.3.2.4

and 3. 3 3 1 are required. Where no sacrifice in clarity will result, the

conditions may be plotted as curves on one graph for each frequency range.

A description of the test equipment and test procedures and/or analyses

used to obtain the data shall be provided.

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4.0 QUALITY ASSURANCI-1; PROVISIONS

4.1 ELECTROl-JA GNETIC CO.\:1.-'ATIBILI'l.'Y TEST PLANS

4. 1. 1 Corm.7)osite System

R-AVE 4. 1 2 1. 1 Schedule

The composite system EMC test plan shall be prepared by the integration

contractor, in coordination with the associate..contractors, to outline the

techniques, procedures, and instruMentation to be used for verifying that

the vehicle system and the AGE system of the composite system are capable

of performing in accordance with the requirements of the composite syste,--n

EMC design control plan. The initial submittal of this test plan to MOL SPO

for approval shall be accomplished within six (6) months after issuance

of contractual go-ahead of the Development Phase or as specified by the

procuring activitY.. This composite system Test Plan shall be maintained

by the integration contractor through the life of the composite System

program by revisions at times scheduled by the EMC Control Board.

R-A.VE 4, 1. 1. 2 Content

The composite system EMC test plan shall include separate but related

sections for the vehicle and AGE systems. Each system section shall in-

corporate the electromagnetic compatibility design requirements for the

component subsystems and the general testing procedures for them and their

respective interfaces with the other subsystems of the vehicle and the AGE

as applicable. Of primary importance will be:

a. Susceptibility threshold cur.N.,e

b. The 6 db point for the EMISM

c. Test conditions

d. Frequency response or response time of test equipment

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4. 1. 2 Subsystems and Epiprnents

R-AVE 4. 1. 2. 1 Schedule

Each associate contractor (this includes the integration contractor in his

function as a hardware contractor) shall submit to the integration contractor

within ninety (90) days after issuance of contractual go-ahead of the Develop-

ment Phase or as specified by the procuring activity an EMC test plan for

each equipment or subsystem of the vehicle or ACE systems for which he

has contracted. Eachs such test plan shall be used by the integration

contractor in preparation of the initial composite system EMC test plan and

shall be submitted individually to MOL SPO for approval. Each such subsystem/

equipment test plan shall be revised at time(s) specified by the integration

contractor or the EM.C. Control.Boa.rd, with the. latter the governing factor.

MOL, SPO shall convene the EMC Control Board to handle the resolution

of problem areas, assign action items to responsible contra.cter(s), and

schedule such action(s).

lc- AVE 4. 1. 2. 2 Content

Each subsystem/equipment EMC test plan shall present the methods, tech-

niques, procedures, and instrumentation to be used for testing to verify

the requirements of the applicable EMC design control plan(s). Items to

form part of the affected Test Plan shall include:

a. Nomenclature and serial numbers of test equipment to be used.

b. Methods of calibration to be used.

• c. Detector functions to be used on measuring equipment.

d. Methods of loading and triggering.

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margin. For example, an engine nozzle :notion which has a tolerance of

4-X50; the interference •voltage •at the input of the servo amplifier (with'

sufficient error signal to eliminate the "deadband") shall be 6 db below

the point at which the +X% or -X% engine motion tolerance is reached.

In the event that the "dcadband" cannot be eliminated, the voltage point

(level) at the driving amplifier input, one fourth of the way between zero

volt and the firSt indication of system actuation or motion at the amplifier

output, shall be the 6 db monitoring point.

t...AvEil. 1.2.2- 3 Criteria for the Selection of Critical Test Points

Test points shall be those points which monitor low-level signal circuits

or other low-level critical circuits of an equipment, subsystem, or system,

which are susceptible to EMI. Tests shall be performed to determine the

most critical or susceptible points in an equipment or subsystem. All sub-

systems on the vehicle shall have a minimum number of critical points which .

will adequately monitor system, subsystem, and equipment performance.

The critical test points, together with a justification for their selection,

shall be submitted for approval with the test plan.

nvE 4. 1. 3 Test Report Schedule

The reporting of the results of each EMC test plan shall normally be made

by the responsible associate contractor within thirty (30) days of completion

of the test, e.xcept-in those cases where Mal, SPO specifically instruct:: perform-.

ance at or within a different time, to the integration contractor and to MOL SPO.

The results of each EMC test plan shall be reported in accordance with

AFSCM/AFLCM 310-1, Vol LI and MIL-STD-831.

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e. Operation of test sample.

Control settings on test sample.

g. Frequencies at which interference might be expected, local oscill7:tor, intermediate frequencies, multipliers, etc.

h. Response time of test equipment for transient testing.

1. Interfaces with other vehicle and AGE subsystems/ equipments.

Each set of test instrumentation shall, whenever practicable, be separate

and distinct from other support equipment which will be concurrently

monitored as an integral part of the operational system complex. Each

EMC test plan shall specify the method of connection to each monitored

circuit and its associated support equipment and shall describe all isolation

techniques, rejection filters, detectors, scaling and equalizing networks, •

recorders, and other components, parts, of methods used to monitor

electro-interference as required by this specification, together with com-

plete test procedures. •

Detailed step-by-step test procedures based upon the test plan shall be

prepared by the contractor as required for his use. These test procedures

shall not be subject to procuring agency approval, but shall be made available

for its review.

R -AVE 4. 1. 2. 2. 1 Input Circuits

Input circuits shall be monitored on equipments having outputs which

operate such devices as solenoid valves and relays,' which rapidly change'

state from zero to full output.

R-AVE 4. 1. Z. 2. 2 Deadband Circuits

Circuits which have an inherent lag or "deadband", such as servo systems,

shall have an error signal introduced to eliminate the lag or "deadband"; the

circuit shall be op the threshold of operation. System tolerance will then be

used as a means of determining the electromagnetic interference safety

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-1.2 /NTERFERENCE EASC RING

R-AVE 4.2. 1 Vehicle and AGY!: Subsystem and System Test Equipment

The equipment used to test vehicle and AGE system and subsystem corn--

patibility shall be capable of measuring at least 6db below the s•uscepti-

bili‘ty•threshold over the full frequency range of the circuit under test.

:Provisions shall be made to permanently record the EMISM. Liberal use

shall be made of wideband oscilloscopes, wideband transients detectors,

circuit monitors, recorders, signal conditioners, or any other type of test

equipment that is capable of monitoring system and subsystem critical test

points. The ec,uipment used shall have the approval of vtOL SPO.

R-AVE 4. 2. 2 Subsystem and Equipment

Instruments used,tp,perform the measurements required by this specifica-

tion shall be the highest quality equipment available for making required

measurements under applicable program funding constraints. Suitable co'rn-

mercially available and approved instruments are listed.by category in Table

1; the categories indicate the capabilities of the instruments to comply with

the requirements of this specification.

R-AVE 4, 2, 2, 1 Category A

Category A instruments are those approved interference measuring instru-

ments which arc capable of adequately measuring the parameters of inter-

ference signals as required by this specification. Only combinations of

Category A-rated instruments may he used for the required measurements.

Instruments that have been modified from Categories B or C to meet Category

A requirements shall not be used unless a distinctive non-removable label

has been attached by the instrument manufacturer. Any restrictions on the

usage of the modified instrument or any of its accessories shall be indicated

on the label.

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C; ate- gory eclue.ncy IV, a r.ta l C e

20 cps to 50 kc FMC •- 30 20 cps to 15 Ice NF-315 30 cps to 15 kc. NM-40A 15 1:c to 150 kc NM-30A 15 kc to 150 kc T-X NF-105 0. 15 to 25 Mc NM-20A, E, NM-22 0. 15 to 30 Mc T-i‘/NY:105:= 20 to 400 Mc NM-30A3 (Ser. No. 191-1

or higher) Stoddart 20 to 200 l'f:c T-1/NF-105 Empire 200 to 400 Mc T-2/NF-105, Empire 400 to 1000 Mc T-3/N.F-105'' Empire 375 to 1000 Mc NM-50A (Ser. No. 222-1 and

higher):NM-5013, NM-52 Stoddart 1 to ZI Cc FIM Polarad .1 to 21 Cc NF;-112 Ernpir e 1 to 10 Cc NM-62A 'Stoddart 1 to 15 Cc CFI Polarad

30 cps to 15 ;:c.-. : .NM-'',0A8 Stoddart 375 to 1000 Mc NM-50A5 (Ser. No. 190-50

and below) Stoddart

0. 15 to 30 Mc T-A/NF-1056 Empire 20 to 400 Mc NM-30A5 (lower than

Ser. No. 121-1) Stoddart 400 to 1000 Mc T-3/NF-105 1 Empire

'This table is subject to change upon reasonable notice to include new instruments having superior performance characteristics and to change the category of older instruments which have become •

2 This category applies only to tuning units purchased after 11 March 1957.

3This category applieS only when power supply 91226-1 is used.

`This category applies to instruments purchased after 9 May 195'6. 5These instruments can be modified to Category A reqUil-..,ernents by the manufacturer. 6This category applies to instruments purchased prior to 11 March 1957. The Manufacturer can supply information on the changes necessary to modify the tuning units to Category A requirements.

7This category applies to instruments purchased prior to 9 2,4ay .1956. These instruments can be modified to Category A requirements by the instrument manufacturer.

8Such instruments with an unmodified receiver shall be modified by connecting the "wideband" amplifier input on the output or the installed ZO kc cutoff low pass filter.

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A Fairchild Empire Stoddart Stoddart Empire Stoddart Empire

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isIRO APPROVED FOR

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R _A \TE 9.2.2. 2 Category

Category 13 irstruzncnts are those instruments which are in general testing

use but which do not adequately measure the parameters of interference

signals as required by this spe;-ification.

Any such instrument must be modified to the Category A rating to permit its

use and must carry a non removable label certifying such uprating by the

instrument manufacturer or the contractor-user, as applicable.

R--AVE 4.2. 2.3 C

Category C instruments are those which have been recently developed• but do

not meet Category A requirements, and which can be modified by the manu-

facturer to attain a Category A rating.

Category C instruments shall not be used until all necessary modifications to

up-rate them to Category A have been accomplished. Each shall carry a

non-removable label certifying such by the instrument manufacturer or the

contractor-user, as applicable.

4. 2. 2. 4 Broadband Spectrum Analyzers

r • •

Broadband spectrum analyzers may be of assistance in determining areas of

interference and reducing overall test time.

4.Z. 2. 5 Automatic/Semiautomatic Test Instrumentatior.

Contractors should be alert to, and take full advantage of, the use of auto-

matic or semiautomatic :est instrumentation which will markedly reduce •

the test time required. Use of such devices 'shall be described in the ai_;p 7 -

cable test plan.

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t-AVE 1. 3 OPERATION CY' ME1,.:;1_11:tING IN S RUNIFNTS - ---

For both conducted and radiated iotei- furence measurements, the instruments

used shall be calibrated and operated as indicated in their respective instruc-

tion manuals, subject to modification thei cof as noted in the affected EMC

test plan.

R. 4.3. 1 Calibration

Interference measuring instrumentation shall be maintained in a known con-

dition of accuracy. Periodic checks on the calibration accuracy shall be

made with laboratory generators. Re-calibration shall be accomplished

when the standardized gain Setting fails to reflect a meter reading within

plus or minus 20 percent of the known input signal. Substitution-type

measurements can be used in lieu of the calibrated method. It is therefore

.not necessary to caliVrate (adjust to a known value) the gain of the inter-

ference meter prior to making measurements. It shall be permissible to

'use either a calibrated sine wave or calibrated impulse noise generator (as

appropriate) in substitution with the unknown at the time of measurement,

Impulse noise generators which are integral with, or which accompany, an

interference meter must be periodically -checked against laboratory standards

to detect degradation due to time, usage, and transportation handling.

R-AVE 4 . 3. 2 Generator Accuracy

Laboratory-type signal generators and impulse generators capable of an

output voltage accuracy of at least 20 percent shall be used to calibrate

interference•measuring instruments and for substitution measurements. ,

R-AVE4. 3. 3 13.roadband Interference :V.eaiurernents

Broadband interference shall be measured by using an impulse generator

with the substitution technique (see Section 6.0), or by calibrating the

interference measuring instrument so that it reads directly in decibels above

one microvolt per unit bandwidth. The peak detector function on the inter-

ference measuring instruments shall be used for broadband and pulsed cw

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NRO.APPROVED FOR RELEASE 1 JULY 2015

iihe process tho meter to re -1 voltage per

unit bandwidth consists of dividing the meter reading; by the in-Ipulse bend-

-Width (see Section 6. 0) of the rneior.

R-AVE 4 3.4

CV,' Interference :.,./i..easurcrrients

CV/ interference shall be measured by calibrating the interference

measuring instrument so that it roads directly . in decibels above one

microvolt or by using a signal generator with a substitution technique.

R-AVE 4, 3. 5 Pulsed CV,' Interference Measurements

PulSed CW shall be measured in accordance with the procedures and limits

used for broadband interference.

R-AVE 3. 6

Monitoring.

The interference 31-1e.a.suring, instrument shall be monitored with a headset,

loudspeaker, oscilloscope, or other indicating devices, during all

measurements. Precaution shall be taken to ensure that the monitoring

does not influence the meter reading on the interference measuring

equipment.

When making "Peak Detector Function" readings on interference which is

steady, in the sense that there is no functional reason for it to vary with

time, the interference meter output shall be observed for a least ten

seconds, and there shall be ho appreciable variation within that time.

R-AVE 4. 3. 7 Bonding of Measuring Instruments

R-AVF,

interference measuring instruments used for radiated or conducted

measurements shall be grounded utilising the best available techniques

consistent with current MIL specification methods. Such methods shall

be delineated in the final EMC Test Plan.

4. 3, 7. 1 Rod Antennas

The counte..- poise on rod antennas shall be bonded to the ground plane with

a strap of.such length that the rod antenna can be positioned correctly. The

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strap shall be as wide as the cou;-:terpOi 55. This applies to rod antennas

utilizing the interfcrOnCe rrieL?.;3111:5ng inst instruments as a counterpoise and to

rod antennas mounted on a separate counterpoise.

R-AVE 4. 3. 7.2 Instrument Groun:'.ing,

The interfcrrence measuring instruments shall be physically grounded with

only one connection. If a copper strap is used, neither the ground clip, the

ground terminals, nor the power supply shall be connected to ground.

-t*

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.R-A\TE 4.4 . TEST

The interference measuring instrument shall be slowly tuned throui;li each

frequency octave.and the frequencies at w,hich the ma-,:imt.trii interference or

susceptibility is obtained sh.zW be selected as test frequencies. Test fre-

quencies shall not be selected prior to the interference test, except when

making broadband transient interference measurements. A minimum of

three measurements shall be raade in each frequency octave. If test Ire-

quencies arc pre-selected dui Mg broadband transient tests,? r:-.inimurn of

three measurements shall be made in each frequency octave below 1 Mc

and five measurements per octave above 1 Mc. The affected test report shall

include a certification that the test frequencies v.,ere selected after each

octave was scanned.

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r, 45

TUNING

For cquiprnent containin.7 Oscillator circuits, the interference measuring

ins:trument shall he tuned to, and rnea5;urements• should be made at, the

primary oscillator frec;uency and at. all h;,,rmonics up to the third

carrior harmonic (if the output carrier frec,:ency is different from the

primary oscillator freciuency) above the highest carrier harmonic which

measures 6 db below the allowed limit, Additiona.1 Cht?CkS shall be made

by scanning for and measuring any signal or spurious response that can

be anticipated,

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\IRO APPROVED FOR RELEASE 1 JULY 2015

R-AVE

4.6 TEST CONDITIONS

4.6. / System

All electronic and electrical equipment included in the applicable system

test plan shall•be included in the system test complex and shall be in

nd'rroal operating condition as deterznined by the test procedures and tech-

niques specified in the detailed subsystem test plans. Specific provisions

shall include the following:

(a). All support equipment normally operating during a standard countdov.m and launch shall be operating.

(b) All flight systems shall be operating.

