& DATE 20 FEBRUARY 1962

REVISED 15 NOVEMBER 1962

GEMINI SPACECRAFT
ELECTRICAL SYSTEM SPECIFICATION [U)

8
REPORT 638 SERIAL NO.

c
CONTROL NO. ~67466

MCDCHVIMELL AIRCRAFT COt*f»OFlATIOI\l

£NT CONTAINS INFORMATION A F FECT ING T H E N AT IO N AL DE FEN SE

LAWS. TITLE
i 794, THE TRANSMISSION OR
NNER TO AN U N A U T H O R I Z E D PERSON is PROHIBITED GY

SUBMITTED UNDER NASA CONTRACT NAS 9-170

GEHUI
.''--
--•- '>

Unclas
 MOOOA/A/H
DATE 20 February 1962 ST. LOUIS, MISSOURI PAGE

REVISED 6 June 1962 REPORT. 8638

REVISED , MODEL . Gemini

APPROVALS

Prepared by:
F« b. Jcmes - Specifications Group

Approved by:
L. M. Parker - Sr. Specifications Engineer

G. J< keber - Assistant Project, Engineer hlectrical

W. J. Bmtz - ProjectTEngineer
 MCDONNELL
DATE 20 February 1962 ST. LOUIS, MISSOURI PAGE
;
REV^SEi 11 ^ JUIV -IffST' '"""

REVISED 15 November 1962 MODEL Gemini'

TABLE OF CONTENTS
PARAGRAPH TITLE PAGE NO.
TITLE PACE
APPROVALS i
LIST OF TABLES AND FIGURES iv
LIST OF EFFECTIVE PAGES V
INDEX OF REVISIONS vi
1. GENERAL 1
1.1 Scope 1
2. APPLICABLE DOCUMENTS •1 •
2.1 General 1
2.2 Government Documents 1
2.3 McDonnell Documents 1
2.3.1 Reports 1
2.3.2 Drawings 1
2.3.3 Process Specifications 2
2.U Supersedence U
3. DESCRIPTION 6
3.1 General 6
3.2 Power Distribution 6
3.3 System Management 7
3.3.1 Visual Indications 7
3.3.1.1 Power Transfer Warning Light 7
3.3.1.2 Battery Condition Indicator 7
3.3.1.3 Ammeter 7
3.3.1.U Voltmeter 10
3.3.1.5 ©2 Quantity and Pressure 10
3.3.1.6 H2 Quantity and Pressure 10
3.3.1.7 Stack Malfunction Indication 10
3.3.1.8 Coolant Pump Warning Lights 10
3.3.1.9 Fuel Cell Ammeter 10
3.3.2 Switches 10
3.3.2.1 Switches - Fuel-Cell Battery Subsystem 10
3.3.2.2 Switches - Silver- Zinc Battery Subsystem 12
3.3.2.3 Bus Tie Switch 12
3.3.2.U Voltmeter Selector Switch 12
3.3.3 Mission Electrical Procedures 12
3.3.3.1 Pre launch 12
3.3.3.2 Launch Through Insertion 12
3.3.3.3 Catch-Up Through Orbit 13
3.3.3.U Retrograde and Re-entry 13
3.3.3.5 Landing and Post-Landing 13
 MCDONNELL
DATE 20 February 1962 ST. LOUIS. MISSOURI PAGE iii
REVISED 6 June 1962 REPORT. 8638
REVISED November 1962 MODEL . Gemini

TABLE OF CONTENTS (Continued)

PARAGRAPH TITLE PAGE NO.

3.U Circuit Protection Ik

3.5 Components 15
3.5.1 Requirements 15
3.5.2 Batteries 15
3.5.2.1 Fuel-Cell Battery Subsystem 15
3.5.2.2 Silver-Zinc Batteries 18
3.5.3 Relays 18
3.5.1* Switches 19
3. 5. U.l Toggle Switches 19
3.5.U.2 Rotary Switches 19
3.5.U.3 Limit Switches 19
3.5.U.U Telelights and Telelight/Switches 19
3.5.5 External Power Connections 19
3.5.6 Connectors 20
3.5.7 Circuit Breakers 20
3.6 Fabrication 20
3.7 Installation 21
U. ENVIRONMENTAL CONDITIONS 22
U.I General 22
5. QUALITY ASSURANCE 22
5.1 General 22
6. RELIABILITY 22
6.1 General 22
7. DATA REQUIREMENTS 22
7.1 General 22
8. TESTING 23
8.1 General 23
8.1.1 Battery Tests 23
8.1.3 Spacecraft Systems Test (SST) 2k
8.1.U Simulated Orbital Mission 2k
9. DEFINITIONS 25
9.1 General 25
APPENDICES
Appendix I EQUIPMENT LIST 37
Appendix II CHANGE LIST 39
Addendum A ELECTRICAL SYSTEM - SPACECRAFT NO. 1 Al
 MCDOhlhlE
DATE
20 February 1962 ST. LOUIS, MISSOURI PAGE
iv

Bcrx/icrn Gemini
•

LIST OF TABLES
AND FIGURES

TABLE TITLE PAGE

Table I Environmental Conditions for Electrical Equipment

Located in the Pressurized Cabin 26
Table II Environmental Conditions for Equipment Located in
the Re -Entry Module External to the Pressurized
Cabin 27
Table III Environmental Conditions for Electrical Equipment
Located in the Adapter 28
FIGURE

Figure 1 Installation - Electrical Power System (illustration) 5

Figure 2 Electrical Power System (Schematic Diagram) 8
Figure 3 Power Management Controls and Displays (illustration) 9
Figure h Fuel-Cell Battery Subsystem (Schematic Diagram) 16
Figure 5 Stack Assembly - Fuel-Cell Battery Subsystem
(illustration) 17
Figure 6 Gemini Spacecraft Vibration Spectra Equipment
Category A 29
Figure 7 Gemini Spacecraft Vibration Spectra Equipment
Category B 30
Figure 8 Gemini Spacecraft Random Vibration Power
Spectral Density 31
Figure 9 Gemini Spacecraft Acoustic Environment Spectrum
(Re -Entry Module - Inside Pressurized Cabin) 32
Figure 10 Gemini Spacecraft Acoustic Environment Spectrum
(Re-Entry Module - External to Pressurized Cabin) 33
Figure 11 Gemini Spacecraft Acoustic Environment Spectrum
(Adapter) 3* "
Figure 12 Gemini Spacecraft Acoustic Environment Spectrum
(External or Partially External to the Spacecraft
primary structure) 35
Figure 13 Gemin^, Spacecraft Design Load Factors 36
 MCDONNELL
DATE 6 June 1962 ST. LOUIS, MISSOURI PAGE

REVISED November 1962 REPORT. 8638

REVISED MODEL . Gemini

LIST OF EFFECTIVE PAGES

The pages of this report currently in effect are listed below in numerical order. R
E
TITLE PAGE V
i through vi
1 through U3
Al through AID
 MOOOJVJVE
DATE 6 June 1962 ST. LOUIS. MISSOURI PAGE .

REVISED July 1962 REPORT 86^8

REVISED November 1962 MODEL Gemini.

INDEX OF REVISIONS
PAGES AFFECTED
DATE REMARKS REVISED BY APPROVED
REVISED ADDED REMOVED

6/6/62 Title v & vi See Appendix II

Page
i F. E. Jones L.M. Parker
ii - iv 15 - la
1-3
6/6/62 5 - U* See Appendix II
F. E. Jones L.M. Parker -

7/11/62 ii and
vi
6, 10,
11, 18,
37, 39
and UO

11/15/62 1-12 1*2, 1*3 See Appendix II

1U, 15, Al - A10
16, 18,
19, 20 R.D. Korando L.M. Parker
Title Pg,

vi
 MCDONNELL
DATE 20 February 1962 ST. LOUIS, MISSOURI PAGE

REVISED 6 June 1962 REPORT. 8638

REVISED I1? November 1962 MODEL . Gemini

1. GENERAL
1.1 SCOPE.- The purpose of this specification is to delineate the
applicable documents, description, environmental conditions,
reliability and quality assurance provisions, data requirements, testing, and
definitions pertinent to the Gemini Model 133? spacecraft electrical system.
This document is not to be construed as, or used for, an inspection guide.
2. APPLICABLE DOCUMENTS
2.1 GENERAL.- It is the contractor's intent, relevant to the use of
Government specifications in the design, fabrication and instal-
lation of the electrical system, to utilize existing specifications where
practicable. In cases where the subject matter is applicable but the specific
requirements are not compatible due to the advanced design of this system, the
specifications and documents referenced are followed only to the extent that
the intent of such requirements are met.
2.2 GOVERNMENT DOCUMENTS.- Government specifications, standards, and
publications listed in McDonnell Report 8357 form a part of this
system specification to the extent specified in Paragraph 2.1.
2.3 MCDONNELL DOCUMENTS.- The following McDonnell documents are
applicable to this system specification insofar as their content
concerns the system described herein.
2.3.1 REPORTS
8357 "Gemini Spacecraft Applicable
Documents"
8518 "Electrical and Electronic Equip-
ment Design Requirements for
Model 133?"
8580-3 "Project Gemini Reliability Plan"
8580-5 "Project Gemini Test Plan"
8580-7 "Quality Assurance Provisions
(Plan) for Project Gemini Space
System"
8580-8 "Model 133P Gemini Program
Documentation Plan"
8612/MB-10U8 "Gemini Spacecraft/Launch Vehicle
Interface Specification"
2.3.2 DRAWINGS
52-79700 Battery, Fuel Cell
52-79702 Battery, Storage
 MCDONNELL
20 February 1962 ST. LOUIS, MISSOURI PAGE 2