All pertinent missile test range support equipment such as radar, command transmitters, communica-tion transmitters, etc., shall be operating and

; directed at the vehicle.

(d) Mobile service or other such towers shall be removed

(e) A complete mission profile shall be performed. This shall include a simulated prelaunch, launch ascent and orbit. All systems will be operating, normally.

4. 6. 2

R-AVE 4.6. 2. 1

(f) Provisions shall be made for remote monitoring of the critical test points

(g) During tests, all electronic subsystems shall be operated in the modes or conditions expected to be most susceptible to interference.

Subsystems and Equipments

Ambient Interference Level

It is desirable that the ambient interference level during testing, measured

with the test sample de-energized, be at least 6 db belov:, the allowable

specified interference limit. However, in the event that at the time of

measurement, the levels of ambient interference plus test item interference

are not above the specifiedlimit, the tested item shall be considered to

have met the specified requirement. This requirement shall apply equally

to bbth radiated and conducted ambient interference levels.

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A shielded enclosure or screen room may u::ed if 21 Or desired.

If a shi c.lded ench--)sure is used, the minimum length shall be such that a

35 Mc tuned dipole can be placed roon: with at least 1?. inches

clearance between the antenna extl:ernitles and the shielded enclosure.

R-AVE/l. 6 . 2 . 2 Ground Plane

A. copper or brass ground plane, 0.01 inch thick minimum for copper,

0.025 inch thick minimum for brass, 12 square feet or more in area, with

a minimum width of 30 inches, shall be used. In a screen room, the ground

plane shall be bonded to the shielded room at intervals no greater than 3

feet and at both ends of the ground plane. The ground plane and sci:ecn

room walls may be considered equivalent to a vehicle spLcefran-le for pur-

no=,es of .no.rmal installation. For large eG.. .

mounted on a metal test stand, the test stand may be considered, for testing

purpoSes, to be part of the ground plane and shall be bonded accordingly.

When a shielded room is not used, the measuring equipment may be placed

on a solid support for operation. The support may be solid earth, steel or

iron flooring, metal bedplate, metal-covered planking, or the like.

R-AVE Bonding

Only the provisions included in the design of the equipment and specified in

the installation instructions in compliance with the EMC test plan,- shall be

used to bond units, such as equipment case and mount, together or to the

ground plane. If bonding straps are required to complete the test setup,

they shall conform to the requirements of paragraph 3.2.4. Connec-

tions made with such bond straps shall have clean metal-to-metal contact.

R-AVE 4 6. 2.3.. 1 Shock and Vibration Isolators

Shock or vibration isolators shall be used in the test setup, if they are

required in the operational installation. If bonding straps are supplied for

such isolators, they shall be connected to the ground plane. Bond straps

will only be used as specified in the operational installation.

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R-AVE 4, 6, 2.. 3 . 2 Crou •

When an CN.terrill terminal or con:..ect-Jr avztilable for a ground connection

on the test sample, this terminal _...all be conn ected to the ground plane, if the

terminal is normally grounded in the instz:Ilation. If the installation conditions

are unknown, the terminal shall not be grounded.

R-AVE 4. 6. 2. 3. 3 Portable Emlini•nent

Portable equipment that is intended to be grounded through a power cord shall.

• not be bonded to the ground plane unless specific operating conditions require

bonding. In such case(s), bonding shall be utilized.

R-AVE 4. 6. 2. 4 Power Supply Voltage

The power supply voltages at the equipment terminals shall be within the

tolerances specified in the detail :, pr.t.cification for the test sample. 'I he AVE

test sample shall be operated at the maximum and minimum operating voltages

for audio conducted,:s;usceptibility. For all other tests the operating voltage shall

be within equipment voltage limits. All AGE tests will be conducted at nominal

line voltage.

R-AVE ' 4. 6. 2. 5 Arrangement and Operating Conditions

The general arrangement of equipment, interconnecting cable assemblies,

and supporting structures shall be such as to simulate actual installation and

usage insofar as practicable. The front surface of each unit shall be located

4 inches - 1/2 inch from the edge of the ground plane; interconnecting cables

shall be routed between the units and the edge of the ground plane. In those

cases where equipment size exceeds the ground plane dimensions, the above

instructions shall be adhered to as closely as possible.

R-AVE 4. 6. 2. 5. l Feed-Through Capacitors

Ten microfarad feed-through capacitors shall be required in the test sample

power lines when making interference measurements, unless the operational

power supply is being used to supply power to the test sample. These

capacitors shall be so selected that their respective temperature rise is not

mere than 5°C.

• C. 5", r r"Th

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When phase is important for specific test samples, matched capaci:or ,-:

be used. A bleeder resistor shall he con;lected across the capacitors to reduce

shock hazard. Figures 9 and 10 typical test setups utilizing the capacito-rg.

Feed-through capacitors may not be feasible in certain instances, as when

initial charging current would damage the test sample, when the total re-

active c;urrent would degrade the ac power supply, and, in some situations,

when testing switching devices. In such situations, the associate contractor

will specify Other methods or techniclues in the affected test plan. Neither

feed-through capacitors nor other impedance standardization devices shall

be used if the test sample is powered by the operational power supply.

R-AVE . 6.2. 5. Z Dummy Antennas

Any dummy anternas;:u:sed shall have ele.ctrical characteristics which closely

simul;:lte those of the norrnal antenna, and shall be shielded whore possible.

The dummy antenna shall be capable of handling the power required and shall

contain any unusual components which are used in the normal antenna such

as filter, crystal diodes, etc.).

A minimum 5-foot 'length of double shielded coaxial cable or special lines as

specified in the test requirements, shall be used between a transmitter and

its dummy antenna.

R-AVE4. 6. Z. 5. 3

Test Sample Leads

The test sample leads to the reqUired feed-through capacitors, when used,

shall be 24 inches -; 1 inch in length, where possible, and shall be so arranged

that the distance between the leads and from each lead to ground or grounded

enclosure is approximately 2 inches.

Interconnecting leads between units comprising test sample shall be between

_Z and 5 feet long. Leads from these units to auxiliary equipment, such as

meters and loads, shall be 5 feet long. The above is not a requirement for

audio frequency testing. In lie,t of these' requirements, an actual system

harness may be use,:. to interconnect the test c,-:ecimen with associate -3_ sources

or loads.

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R-AVY, 4.6.2.6

h C test sample shall be ord on the plr::ne for ina:,;imunn inter-

ference effects within allowable opc -!.ating reouiremonts. Those interference

measuring instruments which use a roil antenna shall be so placed that the

rodantenn;.-± is in a vertical posit:on and time instrument panel or counter-

poise is 6 inches below the level of the ground plane. The rod antenna shall

be located at the point of maximum interference indications while the test

sample is operating in the steady state mode. This maximum is obtained

by moving the antenna along a line para.11,-,1 with the edge of the ground plane.

Those interference ineasuring instruments Which use a resonant dipole

antenna shall have the dipole positioned parallel with the front edge of the

ground plane. Its height shall be 12 inches - 1 inch above the. level of the

R.-AVE

ground plane and its center shall be adjacent to the geometrical center of

the units under test. The rod or the dipole antenna shall be located at the

distance from the test sample specified in the typical test setups. When the

dimen:-3ions of the dipole or directive antenna become smaller than the test

layout, the antenna. shall be moved parallel to the edge of the oround plane

to keep its sensitive elements adjacent to the point of maximum leakage or

susceptibility. In place of the above, more than one antenna may be used.

with the details delineated in the final Fish test plan. At frequencies from

25 up to and including 35 megacycles the measurements shall be taken with

the dipole antenna adjusted to35 Mc. The dipole antenna shall be adjusted

to the proper length at all frequencies above 35 Mc.

4.6.2.7 Antenna Orientation and Positioning (Free Snace)

Those interference measuring instruments which use a rod antenna shall be

so placed that the rod antenna is in a vertical position. Those interference

measuring instruments which use a dipole antenna shall be so placed that the

antenna is parallel with the test sample and on. the same level as the mid-

point of the test sample. The antenna shall be at the distance from the test

sample specified in the typical test setups. The antenna shall be located

at a point around the perimeter of the test sample where maximum inter-

ference signal is received.

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R-AVE; 4. 6. 2. 8 Loads

The equipment under test shall be loaded v.,ith.the full mechanical and

electrical load, or equivalent, for which it is designed.

This recuirernent specifically includes electrical loading of the contacts

of mechanisms which are designed to control electrical loads ever, though

sach loads are physically separate from the equipment under test. Opera-

tion of voltage regulators and other circuits which operate intermittently is

required. The loads used shall simulate the. resistance, inductance, and

capacitance of the actual load. All input and output circuits, v.•hethee power,

signal, or control, which are otherwise unterminated in the test sarnple,

shall have impressed upon them appropriate simulated signals, with equiva-

lent circuit termination impedance.

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TES'' M77THOD .'.3

4. 7. 1. ". Composite System

Tests to indicate improper (inadvertent or unacceptable) responses for the

composite system shall be based upon the general test approz,;ches of para-

graph 4 7. 1. 3. Tests shall be devised, to demonstrate compatibility of the

composite system over the complete spectrum associated with each component

system and that of the individual subsystem and ec.juipments of the systems

including its expected external electromagnetic environment. lnstruirientation

used shall have frequency responses adequate for this task. Vehicle and AGE;

system and subsystems capable - of :transmisSionor:reception at a multitude of

frequencies shall be tU Stedl at the minimum number of frequencies

to indicate cictctromagnetic compatibility. Frecueneies shall be i:idicated in

the interference test'plan, when applicable for a specific test approach.

?.-AVE 4. 7.1. 1 Implementation

The integration contractor shall establish test criteria for determining

compliance with this specification in terms of performance requirements

and definitions of vehicle and AGE system component and subsystem imp roper

responscs. These criteria sha..1 be included in the test plans specified herein,

along with detailed test methods, instrumentation, critical points, monitoring

points, and intended functioning of each subsystem.

R-AVE 4. 7.1. Z . Improper Response

4. 7. 1. 2.1 Inadvertent Response

Criteria to• provent inadvertent response shall be defined in terms of the

margin (EMISM) between interference levels and circuit. thresholds of opera-

tion at critical points within each subsystem. This margin, or separation,

shall be a minimum of 6 db exclusive of instrumentation errors but may be

greater than 6 db depending upon the characteristics of the particular subsystem.

If the criteria for inadvertent response at critical subsystem points cannot be

determined prior to test for inclusion in the test plan, these criteria may be

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determined as part of the test. In such cases, the integration contractor shall

specify the test approach to be used in demonstrating that a 6 clb minimum

Elv1.15M exists at these critical points.

4. 7.1. 2. 2 Unacceptable. Response

Criteria for unacceptable response shall be in terms of performance limits

at a monitoring point at the output of the subsystem components. The

occurrence of unacceptable responses at those monitoring points during

testing Will constitute failure to meet the 2'ecwuiroINents of this specification

and are mandatory correction items. The EMISM for unacceptable response

shall. be 6 db, exclusive of instrumentation errors, and shall be determined ..:-., •

from a point_at which the,output, of the equipment under test reaches the

extremes of its acceptable tolerance. Out of tolerance operation of the

equipment resulting from interference is considered unacceptable

response.

4. 7.1. 3 Test Approaches

Tests shall be performed to demonstrate compliance with the improper

response- requirements of this specification. One or more of the following general

test approaches may be used:

a. Injecting interference at critical system points at a 6 db higher level than exists, exclusive of instrumentation errors, while monitoring oth: r system points for improper responses.

b. Measuring the susceptibility of critical system circuits for comparison to existing interference levels, to determine if a 6 db margin exists, exclusive of instrumentation errors.

c. Sensitizing the system sous to render it 6 db more susceptible: to interference exclusive of instrumentation errors, while monitoring for improper responses.

4. 7. 2 Equipment Test Methods

The radio frequency interference generation measurements described belov,, are

directly suitable for the measurement of steady state signals. In the case

of short duration signals having very low repetition rates, special test

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rricth, ods may be i _..red. The Scat (11.7.rat_ch shall he considered to be

the duration of the interference pulse at the output of the second detector

of the interference mce:er.

R.-AVE Into. rfe r c

Conduct:cc.] interference measurements shall be made over the frequency

range of 30 cps to 100 lie, using a clans-on interference current measuring

(meter) device and an appropriate receiver from Table ). In the• case of

a component with a large number of similar inputs or outputs, the conducted

interference measurements may be limited to representative conductors

in each cable. A typical test setup is shown in Figure 11. The test

conditions shall be as described in Paragraph 4.6.

For steady-state interference measurements, the current probe shall be

positioned at the p-:in-t .of interference on the lead to be tested.

This maximum interference point shall be located at each test frequency

for steady-state operation where the physical. length of the test specimen .

cable is greater than A/20, (A , free space wave length at the test frequency),

The location of the current probe shall be fully described in the test report.

Switching transients may be measured withwideband (minimum - 10 Mc)

oscilloscope directly connected across the test sample/signal/power leads.

R - A VE Radiated Interference

Radiated interference measurements shall be made from 15 kc to 10 Cc

for broadband/impulsive interference and 15 KHZ to 10 GHZ for CV. and

pulsed CW interference. Tipieal test setups are illustrated in Figures 12,

13 and 14. In the frequency range from I to 10 Gc, the measuring distance

shall be 3 feet. The antenna polarization and direction shall be adjusted for

maximum pickup. The antenna and measuring system correction factors

to be used are those specified by the interference measurement instrument

manufacturer. The test conditions shall be as described in Paragraph 4.6.

4.7.2.3 Transmitter (Keydown)

The transmitter shall be operated into a matched dummy load. A suitable

coupling device shall be used to sample the transmitter output and to protect

the measuring equipment, such as a bridge "T" or other filter rejection

network. Transfer and other characteristics of such devices shall be fully

described in the test report. Attention should be given to oscillator frequency

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and harmonic:;, outputs from frequ.eney multipliers and crystal saver

circuits, beat frequency oscillator outpu'Ls, etc. External filters shall

not bc' used for complanec with the spcciedIamts herein without

MOL sPc-) approval.

R-AVE 4. 7. 2. - 4-

•• , • tr -, -hs ,-nitter shall meet cono..icieo

c'r• 3-3, tic

erhLna tior (1;e;,•do-•..--.)

s :1-•jc.ote t o of:-

f recidc,,o ty ,•_!rt er L;y at level 35 bnlov.. the fundan-,ental power. The off-

frequency n::•.] shall be within percent. of given funklan-:ental frecuency

yet outside the fundarric.ntz.1.1,..,nd c; ful•thei-, at least one of the, sum and

differ.::!nce .h ,?terodyne pre :;hall be in the rani;C: of 0. If) to 10, C:Or.!

Mc. Tic: tram:rnitre;. modolated Cid r noln-nally or 30 per-scat at

400 cps. As on alternate tt:st, condition, the off-frecducnoy be at

h-vol oh fund:..hnental power, the

3.3.1.1.3.2. is ch:tnged accordingly, to flito.tei,;:stiun-leni,.-..tion. The c:::-.7-

fre:inency sii, na.) shall be amplituclemodalated 30 percent at 1000 cps. The

transmitter and the off'freouency source shall ha.ve their outputs co nnec.tc(f.,

Z.);),':rr ly a to 1:10 et cZ;re'.11, t

the off- fr equency '11 he meaL•u. byz....restivc.' tc' transn., 1 ' o4"'-frequer.cy

and spurious le ■.'els shall . be rn,:...cIe at the transmitter output. with the same

meter couplin; ,, - icc used in paragr-tlph

R-AVE 4.7.?. 5

Susceptibilit ,.•

When performing susceptibility tests - on receivers; all exte-rnal and internal

controls shall be set for maximum signal plus noise-to-noise ratio. All

external and internal controls for squelch or limiting shall be set ,to give

minirnum limiting action. On other equipment, all external and internal

controls shall be set for rni,,-:r.nitzn indication of susceptibility, or, if this

C2.USOs an . equipment to malLincticn or to 1:..ccorr..e inoperable as a result of

such a control setting, the critical control shall 1.-.•e zdjustod as directed in

the ec...tipment instruction manual. The equipment under test shall not be

supplied with any inputs other them those required to energize the ecuip.,rnent,

to render the ecluiprnent capable of re.spon,:ing to int erferE.:ace, and. to provide

indication of opera10n:

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7731

R-AVE

1.7.?. 5. 1. C -_:-,:ctec7. 30 ens tc, 130 1-c

The Voltage levels indicated in Fire s -ze the ripple vol -:75 applied in

series with each power input of th,.:1::.st, The voltT-,:.;e u 111 be measured

as shown in 1::'igure 16 with the equ.p•1-,e.r.,t piwor sou see connected and the equipment

under test operating. Tests will be i-nade over the frequency rouge of 30 epf; to

150 he. if no malfunctions occur, the test shall be repeated at a 6 db higher

voltage level or the malfunction threshold level, K;hiche,:er is 10-,cr. However,

it an;_-- lysis or prior test data indicates that equi.7-in-:ent dal-nage above the normal

susceptibility test limits will result, those malfunction threshold level tests need

not- be performed and the susceptibility threshole, shall be the susceptibility test

limits. Equipment need not be qualified to the 6 db higher voltage- level. These

6 db tests may be run on development hardv..are. In those cases where the power

lines are heavily bypassed at the equipment, presenting a very low impedance to

the injected interference voltage, the followl:-, procedure may be followed.

The irit.-1'fOrell.Ce voltage injected into the pc,\ver line may be measured across

the secondary of the transformer provided the do power source used to supply

the equipment under test has an impedance of 0.1 ohm or lens. The audio fre-

quency ripple current from the interference generating source may be limited to

that resulting from an audio frequency generator having a 1/2 ohm output impedance.

Further, if the impedance of the power line looking into the equipment under test

is so low at the higher frequencies that the required test voltage cannot be attained

with a 50 watt generator, the following procedure may be used. Measure the ac

drive voltage of the amplifier output stage which produces the desired voltage in

series with the power line at 1000 cps. Maintain this drive voltage while making

the test over the required frequency band between 30 cps and 150 kc. The output

transformer characteristics should be flat over this frequency.

4.7.2.5.1.2 Conducted, 150 kc to 400 Mc

The test setup for 150 kc to 400 Mc shall be the same as in Paragraph 4.7.2.1,

except that the 10-rnicrofarad capacitors shall. be removed. If no malfunctions

occur, the test shall be repeated at a 6 db higher voltage level or the malfunction

threshold level; whichever is lower. However, if analysis or prior test data

indicates that equipment damage above the normal susceptibility test limits will

result, these malfunction threshold level tests need not be performed and the

susceptibility threshold shall be the susceptibility test limits. Equipment need

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not be qualified to the 6 (11, higher vol_ These 6 dip tests may be run

on. devc.:loprnent hardware. An att.,.:nuator, or equal terrnimAion, shall be used

at the end of the coaxial cable to properly terminate the signal source. A

coupling capacitor, having an j art C C of 5 ohms or less at the test frequency,

shall be connected from this terlriinntion to the lead under test. The capacitor

may be charged during the test to maintain the spoe'!-Jiied impedance. The signal

SOUIzCe output required is the applicable. 1 plus the nominal termina,tion

insertion loss. The test signal shall be applied. to each power lead in turn. When

necessary, components can be added in series with the power leads to isolate

the power source. The output impedance of the signal generator shall be aS

low as practicable and no greater than 50 ohms. Tests shall be made over the

frequency range of 150 1:c to 400 Mc. The rf signal shall be modulated 30 percent,

400 or 1,000 cps, on,:equipments that are not designed for other modulation

frequencies or special forms of modulation. When applicable, actual modulation

frequencies or special forms of modulation shall be used as appropriate.

R-AVE4.7.2.5.1.3. Conducted Transient

The transient or pulse shall be induced in or across the power lines and between

each power line and case in both the plus and minus polarities. A typical pulse

shape with definitions of amplitude, rise time and pulsewidth is shown in Figure 17.

The pulse repetition rate shall be at least two (2) pips. The transient generator

shall be..capable of delivering at least 30 x 10-3

joules to the test sample. If the

transient cannot be generated across the test sample with 30 millijoules, then the

component is assumed to have passed the test. The transient voltage shall be

measured across the input terminals of the test sample with the test sample operating.

Schematics of a suggested type of test equipment are shown in Figures 18 and 19.

4.7.2.5.2 Audio Frequency Induced

R-AVE 4.7.2.5.2.1 Induced into Cables

Interconnecting cables shall withstand, without evidence of equipment performance

degradation, the application of a magnetic field caused by a wire carrying 20 amperes

rms at 400 cps spaced 2 inches away. Other test frequencies, up to 15 kc depending

on the anticipated environment, shall be used as directed by the detail specification.

Power input and output leads are exempt from the requirement of this paragraph.

The applied magnetic field shall be generated by the current in a wire routed 2 inches

For EK non-interfacing equipment, use amplitude of 30 volts., for all 3 tests. All contractors use 30 volts for return lead to case test.

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away and parallel to the cal_je uncle]: test fa a istalicc_ of 5 feet. The wire

shall be oriented in two angular positins, 00 degrees, a -part. about the cable.

To implement this, two wires 90 degrees -,part may be routed, and the current

then 'switched from one to the other (figure 21). Cabling of the test sample

shall be routed at least 2 inches away froi-n the ground plane or equipment rack.

The current carrying wires shall break from the test sample cable at

least 6 inches short of the cable connectors. The wire return leads shall be

kept at least 2 feet from the. cable under test and from all other cables of the

test sample. Cables need not be tested individually, but may be tested in whatever

bundled configuration is convenient. Regardless of the number of current

carrying wire segments installed for test, only one wire segment shall be

energized at a time.

14-11-VE 4.7.2.5.2.2 Induced Equipment

Equipment shall withstand, without evidence of performance degradation, an

ambient magnetic field at 400 cps. Other test frequencies may be used, as

defined by the affected test plan. The applied magnetic field shall be

generated by a minimum current of 20 amperes rills in a straight wire segment

which is located 2 inches from the sample unit periphery and from sample

interconnecting cables. The various units of the sample shall be individually

tested. The segment shall be oriented as necessary to thoroughly probe each

unit for susceptibility. The length of the segment shall be such that it extends,

at each end, 2 feet past the unit under test. The leads supplying current to

the segment shall be routed at least 2 feet from any portion of the sample and

from the segment itself (that portion of the segment directly opposite the unit

under test).

14-AVE 4. 7. 2. 5. 3 Radiated Field Susceptibility

The radiation field shall be established with a signal generator driving

the antenna listed below. The fields specified are those calculated

(assuming plane wave/free space propagations) to exist at the equipment

under test. The test setup is shown in figure 22 for the long wire antenna

and is similar to figures 13 and 14 for the other antennas, with the signal

source replacing the interference meter. For the dipole and directive

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NRO APPROVED FOR G. . RELEASE 1 JULY 2015

antennas, the power delivered to the antenna shall be rnonitored. Figure

2.3 may be used for ease

dipole antenna.

in establisl:ing the required power level for the

1'1- Cane 31C: y Field Strength Antenna , 0.0.15 to 35 Mc . 10 vim Long Wire

35 to 1000 Mc 5 vim Tuned Dipole or Directive Antenna

1 to 10 Cc 5 vin-, Directive Antenna

In the long viire antenna test over the frequency range of 15 kc to 35 Mc,

the field shall be established by a known current flowing through an un-

shielded v•ire terminated at the far end to the ground plane. The wire shall

be routed 1 foot from the equipment under test. Figure 24 may be used for

convenience in establishing the equivalent field strength based on the

measured current in the line.

4.7.2.6 Intermodulation

Receivers, preamplifiers or antenna couplers shall not produce an output

indication when two sine wave signals, representing undesired signals,-

are connected to the input terminals of the test sample. The two fre-

quencies shall be chosen so that their sum or difference is equal to the test

frequency and so that neither will give an output when applied alone. The

magnitude of each shall be 100 my at the test sample terminal; one shall be

modulated 30 percent with a 1000 cycle signal, and the other 30 percent

with a 400 cycle signal. Impedance matching networks shall be used as

required.

R- EVE 4.7.2.7 Receiver Front End Rejection

This test shall be performed with signal generators equipped with an

accurate attenuator and capable of a signal output at least 80 db greater

than the minimum signal perceptible at the tuned frequency of the particular

receiver being tested. If necessary, matching networks shall be used to

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obtain a 50-olim (+_20 percent) outp,it. AU measurements all be corr:ected

to account for any changes in output voltages due to o f-

networks and be equal to the o,:.encircuit voltage at the output terminz.ls.

(a) with a 50-ohrn coaxial cable and tuned to the same With the signal generator and receiver connected

frequency, the generator setting which gives the minimum perceptible reading above tbe receiver background noise shall be noted. Modulation may be used in conjunction with an output meter, if the receiver is not equipped to 2ive meter indications of cw signals. The frequency range between ISC kc and 10 Gc shall then be scanned v., ith the generator output preferibly set at least SO db above the output originally noted. Those free q uencies at which output signals are obtained shall be investigated to obtain the generator reading which corresponds to the original receiver output signal. Since all signal generators emit a substantial amount of harmonics, care should be taken that .the receiver is not erroneously rejected because of such spurious signal content.

(b) Front end rejection is calculated with the following formula:

Front end rejection = 20 log V 2 /V i

V 1 Signal generator voltage required for minim-urn perceptible receiver output on channel or Ire-

, quency under test.

V 2 Signal generator voltage required for rrir,:----urn perceptible receiver output at all other frequencies.

When this test cannot be accomplished clue to the possibility of crystal bu'rn.-

out or other reasons, the test signal shall be injected into the test sample

by using a suitable antenna fed from a signal generator. The test procedure •

to be used shall be included in the test plan.

R-AVE 4. 7. 2. 8 Isolation Resistance Measurements

Add new paragraph, title and text:

Prior to the conduct of interference and susceptibility equipment tests,

(

the 1.0 megohm minimum dc resistance requirement of Paragrap.h 3.2.5. 3

shall be verified on each separate component

in accordance with Method 302 of MIL-STD-202C. Unless other-

wise restricted because of circuit or component damac:e hazards, the test

potential shall be 500 volts+ 1050, per. Test Condition B of Methbd 302.

t'ne t2st -potential is the h_cl-:est. ac: -:.;tabl& voltam L- 6 0 0 6

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5. G PREP.e% RATION 17.

Not applicable.

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6. 0 NCti'ES

6. 1 IN'3.'ENDED

The test proc ed;i arC 5,;.tendee. o 0.115',1Yi• that

the electrical and electronic eqUiprnents of the connposite systc..rn components

space vehicle and AGE systems and their respective subsystems will operate

properly in service use when subjected to electromagnetic interference. voltages

and will not cause malfunctions by generation of, or response to, interference

voltages,

6. DYTINITIO:■S

The connotations described below shall obtain for the purposes of this

specification.

6. Z. 1 Aerosr.nace Ground Equipments (AGE)

The equipments required on land or water at a launch complex to maize an

aerospace composite system operational in its intended environment. This

includes all equipments required to install, launch, arrest, guide, control,

direct, inspect, test, adjust, calibrate, appraise, gauge, measure, assen-,b1c,

disassemble, handle, transp::,-_- t, safeguard, store, service, repair, overhaul,

maintain, and operate, as applicable, the composite system. This definition

applies regardless of the method of development, funding, or procurement.

AGE is subclassified as operating ground equipments (OGE) and maintenance

ground equipments (MUE). The tern: aerospace ground equipments has re-

placed the terms ground support e,-juipments (GSE) and groundope. re.ting

equipments (GOE:),

6. Z. 2 Ambient Interference

Ambient interference, for the purpose of this specification, Is the interference

level emanating from sources other than the test sample, including the internal

. background noise of the interference measuring equipment.

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6.2. 3 A ntenna Induced i.. rovolts

Antenna inc!uced nair rovr.lts i -- that voltage v..hich exists across te op....-

circuited antenna terminals.

6. 2.4 Associate Contractor

An aerospace industry concern which has directly contracted with the United

States Air Force Space Systems Division (SSD.] to supply spar.- o vehicle sub-

systern(s) or equipment(s), aerospace ground equipment end item(s), rnaterial

or services, or any con-.bination thereof for a specific program. It is to be

noted that an associate contractor may be as.,.;ignecl by SSID to function as the

integration contractor for the program, in which event the contractor carries

out a dual role as materiel 'supplier and as integrator.

6 .Z . 5 Certincation

A signed st at cm ent, by a responsible representative of a manned spacecraft

progS,arn certifying that the space vehicle ordnance systems:

(a)

Have been tested and evaluated in accordance with the requirements of this specification.

(h)

Comply with the criteria established by this specification.

6. 2. 6 Component

A component is a functional pat of a composite system, system, subsystem,

equipment, or assembly essential to operational completeness of that of which

it is a part. Examples are a manned vehicle system of a composite system,

a subsystem of the vehicle system, an antenna of the co....munications

subystem, and the case of an electronic device.

6. 2. 7 , Composite System

A comp.)site system consists of all or part of:

a. the vehicle v...hich will consist of one or more stages and capsules or modules each of which may comprise all or part of these subsystems:

1. spaceframe, including en•Tironment control, separation and joir.'ng mechanisms, o'oservation and access areas and provisions therefore

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Z. propulsion, inCuding, prinary, secondary, tertiary

3. electrical power, includin: power sources, such as batteries, solar arrays, fuel cells, and inverters

guidance and control, including attitude control and

F:I.Lbi 1lret:('n, orl:tai adjustment

5. conlinunic,-itions, including telemetry, data link

6. life support which will comprise those devices, plumbing, wiring, sealing, seating!, etc. which are installed in the rife support compartments, bays, or other areas of the appropriate capsule(s) or

module:(s)

7. experimentation and observation equipments, 5011-contained power therefor, end the various acces-sories attendant thereon

b. the astronaut stlbsyster.-. which will include those equipments, materials, and items worn or carried by the individual men, such as radio transmitters and receivers, light sources, body functions, psychophysiological equipments, etc.

c. the aerospace ground equipment system (AGE) consistiili; of:

the operational ground equipment (OGE) subsystem which includes the instrumentation, control and checkout consol.es, cabling, wirint!,, cominunications, ground electrical power, fluid loading, (wheter liquid or gas), handling, including erecting, mating, demoting, adjusting, calibrating, corn:nand loading, and all other material required to conduct pre-countdown tests, countdown, and lancb

Z. the maintenance ground equipment (MG.E) subsys tem

which includes those items and materials of the types noted in (1) above, (OGFA, v..hich are used to maintain the vehicle system in, o restore it to, a state of readiness for launch, countdown, and pre-countclo\vn tests.

Note: Since the following are not subject to this specifica.t.ion, they are listed for information as to the elements of a composite system.

t. the telemetry, tracking, and command system .which

consists of:

1. the ground station network and the facilities and equipments thereof which are used to acquire data

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telernetcred from the vehicle fron-1 before launch throgh useful oT-1);tal le arnl rec-c,very, data and infc,rination on vehicle performanc.e, internal and :e:mal e.nvironment, data link transmissions, and, as applicable, conDri-.and

I oading

Z. the inter-station communications links, includinz landline, radio, subn'iarinc cable, etc.

3. the control center for ti- is notv.'ork, its inter-station Enks, and its data and inorrhation process-ing, and reduction facility(s) and equipments

4. the Advanced Range Instrumentation Shi25 (A..RIS) which function as mobile station:: and supply' similar info nation to the control center

c. the recovery system which consists of the facilities, ships, land vehicles, L- round effect machines, forces,

and their respective equipments which are used for air, water, or ground recovery of the manned capsule(s) or

module (a).

For purposes of this specification, the operational environment shall be

understood to be that of the launch environment, including pre-countdown

tests, countdown, and launch, as encompassing the worst environment to be

encountered by the composite system, its component systems, and their

respective subsystems and equipments.