REVISED 6 June 1962 REPORT 8638

REVISED 15 November 1962

2.3 .2 DRAWINGS - (Continued)

52-79703 Relays, Control and Power

52-79705 Switches, Control

52-79706 Rotary Switch

R
52-79708 Ground Unbilical E
V
52-79710 Telelights and Telelight Switches

52-79711 Floodlight

52-79713 Power Relay

52-79715 Relay, Special

52-79717 Shunt Resistor Assembly

52-79721 Circuit Breaker

52-79722 Diode

52-7972^ Light Switch Assembly

52-81707 Voltmeter

52-83701 Reactants Supply System

52-90000 Finish Specification

2.3 .3 PROCESS SPECIFICATIONS. -

1333^ Preparation and Application of Coating to

Interior Surfaces of Sealed Cabin Area of
Model 133

16001.5 Marking of Model 133 Parts and Assemblies

17^00 Installation of Electrical Wiring in Model

133
171*10 Fabrication of Electrical Wire Assemblies
for Model 133

17^10.1 Assembly of Electrical Cable Terminals and

Splices for Model 133
DATE 20 February 10,62 ST. LOUIS, MISSOURI PAGE

REVISED
6 June 1962 REPORT. 86^8

REVISED 15 November 1962 MODEL .

2.3.3 PROCESS SPECIFICATIONS - (Continued)

17U10.2 Assembly of Electrical Connectors for R

Model 133 £
V
20106 Storage and Handling of Silver-Zinc
Batteries for Model 133

20500 Fabrication and Housekeeping Policies

Applicable to Model 133

OOliriDEMTlAL
 MCDONNELL
DATE 20 February 1962 ST. LOUIS, MISSOURI PAGE
1
REVISED I ? November 1962 REPORT. 8638
REVISED MODEL . Gemini

2.U SUPERSEDENCE.- If any of the specifications, standards, drawings

and publications which form a part of this system specification
are superseded during the life of the contract of which this system specifica-
tion is a part, the later issue may be used.

ooirriDBMr
 MODOJVJV£
DATE 20 February 1962 ST. LOUIS, MISSOURI PAGE

'REV.SED July 1962 REPORT. 8638

REVISED
15 November 1962 MODEL . Gemini

3. DESCRIPTION

3.1 GENERAL.- The function of the Gemini spacecraft electrical system

is to supply and distribute electrical power of the proper voltage
to all spacecraft devices requiring electrical power for operation, with a
minimum of interference between the various subsystems and devices. Power
sources are capable of supplying sufficient power to the electrically-operated
equipment for completion of a lii-day orbital mission or a 2-day mission inclu-
ding rendezvous and docking, plus a post-landing period of 12 hours and a pre-
launch period of two hours. Power consumption is minimized to the greatest
practicable extent compatible with system requirements.
3.1.1 P010ER SOURCE.- The electrical system is a 2-wire, grounded system
utilizing fuel-cell and silver-zinc batteries as described in Para- R
graph 3-5.2 and its subparagraphs as sources of DC power. The fuel-cell battery E
subsystem is located in the equipment section of the adapter. The silver-zinc V
batteries are located in the re-entry module of the spacecraft, outside the
pressurized area.
3.1.2 AC POWER.- Devices utilizing AC power are supplied by self-con-
tained inverters within the individual systems. These inverters
are not considered a part of the electrical system, but are treated as inherent
elements of the system which they serve.
3.1.3 WIRING AND CONNECTORS.- For purposes of this specification, the
wiring and connectors which interconnect components of systems
other than the electrical system are considered a part of the electrical system
and meet all applicable requirements specified herein.
3.2 POfeER DISTRIBUTION.- DC power distribution to the utilizing systems
is accomplished through a main bus subsystem and an isolated bus
subsystem each of which is independent of the other. (See Figure 2 for power
distribution schematic).
3.2.1 MAIN BUS SUBSYSTEM.- In a normal mission, the main bus is energized
by the fuel-cell batteries from prelaunch until approximately
Tr-AT minutes, at which time the main silver-zinc batteries are manually
switched to the main bus circuit. The silver-zinc batteries will be manually
switched to the main bus in parallel with the fuel-cell battery subsystem during
the launch phase of the mission to insure continuity of electrical power in
case of an abort.
 MGDOJVJVfi
DATE 20 February 1Q62 ST. LOUIS, MISSOURI PAGE

REVISED 6 June 1962 REPORT. 86^8

REVISED 15 November 1962 MODEL . Gemini

3.2.2 ISOLATED BUS SUBSYSTEM.- The isolated bus subsystem consists of

two squib buses and a control bus energized by three isolated
silver-zinc batteries throughout the mission. The functions of this subsystem
are to supply power to the pyrotechnic ignition devices through redundant,
isolated, parallel circuits from power source to igniter and to supply power to
solenoids and control relays. The control bus is energized by both squib buses
and a separate battery, but isolated from each by diodes. In the interest of
launch site and in-flight safety, provisions are incorporated for disarming the
pyrotechnic circuits. A master arm switch is provided in the blockhouse.

3.3 SYSTEM MANAGEMENT.- Provisions are incorporated on the instrument

panel for monitoring and managing the power source. Visual in-
dications and control switches are depicted in Figure 3 and described in
succeeding paragraphs. Monitoring and switching procedures will be followed,
consistent with readings obtained throughout the mission. A tentative program
for these operations is outlined in Paragraph 3-3-3.

3.3.1 VISUAL INDICATIONS.- Visual indications of electrical system events,

conditions, outputs, and malfunctions are provided, consisting of
warning and indicator lights (see Paragraph 3«5-^«*0 and single and multiple-
reading meters.

3.3.1.1 BATTERY POWER WARNING LIGHT.- At Tr-5 minutes, an amber warning

light located in the sequence-light cluster along the left-hand
side of the center section of the instrument panel apprises the astronauts that
power usage should be transferred from the fuel-cell source to the silver-zinc
source due to impending separation of the adapter equipment section. When all
main battery switches (see Paragraph 3«3«2.2.l) are in the ON position, the
light is illuminated green.

3-3.1.2 BATTERY CONDITION INDICATOR.- Deleted.

3-3.1.3 SECTION AMMETER.- A dual-reading ammeter is installed on the right

hand section of the instrument panel. The vertical scales cover
a range of 0 to 50 amperes. During the launch through insertion phase of the
mission the ammeter will indicate the current flow of: (l) Stacks 1A through
IB and silver-zinc batteries Ml and M2; (2) Stacks 2A through 2C and silver-
zinc batteries M3 through M5. During the orbital phase fuel-cell section
currents are indicated. During re-entry, landing and post landing the ammeter
indicates the silver-zinc battery currents. (See section 3-3.3.)

3.3.1.^ VOLTMETER.- A voltmeter and associated selector switch is provided

on the right-hand section of the instrument panel. The selector
switch provides a means of monitoring fuel-cell stack voltages, common control
bus voltage, squib bus 1 and 2 voltages and main bus voltage.
 MCDONN
DATE 20 February 19&2 ST. LOUIS, MISSOURI PAGE

REVISED
6 June 1962 REPORT.

REVISED
1$ licwMbar 1962 MODEL .

ELECTRICAL POWER SYSTEM SCHEMATIC

LOADS LOADS

MAIN BUS

3
AGE-MAIN '
cn
BUS-1
SWITCH GND. TEST
POWER

JSQUIB BATT ON

SW.

I
>c
^x^
AG-ZN
S-l
rr^°FF 1
OH
SQUIB BATT.
S-l PWR SW.
I"
] ' 2«o__
M__^^ *io-J ^^~

'— ^io— ^| .
1 AGE-SQUlfS BUS (£ ~] •- —t

u.
[ OFF SWITCHOVER RELAYCJ). RLY. <H'- 1
ON'JL IPr 1
AGE-SQUIB BUS S/ OFF
AGE - SQUIB BUS/
MAIN POWER SW.
2
SQUIB ARM SW. (B.N,
 I 1.) SECTION CONTROL SWITCH (ON)
(A) OPENS H20 DRAIN
(B) APPLIES H2 & Oj REACTANT
2.) COOLANT INTERLOCK
(A) COOLANT PUMP MUST
BE OPERATING
3.) SECTION POWER SWITCH (ON)
(A) CONNECTS SECTION TO BUS
IF ITEM 1 AND 2 ARE SATISFIED!
4.) STACK REMOVAL SWITCH (OFF)
(A) EL
ELECTRICALLY DISCONNECTS
. STACK STACK FROM BUS
"
. 2-B
fl (B) SHI
(B) SHUTS OFF H, TO
INDIVIDUAL STACK
INI

STACK
2-C

I.) SILVER-ZINC BATT. CONTROL SW5.

PURGE_SUPPLY_ _ _) ' (A) CLOSED DURING LAUNCH
(B) OPEN DURING ORBIT
(C) CLOSED AT TR - AT

SAFE

BOOST-INSERTION-ABORT BUS -1
ARM ~~~

SQUIB BATT. S-2 BOOST-INSERTION-ABORT BUS -2

RETROGRADE BUS -1

RETROGRADE BUS -2

LANDING AND POST LANDING BUS -1

LANDING AND POST LANDING BUS -2

iURE 2
"Page missing from available version"
 JlfOOOJVJVC
DATE 20 February 1Q62 ST. LOUIS, MISSOURI PAGE 10

REVISED 11 July 1962 REPORT. 8638

1
TV! 17 ¥ T\ T7 TVT T* TAT
REVISED 13 November 1962 MODEL . Gemini

3.3.1.5 02 QUANTITY AND PRESSURE.- A dual-reading, vertical-scale instru-

ment is provided on the center section of the instrument panel
for monitoring the fuel-cell oxygen supply.

3-3.1.6 H2 QUANTITY AND PRESSURE.- A dual-reading, vertical-scale instru-

ment is provided on the center section of the instrument panel
for monitoring the fuel-cell hydrogen supply.

3.3.1.7 STACK MALFUNCTION INDICATION.- A horizontal row of six telelight/

switch assemblies is provided on the right-hand instrument panel
for indication and override of unsatisfactory conditions in individual fuel-cell
stacks. An amber telelight indicates low stack current, no voltage, or reverse
current operation. The switch portion of the telelight assembly disconnects
the affected stack from the bus. (See Paragraph 3.3.2.1.5.) Illumination of
red lights in three of the six telelight/switch assemblies indicates an out-of-
tolerance pressure differential in the corresponding fuel-cell battery section.
R
3-3.1.8 COOLANT PUMP WARNING LIGHTS.- One warning light is provided for E
each coolant pump in the redundant cooling loops. (These loops V
are common to the fuel-cell, cabin, and equipment cooling systems and are pro-
perly part of the environmental control system. The warning lights are refer-
enced here only because they are included in the fuel-cell monitoring procedure
(see also Paragraph 3.3.2.1.6). These lights are illuminated when an energized
coolant pump motor becomes inoperative.

3.3.1.9 FUEL-CELL AMMETER.- A fuel-cell ammeter is provided for measuring N

the current flow through any stack. Selection of a particular
stack is accomplished by a fuel-cell ammeter switch located on the right-hand E
section of the instrument panel (see Paragraph 3«3«2.lA). The ammeter range
W
is 0-20 amperes.

3-3.2 SWITCHES

3-3.2.1 SWITCHES - FUEL-CELL BATTERY SUBSYSTEM

3-3.2.1.1 CONTROL SWITCHES.- Individual control switches are provided for

each fuel-cell battery section. These 2-position (ON-OFF) switches
are utilized to control reactant flow to, and by-product water from, the fuel-
cell battery subsystem. Selection of the ON position of each switch opens
solenoid valves which permit reactant and water flow, activating the section.
This switch also acts in conjunction with the section power switch (see Para-
graph 3.3.2.1.2) as a protective series connection which prevents application
of an inactive fuel-cell section to the main bus.

3-3.2.1.2 POWER SWITCHES.- Individual 2-position (ON-OFF) power switches

are provided for application of each section of the activated
fuel-cell battery subsystem to the main bus.
DATE 20 February 1962 ST> LOUIS> M1SSOURI PAGE 11.
REVISED 11 July 1962 REPORT 86^8
t l
REVISED 15 November 1962 ^G&&&&&& f t4l^r MODEL Gemini

3.3.2.1.3 PURGE SWITCHES.- Individual 3-position (H2-OFF-02) momentary con-

tact switches are provided for purging each section of the fuel-
cell battery subsystem. Selection of the H2 position of the switch opens
solenoid valves in the hydrogen circuit downstream from the battery section,
permitting expulsion of any impurities within the section. Selection of the
62 position performs the same function for the oxygen circuit. Immediately
upon release of the actuated toggle, the switch returns to the OFF position.
3.3.2.1.14. BCI SELECTOR SWITCH.- Deleted.
3.3.2.1.5 STACK DISCONNECT SWITCHES.- Individual switches are provided for
withdrawing any desired fuel-cell stack from the main bus circuit
in case of stack malfunction or non-operation. These switches are integral
parts of the telelight/switch assemblies used for stack malfunction indication
(see Paragraph 3.3.1.7).
3.3.2.1.6 COOLANT PUMP SELECTOR SWITCHES.- Individual 2-position (ON-OFF)
selector switches are provided for selective operation of the
coolant pumps in both primary and secondary cooling loops. (These switches
like the associated warning lights, paragraph 3>3«l'8j are part of the environ-
mental control system and are referenced here because of inclusion in the fuel-
cell monitoring procedure.)
3.3.2.1.7 HEATER SWITCHES.- Individual 3-position (AUTO-OFF-MAN) switches are
provided for the fuel-cell hydrogen and oxygen supplies. These
switches are mounted on the center section of the instrument panel immediately
below the fuel-cell reactant quantity and pressure indicators, and are employed
to control heating elements mounted in the reactant storage tanks. In the
AUTO position, power to the elements is controlled by a pressure switch which
closes when pressure drops to a preset level. As the reactant temperature rises,
pressure increases until the pressure switch reaches its cutoff point, at which
time the heating elements are de-energized. In the MAN position the 09 and/or
H2 reactant pressure gauges are monitored for an optimum pressure level set forth
in M.A.C. SCD 52-83701. The MAN position is momentary, therefore upon release,
the power is removed from the heating element(s).
3.3.2.1.8 LOGIC OVERRIDE SWITCH.- Deleted.
3.3.2.1.9 CROSS-FEED SWITCH.- A 2-position (X-FEED - NORMAL) switch is pro-
vided for controlling two normally-closed solenoid valves located
downstream from the pressure regulators in the fuel-cell reactant supply lines.
Selecting X-FEED position energizes the solenoid valves, enabling reactants
from one pressure regulator to enter the supply lines normally served by the
other regulator. This permits use of a fuel-cell section which has been de-
prived of reactants by a shutoff valve or pressure regulator which has failed
closed.
3.3.2.1.10 FUEL-CELL AMMETER SWITCH.- A multiple-position rotary selector
switch is located Immediately below the fuel-cell ammeter. This
selector switch allows current readout of each fuel-cell stack. The positions
are F.C. Stack 1A, IB, 1C, 2A, 2B, 2C respectively.
 MOOOJVJVJE
DATE 20 February 1962 ST. LOUIS, MISSOURI PAGE 12
REVISED 6 June 1962 REPORT. 8638
REVISED 15 November 1962 MODEL . Gemini