6. 2. a Contractor-Fu'rnishc..-.0. Aer,-Jspace F..cuipment (C.FAE)

CFE is that piece(s) of equipment that is furnished by, and included in a system

or subsystem by an associate contractor as a comi:fpnent(s) of the subsystems

and equipments for which it has contracted with the procuring activity.

6. 2. 9 Critical Test Point

_• _ A critical test point is a point in a component subsyStem or system that.

is considered susceptible- to--electrornagneti,c interference, because of

sensitivity or inherent susceptibility, and which is important to mission

objectives. Critical test points shall be chosen for -demonstrating—

,- complianc:; to the 6 db EMISM requirement.

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t • .

6.2. IC' Current Sensitivity

The least iimount of current required to initiate a particular EEL) at a -

specified probability and confidence when conditions of ET:i-,D topeiature and

power api,lication are specified.

'6. 2. 11 Detectors

A. detector is any instrumentation device, including dc converters, rejection

filters, scaling resistors, flip-flops, zener diodes; or other parts or circuits,

used ,specifically and only al the monitored paint of piel:-up to provide data and

information as to subsystem or equipment performance to environment.

6. 2. 12 Electroexplo5-ive Device (EED)

A device in which electrical energy is used to cause initiation of explosives

etontained Th.e testy s limited in us..! to single comt:,onetits such as

primers, detonators, squibs. switches, etc. as opposed to fuses, S-A devices,

etc. which Cont-ain a number of individual explosive components the outp:t of

one forming the input to another and all of which being triggered by an eiectro-

explosive device.

6. 2. 13 Electromagnetic Environment

The electromagnetic environment or area interference level is the signal and

noise complex within which a space vehicle or system and their respective

subsystems or equipments are likely to be immersed in operational use.

6. 2. 14 Electromagnetic Interference Safety Mar -, in (i-2MISM)

The EMISM shall- be defined as the ratio between the susceptibility threshold

and the interference present on a critical test point n r siEnal line. The

EMISM shall be 6 db exclusive of instrurintittion errors.

6. 2. 15 Electro-Interference

Electro-interference is an undesired electrical phenomenon which is created

by, or which adversely affects, any device whose normal functioning is predi-

cated upon the utilization of electrical phenomena. Electrical interference is

known colloquially, and is referred to, as radio and electrical noise or inter-

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ference, hash, jitter, grass, in.lriting, ambiguity, cross modulation, TV

interference (TV:), burn, etc. The v'orcl "interference" may be used along or

with appropriate modifiers in reference to some manifestation of electro-

int erfe relic c when mutually under F. t o. Ehclro-ir.tenferencc also includes

ground 10();s, radiated as well as cor;ducted noise, and self-g e nerated as well

as mutually- coupled crfere r.c e as it affects a component.

6. Z.16 C.' Ilt

Equipment is a majC:r functional part of zi :-Iy.;tern or subsystem, usually

consisting of several components, which is essential to operational complete-

ness of the syste m or subsystem. Examples are inertial platform of a

guidance subsystem, a radio command set and ground electrical power supply

of the operational around ec-juipment subsystem.

6.1. 17 Fire

The ignition of the prince explosive surrounding the bridgewire.

6.?.. 18 • Firin7 Circuit

The firing circuit of an installed EED includes 'all of the electrical circuits

and components between the initiation power source and the electroexplosive

eleiucnt of the EEL). The firing circuit power source shall be considered as

the last point of the electrical power entry to the ET-21) during the arming-firing

sequence.

6. Z. 19 Government-Furnished Eciu .:)ment (GFE)

GEE is that piece(s) of equipment which is furnished by the military directly

to the associate contractor for inclusion as such in a system or subsystem of

a composite system. 6.2.20 Improper Response

A subsystem or equipment response which may be either inadvertent or

unacceptable.

6.2:21 Im-)ulse Bandwidth

The impAse noise bandwidth of the interference measuring instrument should

be used in calculations involving broadband noise. Effective (random) band-

width should not be used.


6.2.22 lsiV

For the purpose of this spec ificdt ',on„ all broadband noise, ineludir.,, random

noise. is considered to be impulsive interference.

6.2.23 Inadvertent i.Cspors2

a An i nadVertcot response is a proper subsyst ICI response (s.vithin

normal range of limits) actuated by electro-interference but Occurring at

other than the normal operational cycle, which in turn causes improper

response to the total space system (e.g. , an automatic flight control system

comrnan(Jing a maximum pitch rate due to electro-interferencle at ruaxirnuier

velocity which overstresses the airframe, causing disintegration of the vehicle

in flight).

6. 2.24 Integration Contractor ••-• •

In an aerospace program, the associate contractor assigned by the procuring

activity the task of coordinating the activities of all of the associate contractors

to assure achievement of the planned con:posite Sy5teril electromagnetic

compatibility. Such coordination is subject to the apprOval of the procuring

activity.

6. 2.25 Interference Control

Interference control is that design, placement of components, shielding,

employment of rejection filters, and other techniques which effectively

regulate the interference environment and/or susceptibility of individual

Space Sy',3tein components.

6. 2.26 Maintenance Ground 1-2c,uipments (.:\fiCiE) - —

Those equipment end items of an aerospace ground equipment system which

are essential elements thereof for the maintaining of the operating ground

equipments in, or restoring them to, readiness condition for the respective

pre-countdown tests, countdown, and launch of the space vehicle; such end

items include calibration standards and testing equipments, collimators,

timing references, etc.

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(, . i. 2,7 1 C. 1" 0 t 5 1: 3 i•

The nez rest iti ,pl'O.C.11 to a f.tanclard u;lit of -measurement of 1...iro,-..;21.-,ancl radio

interference if in terms of iTlicrovolts; pe gacycle. Interference intensity

in n-iicrovolt:', er megacycle per m e g ac.ycle is equa l t o th e o f r oot

/neat) scare sine wave microvolts Nun-lc:cit.:lazed) applied to the input of he

measuring circuit at its center frequ.2ncy that will result in detector peak

respon;.c in the circuit equal to that resultin, from the interference pulse

being nicaf.:ur cI , divided by the impulse b;ndwidth of the circuit in megacycles.

The impulse band,.vidth is the area divided by the height of the voltage respon s e

versus radio frecrue;.cy selectivity curve from antenna through the peak

detectot- . Impulse bandwidth is approximately equivalent to the bandwidth

between the 0.45 voltage points on the selectivity curve.

o t r nt

0.1e Cr more points in a subsysten-; us ed to observe or measure unacceptable . ;

or inadvertent responses of the subsystem. Monitor points for determining I I

unacceptable response shall be at the output of each subsystem and need riot I

be electrical in nature. Monitor points used in conjunction with critical I

points in determining that no inadvertent response exists in the subsystem

1 may be located at either internal subsystem points or at the subsystem output.

If these monitor points occur at internal subsystem location, they will be

!

I

electrical in nature Z-..1-,Ci W1.1! he required due to the presence of non-analog. •

I I

circuitry bczween the critical points and the subsystem output. I I

i

1 6. "L 29 No-Fire

l I

6.Y. . The failure of an EED to tire upon the application of I

electrical energy, or i

.(b) The rendering of an EED to a pern-.a.nent inoperative state without any ignition process occurring (duciding).

6. 2. 30 - No-Fire Current I i

. t The current sensitivity at which no more than one 1:1-1:13 per thousand will fire 1 t

1 with a confidence of 95%. I

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No- Yirc Povie

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The power ser.:•;itivity at which no more than one EED per thousand will fire

with a confi denc eof c):.;%.

6. Z. 32 Octave

An octave is a frequency ratio of 1 to ?.; i.e., from I to 2 MC, 2 to 4 Mc,

500 to 3000 Mc, et cetera.

6. 2.33 Open Space

The term open space, as used in this specification, is intended to designate

an ideal site for radiated int erfemence measurements. This ideal site should

be open, flat terrain at a considerable distance (100 feet or mor e) from

buildings, electric pc,wer lines, fences, trees, underground cab] s, and pipe

lines. This site should have a sufficiently low ambient level or radiated

interfcrence16' permit testing to the governing radiated interference limit at

any test frequency selected.

6.2. 34 Operationl IThvironinent

The aggregate of all conditions and influences which may affect the operation

of a composite system, vehicle systermand AGE system and their respective

subsystems and equipments, including physical location and operating charac-

teristics of surrounding or nearby equipments, temperature, humidity, z

pressure, acceleration, shouk,.vibration, radiation, contaminants, climatology,

corrosion, and other modifying conditions during pre.-countdown tests, count-

down, and launch. 1

6. 2. 35 Operaiing Gi ound Equipments (0,3E)

Those equipment end items of an aerospace ground equipment system, which

are essential operating elements thereof and which are used to directly

support pre-countdown tests, countdown, and launch of the vehicle; these

include such diverse end items as the launch complex cables, cameras, and

antennas and the system and subsystem test consoles and instrumentation.

1..—„—.____.-.—....—..------ ,—

L - 6 0 0 6

C


6.2. 3f, Operator and Observer :(:"itions

In those cases %,..here the operatoi's or observer's location seems to vary a

measurement reeding, a rninirnUni of 3 feet should be rntained

between his body and the antenna; the ci,:erator should change position slightly

until a vr,z1xinittiri reading is obtained. In all cases, as few observErl'S as

possible should be present in the screen 200m during the radiated

measurements.

6. 2. 37 POV.'C'r SC1iF;itivity

The least amount of electrical power reciuired to initiate a particular EZ,I)

at a specified probability and confidence when conditions of LED temperature

and power zlpplication arc specified.

6. 2. 3i; n a (7 .11 C' V %.! r FT End Reiectio,-,

Front-end rejection is the measured capability of a receiver, exp -i-es:iee, in

ciecibel;;, in rejecting signals at the antenna terminals that are outside the

channel, or frequency, to which the receiver is tuned. •

6.2.39 Receiver Internal BackrIround Noise

The receiver internal bacl:ground noise is the receiver Output obtained at the

test location, under the following conditions:

(a) All control L at standard settings.

(b) All other space vehicle eciuipinent off.

(c) A shielded dummy antenna connected to the receiver input.

6. 2.40 RE Field Intensity

The power flux density of electro-magnetic waves passing through a surface

normal to the direction of propagation.

6. 2.41 RE Field Strencth

The magnitude of the electric or magnetic field vector (E or H) at a given '

location resulting from the passage of radio waves.

. . .

L - 6 0 0 6

CcJPY •


6. 2. 42 R).;- Radiation llaza..-_

Tri-service limit for exposure to rf radiation for human safety ha.s been

established at 0. 0/ watt/cm2 at any frequency. It is possible to encounter

even higher power densities than this established safe maximum limit during

sthe testF required by this specification; howaver, these exceedin g ly high

densities are usually localized. Power densities of C.030 %vatticin have

been rneaS1.1 d on equipment near tuning adjustme iltS. A C 11:-to safety

precautions are recommended. This warning is intended to produce a healthy

respect for rf radiation.

6. 2. 43 It" Su s c ept ibi llt y

The magnitude of the smallest electric field expressed as an 'rf field intensity

or rf field strength capable of producing the no-fire current or no-fire power

iii an 371:::].).

6. 2. 44 Shield

A metallic barrier which completely encloses a device for the purpose of

preventing or reducing induced energy.

6. 2.45 • Slide-Back Circuit

To obtain a true peak reading, use is made of the slide back circuit technique.

Such a circuit consists of an adjustable bias on the detector diode which blocks

signals which produce voltages less than that required to ove•i- corne the bias. . •

The procedure is to adjust the bias manually until the output •indication just

disappears, using the highest possible gain of the output. stages. At this print,

the bias is just equal to the peak value of the applied signal.

6. 2.:6 Standard Antennas

Because of the non-uniformity of the electro-magnetic field which usually

exists close to a test sample, it is imperative that tests for radiated inter-

ference be conducted with antennas identical to those specified. Attempts to

correlate results obtained with other antennas by reducing the results to

L - 6 0 0 6

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mic:rovolts re nleter, b.ased calculations and ant.•..nna

effective height, inlay lie erroneo,..:n and will hat be acc eptecl a:.; indicating

coinpliairt:e with this specification.

u stitu t ien echnieue

This ten describes a method of Lnez, eu rr interfercnce. The rroethod depends

• on the use of a calibrated signal generator whose output is of sinnilar character

to that of the und;nown signal; that is, use of an imulse noise generator for

broadband noise measurements and a sine wave generator for cw rneasure-

rnents. The method is: connect the interference meter .to the ui:lmown signal

and record the reading. Disconnect the meter (at the meter terminals) Iron

the unl;no,,vn and connect it to the signal generator output. i,djust the signal

generator oulput level to obtain the previous reading. The unkno,_‘..n signal is

then considei ed to be .equal to the signal gent rater output in \vhatever units ,•• •

the generator calibration is stated.

Suhcy: tei n

A subsystem is a major functional part of a vehicle or aciospaca ground

equipm-ent system, usually consisting of several equi;ainents %,.hich are .

essential to the operational completeness of the subsystem. Tiliearnples are

the coinrrinieations subsystem of a space vehicle and the communications

checl;"out subsystem of the AGE..,

6. %. 49 SusCc.:ptibility

'',usceptibility is that characteristic which causes an equipment to malfunction

or exhibit an unde.sirable response when its case or any external lead or .

circuit, excepting antennas, is subjected to the specified radio or audio

frequency voltage or field. Unless otherwise specified, the term "no

inadvertent response" may be taken to mean that the extraceous electro-

magnetic energy which is introduced into a sample is 6 db below that which

would produce operation, actuation, or functioning of the sample.

L - 6 0 0 6 - Con's- of

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6.2.50 SiisceDtibilyit- Threshold

The curve that gives the relation between , frequency (30 cps to 10 gc) and the

relative intensity of the signal at a critical test point which just causes opera-

tion or a response in the equipment, subsystem, or system.

b,2.51 System

A system is a major component of a composite system, including its subsys-

temn and equipments and in all related equipments, materials, services,

and personnel required to make the system a complete element of the com-

posite system and operational in its planned environment.

6.2.52 Unacceptable Resnonse

Unacceptable response or unacceptable degradation of performance is an

abnormality in the expected operation or output of receiver or subsystem • .

due to electro-:interference which may be considered improper. A complete

subsystem or. system failure would be termed a malfunction.

L - 6 0 0 6

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-13 ADJUSTAE3LE TRANSFORMERS

fla I 200 2 NOr■ NAL

RI 1K S2 POT. NOM.

Figure 19. Spike Generator, AC Lines

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EQUIPMENT UNDER TEST

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Core material •Ferrox Cube Company of America

(or equal)

Turns - Primary (12)

Secondary (12)

E section 783 E 608

I section 7E3 B 608

Copper sheet 1 mil thick 0. 75 inch wide

Copper sheet 5 mil thick 1 inch wide (Bifilar wound)

Layer insulation 10 mil teflon tape

Core gap = 0. 1 inch per leg

?rimari open-circuit inductance = 12 microhenry e-- 10 percent

primary resistance = 0.047 ohm •..

secondary resistance := 0. 006 ohm

Secondary load current = 43.5 amps

Figure 20. Pulse Transformer Specifications

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A


GE APPENDIX

The following paragraphs of SAFSL 30005 are not applicable to GE because

the GE segment does not contain equipment pertaining to these paragraphs.

In the event changes are made to the GE segment to include equipment which

pertains to these paragraphs they shall. apply.

3. 3. 1. 1. 3

3.3. 1. 2. 5

3.3. 1. 2. 6

/' 4. 7.2. 3

4. 7. 2. 4

4. 7. 2. 6

4. 7. 2. 7

L..- 6006

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• • . • •••• .! •

EK ZT:=DIX

AppLicv LY'•!TTS)

3.3.1.1.2

The conucte0 and radiated generated interference limits of

3.3.1.1.1 anf sh.....11 not aply to interference sources

switehin (1) less than 5 volts at loss than 5 millioperes,

(2) less than 1.75 volts at less th.an 1.75 .c.ipercs and (3)

rates of eurront ehanz-:e of less than 30,000 :.:-nperes per

second.