3.3.2.2 SWITCHES - SILVER-ZINC BATTERY SUBSYSTEM

3.3.2.2.1 MAIN BATTERY SWITCHES.- Five 2-position (ON-OFF) switches
are provided, one for each main battery. These switches permit
connection or removal of any main silver-zinc battery from the main bus.
3.3.2.2.2 SQUIB BATTERY SWITCHES.- Individual 2-position (ON-OFF) switches R
are provided for control of the squib batteries. The common E
control bus is activated by throwing any of the squib battery switches. Squib V
bus 1 and 2 are activated by their respective control switches.
3.3.2.3 BUS TIE SWITCH.- Deleted.
3.3.2.U VOLTMETER SELECTOR SWITCH.- A multiple-position switch is provided
for applying the voltages obtained at various points in the elec-
trical system circuits to the voltmeter (see Paragraph 3.3.1.4).
3.3.3 MISSION ELECTRICAL PROCEDURES.- During the course of a mission,
periodic electrical system monitoring and power management is
necessary. In order that these functions may be punctually accomplished,
routine checkout procedures are established. Tentative operational schedules
are categorized in accordance with mission phases and outlined in the following
paragraphs.
3.3.3.1 PRELAUNCH.- During the prelaunch phase of the mission, while
ground power is utilized, bus voltages will be monitored and
relayed to the blockhouse on request. The fuel-cell battery system will be
activated and reactant quantity and pressure monitored. Switch positions for
transfer to spacecraft power will be selected and verified. Voltage and current
will be monitored during transfer to spacecraft power, and launch-readiness of
the electrical system verified.
3.3.3.2 LAUNCH THROUGH INSERTION.- During this phase of the mission,
voltage, current, hydrogen and oxygen quantity and pressure, and
the coolant pump warning lights will be monitored. In the event of unsatis-
factory output from any portion of the electrical system, an attempt will be
made to restore the malfunctioning unit to normal operation. If this fails,
the unit will be removed from the circuit, or a back-up method will be employed.
In the event of a total fuel-cell subsystem failure, the fuel-cell subsystem
and all non-critical equipment will be shut down and abort preparations made.
DATE 20 February 1962 ST. LOUIS, MISSOURI PAGE 13
REVISED 6 June 1962 REPORT. 8638
REVISED MODEL . Gemini

3.3.3.3 CATCH-UP THROUGH ORBIT.- After a successful insertion, the main

silver-zinc batteries will be removed from the main bus. Per-
iodic fuel-cell system purging will be accomplished as necessary to maintain
optimum output conditions. Battery conditions will be monitored periodically.
Near the end of the final orbit, at approximately Tr-$ minutes, the silver-
zinc batteries will be switched on and fuel-cell system power terminated.
Voltage and current will be monitored during this transfer. Any power equip-
ment malfunction during this phase of the mission will be treated in accordance
with the procedure outlined in Paragraph 3«3.3»2. N
E
3.3.3.1* RETROGRADE ANiJ RE-ENTRY.- During the retrograde and re-entry W
phases of the mission, electrical conditions will be closely
monitored to insure that the system remains functionally secure throughout
increased vibration and elevated heating periods. Override action will be
taken if necessary in accordance with applicable procedures outlined in Para-
graph 3.3.3.2.
3.3.3.$ LANDING AND POST-LANDING.- During the landing phase of the mission,
the electrical system outputs will be monitored and any necessary
override actions accomplished. Upon landing, all unnecessary electrically-
powered equipment will be shut dovm to conserve power. Recovery equipment
will be activated and system checks accomplished to determine availability of
necessary post-landing power.

O'OliriDDIfl'lAL"
 MCDONNELL
20 February 1962 ST. LOUIS, MISSOURI PAGE 1L
REVISED 6 June 1962 REPORT 8638
REVISED 15 November 1962 ,. fOmFIDEMTIAL * MODEL Gemini

3.U CIRCUIT PROTECTION.- Electrical circuit protection is provided

for the purposes of fire protection and/or prevention of system R
wiring damage due to insulation failure. Protection is limited to areas in
which input power is capable of producing current which is sufficient to damage
the wire. Circuit protection is accomplished through the use of sequence
switching, fuses and/or circuit breakers, and reverse-current coils. Pyro
switches are provided for de-energizing interface circuits prior to severance
of spacecraft sections. Circuit breaker panels are provided which combine on-
off switching provisions with circuit protection in some cases.
DATE 6 June 1962 ST. LOUIS, MISSOURI PAGE 15
REVISED 1*7 November 1962 REPORT. 8638
REVISED MODEL . Gemini

3.5 COMPONENTS

3.5.1 REQUIREMENTS.- The general design requirements for electrical

equipment used in the Gemini spacecraft are set forth in M.A.C,
Report 8518.
3.5.2 BATTERIES
3.5.2.1 FUEL-CELL BATTERY SUBSYSTEM.- Two fuel-cell battery sections are
located in the equipment section of the adapter. Each section
consists of three stacks, contained within a pressurized sealed tank (see
Figure U). Each stack consists of a sufficient number of series-connected
cells to.maintain system voltage within established limits during all mission
phases that require power produced by the fuel-cell batteries (see Figure 5)»
For normal operation, all stacks in a section are electrically connected in
parallel to the main bus through individual ON-OFF switching provisions. The
fuel-cell battery system utilizes hydrogen and oxygen reactants stored in a
supercritical cryogenic state (see Paragraph 3.5.2.1.1). Cooling of the
fuel-cell battery system is provided by an active liquid cooling system. The
cooling system consists of two parallel loops, each having redundant pumps.
Each loop circulates coolant through the cabin heat exchanger, suit heat ex-
changer, equipment cold plates, and reactant and oxygen supply heat exchangers
as well as the fuel-cell battery system. Each loop dissipates the accumulated
heat through an external radiator located on the surface of the adapter plus
heat exchangers used to raise the temperature of the fuel-cell battery reactants
and environmental oxygen. For normal orbital periods one-pump, one-loop
operation is sufficient for cooling. During peak load period, both loops with
two pumps, as required by the load, will be utilized. The potable water by-
product of battery operation is transported to a central water reservoir located
in the crew compartment of the re-entry module. The water reservoir provides a
visual means of gauging the amount and condition of water contained plus a means
of positive removal of the water. Provisions are incorporated to allow purging
of inert gases from the fuel-cell battery as required. The total fuel-cell
battery system, including both fuel-cell sections, reactant supply tanks, and
the associated portion of the cooling system is installed in the adapter section.
Any two of the six fuel-cell stacks are capable of supplying the basic electri-
cal power requirement during orbital periods for both the missions specified
in Paragraph 3«1> excluding rendezvous and docking phases.
 MCDONNELL.
DATE
20 February 1962 ST. LOUIS, MISSOURI PAGE
16
6 June 1962 REPORT.
8638
REVISED
15 November 1962 GEMINI
REVISED MODEL .

FULL CELL BATTERY SUBSYSTEM

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FIGURE 4
CENTER PAUL
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/ /••f*3!.-s--//-- />^w/v.:ow>:/x':>
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 *f ODO/VJVi
DATE 6 «fyne 3962 ST. LOUIS, MISSOURI PAGE lfi_

REV1SED 11 July 1362 REPORT 8638

REVISED 1$ November 1962 fPfirir TINT! I'l I MODEL Gemini

3.5.2.1.1 REACTANT SUPPLY SUBSYSTEM.- The fuel-cell reactant supply subsystem

is installed in the adapter section. This subsystem stores in a
fluid state, at supercritical pressures and cryogenic temperatures, the hydrogen
and oxygen reactants which comprise the fuel and oxidizer utilized in the
operation of the fuel-cell battery subsystem. Reactant pressurization is
accomplished by individual heating elements contained within the H2 and 02
tanks. These elements are segments of a closed-loop circuit which automatically
maintains pressure within predetermined limits (See Paragraph 3.3»2.1.7 for
switching provisions). The hydrogen and oxygen pass through heat exchangers
which are components of the spacecraft cooling system. These heat exchangers,
through which warm return coolant is circulating, warm the reactants to a
temperature suitable for application to the fuel-cells. Sensors within the
reactant supply subsystem provide discrete electrical signals for quantity and
pressure in individual tanks and reactant temperature downstream from the heat
exchanger (preheater). Materials used in the reactant supply subsystem which
are in direct contact with the oxidizer are not subject to pyrophoric reactions.
3.5.2.2 SILVER-ZINC BATTERIES
3.5.2.2.1 MAIN BATTERIES.- Five liO.p ampere-hour 16-cell main
batteries of the silver-zinc type are provided. Open-circuit
potential of these batteries is 29.6 volts maximum, with a plateau voltage of
approximately 25.3 volts. Each battery is activated and sealed at sea level
pressure. Battery cases are vented to permit escape of gases and are provided
with suitable pressure relief valves. Cases are designed and constructed to
withstand an interior-to-exterior differential pressure equal to 1.5 times the
maximum relief pressure setting without permanent deformation or deformation
adversely affecting battery operation. Venting provisions are designed to pre-
clude electrolyte loss. The vent fitting and electrical connector are mounted
as an integral part of the battery. Batteries are capable of operating in a
weightless state, in any attitude except with cells upside down while under
any acceleration force within the limits specified in Table II.
3.5.2.2.2 SQUIB BATTERIES.- Three separate high-discharge-rate 16-cell
silver-zinc batteries are provided for supplying power to an
isolated bus system. These batteries are isolated, both electrically and
mechanically, from the other silver-zinc batteries and will maintain 16.0 volts
at the terminal under a 100-ampere load for one second.
3.5»3 RELAYS.- The electrical relays used on the spacecraft are of
sufficiently rugged construction to withstand the mechanical
stresses, shocks, and vibrations characteristic of the planned mission. The
switching mechanism is completely enclosed in a hermetically sealed cover, and
is capable of operation in any position. Contact bounce is minimized to the
best value obtainable consistent with closure-time requirements. Relays shall
be of the immediate-closing, time-delay, and/or slow release type, dependent
on the function performed in the individual circuit.
DATE o June lyo ST< LOU|Sj M , SSOUR , P AGE 12_
REVISED 1^ November 1962 REPORT 8638