Brush-type e-c. roto:.-s shall have an i3oletion reeistance betws.en

power lads and motor frem,a of 50,030 eh,-Is or nave. Electrical

components whose lea%ac tests involve circuits w'nich colitain

motors viAl have.secifiction limits adjusted to reflect the

effects of the E.sociated nol.ors.

1; 3. . EL)PT,TC,' TiLw • 'rest Enort Sc1ad Je

The Contractor shall samit to rayspo all data and results for

uste!A level E..".0 tests on the 0:,..alification lode). 30 days after

eolaction of the ter3t. In addition, the Contractor shall subnit

any signifieart reaults of system level EC tests on other

r_oaels within 3d days of the test cc:Ipletion.

L- 6006

• of. -";:" Copy

JI.

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I-. rj ••-• r r . r

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EK APPENDIX (continued)

The following paragraphs are not applicable to Eastman Kodak

Company because the Eastman Kodak Company segment does not

contain equipment pertaining to the paragraphs. In the event

changes are made to the EK segment to include equipment which

pertains to these paragraphs, they then shall apply.

3. 2. 5. 4 EED Firing Circuits

3. 3. 1. 2. 5 Intermodulation

3.3. 1. 2. 6 Receive Front End Rejection

3.3. 1. 3 - 3.3. 1. 3. 2. 3 Electroexplosion Devices (EEDS)

3.3.3 -3.3.3..'2.3.' - Validation of EED and FED Initiator Circuit

4. 7. 2. 3 Transmitter (Keydown)

4. 7. 2. 4 Transmitter Crossmodulation

4. 7. 2. 6 Intermodulation

4. 7. 2. 7 Receiver Front End Rejection

As an:alternate to maintaining the transient generator at + 100 v

during component operation, transient susceptibility testing may be

done with a transient source whose unloaded output voltage has been

set at + 100 v. To obtain the 30 niillijoule level, a 6 niicrofarad

capacitor will be used as an energy source of the transient. Peak

transient current will be limited by an equivalent generator output

impedance of 1 ohm.

lTh '72 cm,, r, r: ,. ; H. e

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aFJF- P' aLtniX.1 HANDLING - NRO APPROVED FOR

RELEASE 1 JULY 2015_

WIRING HARNESS SPECIFICATION

FOR THE MOL SYSTEM

SAFSL EXHIBIT 30006

6 JUNE 1968

•

c 1.13 g2 T71131 ka

SPECIAL

HANDLING

Mat A-6* AP (Signed

(Signed)

(Signed) //


CERTIFICATION OF DOCUMENT CLASSIFICATION

I HEREBY CERTIFY THAT ALL PAGES OF THE ATTACHED DOCUMENT

1\t • •1.1. >> .) V \\ 0.1 \NI

( Document Title or Other Identification)

CARRY PROPER SECURITY CLASSIFICATION MARKINGS.

(Signed) :44

/7,/ i 5.\(SL /•. 11_,■

4-5

(Signed)

(Signed)

(Signed)

(Signed)

(Signed) /

. • SECRET

SPECIAL HANDLING

T.T4 T7') SPECIAL tt) L

L 6009

Coplr"r Page /2,._

NRO APPROVED FOR RELEASE 1.JULY 2015 . -

S E VIPAD/-1‘

3P9OG



to scope subsequent proposals.

(Signed)

(Signed) •',Q \J ..15 ftlAy /94f

(Signed) ----)/ 14,-A1f„--- , (Signed)

•

(Signed ?-74 /ker

•

(Signed)

NRO APPROVED FOR

Kum- bPLCIAL HANDLING

RELEASE 1 JULY 2015

1.0 SCOPE


2. 1 Specifications

2. 1. 1 Military

3 0 REQUIREMENTS

3. 1 General Requirements

3. 2 Electromagnetic Compatibility

3. 2. 1 Shield Terminations

3. 2. 2 Redundant Wiring

3. 2. 3 Spare Wires

3.3 Propellant Compatibility

3.4 Flammability

3. 5 Connector s

3. 5. 1 Non-coaxial Connectors

3. 5. 2 Coaxial Connectors

3. 5. 3 Finish

3. 5. 4 Strain Relief

3. 5. 5 Orientation

3. 5. 6 Angle Connectors

3.6 Protection

3.6. 1 Abrasion Protection

3. 6. 2 Connector Protection

3.7 Splices

3. 7. 1 Rework

3. 8 Wires and Cables

3. 9 Wiring Harness Forming

3.10 Wire Lay

3. 10. 1 Parallel, Straight or Random Wire Lay

3. 10. 2 Twisted, Helical, or Contrahelical Wire Lay

3.11 Wiring Harness Breakouts

3. 12 Wiring Harness Ties

3. 13 Jacketed or Molded Wiring Harnesses

3. 14 Handling

3. 15 Installation

3.16 Rework and Repair

7r7)77 SPECIAL HANDLING

L =6 0 0 9

Copy301Of

Page of


- - :

5PECIAL HANDL! NG

4.0 QUALITY ASSURANCE PROVISIONS

4. 1 General

4.2 Acceptance Tests

4. 2. 1 Examination of Product

4.2.2 Electrical Continuity _

4. 2. 3 Insulation Resistance

4. 2. 4 Dielectric Strength

4. 2. 5 Order of Electrical Tests

5. 0 PREPARATION FOR DELIVERY

6. 0 NOTES

6. 1 Definitions

6. 1. 1 Wiring Harness

APPENDIX "A"

APPENDIX "B"

APPENDIX "C"

APPENDIX "D"

SPECIAL t--71 A

1.4-6 009

•CopY.

Page 4L of Lz-


SPECIAL HANDLING

1.0 SCOPE

This specification covers the general requirements for electrical wiring

harnesses external to components which are installed in spacecraft. All

deliverable data and/or documentation specified in this Exhibit shall be in

accordance with the respective contractor's CDRL (DD 1423) or equivalent as

detailed by Form 9.


The following documents of the issue date shown form a part of this

specification to the extent specified herein:

2.1

Specifications

2.1.1 Military

MIL- C- 26482D Conne ctors, Electric, Circular, Miniature,

Quick Disconnect, Environment Resisting dated

2 January 1968.

MIL- C-38300

Connectors, Electronic, Circular, Multicontract,

High Environment, Quantitative Reliability,

General Requirements for, dated 15 August 1963

with amendments and supplements.

MIL-C-38999

Connectors, Electric, Miniature, Quick-Disconnect

with Removable Crimp Contacts for Special Weapons

System Circuitry, Established Reliability, dated

21 August 1967.

MIL-P-26539B Propellant, Nitrogen Tetroxide, dated 15 Oct 1965.

MIL-P-27402A Propellant, Hydrazine-Uns-Dimethyhydrazene

(50% N2H4, 50% UDMH) dated 24 February 1967.

MIL- P- 27404

Propellant, MonoMethyl Hydrazine, dated 3 Apr 1962.

MIL- P- 27408

Propellant, Nitrogen Tetroxide Nitric Oxide (90% N204 -10% NO2), dated 5 May 1967.

MIL-S-23190B

Strap, Cable, Adjustable, Plastic, dated 27 July 1966.

MIL-W-8160D

Wiring, Guided Missiles, Installation of, General

Specifications for, dated 24 December 1963.

MIL-W-16878/4A Wire, Electrical, Type E, 200°C and 260°C,

600 Volts (Insulated High Temp) dated 5 July 1961.

MIL-W-22759 Wire, Electric, Fluorocarbon-Insulated, Copper

and Copper Alloy with amendments dated 3 Jan 1968.

172 9 7, SPECIAL

pl .1,1-1 _I LI 14 A mni

• IL - 6 0 0 9

CoPygld

Page of

HANDLING NRO APPROVED FOR _ RELEASE 1 JULY 2015

• MIL- C-22557A Connectors, Co-axial, Radio Frequency,

Miniature, (Screw-on), General Specification

for, dated 26 January 1967.

MIL- C-24308 *, Connector, Electric, Rectangular, Miniature,

Polarized Shell, Rack and Panel General

Specification for, dated 30 November 1967 with

supplement.

MIL-C-39012

Connector, Co-axial, Radio Frequency, General

Specification for, dated 23 May 1966 with

Amendments and Supplement.

MIL- C-23329A Connector, Co-axial, Radio Frequency, Series

SC, dated 15 February 1965 with Supplements

and Ammendments.

MIL-W-81381(AS) Wire, Electric, Polymide-Insulated, Copper

and Copper Alloy, dated 15 October 1966.

NAS 1599

Connectors, General Purpose, Electrical,Miniature

(Rev. 3)

Circular, Environmental Resisting, 200°C Maximum

Temperature, dated 15 October 1966.

MS 33586

Metals, Definition of Dissimilar, dated 16 Dec 1958.

MSC-PPD-2

Propellant, Inhibited, Nitrogen Tetroxide, dated 6 January 1966.

SAFSL Exhibit Electromagnetic Compatibility Requirements, 30005 Orbiting Vehicle, General Specification for the

Manned Orbiting Laboratory, dated 7 June 1968.

SAFSL Exhibit Nonmetalic Materials Combustion & Atmospheric 10010 Contamination Control Standard.

3.0 REQUIREMENTS

3.1 General Requirements

In the case of a conflict between this document and any applicable

document, this document shall prevail.

3.2 Electromagnetic Compatibility

The wiring harness shall be designed and installed to aid the

system in meeting the electromagnetic compatibility requirements of SAFSL

Exhibit 30005. The wiring harness shall comply with the SAFSL Exhibit 30005.

requirements

grounding.

for wire routing, signal

SPECIAL -•• HANDLING

la- 6 0 0 9 • Ii

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7 p FTV77

separation, wire twisting, shielding and


tszolnrcT OL1Jii-Li

SPECIAL HANDLING

3.2.1 Shield Terminations

Shield terminations shall be in accordance with SAFSL

Exhibit 30005. Shield terminations at the same end of the harness shall not be

successively connected in series, one to another with one end of this chain being

grounded or carried through on connector contacts.

3.2.2 Redundant Wiring

Where practicable, redundant-circuit wiring shall be

routed in separate wire bundles, and separation of wire bundles shall be main-

. tained to the maximum extent possible, including the use of separate connectors.

3.2.3 Spare Wires

All wire harnesses located in inaccessible areas of the

Orbiting Vehicle that contain circuits which if inoperative will result in a launch

countdown termination shall include spares. Inaccessible areas are defined as

"those areas where replacement wires cannot be installed on the launch pad".

All spare wires shall be terminated in connectors at each end of the harness.

3.3 Propellant Compatibility

In those areas subject to exposure to hypergolic propellants the

wiring harness and all parts used in the wiring installation shall be compatible

with the MOL system propellants which are specified in MIL-P-26539A, MIL-

P-27404, MIL-P-27408, MSC-PPD-2, and MIL-P-27402, except for direct

contact as a result of spillage or immersion. The wiring harness shall be

capable of continued operation folloWing short duration exposure to spacecraft

propellants as a result of spillage; however, extensive spillage prior to launch

shall be sufficient cause for replacement of affected wiring harnesses.

3.4 Flammability

The design of the wiring harness shall minimize effects of

potentially catastrophic fires within the AVE by reducing the quantity of flammable

materials, limiting ignition sources and limiting flame propagation paths. SAFSL

Exhibit 10010 shall be used as a guide.

3.5 Connectors

3. 5. 1 Non-coaxial Connectors

Connectors shall be of the removable crimp-contact

type, except where use of such connectors is not feasible or where approval of

L - 6009

Copy?"7:of rj 77 SPECIAL OL 0 G ' Page 2 of gr

u Da. HANDLING NRO APPROVED FOR RELEASE 1 JULY 2015

another type has been granted by the MOL System Office. Each connector

shall meet the performance requirements of one of the following specifications

as a minimum:

a) MIL-C-26482

b) MIL- C-38300

c) MIL-C-38999

d) NAS-1599

e) MIL-W-8160, paragraphs 3.7.6; 3.7.6.1, 3.7.6.2, 3.7.6.3,

exclusive of subparagraphs.

1) MIL-C-24308

3. 5. 2 Co-Axial Connectors

Each co-axial connector shall meet the requirements of

one of the following specifications:

a) MIL-C-39012

b) MIL-C-23329

c) MIL-W-8160 - paragraph 3.7.6.4

d) MIL-C-22557

3. 5. 3 Finish

The finish of connector shells and accessory hardware

shall provide an electrically-conductive path from mated plugs to receptacles

from cable-clamp screws to connector shells. Connector finishes shall not flake,

peel, chip, corrode or sublimate when subjected to their normal handling,

storage and operational environments.

3. 5. 4 Strain Relief

All wiring harnesses terminating in connectors shall be

provided with some form of strain relief to relieve the strain on the wire

connections at the connector contacts which is exerted when the connector is

handled. Acceptable forms of strain relief are strain-relief clamps, potting,

and shrink-fit plastic boots.

3. 5. 5 Orientation

The wiring harness shall be so designed that the nominal

orientation of connectors at wiring harness terminations will not require

connector rotation to mate the connector.

7,1 r7, •

• S 11 'j ( -• J:i.1

SPECIAL HANDLING .

; 600 99

;0_ copy, 15f

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r C41 461 a.

HANDLING

3. 5. 6 Angle Connectors

Where space limitations do not permit the wiring harness

clearance in mating and demating of the harness connectors, angle connectors

or backshells should be used.

3. 6 Protection

Protection of wiring harnesses shall be inaccordance with para-

graphs 3.9.3, 3.9.3.1, 3.9.3.2 and 3.9.3.5 of MIL-W-8160. Harness design

and manufacturing techniques shall be specified and controlled so that potential

ignition due to damaged wire insulation shall be minimized.

3.6. 1 Abrasion Protection

The wiring harness shall be provided with protection

from abrasion from adjacent hardware and ground and flight crew action and

prevent damage in areas of potential chafing, nicking, scuffing or cutting.

3. 6. 2 Connector Protection

Wiring harness connectors shall be provided with

protective plastic caps or other suitable means to protect them from damage

and contamination during handling, shipping, storage, and installation.

3.7 Splices

Splices shall not be used in wiring harness assemblies.

3. 7. 1 Rework

The use of splices in, the wiring harness rework shall be

used only with the approval of the loCal government representative.

3.8 Wires and Cables

Selection of wires and cables for wiring harnesses shall be in

accordance with paragraphs 3. 6. 1, 3. 6. 1. 5, 3. 6. 1. 6, 3. 6. 1. 6. 1, and 3. 6. 1. 6. 2

of MIL-W-8160. The voltage drop from the main power bus to the using sub-

system shall not exceed two (2) volts under continuous operating conditions at

the minimum specified main bus voltage unless otherwise approved by the

procuring activity. Wires and cables shall meet the requirements of MIL-W-

22759, MIL-W-81381 or MIL-W-16878, or MIL-C-17 as a minimum.

3. 9 Wiring Harness Forming 37

Where a wiring harness must conform to a three-dimensional

7 7 77 SPECIAL .- 3iI.JabiLli H A 11 D L 1 1'4 G

L-6009

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br Lc! AL HANDLING

configuration in the installation, the wiring harness shall be fabricated on a

three-dimensional form or layout, except where fabrication on a two-dimensional

form or layout provides sufficient flexibility to proclude excessive strain, on the

harness in the installation. Where a two-dimensional form is used, the require-

ments of paragraph 3.9.5 of MIL-W-8160 shall apply.

3.10 Wire Lay

3.10.1 Parallel, Straight or Random Lay

A wiring harness may 'Lie fabricated with a parallel,

straight or random wire lay over that portion of the harness which is permanently

installed in the Orbiting Vehicle and which is not subject to movement after

installation.

3.10.2 Twisted, Helical, or Contrahelical Wire Lay

Wiring harnesses, consisting of more than four con-

ductors which are terminated in connectors and which are subject to mating and

demating, shall be fabricated with a twisted, helical, or contrahelical wire lay

over that portion of the harness which is subject to movement during the mating

and demating operations.

3.11 Wiring Harness Breakouts

Wiring harness breakouts shall be brought out in the direction in

which the breakout is routed. Breakouts shall be fabricated to provide minimum

stress on the conductors and shall be provided with adequate support to maintain

the breakout configuration during handling and installation.

3.12 Wiring harness Ties .

Wiring harness ties shall not be made close to the back of

connectors so as to subject the conductor connection to undue strain. The

distance from the first tie to the back of the connector shall not be less than

one and one-half (1 1/2) times the outside diameter of the connector.

3.13 Jacketed or Molded Wiring Harnesses

A wiring harness which is completely jacketed in heat-shrinkable

tubing or which has a molded jacketing shall have a twisted, helical, or con-

trahelical wire lay over the entire jacketed or molded length.

3.14 Handling

Means shall be provided to protect the wiring harness from damage

v71177 SPECIAL • • ma

- - -- 60 09

'1.21 f 1/7- Copv c

HANDLING NRO APPROVED FOR RELEASE 1 JULY 2615 •

and contamination during handling, shipping, storage, and installation, and

adequate support shall be provided to maintain the configuration or prevent.

damage to preformed bends during these operations.

3.15 Installation

Installation of wiring harness shall be in accordance with

paragraph 3.10 and subordinate paragraphs of MIL-W-8160. Approval by the

prOcuring activity is not required for use of alternate support devices.

3.16- Rework and Repair

The contractor documentation shall include in-process inspection

of the wiring harness, as well as the acceptance, inspection acceptance or other

test criteria which shall be applied to assure that the harness will meet the

mechanical and electrical requirements.

4.0 QUALITY ASSURANCE PROVISIONS

4.1 General

The contractor documentation shall include in-process inspection

of the wiring harness, as well as the acceptance, inspection acceptance or other

test criteria which shall be applied to assure that the harness will meet the

mechanical and electrical requirements.

4.2 Acceptance Tests .

Each wiring harness delivered for acceptance shall receive, as

a minimum, the following tests:

4.2.1 Examination of Product

4.2.2 Electrical Continuity

4.2.3 Insulation Resistance

This test shall be performed at a dc potential of at least

500 volts. The insulation resistance between each conductor and every other

shield, and between each conductor and connector shell shall be greater than

100 megohms. Component pigtails may be excluded from this test.

4.2.4 Dielectric Strength

This test shall be performed at a 60-hertz ac potential

which is no less than 75 percent of the rms value of that specified for acceptance

SZP SPECIAL HANDLING

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so se vd ai an HANDL! NU NRO APPROVED FOR RELEASE 1 JULY 2015

testing of the associated harness connectors or at 1000 volts rms plus twice

the maximum working voltage of the harness, whichever is the lesser. The

test potential shall be applied for one minute at a rate of no less than 500 volts

rms per second until the desired test potential is reached. The test potential

shall be applied between each conductor and every other conductor, between

each conductor and every conductor shield, and between each conductor and

connector shell. (Coaxial cables are, and component pigtails may be, excluded

from this test). The test time may be reduced if a correlated higher test

potential is used or if the test is repeated.

4.2.5 Order of Electrical Tests

The electrical tests shall be performed in the following

order:

a) Electrical Continuity

b) Dielectric Strength

c) Insulation Resistance

5. 0 PREPARATION FOR DELIVERY

Not applicable.

6. 0 NOTES

6. 1 Definitions

• 6. 1. 1 Wiring Harness

A wire bundle external to the components made up of

wires and/or cables and connectors or other terminations.

,t)

: L-60 09

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SPECIAL • HANDLING

Copy 06f

Page 12.---of

NRO APPROVED FOR RELEASE T JULY 2015

sErypiET tt.:1 AL HANDL! 11G

APPENDIX "A"

DAC DEVIATIONS

1. ; Paragraph 3.2. 3 - •

Revise the last sentence to read as follows: "All spare wires shall be terminated in connectors at each end of the wire harness (except for Douglas Flyaway Umbilical)".

2. Paragraph 3. 5. 4 -

Revise the last sentence to read as follows: "Acceptable forms of strain relief are strain-relief clamps, potting, shrink-fit plastic boots, and wire sealing grommets."

3. Paragraph 3.7 -

Revise the sentence to read as follows: "Splices shall not be used in wiring harness assemblies except for connecting spare wires in the Douglas Flyaway Umbilical wire harness."

7 SPECIAL e% I IL _It. Ir.

L - 6 0 0 9

Coi?. 2,10f / 2. (i7

NRO APPROVED KIR RELEASE 1 JULY 2015

"""" HA NDLI NG

APPENDIX "B"

EK DEVIATIONS

1. 3.7 Splices

Add to the end of the existing paragraph as follows: "The use of splices are permitted in circuits used for test purposes."

2. 3.6 Protection

Delete reference to Paragraphs 3.9.3.1 and 3. 9. 3. 5 of MIL-W-8160 D in the first sentence.

The above exception is taken because the requirements deleted are not applicable to Eastman Kodak because the EK segment does not contain equipment pertaining to these paragraph requirements. In the event changes are made to the EK segment, to include equipment which pertains to these requirements, they shall then apply.

3. 2.0 Applicable Documents

In all references to MIL-W-8160 D throughout SAFSL Exhibit 30006, substitute the following:

Eastman Kodak harnessing shall meet the applicable requirements of Eastman Kodak Document 401-119.

e,- 5:. P .:. 7,7 SPECIAL 1 1_ • . P._ A ton; 1 tin

— L -6009

CopV'

Page /4i- of Li:-

•

NRO APPROVED FOR. RELEASE. 1 JULY 2015

brtCIAL HA NDLI

APPENDIX "C"

GENERAL ELECTRIC CO. DEVIATIONS

1. The following paragraphs are not applicable to General Electric because the General Electric Company's segment does not contain equipment pertaining to these paragraphs.

In the event changes are made to the GE segment to include equipment which pertains to these paragraphs, they then shall apply.

Paragraphs:

3.7.2 All.

3.8 Reference to Paragraph 3. 9. 3. 1 & 3.9.3.5 of MIL-W-8160.

2. Paragraph 3.9

For the GE DRV: splices may be used in design and in rework of

harness assemblies in all but unprotected power circuit wiring, EED

wiring or coaxial wiring. However, these splices shall be kept to a

minimum consistent with high integrity, low weight and minimum

_volume design.

3. Paragraph 3.2.1 Except for the GE DRV

4. Paragraph 3.4 Except for the GE DRV



1721,- SPECIAL 'S 4 s! C4 A FAA 5'31 1 PI r4

1.1

09

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HANDLING

APPENDIX "D"

MAC DEVIATIONS

The following are exceptions or deviations to specific paragraphs of SAFSL

Exhibit 30006.

3.5. 1 Non-coaxial Connectors (Exception)

(a) Connector finishes need not be cadimum plated provided they meet the requirements of Paragraph 3. 5. 3 herein.

(b) Bendix PT connector pin retention shall meet or exceed the required pin retention of MIL-C-26482 after connector potting.

3.5.1 Co-axial Connectors (Exception)

(a) Connector finishes need not be cadimum plated provided they meet the requirements of Paragraph 3.5.3 herein.

(b) Bendix PT connector pin retention shall meet or exceed the required pin retention of MIL-C-26482 after connector potting.

3.7 Splices

3.7.1 Rework

Splices may be used in original design and in rework Of harness assemblies in all but unprotected power circuit wiring, EED wiring or coaxial wiring. However, these splices shall be kept to a minimum consistent with high integrity, low weight and minimum volume design.

4.2.4 Dielectric Strength

The test potential for thermocouple wiring shall be no less than 250 volts rms.

SPECIAL HANDLING

Lctop6vO 7lt,00 9 f Libc,/

Page' of

T

• • •


SAFSL EXHIBIT 30012

-

DESIGN LOADS

FOR THE

140L ORBITING VEHICLE

6 JUNE 1968

1-IA1:49LS. VIA " BYEMAN CONTROL. SYSTEM ONLY,

•

SECRET SPECIAL HANDLING L-6002

ICopya of t/i) Page of jt7

A.,NPQ■t:J• Syzte.:as Prorfram Office B.

- Aerozpac7; CorporaLIon R. H. Herndon

: - DottlaE- Aircra ft Cc::ipany B. P. Crass

•

/-, General Electric ompsny C. kbbate

McDonnellilsrAics Company R. E. Rolte

it4:1 g- 5=4 East;:r.e0Wdak A. S. Bennett

Se-. rot-

•

—11,-6002

Copy_ =2/ of do — r." ..as

SECRET SPEC!AL .timIDLING

•:— NRO APPROVED FOR RELEASE 1. JULY 2015

-SE-C44.1-: SPECIAL HANNAH / 6; ji

• :II..., • • ..v .•.1..■••••6

' REVIEW OF

SAFSL EXHIBIT 30012

DESIGN LOADS CRITERIA FOR THE

MOL ORBITING VEHICLE

May 21, 1968

The undersigned has reviewed the document and understands the contents to the extent necessary to scope subsequent proposals.

NOTE: Signature acknowledges agreement with this document, but such agreement does not extend to the documents referenced herein which are not yet agreed upon.

•

- NRO APPROVED FOR -RELEASE 1 JULY 2015

74)torrit&P

SAFSL Exhibit 30012 Action Items

•

1. EX: t64rovide—Segcriptioh of subsystem "B" for paragraph 1.1. Due

23 May 68.

2. GE to provide description of subsystems except subsystem B for paragraph

1.1. .Due 23 May 68. (2.0.,,,,NO4rVe.

3. Aerospace to provide table from SAFSL Exhibit 10011 for paragraph 3.11.

Due1 August 1968

MACASTRO to supply Gemini B loads table data per paragraph 3.1 based on

-.contractor's alternate analysis loads. Due 1 July 68.

5. MACASTRO to supply Gemini B component load factors per paragraph 3.10.2

. based on equipment design load factors identified in the Gemini B

Structural Design Criteria, MAC Report E -168. Due 1 September 68.

• 6. Douglas to update Table 3.10.1-2 to include all subsystem equipments.

Due November 1968.

7. Douglas to provide tables to define load factors resulting from buffet/

acoustic analysis as per paragraph 3.10.2. Due 1 November 1968.

-9E-Glig-SPECI HANDLING L-6 0 0 2

Copx.,Pf of 110 Page 3 of

NRO APPROVED FOR RELEASE tJULY 2015

DESIGN LOADS FOR THE MOL ORBITING VEHICLE

1.0 SCOPE - •

(K) 1.1 Item Description - This document sets forth the design loads for the

:MOL Orbiting Vehicle during all mission phases. This document as applicable

to AVE only.

Subsystem description is given in annex TBD. Mass properties, stiffness

properties, orbiting vehicle external configuration and associated dynamic

modeling for each of the noted subsystems are provided in IFS-MOL-101002,

IFS-MOL-101004, IFS-MOL-707017 and IFS-101.12. Loads resulting from

externally applied sources are specified herein.

(M) 1.2 Definitions - For the purpose of this specification, the following

. definitions are valid.

(M) 1.2.1 Limit Load - The maximum anticipated load, or combination of loads,

which a structure may be expected to experience during the performance of

- specified missions in specified environments.

00 .1.2.2 Ultimate Load - Obtained by multiplying the limit load by the ultimate

factor of safety.

(R) 1.2.3 Factor of Safety - A factor to account for uncertainties and variations

from item to item in material properties, fabrication quality and details,

internal and external load distributions, random behavior characteristics of

• '" •

L- 6002 SECRET SPECIAL` SPECIAL 11MIDLIIIG

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_ _

LbliiL


the applied environments, i.e., steady-state aerodynamics, engine thrusts and

thrust transients, gusts, etc. MOL factors of safety are defined in SAFSL

Exhibits 30044 and 12004 and have been appropriately combined with the limit

loads to estabthlrultthlte loads contaiqed herein.

(M) 1.2.4 Components - A component is defined as the lowest level of assembly of

parts, arranged within one package (black box), that will permit performance

of a prescribed function. Examples of components are valves, actuators,

amplifiers, batteries, junction boxes, etc. Vehicle structures are not con-

sidered as components.

(R) 1.3 Design Conditions - The design loads as specified in Section 3.0 shall be

combined with the appropriate environments as specified in SAFSL Exhibits 10003

and 12003 in the manner as specified in SAFSL Exhibits 10004 and 12004, respec-

tively, and shall be combined with the launch and ascent trajectory data

specified in IFS-MOL-101002 and IFS-MOL-101004.

(M) 1.4 Coordinate System - The Coordinate system utilized herein

is given in SS-110L-1B.

(K) 1.5 Documentation Reauirements - All deliverable data and/or documentation

specified in this exhibit shall be in accordance with the raspective contractor's

'On (DD 1423 or equivalent) as detailed by Forms 9.

(B) 2.0 APPLICABLE DOCUMENTS - The following documents of the exact issue shown

form a part of this specification to the extent specified herein. In the

event of conflict between documents referenced, here and content of Section 3,

.•••■••

SEMI SPECIAL HANDLING

L-6002 Copy,d/ of cf0

Page c of V?

• - NIRO APPROVED FOR RELEASE 1 JULY 2015.

SECRET SPECIa HA21.13

the detailed content of Section 3 shall be considered a superseding

requirement.

•

SPECIFICATIONS • Military

SS-MOL-1B System Performance and Design Requirements-General Specifications

L-6002 Copy:70/ of 40

-72

SAFSL Exhibit 30033

SAFSL Exhibit 30044

SAFSL Exhibit 10011

SAFSL Exhibit 12003

SAFSL Exhibit 12004

Other

IFS-MOL-101002 20 July 1967

IFS -E0L-101004

Environmental Design Criteria and Test Requirements for the MOL System Orbiting Vehicle, less Gemini B, and AGE

Structural Criteria for Laboratory Vehicle for MOL Prograa

Crew Systems Design Compatibility Criteria

Environmental and Test Requirements-Gemini B Spacecraft

Structural Specification--Gemini B Spacecraft

Orbiting Vehicle CEI No. 207001A to T-IIIM

Orbiting Vehicle CEI No. 207001B to T-IIIM

IFS-MOL-707017 Laboratory Vehicle, CEI No. 207013A to 22 December 1967 Mission Payload System Segment AVE,

CEI and GE AVE, CEI KOL010A1

IF 101.12 28 February 1968

Dynamic Mission Payload System Segment to Photographic System Interface Specification for the MOL System CDRL Item No. 64, Data Item No. E-106

SECRET SPECIAL WRING

SPECIAL HANDLING NRO APPROVED FOR

- RELEASE 1 JULY 2015

(R) 3.0 Loads - The loads and factors defined in this paragraph, based on con-

ditions noted in Table 1, except for Gemini II', shall be used for design of th'e

MOL Orbiting- Vehicle% For-Gemini B spacecraft see paragraph 3.1.

a

(R) 3.1 The load conditions specified in Tables TBD* to TBD* and the loads speci-

fied in Tables TBD* through TBD* shall be used for design of the Gemini B

spacecraft for launch and ascent. Specific design requirements for the various

Gemini B loading conditions are as follows:

A. Gemini B shall be designed to withstand the engine shutdown loads

induced at T-IIIM, Stage 1, booster cutoff of 430,000 inch pounds

of bending moment and 24,000 pounds of tension at Gemini B station

Z 103.44 (OV station 802).

B. Components located in the Gemini B pressurized cabin shall be designed.

to withstand landing loads as specified in Figures 1 and 2.

C. Gemini B shall be designed to withstand the loads during the reentry

phase as specified in Appendix TBD*.

(1) 3.2 The load conditions specified in Table I and the loads specified in

Reference Tables II through IV shall be used for design of the Laboratory

Module and Mission Module. Transportation and handling loads for the Labora-

tory Module and Mission Module are as specified in Table TBD.**

*To be supplied by MCASTRO **Transportation and handling loads for the LM and MM are contained in IF 101.4.