3.5.U SKETCHES
3.5.1i.l TOGGLE SWITCHES.- Toggle switches used in the Gemini Spacecraft
are sealed so as not to constitute a fire or explosion hazard,
and are of construction sufficiently durable to withstand mechanical stresses
imposed during the missions specified in Paragraph 3.1. Travel between extreme
positions is between 26 and k6 degrees. Terminals are permanently and legibly
marked on the switch housing.
3.5.b.2 ROTARY SWITCHES.- The rotary switches used in the Gemini spacecraft
incorporate housings which completely enclose the switching
mechanism. The switches are sealed so as not to constitute a fire or explosion
hazard. All terminals are solder-type, located on the back of the housing,
A positive detent mechanism is provided, which minimizes the possibility of
the movable contact coming to rest between contact positions. Contact arrange-
ment is permanently marked on the switch houseing. Switches are constructed
to withstand temperature, pressure, and acceleration variables encountered in
the course of the missions described in Paragraph. 3•!• R
E
3.5.U.3 LIMT SWITCHES.- Deleted. V
3.5.U.ii TELELIGHTS.- The telelights used for functional indication on the
Gemini spacecraft incorporate opaque legends on translucent
backgrounds, with legends appearing dull black when the lamps are de-energized.
The dual parallel-connected lamps are red, amber, or green as dictated by
telelight usage. Coloration is effected by the installation of filters on the
lamps. Test terminals are provided, with an internal diode arrangement to
prevent1 energizing the input circuit when test voltage is applied.
3.5.it.U.I TELELIGHT/SWITCHES.- The telelight/switches incorporate the
features described above, and in addition provide an integral
switching capability. The positive-break switch is housed in a hermetically-
sealed case and actuated when the telelight display is pressed. Switches are
of the momentary-contact type, which automatically return to normal position
upon release, and alternate-contact type, in which each successive actuation
results in repositioning to the alternate set of contacts.
3.5.5 EXTERNAL POWER CONNECTIONS.- Prior to launch, external power is
supplied to the re-entry module to prevent undue depletion of the
spacecraft power supply. This is accomplished by means of an electrical dis- R
connect assembly. The adapter and re-entry module also contain electrical E
connections for monitoring spacecraft parameters during prelaunch checkout. V
Each disconnect assembly consists of a plug and receptacle assembly and a
coupling device for securely retaining these components in the engaged position.
The disconnect assembly is capable of positive disengagement/separation both
electrically by a solenoid device and manually by a lanyard-initiated mechanism.
The re-entry module disconnect is normally released at approximately T-30
seconds. The adapter module disconnect is normally released at T+3 to T+5
seconds, with the backup device actuated by movement of the launch vehicle.
DATE 6 June 1962 ST. LOUIS, MISSOURI PAGE 20
REVISED November 1962 REPORT. 86^8
REVISED MODEL . Gemini

3.5.6 CONNECTORS.- Miniature bayonet (Bendix Pygmy) type connectors are R

used throughout the electrical subsystem, except at external power E
and interface connections. See Paragraph 3*5.5 for external power connectors V
and M.A.C./Martin Report 86l2/MB-10li8 for interface connector specifications.
3.5.7 CIRCUIT BREAKERS.- The circuit breaker/switches used in the
Gemini Spacecraft are of the magnetic type. Choice of this type
is predicated on its relative insensitivity to thermal changes, which enhances
stability characteristics through temperature variations encountered in orbital
missions. Hermetically-sealed integral switches are incorporated which provide
capability of complete deactivation of selected circuits.
3.6 FABRICATION.- The methods and procedures utilized in the fabri-
cation of the electrical system components and subassemblies are
in accordance with applicable M.A.C. Process Specifications as listed in Para-
graph 2.2.2, Government specifications insofar as practicable, and established
spacecraft standards. Only materials of highest quality are used. Temperature-
resistand and insulating materials are used wherever necessary to insure ful-
fillment of the electrical system's function in contributing to completion of a
successful mission. Miniaturization and weight reduction are emphasized in
system design. Wherever possible, existing components and items of equipment
are used to reduce the lead time necessary for development of the system. De-
velopment-type items are obtained through liaison with, procurement from, and/or
assistance of, reputable manufacturers. Spare pins, with short wire segments
attached, are provided in various connectors throughout the electrical system
to provide for growth, routing changes and/or special circuits. Test connectors
are incorporated at various points to facilitate connection of aerospace ground
equipment during spacecraft systems testing and prelaunch checkouto
 MODOJVAU
DATE 6 June 1962 - ST> LOU1S> M|SSOURRl
, PAGE
PAGE 21_
REVISED REPORT 86^8
REVISED «MJb«OvUliA£tflIllLMHM» MODEL

3-7 INSTALLATION.- Installation of system components and equipment

is in accordance with applicable M.A.C. Process Specifications as
listed in Paragraph 2.2.2, contractor and vendor engineering drawings, and
Government standards insofar as practicable. Location of items is based on
function performed, associated equipment, communications interference, environ-
mental adaptability, heat generation, space limitations, accessibility, and
crew station compatibility. Possibility of shorting due to moisture, corrosive
atmosphere, floating debris, and/or detached equipment is minimized by elimina-
tion of exposed powered electrical connections throughout the system. This
is accomplished by insulating and/or sealing terminals, connections, splices,
bare conductor sections, lugs, studs and solder pots with potting, coating, or
sealing compounds, paint, tubing, sleeving, plastic foam and/or mechanical
covers. Wherever feasible, non-captive wire bundle installation is utilized,
i.e., removal of wire bundles may be accomplished without removing or separating
soldered or other permanent-type connections.
DATE * June 1962 ' ST. LOU.S. M.SSOUR, PAGE 22.
REVISED REPORT
8638

k. ENVIRONMENTAL CONDITIONS

U.1 GENERAL.- This system and its components vill "be capable of .
acceptable performance when subjected to the environmental
conditions as specified in Tables I, II or III, as applicable, except as
otherwise specified in individual paragraphs herein.

5« QUALITY ASSURANCE

5»1 GENERAL.- System components and materials are subjected to both

acceptance tests and design approval tests. Acceptance tests
include, but are not limited to, those tests performed to insure that the
materials, workmanship, and performance of components are not substandard
and that the components have been manufactured to approved drawings and
specifications. Design approval tests are defined as those tests conducted
on preproduction and/or production equipment to determine that the design
of the equipment complies with all requirements therefor. Production-line
surveillance is maintained during fabrication, assembly and installation of
all components and subassemblies to insure that all methods, procedures and
ambient conditions are maintained in accordance with existing specifications
and established spacecraft standards. Quality assurance provisions are in
accordance with M.A.C. Report 8580-7, "Quality Assurance Provisions (Plan)
for Project Gemini Space System".

6. RELIABILITY

6.1 GENERAL.- An active reliability program is established and

conducted throughout the design, development, fabrication, and
installation of the Gemini electrical system. Adequate testing, both in-plant
and/or vendor/subcontractor-accomplished, is performed to insure a reliability
factor which does not deteriorate the overall probability of a successful
mission. Mission safety is emphasized in the design approach, back-up and
redundant systems are utilized where necessary, and every effort is made to
minimize system complexity. Reliability provisions are in accordance with
M.A.C. Report 8580-3, "Project Gemini Reliability Plan."

7. DATA REQUIREMENTS

7«1 GENERAL.- Applicable design information and performance reports

are submitted in accordance with the requirements specified
in M.A.C. Report 8580-8, "Model 133P Gemini Program Documentation Plan."
 6 j 1Q62 flf OOOHfJIfl
• ^2£ ST. LOUIS. MISSOURI PAGE 23

REVISED ; REPORT 8638

REVISED ^£&$HP$&£9t4*Ml^^ MODEL Gemini

8. TESTING
8.1 GENERAL.- In addition to the acceptance, design approval, and
reliability tests described in Paragraph 5.1 and 6.1, the elec-
trical system will undergo numerous other tests, both as an individual system
and as an integrated portion of the spacecraft system as a whole. Details of
the various tests are itemized in M.A.C. Report 8580-5. Basic test groups are
described in the following paragraphs. Throughout the testing program, system
performance and interaction with other systems will be monitored, recorded,
and evaluated. Design, fabrication, procedural, and/or installation corrections
and improvements will be implemented where necessary as a result of these
evaluations.
8.1.1 BATTERY TESTS.- A prototype fuel-cell battery system (less
reactant tank's) will be assembled and tested for fuel flow, purge
requirements, voltage regulation, and susceptibility to voltage fluctuations.
This prototype system will be upgraded to a production system as parts become
available, and installed in the compatibility test unit, where it will be N
employed to power the spacecraft systems in a simulated mission evaluating the E
batteries under actual spacecraft systems loads and transients. Switchover W
from fuel-cell to silver-zinc batteries will be accomplished during this oper-
ation. The reactant storage system will be separately tested under critical
fuel flow.
The fuel-cell battery/reactant storage system will be installed
in an altitude chamber and tested under simulated orbital load (which will be
determined from tests performed with the spacecraft systems of the compatibility
test unit) until the reactant supply is totally depleted, to determine the
ampere-hour capacity for a single fueling.
8.1.2 COOLING SYSTEM TESTS.- The common cooling system which serves
the fuel-cell power supply, equipment cold plates, and environ-
mental system heat exchangers will be tested in production prototype form in
a simple mockup which simulates component spacing and geometric relationship.
Heating elements will simulate equipment heat loads and the production proto-
type power supply or heating elements will provide the fuel-cell battery heat
load. The tests will evaluate flow rates, pressure drops, and heat transfer
characteristics of the radiator and cold plate/circulation systems, both
separately and combined, under ambient and simulated altitude conditions. Ihe
complete production prototype system will be installed and tested in the
compatibility test unit and with the production prototype fuel-cell system
(see Paragraph 8.1.1). The complete spacecraft cooling system will be tested
under simulated mission environmental conditions during the course of the
simulated orbital mission (see Paragraph 8.1.1;).
 . T . . MOOOAfJVJ
DATE b. June 19&2 ST> LQU|S> M1SSOUR1 PAGE

REVISED REPORT 8638

8.1.3 SPACECRAFT SYSTEMS TESTS (SST).- The production electrical system

or sections thereof, as required, vdll be utilized in conducting
overall spacecraft systems tests, including individual system operational tests,
integrated system operational tests, and simulated mission tests. These tests
will be performed on production spacecraft systems which are in sufficient
stages of completion to permit accurate evaluation of data relative to delivered
spacecraft configuration. E
W
8.1.U SIMULATED ORBITAL MISSION.- A complete electrical system will be
installed in a spacecraft which will be used in a complete
simulated mission, run at reduced.pressures to simulate altitude, elevated
temperatures to simulate launch and re-entry heat loads, and reduced temperatures
to simulate orbital conditions. Sequential operation of the electrical system
will be accomplished, and all performances under extreme environmental conditions
will be monitored, recorded and evaluated, and any unsatisfactory conditions
corrected.
 .
DATE _ 6 June 1962 _ $Tt LOU1S> M|SSOUR, PAGE _ 25
REVISED _ REPORT _ 86"38

REVISED _ • ClOJiriMPfTOH^ MODEL _ Gemini

9. DEFINITIONS

9.1 GENERAL.- The terms listed below are used, in this specification
and are defined as follows:

Spacecraft - The adapter module and re-entry module. This

term applies either with or without the launch vehicle
„ mating section of the adapter module.

Adapter - That portion of the spacecraft used primarily

to support the re-entry module on the launch vehicle.

Re-entry Module - That portion of the spacecraft which

houses the crew. The part of the spacecraft which re-enters \
the earth's atmosphere.

Tr-AT - An arbitrary time prior to retrograde firing,

just prior to equipment-section jettison, at which time
re-entry preparations and sequencing are normally initiated.

Equipment Section - The central portion of the adapter

which houses systems used during the orbital
phase of the mission; jettisoned prior to retrograde
firing.
 DATE

REVISED
MCDONNELL
ST. LOUIS. MISSOURI
REVISED

ENVIRONMENTAL CONDITIONS F
Equipment
Life
Prel
Environment
Ambient Temperature 20°F
Anbient Pressure 23.5
Temperature-Pressure N.A.

Relative Humidity
Rain MIL-
Salt Sea Atmosphere MIL-;
Sand and Dust MIU
Fungus (2) MIL-:
Oagrgen Atmosphere 100*
Shock (3) (U) (5) N.A.

Acceleration (3) (U) (6) N.A.

Vibration
Equipment Category A (Figure 6) (7) Proti
Equipment Category B (Figure ?) (8) Prot<
Random (Figure 8) Proti
Acoustic Noise Proti
Radio Interference MIL-:
Atmosphere I.A.

NOTESt
1. N.A. • Not applicable.
2* Applicable to untested and untreated materials only.
3* "Lateral Spacecraft Axes" refers to both the pitch
and yav asss as defined for Spacecraft control.
U. All shock and acceleration loads in this table are
limit loads* Satisfactory performance is required
during and/or after limit load application, which-
ever is appropriate* Kb equipment shall tear loose
from its mount and internal parts shall be contained
under application of ultimate loads. Ultimate load
is 1.36 times limit load*

M»C Iltu ( R E V 25 AUG

 PAGE _ 26
REPORT. 8636L
MODEL .

TABLE I
ELECTRICAL EQUIPMENT LOCATED IN THE RE-ENTRY MODULE IN THE

>

inch Operation Launch Orb

:o 160°F 0°F to 160°F 0°F to 16

10 15.5 psia 15.5 to 10-12 psia 6.0 to 1C
;D 16C?F at 15.5 to lO'12
psia
160°F at
) IQGfc 15* to 100* 5C# to 8C
•5272C, Procedure II N.A, N.A.
•5272C, Procedure I N.A, N.A.
•5272C, Procedure I N.A, N.A.
•5272C, Procedure I N.A. N.A.

?2 at 15.5 psia lOCtf Og at 6,0 psia 100$ 02 a

N.A, N.A. (1)

Longitudinal Space- Og
craft Axis: 1. g
to 7.25 g linearly
witn time over 326 sec.

rbed Curve I Curve II

jted Curve I Curve II
:ted Curve 1 Curve II
rtad 135 db Over-all N.A.
See Figure 9
.26600 MIL-I-26600 MIL-I-266
N.A. N.A.

5. Longitudinal and Lateral do not act

simultaneously.
6* Longitudinal and Lateral act simultaneously.
7. Equipment items which are mounted to space-
craft primary structure directly, or through
intervening structure and/or are of soffi-
eientV small mass that the mechanical
impedance of the spacecraft structure as seen
by the equipment installation attach points
can be considered effectively infinite* Most
equipment items will fall into this category.
.ESSiJRIZED CABIN

Re-Entry Post-Landing

200°F -15° to 160°F

12_Dsia 10-12 to 15.5 p 15.5 psia
psia 200°F at 1C'12 to 15.5 N.A.
psia over 10 HLn,
15* to 10056 15* to 100$
N.A.
N.A. N.A.
N.A. N.A.
N.A. MIL-E-5272C
Procedure I
6*0 psia 03 at 6.0 psia N.A.
See Figure 13 15 g's in any
direction
11 millisecond
duration
Longitudinal Spacecraft 1 g
Axis: I5g, 30 R
second duration. E
Lateral Spacecraft Axis; V
U.5 g, 30 sec, duration
Curve III N.A.
Curve III N.A.
Curve III N.A.
Sane as for Launch N.A.
MIL-I-26600 KIL-I-266CO
N.A. N.A.

8. Equipment items or complete system installations of

sufficiently large siae and mass that the mechanical
impedance of the attach points cann«t *» taken AS
infinite, and the feedback affect has been, therefore,
given consideration.
DATE Jam 1O£9 MCDONNELL
ST. LOUIS. MISSOURI
REVISED

REVISED

ENVIRONMENTAL CONDITIONS

Environment Prel&unch Operation

Amoient Temperature 20°F to 160°F
Ambient Pressure 1$.5 psia
Temperature-Pressure N.A. (1)

Relative Humidity 15* to 100*

Rain MIL-E-5272C, Procedure II
Salt Sea Atmosphere MIL-E-5P72C, Procedure I
Sand and Dust M1L-E-5272C, Procedure I
Fungus (3) MIL-E-5272C, Procedure I
Shock (U) (5) (6) N.A. (1)

Acceleration (U) (5) (8) N.A. (1)

Vibration
Category A (Figure 6) (9) protected
Category B (Figure 7) (10) Protected
Random (Figure 8) Protected
Acoustic Noise (11) Protected
Radio Interference MJL-I-26600
Explosive Atmosphere B.A.