L-6002

I Cop.-Tr-7/ of • _

SECRET S?ECIAL HAULING

• NRO APPROVED FOR

. RELEASE 1 JULY 2015

4rEfrifttjnt;IAL

(R) 3.3 The load factors spedified in Table VI shall be used for - design of the

Laboratory Module equipment and support structure (birdcage).

•••••

(R) 3.4 Th'e'io-id-fEiCiO7-ihecifi.ed in Table,VII shall be used for design of

Laboratory Vehicle Subsystem 'B'.

(R) 3.5 The load factors specified in Table VIII shall be used for the design of

Laboratory Vehicle Subsystem 'C'.

(H) 3.6 The load factors specified in Table IX shall be used for the design of

Laboratory Vehicle Subsystem 'D'.

(8) 3.7 The load factors specified in Table X shall be used for the design of

Laboratory Vehicle Subsystem a.

(8) 3.8 The load factors specified in Table XI shall be used for the design of

Laboratory Vehicle Subsystem 'E'.

(R) 3.9 The load factors specified in Table XII shall be used for the design of

Laboratory Vehicle Subsystem 'F'.

.(T) 3.10 Components Not Included in Paragraphs 3.3 - 3.9

Two conditions shall be considered in design/evaluation of components and

subsystems not included under paragraphs 3.3 - 3.9: (1) The ascent transient

conditions listed in Table I and (2) Random vibration induced by buffet and

acoustic noise. It shall be a design goal that components and subsystems not

. - •

R SPECIALBANDLING L- 6002

Copt's >/- / of /0

• SeLUIAL NRO APPROVED FOR RELEASE 1 JULY 2015

vv.

included under 3.3 - 3.9 shall have fundamental resonant frequencies including

their immediate support structures and/or vibration isolators above 30 cps.

When this condition is not met, documentation and/or test results which

evaluate design Adequacy for vibration and transient loads must be submitted - - V

to SPO for approval.

(R,T) 3.10.1 Ascent Transient Conditions

Laboratory Vehicle components meeting the natural frequency requirements of

paragraph 3.10 shall be designed to the load factors of Table 3.10.1-1.

Components not meeting the 30 cps frequency requirement shall be designed to

the load factors of Table 3.10.1-2. For OV components not meeting the natural

frequency requirements of 3.10 and not listed in Table 3.10.1-2, analyses

shall be performed based on load factor time histories obtained from the SPO

or from the response spectra of Figures TBD through TBD.

(R) 3.10.2 Random Vibration Load Factors for Buffet and Acoustics

The load factors specified in Tables TBD** to TBD** which are buffeting effects

measured during rigid body fluctuating pressure test and/or random vibration

values, shall be used for the design of Laboratory Vehicle structural rings,

frames and minor weight items (50 pounds or less) attached to the external

shell. (Note: **data to be inserted following SPO approval of contractor

.buffet analyses.)

(R) 3.11 The load factors specified in Table TBD* based on SAFSL Exhibit 10011

shall be used for the design of Laboratory Vehicle equipment subjected to crew

system induced loads.

0 vill'Provide table

L-6602

Copy,i/ of Page ci of Lti7

SECRET SPECIAL HANDLING

NRO APPROVED FOR - - RELEASE 1 JULY 2015

•

Gemini B components and support structure shall be designed to withstand

such factors specified in Table 3.10.1-3*.

a -•

•

Note: Requires change to paragraph 4.d. page 8 of SAFSL 10004.

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BYE-SL-0081-68 Copy #

$1 Pages

3 July 1968

TO: R. Johnson, R. Pepping, M. Malkin and J. Sewell

SUBJECT: Paragraph Modification and Table Addition to SAFSL Exhibit 30012

Please make the indicated change to Paragraph 3.11 and insert the attached Table 3.11-1 in SAFSL Exhibit 30012, "Design Loads for the NOL Orbiting Vehicle."

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L. D. PAIGE 2 Atch 1. Change to Para 3.11 2. Table 3.11-1

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BYE-SL-0015-68 ATTACHMENT 1 Copy 11 Paces

REPLACEMENT PAGES

for

SAFSL Exhibit 30020

"SYSTEMS TEST AND OPERATIONS PLAN"

dated

Jane 1968

), 1-1ANZIL.17 VA BYEMAN. • tor-rnou SYSTEM ONLY

. •:- •

(Signed) -71;

(Signed)

(Signed)

(Signed)

(Signed)

(Signed)

(Signed)

(Signed)

vu A. 54 -1-1

NRO APPROVED FOR RELEASE 1 JULY 2015 -WM-SPECIAL HANDLING

S AFSL EXHIBIT 30020

SYSTEMS TEST AND OPERATIONS PLAN



to scope subsequent proposals, provided the required

CDRL (DD Form 1423 and Forms 9, or equivalent

thereof) is received with the RFP.

--est-eftErf SPECIAL HAWLING


BIE-SL-0015-68 Copy # 1 Page

'7 roq 1"4

9 July 1968

SUBJECT: Change Pages for SU'SL Ejlibit 30020

TO: R.L. Johnson, R. Popping, 14 Nhjkin and J. Sowell

The atLaehed repl2ecm3nt pages are to be inserted in the June 1968 issue of SAYSL KOIlbjt 30020, uSystems Test and Operations

L. D. PAIGE

1 Atch SAFSL Exhibit 30020 Replacement Pages

Cy to: SL-5 SL-6 SL-7 SL-12 SL-13 SL-14 SL-16 J, Chalmers/

1Th". fr f:rt çlpa

t. r !

HANDLE VIA. ill'EMAH CONTROL SYSTEM ONLX

NRO APPROVED FOR (D) weriti+j+dspEciAL

RELEASE 1 JULY 2015

SAFSAL EXHIBIT 0020

SYSTEM TEST & OPERATIONS PLAN

JUNE 1968

B. A. HOHMANN

W. F'. SAMPSON S. M. TENNANT

B. P. LEONARD

gECP DT SPECIAL HANDLING HANDLE VIA entEcari

CONTROL SYSTEM ONLY.

S pr f7, F!'s [L — 5 9 9 9 Copy ,',3 of ,[9

Paoe , -Of ---


(D) SLGfhr, f SPLCIAL HANDLING

TABLE OF CONTENTS

Page

1. 0 PURPOSE 3

2.0 SCOPE 4

3.0 TERMINOLOGY 5

4.0 TEST AND OPERATIONS REQUIREMENTS AND POLICY 10

5. 0 MANAGEMENT STRUCTURE 14

6.0 TEST AND OPERATIONS DOCUMENTATION 18

APPENDIX A - ABBREVIATIONS 33

■•••■•.,

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1.0

PURPOSE

This document is directive and shall be used by all agencies for planning

the ground test and flight operations programs. The System Test and

Operations Plan (STOP) identifies and defines the policies and require-

ments common to both "Test" and "Operations" and the interrelationships

required for standardizing lower level planning documentation.

Co r..2 ,•••") 7-N r.7.1171

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2. 0

SCOPE

This document covers the test and operational aspects of the MOL Program.

The concepts and principles contained herein shall be applied against all

aspects of the MOL Program. For purposes of standardizing definitions,

policies, responsibilities, and requirements the most complex version of the

MOL Flight Vehicle (#3) is used herein as a baseline. For other vehicles

similar (appropriate) terminology will be used as necessary.

Documents called out are applicable as specified herein. All deliverable

data and/or documentation specified in this exhibit shall be in accordance

with the respective contractor's CDRL (DD 1423) as detailed by Forms 9

(or equivalent).

•

(23 rT2 1,3 77) r? .1 •

rifirrm: SPECIAL I-IA 'ND! INC

\ .41 [

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3.0

TERMINOLOGY

The following terminology shall be adhered to by all associate contractors

and supporting government agencies in preparing their required plans and

other supporting documents.

Associate Contractor (MOL)

A. C. Electronics Division (ACED)

Aerojet-General Corporation (AGC)

Douglas Aircraft Company (DAC)

Eastman Kodak Company (EK)

General Electric Company (GE)

Hamilton Standard (HS)

Martin Marietta Corporation (MMC)

McDonnell Astronautics Company (MAC)

TRW Systems Group (TRW)

United Technology Center (UTC)

Whirlpool Corporation

Flight Operations (i. e. , Operations) - All activities associated with

MOL operations from prelaunch preparation (simulation/rehearsals,

AFSCF checkout, etc.) through laboratory vehicle disposal, data

retrieval and post flight evaluation.

Flight Vehicle - The flight vehicle (FV) consists of the T-IIIM launch

vehicle and the MOL orbiting vehicle (OV).

Flight Vehicle Timeline (Operational) - A nominal, chronological

sequence, relationship, and status of all FV and ground resources

necessary to perform the MOL real-time operational mission. It

includes the time, approximate orbital elements/location, subsystem

status, consumable profiles, crew activity, and ground support

r7.3 „7,3 :7-3

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A L 1 13 ; NRO APPROVED FOR RELEASE 1 JULY 2015

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associated with the oper.ational sequences required to accomplish

the MOL flight objectives from crew ingress on the pad to Gemini B

splashdown and laboratory vehicle disposal. In the case of the

automatic configuration, the timeline includes all operational

sequences from FV liftoff through OV disposal.

Flight Vehicle Timeline (Test) - A chronological sequence and relation-

- ship of all activities associated with FV hardware from first AVE

arrival at VAFB through FV liftoff and turnaround.

Government Agencies

6595th Aerospace Test Wing (A TW)

Aerospace Medical Division (AMD) (AFSC)

Air Force Satellite Control Facility (AFSCF)

Air Force Western Test Range (AFWTR)

Air Weather Service (AWS)

DOD Manager for Manned Space Flight Support (DDMS)

SAMSO Plans and Operations Office (SMLC)

Ground Test (i. e. , Test) - General term encompassing all test

activity from start of initial in-plant development through FV liftoff.

This activity also includes turnaround.

Laboratory Vehicle - The integrated AVE of and in the mated laboratory

module (LM) and mission module (MM).

Launch Operations - That portion of ground test associated with VAFB.

Includes all functions and activities required to handle, assemble,

maintain, checkout, and launch the MOL FV, turnaround, and all

related plans and procedures.

Liftoff - Event determined by FV motion in the vertical direction as

detected by electrical signal to the ground equipment.

L - 5 9 9 9 sf Copy )•3 of .7. Y),

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Mission - This is part of the orbital phase and is to be used only with

reference to the objectives and operations associated with the MM

experiments.

Orbiting Vehicle - For the manned/automatic mode the OV consists of

the LM, MM, crew equipment, and the Gemini B. For the automatic

mode, the Gemini B and crew equipment are replaced by a support

module.

Software - Computer programs and their associated documentation.

Support Module - The support module consists of a tank section, a

recovery section including six Data Reentry Vehicles, and a fairing

section.

System - The MOL system.

System Segment - A discrete package of system performance require-

ments, functional interfaces, and/or contract end items (CEI's)

contracted to one contractor or assigned to one government agency

directly responsible to the procuring agency for that part of the system's

total performance.

System Test and Operations - MOL system test and operations starts

with in-factory development tests, proceeds with that testing activity

associated with a particular FV, and terminates with recovery of the

data and/or crew retrieval, laboratory vehicle disposal, and post

flight analysis.

Turnaround - Those activities following FV liftoff necessary to

refurbish the launch site for receipt of the next flight hardware.

i f •

HANDLING

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RELEASE 1 JULY 2015

Post Flight' Evaluation - Post Flight Evaluation is that evaluation

conducted to accomplish the following:

a. To analyze and resolve to corrective levels MOL - system anomalies.

b. To verify accomplishment of specific MOL flight test objectives.

Data from design, ground test and flight operations is used to

support post flight evaluation.

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4. 0

TEST AND OPERATIONS REQUIREMENTS AND POLICY

The proper relationship of personnel safety, security, and program objectives

must be recognized during the design, planning, and conduct of MOL Ground

Testing and Flight Operations. No data will be collected nor tests conducted

for the sole purpose of incentive determination.

The general policies contained herein shall be expanded and amplified in both

the General Ground Test Plan (GGTP) and the Flight Test and Operations Plan

(FTOP). The GGTP shall be adhered to by all associate contractors and

supporting agencies in preparing their implementing plans and documents.

/ Additional guidance for preparation of the implementing plans and documents

/ will be provided in the FTOP.

The GGTP defines in-plant development, qualification, and acceptance testing

and launch operations at VAFB through FV liftoff, turnaround, and publication

of final test reports.

The FTOP defines the operations activities from flight crew ingress or FV

liftoff, as appropriate, through lab vehicle disposal. It shall include those

activities required to prepare the flight operations support systems (AFSCF)

and Operational Training and Evaluation Facility (OTEF) prior to launch.

In addition, the FTOP shall include the requirements for Launch Operations

support of the AFSCF and publication of final test reports. The VAFB Launch

Operations Requirement document includes the requirements for AFSCF

support of Launch Operations.

4. 1 Personnel Safety

Personnel safety shall be the prime consideration in all phases of planning,

design, test and operations.

rz E7a 7

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SPECIAL ,r) I

9 9

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(TP) 4.2 Compliance with Program Requirements

The system test and operations program shall be planned and conducted to

verify System Performance/Design Requirements (SP/DR). To insure this,

all test and operations plans (excluding certain Development Plans) submitted`

in accordance with Contract Data Requirements List (CDRL) DD Forms 1423

will be approved• prior to use.

(TP) 4.3 Establishment of a Data Baseline

The planning, conduct and reporting of system level qualification, acceptance

and launch site tests shall produce test data that can be utilized for analysis

during systems level acceptance tests, launch site tests or flight. These data

will constitute a test data base which will be retrievable for use on a timely

basis, as required. The data base is intended for use by the contractors in

support of systems test and operations.

(TP) 4.4 Fidelity of Test

Where practical and significant, ground tests shall be conducted in a simulated

operational environment/configuration. Determination of practicality and

significance shall be made by the associate contractors or supporting govern-

ment agencies with MOL SO approval. While special test programs may be

used in the airborne computer for certain ground tests, verified airborne

computer programs shall nominally be used. To provide the necessary fidelity,

test command messages must be compatible with operational command

messages where hardware configuration permits.

4. 5 Flight Crew Participation

The flight crew shall participate in the system test and operations program

as specified in the hardware /software test and operations plans.

17,1 7Thl r371

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(TP) 4.6 Failure Analysis and Corrective Action

To assure positive control over test and operations problems, failures,

potential failures, and their analyses and corrective action, a reporting

system shall be established in accordance with SAFSL 30002.

(TP) 4. 7 Test and Operations Plans

Test and operations plans shall have as their basic goal the verification that

program requirements are met. In building a test and operations program,

the building block concept of sequential testing in operational modes will

prevail. Each associate contractor shall define the tests and operations

required to satisfy program/contractual requirements. Post operations

evaluation must include recommendations that specifically address subsequent

FV undergoing test.

(TP) 4. 8 Test and Operations Criteria

The criteria used to evaluate test and operational performance shall be

based on the requirements in the CEI and/or other applicable specifications.

Parametric limits necessary for evaluating Qualification, Acceptance, Launch

Operations Testing and Flight Operations shall be established prior to use.

Development Tests are excluded from this policy except as specifically

identified to the associate contractors by the MOL SO.

(TP) 4. 9 Software Policy

During test and training activities prior to launch, both AVE flight support

and system support software will be used in conjunction with various test

vehicles and simulators. Verified computer programs under test must be

essentially identical with that anticipated for use during the operation.

In subsystems used for testing purposes (e. g. , AGE or simulators), special

software may be used to simulate interface reactions which are not actually

present during a test. The simulation must be essentially indistinguishable

from the actual interfacing system as viewed from the software subsystem

under test.

e 7 (73 17?

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BYE-SL-0015-68 Page 2 SAFSL EXHIBIT 30020 Revised July 1968

4. 10 MOL System Readiness

MOL SO test and operations documentation shall define a system to provide

assurance of MOL System Readiness for flight.