NQTKSi
1. N.A. • Not applicable*
2. Immersion in k feet of sea water for 12 hours. Rescue
equipment must operate in this environment.
3. Applicable to untested and untreated materials only.
U. "Lateral spacecraft axes" refers to both the pitch and
yaw axes as defined for spacecraft control.
5. All shock and acceleration loads in this table are
limit loads. Satisfactory performance is required
during and/or after limit load application, whichever
is appropriate. No equipment shall tear loose from
its mount and internal parts shall be contained under
application of ultimate loads. Ultimate load is 1.36
times limit load.
3l»l' (Rlv C 5 At.G 61 )
>AGE 9

»EPORT.

MODEL .

TABLE II
"OR ELECTRICAL EQUIPMENT LOCATED IN THE RE-ENTRY MODULE EXTERNAL TO

Launch Orbit
-6C°F to 16QOF -60°F to 160°F 200°F
15.5 to 10-12 pgia 160°F at 10-12 psia 10-1 2 to 1;

160°F at 10-12 psia 160°F at 10-12 psia 200° F at 1C

10 minut<
15* to 100* N.A. (1) 15* to loo.i
N.A. (1) N.A. (1) N.A. (1)
N.A. (1) N.A. (1) N.A. (1)
N.A. (1) | N.A. (1) N.A. (1)
N.A. (1) N.A. (1) N.A. (1)
N.A. (1) N.A. (1) Area I - 3C
craft, 3<
spacecraJ
Area II «
Longitudinal spacecraft axis: Og Longitudini
Ig to 7.25g, linearly with 30 secom
time over 326 seconds. spacecra
duration,

Curve I Jurve II Curve III

Curve I Curve II Curve III
Curve I Jurve II Curve III
IkS db Over-all, See Figure 10 N.A. (1) Same as foj
MIL-I-26600 KIL-I-26600 MIL-I-2660C
N.A. (1) N.A. (1) N.A. (1)

6. Longitudinal and lateral do not act simultaneously. 10.

7. Area I is the Re-Entry Module between Z Stations
160.00 and 192.00 (Upper Cabin Section and rtCS
Section). Area II is in the ;<e-Entry Module between
Z Stations 103.U* and 160.00 (Main Cabin Section).
8. Longitudinal and lateral act simultaneously. 11.
9« Equipment items which are mounted to spacecraft
prjbiary structure directly, or through intervening
structure and/or are of sufficiently small mass that
the mechanical impedance of the spacecraft structure
as seen by the equipment installation attach points
can be considered effectively infinite. Most equip-
ment items will fall into this category.

~
'HE -PRESSURIZED CABIN

Re-Entry Post-Landing
-15°F to 160°F
.5 psia 15.5 psia
>12
to 15.5 psia over N.A. (1)

to
MIL-E-5272C, U-hr. Immersion (2)
MIL-£-5272, Procedure I
MIL-E-5272C, Procedure I
MIL-E-5272C, Procedure I
I longitudinal space- I5g's in any direction 11 milli-
l along either lateral second duration.
t axis 11 ms duration (7)
See Figure 13 (7)
L spacecraft axis: I5g, lg
i duration. Lateral
t axis: U.5g» 30 seconds
R
N.A. (1)
£
N.A. (1)
V
N.A. (1)
Launch N.A. (1)
MIL-I-26600
N.A. (1)

Equipment items or complete system installation of

sufficiently large size and mass that the mechanical
impedance of the attach points cannot be taken as infinite
and the feedback effect has been, therefore, given
consideration.
Equipment external or partially external to spacecraft
primary structure shall meet the acoustic noise environ-
ment of Figure 12.
DATE MOOOJVJVJ
ST. LOUIS. MISSOURI
REVISED

REVISED

ENVIRQI

Equipment
Life
^ Phase Pi
Environnent
Ambient Temperature 20°F to 160C
Ambient Pressure 15.5 psia
Temperature-Pressure N.A. (1)
Relative Humidity 1# to 100*
Rain MIL-E-5272CJ
Salt Sea Atmosphere MIL-S-5272C,
Sand and Dust MIL-E-5272C,
Fungus (2)
Explosive Atmosphere Hydrogen Ata
Shock (3) (U) (5) N.A.
Acceleration (3) (U) (6) N.A.

Vibration
Category A (Figure 6) (7) Protected
Category B (Figure 7) (8) Protected
Random (Figure 8 ) Protected
Acoustic Noise (9) Protected

Radio Interference MH-T-26600

NOTESt
1. N.A. » Not applicable.
2. Applicable to untested and untreated materials
only.
"Lateral Spacecraft Axes" refers to both the pitch
and yaw axes as defined for spacecraft control.
All shock and acceleration loads in this table are
limit loads* Satisfactory performance is required
during and/or after limit load application, which-
ever is appropriate. No equipment shall tear loose
from its mount and internal parts shall be contained
under application of ultimate loads. Ultimate load
is 1.36 times limit load.
AGE 2JL
EPORT. 8638
IODEL. . Gemini

TABLE III

ENTAL CONDITIONS FOR ELECTRICAL EQUIPMENT LOCATED IH THE ADAPTER

Launch Launch

-60°F to 160°F
15.5 to 10"12 psia
160°F et 15.5 to 10'12 psia
15* to 100*
Procedure II N.A.
Procedure I N.A.
Procedure I N.A.
Procedure I N.A.
sphere (10) N.A.
N.A.
Longitudinal Spacecraft Axis;
l.g to 7.25g linearly with tJ
over 326 sec.

Curve I
Curve I
CUTTC I
155 db Over-all
See Figure 11
MIUT-26600

5» Longitudinal and Lateral do not act simultaneously*

6, Longitudinal and Lateral act simultaneously.
7. Equipment items which are mounted to spacecraft
primary structure directly, or through intervening
structure and/or are of sufficiently small mass that
the mechanical impedance of the spacecraft structure
as seen by the equipment' installation attach points
can be considered effectively infinite. Most
equipment items will fall into this category.
 Orbit

-60°F to 160°F
10"12 psia
160°F at 10"12 psia
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
N.A.
Og
h
e £
V

Curve II
Curve II
Curve II
N.A.

MIL-I-26600

Equipment items or complete system installations

of sufficiently large size and mass that the
mechanical impedance of the attach points cannot
be taken as infinite, and the feedback effect of the
equipment has been, therefore, given consideration.
Equipment external or partially external to
spacecraft primary structure shall meet the acous-
tic noise environment of Figure 12*
0. Equipment will be tested for explosion-proofing
using standard commercial butane-air mixture.

J
 MODOJVJVfJLJL
DATE 6 June 1962 ST. LOUIS, MISSOURI PAGE 29
REVISED REPORT. 8638

REVISED MODEL . Gemini

GEMINI SPACECRAFT VIBRATION SPECTRA

EQUIPMENT CATEGORY A

.00001

FREQUENCY (CPS)
Figure 6
DATE 6 June 1962 ST. LOUIS, MISSOURI PAGE 30
REVISED REPORT. 8638
REVISED MODEL . Gemini

GEMINI SPACECRAFT VIBRATION SPECTRA

EQUIPMENT CATEGORY B

i.o

TO 5 CPS

.10

CURVE
.— — CURVE II
CURVE III

.01
u

•"'

\
.0001 \—V

.00001
10 50 100 500 1000 5000
FREQUENCY (CPS)

Figure 7
 MCDONNELL.
DATE 6 June 1969 r. LOUIS, MISSOURI 31

REVISED 8638

REVISED MODEL

Z
O

CL
U
|

tt O
IU
K
t

<J

Z
111
o

SdD/ z 6 -AJ.ISN3d UBMOd

Figure 8
DATE 6 June 1962_ ST. LOUIS, MISSOURI PAGE 32
REVISED REPORT. 8638
REVISED MODEL . Gemini

(/»

z
UJ

o
2

Ul
UJ
u a:

CO
O u
u
<
t
<

i
zooo' :3a aa - 13A3T

Figure 9
 MGDO/VJVjE
DATE A Jnne 1962 ST. LOUIS, MISSOURI PAGE
8638
REVISED MODEL

LLJ
_J

i
> £
U 2

O <

< <
OQ

t
^f 5
i** "^*
Q.

O
LLJ

«/»

jWD/S3NAd ZOOO' : 3d 90 - T3A3H 38nSS3«d QNnOS

Figure 10
DATE 6 June 1962 ST. LOUIS, MISSOURI PAGE 3il

REVISED REPORT, 8638

REVISED MODEL . Gemini

tt
C

Z iS
ui a:

«/> 1-
°-

t
2
idu

jWD/S3NAQ ZOOO 1 : 3M SO - 13A31 3&nSS3Ud ONOOS

Figure 11
OOliriDDNTLIL >»
 MGOOJVJV£
6 June 196 ST. LOUIS, MISSOURI

REVISED REPORT.