Replaces Page 13

HANnLE VIA BYEMAN CONTROL SYSTEM 0-7g;Si

1 hr. L B E (41


5. 0

MANAGEMENT STRUCTURE

This section identifies the participating test and operations government

agencies and associate contractors and the respective roles and responsi-

. bilities within the MOL system test and operations program.

5. 1 MOL Director

The MOL Director is responsible for establishment, management, and con-

duct of all aspects of test and operations for the MOL Program.

5. 2 MOL Deputy Director

The MOL Deputy Director, the implementing agent of the MOL Director, is

responsible for the integrity of the overall system during all phases of test

and operations.

5.3 MOL Systems Office

The MOL Systems Office (MOL SO), under the direct control and supervision

of the Deputy Director, MOL, directs the test and operations of the overall

MOL system. This includes responsibility for contracting, acquisition of

test facilities, ground test, flight operations, personnel safety, and test and

operations analysis and reporting. MOL SO shall be interpreted to include

the Aerospace Corporation, where applicable, in fulfilling its role as General

Systems Engineering and Technical Direction (GSE/TD) contractor.

5.4 Aerospace Corporation

The Aerospace Corporation is the contractor responsible for providing GSE/TD

for the MOL SO for test and operations functions.

p . SPECIA I, I-TANDI,INC.3

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(TP) ' 5. 5 Associate Contractors

Each associate contractor is responsible throughout the cycle of test and

operations for meeting performance allocations, safety, effectiveness, and

specifications applicable to the associate contractor's hardware. When the

hardware/software delivered by one associate contractor is absorbed in an

assembly to be delivered by another associate, the assembly, host, and/or

integrating contractor herein referred to as the integrating contractor has

the responsibility to ensure that overall test and operations allocations and

integrated test requirements have been fulfilled, and that agreement has

been reached with the delivering associate contractor(s) on all test and

operations requirements, plans, and procedures which will be established

against or performed at the assembled level.

The associate contractor delivering hardware/software to be absorbed in a

higher level assembly is responsible for negotiating with the, integrating

contractor appropriate test and operations requirements, plans, and

procedures. Each associate contractor is also responsible for negotiating

test and operational interfaces relating to his hardware/software with all

affected associate contractors.

System level test and operations analyses are required to ensure that

operational and performance requirements are met. Each associate contractor,

is responsible for detailed analyses appropriate to the software and equip-

ments being delivered by that associate contractor. Additionally, participation

in related higher level system studies will be required.

0 7 r2,73

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Copy1'33 of

Page/ of ,!,e;. T:T „SPECIAL HANDLING

r." 7- 17Thti rir7,! a

L C5 NRO APPROVED FOR RELEASE 1 JULY 2015

Areas of associate test and operations responsibilities are:

a. Hamilton Standard, Division of United Aircraft Corporation -

Hamilton Standard (HS) is the associate contractor for the pressure

suite assembly (PSA) system segment.

b. Whirlpool Corporation - Whirlpool is responsible for providing

the MOL feeding system segment for all MOL manned flights.

c. TRW Systems (TRW) - TRW will provide STC computer programs

for mission planning and evaluations, and for monitoring and

controlling ascent and reentry operations.

d. McDonnell Astronautics Coproration (MAC) - MAC is the

associate contractor for the Gemini B system segment.

e. Eastman Kodak Company (EK) - EK is the associate contractor

for the photographic system segment.

f. General Electric Company (GE) - GE is the associate contractor

for the MM system segment.

g. AC Electronics Division (ACED) - ACED is the associate con-

tractor for the booster inertial guidance system (BIGS) segment.

h. Aerojet-General Corporation (AGC) - AGC is the associate con-

tractor for the booster liquid rocket engine system segment.

United Technology Corporation (UTC) - UTC is the associate con-

tractor for the booster solid rocket motor system segment.

j. Douglas Aircraft Company (DAC) - DAC is the associate contractor

for the laboratory vehicle system segment.

k. Martin Marietta Corporation (IvIMC) - MMC is the associate con-

tractor for the Titan HIM system segment.

*-3 1-7) rTh r-3

L - 5 9 9 9

Copy) 3 of IL

Pagefi, of

C,3

I

t


(TP) At a given site, integrating associate contractor responsibility for the

collation, analysis, optimization and/or publication, as necessary, of the

plans and procedures for integrated development, qualification, and accep-

tance testing, and for the integrated conduct of test (i. e. , "Test Direction"),

.for the integrated hardware level is indicated below under integration con-

tractor. In addition to launc.h operations functions performed by associate

contractors and integrating associate contractors at VAFB, separate support

services to the MOL SO/6595th ATW are required and are specified below

under Support Contractor (Reference SAFSL Exhibit 20023).

Site Integrating Contractor Support Contractor

VF GE

Roch EK

HB MDC (LM/LV), GE (MM)

St. L. MDC

Denver MMC

VAFB MMC (T-IIIM), MDC (OV), GE (MM) MMC (FV), MDC (OV & MS)

5. 6 SAMSO Plans and Operations Office, Communications, and Electronics Division

This agency is responsible for acquisition and installation of the MOL ground

communications system at VAFB in accordance with the requirements of the

. MOL SO. This agency will direct the communication planning contractor in

preparation of the Communication Plan and control the contract for the

communications installation contractor during installation of the communications

equipment.

5. 7 6595th Aerospace Test Wing (ATW)

The 6595th ATW Manned Systems Division (VWM) is responsible for Launch

Operations at VAFB. The ATW, as a direct arm of the MOL SO, is responsible

for the direction, management, conduct and control of MOL Program activities

at VAFB. The ATW interfaces with and ensures AFWTR support.

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4

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,-- L - 5 9 9 9

Copy/3 of Pa ge j"-)

(,) L X„. Li

„ S k"1,7A i '13 LING NRO APPROVED FOR RELEASE 1 JULY 2015

'5.8 SAMSO Deputy Commander, for Satellite Control Operations, AFSCF

This agency is responsible for developing and providing those resources at the

Satellite Test Center (STC) and the AFSCF Global Tracking and Communication

•Networks as necessary to support MOL operations during flight preparation

and through all flight phases as defined in the Orbital Requirements Document

(ORD), This includes the processing and control of data necessary for support

of the flight; the engineering design of telemetry and tracking station equipment,

control consoles, AFSCF system support software, integration of all teleme-

tered data formatting requirements and procedures, and interfacing with AFWTR

and VAFB activities.

5. 9 Air Force Western Test Range (AFWTR)

AFWTR, the lead range for MOL, is responsible for ensuring support of all

launch operations requirements as defined in the Program Requirements

Document (PRD). This includes support from other ranges and government

agencies external to the AFWTR. (Data acquisition during ascent for range

safety decisions will be an AFWTR responsibility). AFWTR will provide

support as appropriate to AFSCF for mission control at the STC.

5.10 DOD Manager for Manned Space Flight Support (DDMS)

DDMS will provide and control the recovery forces necessary to effect

" retrieval of the flight crew, spacecraft and data in the areas specified in the

Manned Recovery Requirements Document and the spacecraft as specified in

the Gemini B Recovery Requirements Document.

5.11 Air Weather Service (AWS) (Military Airlift Command)

AWS is responsible for natural aerospace environment support and services

to the MOL Program.

5,12 Aerospace Medical Division (AMD) (AFSC)

AMD is responsible for providing bioastronautics research, development, test

and operations support to the MOL Program.

r,) 7'1 c73

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'''71 AL' I; A r L t G NRO APPROVED FOR RELEASE 1 JULY 2015

.(13) 6. 0

TEST AND OPERATIONS DOCUMENTATION

'6. 1 General

This section summarizes, for planning purposes, the MOL test and operations

documentation. It does not supersede the requirements of the CDRL. Document

format, content, scheduled submittals, revision requirements, and governmental

approval requirements are governed by the CDRL DD Form 1423 and AFSC

Form 9 (or equivalent) where applicable for each associate contractor. This

section establishes a common basis of reference for:

a. Document Titles and Terminology

b. Documentation Relationships

c. General Scope

d. Input and Integrate Responsibilities

6. 2 Top Documentation

6. 2. 1 System Test and Operations Plan (STOP)

The STOP establishes planning and standardization requirements applicable to

both Ground Test and Flight Test and Operations. It identifies roles and

responsibilities of agencies and contractors involved in MOL test and operations

activities.

6.2. 1. 1 General Ground Test Plan (GGTP)

The GGTP provides a summary of all elements of testing to be conducted

during the development, qualification, acceptance, and launch operations test

programs for which each associate contractor and operating agency is respon-

sible. General requirements, boundaries, and guidelines for the tests to be

performed from start of initial factory development testing through integrated

MOL system level testing and launch are established.

a v„)

...zr i .1 n NRO APPROVED FOR RELEASE 1 JULY 2015

6. 2. 1. 2 Flight Test and Operations Plan' (FTOP)

The FTOP provides guidance to all contractors and government agencies

participating in MO I, flight operations. It represents the MOL baseline for

flight test and operations and is the basis for developing the details of sub-

ordinate documentation. The FTOP also provides program management with

an overview of the operational concepts and philosophies to be employed in

the Operations associated with the flight tests.

The FTOP covers the flight from insertion of the flight crew in the FV or FV

liftoff, as appropriate, and on through publication of final test reports. It

also covers planning and training necessary to accomplish the above.

6. 3 Documentation Tree and Table

A schematic presentation of the top and working level test and operations

oriented documents is provided in Figure 2.

-The functional grouping of test and operations documents in Table 1 is as

follows:

I Top Level Planning Documents

II Ground Test Documents

III Flight Test and Operations Documents

IV Test and Operations Requirements Documents and Support Plans

V Evaluation Documents

The documents, the agency, and contractor responsibilities for inputs to/or

providing the documents, and the responsibilities for integration and pub-

lication of the documents are described.

1

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The release dates for publication of the documents are referenced to the

initial launch (IL), the initial manned launch (IML), the initial automatic

launch (IAL), each launch (L), flight termination (FT), post operations

assessment directive (POAD) issuance, and test (T) schedule.

The definitions below are applicable to Table 1.

Data Requirements

Integrate /Publish

Release Date

A required submittal or input to be integrated which shall consist of and be limited to that contractor's or agency's area of responsibility.

The compilation and publication of inputs, data, and coordinated material.

Approximate date of publication/delivery (as appropriate) of completed document, for use in planning and generating individual associate contractor CDRL's (DD Form 1423), in recognition of peculiar requirements of a particular systems segment.

r

s T SPECIAL 1-1ANDTING

4P-.1 .:.‘" I •(;7701

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• NRO APPROVED FOR CONTROL Lop .

RELEASE 1 JULY 2015

- • .

Control lIalber W I-I S - 809

. Copy Numc.er 1 thru 6 . •

Name of Courier • .

J. F. Chalmers .

Source . •-

J.- F. Chalmers .AddresSee - -

. ,

Distribution - . .

Description, Date, Subject, cy number, number of pages, any other identifying

control number MOL Orbiting Vehicle Power Utilizaton Control SAFSL EXHIBIT 30001

. dated 2 April 1968, 19 pages -

• Attachment's

- • .

Remarks . .

This document same as L- .6,-? 771

c, i.- Receipt Signature Date Invctntory Date I l_Ds,Dos:_tion

1 ,---\ (_._ N CIL,V,.....7,c_9_,__.0

- / 511 76 • J. F. Chalmers

2 ti

D. R. Howard

3 W. F. Sampson S. M. Tennant/ S. S. Strong 4

5 .

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B. A. Hohmann

6 -

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B. Moss

. .

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DocumL-NT. CONTROL. LOG NRO APPROVED FOR '-

:Lb--1 dttL-1--Z 77-- -- - . .

• . - • . ' •

• . Con :::01 liumber . 1_53711

- _

• Copy Nun'oe.r ]A thru 20. •

Name c,f Couier • - . . . B. Haskins, 7 May 1968 -

Source . . •

• A/F :•.

. ...... 1,-3clrestee - -

MOL . . . .

Description, Date, Subject, cy number, number of pages, any other identifying control number

MANNED ORBITING IAB., ORBITING VEHICLE, POET UTILIZATION COBTROL, SAFSL EXHIBIT 30S cys. 124- thru 20; 19 pages each. undated. . .

Attac .

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none. . . .

• . . .

Inventory nate I)isDosition

20. _ __MOLBCF

14 . • . W. Stafford

15 .

. - W. Sheng

1 16 • -

-- - — --- W. D. Pittman

17 .. RS. Gaylord

18 GD McGhee

.

— H. W, Nordylce

20 . J. Meltzer

. . •

- I •

BYE-SL-0015-68 Page 3

SAFSL EXIII.BIT 30020 Revised July 168

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" CI, A D 1. Li NRO APPROVED FOR RELEASE 1 JULY 2015

APPENDIX A

ABBREVIATIONS

ACED A. C. Electronics Division (of General Motors)

AFSC Air Force Systems Command

AFSCF Air Force Satellite Control Facility

AFWTR Air Force Western Test Range

AGC Aerojet-General Corporation

AMD Aerospace Medical Division

ATW 6595th Aerospace Test Wing

AVE Aerospace Vehicle Equipment

AWS Air Weather Service

BIGS Booster Inertial Guidance System

Douglas Aircraft Company

DOD Manager for Manned Space Flight Support

CDRL

CEI

' DAC'

DDMS

EK

EMC

S p PECIAL IIANDLING

HAND I, I .

- 5 9 9 9 Copy of 11/)

?Paget', of

Contract Data Requirements List

Contract End Item

Eastman Kodak Company

Electromagnetic Compatibility

'10 EnIlET SPECIAL r-!ito:t)4...,z:r:


J1,

FT Flight Termination

FTOP Flight Test and Operations Plan

FV Flight Vehicle

FVCOP Flight Vehicle Checkout Plan

FVTL Flight Vehicle Timeline

GB Gemini-B Spacecraft

GE General Electric Company

GGTP General Ground Test Plan

GRRD Gemini Recovery Requirements Document

GSE/TD General Systems Engineering and Technical Direction

HB Huntington Beach

H/B Handbook

HS Hamilton Standard, Division of United Aircraft Corporation

IAL Initial Automatic Launch

IL Initial Launch

IML Initial Manned Launch

L Launch

LM Laboratory Module

LOWG' Launch Operations Working Group

LTC Launch Test Directive

LV Laboratory Vehicle

,_______ 'L-5999

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Z... .: 3 - .1 :-.., - s SPA CIA

II A rID1 4

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es* Li LAZ it-2 A :ND LI CI G

MAC McDonnell Astronautics Company

MCC Mission Control Center

MDC McDonnell Douglas Corporation

MM Mission Module

MMC. Martin-Marietta Corporation

MOL Manned Orbiting Laboratory

MOL SO Manned Orbiting Laboratory Systems Office

MRRD Manned Recovery Requirements Document

MS Mission Simulator

ORD Orbital Requirements Document

ORU Operational Readiness Unit

OTEF Operational Training and Evaluation Facility

OV Orbiting Vehicle

POAD Post Operations Assessment Directive

PP Program Plan

PSA Pressure Suit Assembly

PRD Program Requirements Document

PRE Program Requirements Estimate

ROCH Rochester, New York (EK)

SAF

SAMS()

SCF

SMLC

SP /DR

STC

ST. L.

STO

STOP

Secretary of the Air Force

Space and Missile Systems Organization

Satellite Control Facility

SAMSO Plans and Operations Office

System Performance/Design Requirements

Satellite Test Center

St. Louis, Missouri (MDC)

System Test Objectives

System Test and Operations Plan

.(0) C,ErtrSPECIAL HANDLING SPECIAL

L - 5 9 9 9

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Pa g e f

•. - thwiDLinci NRO APPROVED FOR RELEASE 1 JULY 2015 .

T Test

T-IIIM Titan-IIIM Launch Vehicle

TD Technical Direction

'TOR Technical Operating Report

-TRW TRW Systems Group

TP Test Plans

USAF

UTC

United States Air Force

United Technology Corporation

VAFB Vandenberg Air Force Base

VF Valley Forge, Pennsylvania (GE)

VTS Vandenberg Tracking Station

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