REVISED MODEL .

So
0

T
§8

o o
S3

UJ
a.
o
•/>
a

88 I
i 3
U z
rn «o ...

o
u a
UJ

i
Z so

i
o
-O-

11 I 111 11 I I 11 I 11 I 1 I 11 111 I I I I 11 I 11 I 11 I 11 111 11 I I

WD/S3NAO ZOOO- =38 90 - T 3 A 3 T 3df\SS38d

Figure 12
DATE 6 June 1962 ST. LOUIS, MISSOURI PAGE 36
REVISED REPORT. 8638
REVISED MODEL . Gemini

. .—
< 86

Figure 13
 MODOJVAUE
DATE 6 June 1962 ST. LOUIS, MISSOURI PAGE 37
REVISED 11 .Tnly 1962 8638

REVISED MODEL Gemini

APPENDIX I
EQUIPMENT LIST .

Qty. Nomenclature M.A.C. No.

1 Battery Subsystem - Fuel Cell 52-79700-3
k Battery - Silver Zinc 52-79702-3
3 Battery - Silver Zinc 52-79702-5
* Relay - Control 52-79703
* Relay - Time Delay 52-79701
# Switch - Toggle 52-79705
* Switch - Rotary 52-79706 »
I
* Switch - Limit 52-79707 *
1 Umbilical - Ground 52-79708-3
1 Umbilical - Ground 52-79708-5
* Umbilical - Staging 52-79709
* Telelight 52-79710
=* Telelight/Switch 52-79710
* Telelight/Switch 52-79710
t
* Relay - Voltage Sensing 52-79715
* Fuse/Fuse Resistor 52-79720
* Circuit Breaker/Switch 52-79721
* Shunt

* These quantities will be inserted as firm requirements are determined.

 MODOJVJVfi
DATE 6 June 1962 ST. LOUIS. MISSOURI PAGE 38
REVISED REPORT. 8638
REVISED MODEL . Gemini

APPENDIX I (Continued)
EQUIPMENT LIST

Qty. Nomenclature M.A.C. No.

System - Reactant Supply 52-83701-1
Extended Mission

# System - Reactant Supply 52-83701-3

Short Mission
N
E
W

# One of these systems is used for each spacecraft, dependent on the

mission for which it is utilized.
 MODOJVJVC
DATE 6 June 1962 ST. LOUIS. MISSOURI PAGE 39
REVISED 11 July 1962 REPORT.
8638

REVISED MODEL . Gemini

APPENDIX II

CHANGE LIST •

Following is.an itemized list of changes incorporated in McDonnell

Report 8638 as a result of successive revisions. In instances where con-
flict or confusion may result, the authority for these changes is parenthe-
tically specified; where the reason for change is self-explanatory (e.g.,
rearrangement of format, addition of reference material, rewording for
clarity or additional information, etc.), no authorization is listed.

Section 1
Changes Incorporated in 11 July 1962 Revision
References: A. NASA-M.A.C. Houston Co-ordination Conference - 25-27 April 1962
Paragraph Changes
Title Page Changed "Subsystem Specification" to "System
Specification". (Reference A)
N
Page ii and iii Added pages i through vi; revised Table of E
Contents to reflect present format; added W
Appendices I and II.
*
Page iv Added Figures 2 through 13.

Page v Added Pages 15 through 1*1.

Page vi New page.

1.1 Added "Testing".

2.2.1 Rearranged - added McDonnell Reports 8392,

8580-5, and 8610. Added McDonnell Drawings
52-79706, 52-79709, 52-79710, 52-797H,
52-79715, 52-79720, and 52-83701.
2.2.2 Removed P.S. 17305 and P.S. 17^10.3. (Not
applicable to electrical system.)

3.1 Added..."with .a minimum of interference

between the various subsystems and devices."
Added..."2-Wire Grounded System". Added
Paragraphs outlining AC power and intercon-
necting wiring philosophies. (Reference A)
DATE 6 June 1962 ST. LOUIS, MISSOURI PAGE

REVISED 11 REPORT. 8638

REVISED MODEL . Gemini

APPENDIX II (Continued)

CHANGE LIST

Paragraph Changes

3.2 Paragraph title was: "Fabrication", now:

"Power Distribution"; content changed
accordingly.

3-3 Paragraph title was: "Installation"; now:

"System Management"; content changed accord-
ingly. This paragraph and all subparagraphs
thereto are new paragraphs. (Reference A)

Paragraph title was "Power Distribution";

now: "Circuit Protection"; content changed
accordingly. .Expanded paragraph to include
circuit protection philosophy and methods.
(Reference A)

3-5 Paragraph title was: "Monitoring"; now:

"Components"; content changed accordingly.
With the exceptions noted in the following
paragraphs, this section is the same as
Section 3.7 in the basic issue.
4

.3.5.1 New Paragraph.

3.5.2.1 Reworded to update terminology.
3-5.2.2 Reworded battery description; revised ratings
to reflect later information.
3-5.3 Added voltage-sensing relays.

3.5.^.1 Added toggle travel and terminal marking.

3.5.^.2 New Paragraph.
3-5.^.3 Removed toxic fumes/noxious odors statement
(covered by McDonnell Report 8518; see
paragraph 3«5.1 - Requirements.
New Paragraph.
DATE 6 June 1962 ST. LOUIS, MISSOURI PAGE
8638
REVISED REPORT.

REVISED MODEL . Gemini

APPENDIX II (Continued)
CHANGE LIST

Paragraph Changes

3.5-5 Reworded; expanded to include approximate

release times.
3-5.6 New Paragraph.
3.6 Paragraph title was: "Circuit Protection";
now: "Fabrication"; content changed accord-
ingly.

3.7 Paragraph title was: "Components"; now:

"Installation"; content changed accordingly.
Expanded to add information.
U.l Added... "as applicable".... after tables.

Section 8 Section title was; "Definitions"; now:

"Testing". Content of entire section new.
(Reference A)

Section 9 New Section No. - Content same as Section

8 in basic is§ue.

Revised Tables I, H> and III to reflect

latest information; added Figures 6
through 13 as an adjunct to these Tables.
Added Appendices I and II.
DATE 1S November ST. LOUIS, MISSOURI PAGE

REVISED REPORT. 8638

REVISED . MODEL .

Section 2

Changes Incorporated in 1$ November 1962 Revision

Paragraph Changes

Page ii and iii Revised Table of Contents to reflect new

paragraphs.

Page vi Incorporated 15 November 1962 revision in

Index of Revisions

2.3 Rearranged and renumbered from 2.2.1 and 2.2.2

2.3-1
2.3-2
2.3.3
2.k Renumbered from 2.3
3-1 Divided 3-1 into separate paragraphs and
3.1.1 changed paragraph reference from 3'5-1 to 3-5-2
3-1.2
3-1.3
3.2 Divided 3«2 into separate paragraphs and
3-2.1 updated content
3.2.2
3.3.1.2 Deleted as requirement no longer exists

3.3.1.3 Updated content

1
3-3.l. *
3-3.1.7
3-3.1.8 Changed paragraph reference from 3-3«2 to
3-3.2.1.6

3-3.1.9 Added in accordance with updated design

3-3.2.1.3 Updated content

3.3.2.1.if Deleted as requirement no longer exists

3-3.2.1.6 Updated content

3.3.2.1.7
3.3.2.1.8 Deleted as requirement no longer exists
DATE 15 November 1962 ST. LOUIS. MISSOURI PAGE ->

REVISED REPORT 8638

REVISED MODEL Gemini

Section 2 - (Continued)

Paragraph Changes

3.3.2.1.9 Added in accordance vith updated design

3-3.2.1.10
3-3.2.2.1 Updated content
3.3.2.2.2

3-5.2.1
3.5.2.2.2 Updated content and renumbered from
paragraph 3-5«2.2

3.5.3 Updated content

3.5-5
3.5.6

Fig. 1 Updated content

Fig. 2
Fig. 3
Fig. k

Addendum A Added to reflect Spacecraft No

electrical system.
 DATE 15 November 1962 ST. LOUIS, MISSOURI PAGE Al

REVISED REPORT. ~ Add- A

I REVISED : MODEL . Gemini

ADDENDUM A N
£
ELECTRICAL SYSTEM - SPACECRAFT NO. 1 W
DATE _J November 1962 ST. LOUIS, MISSOURI PAGE -12

REVISED REPORT 8638 - Add. A

REVISED MODEL flftllri m

TABLE OF CONTENTS
Paragraph Title Page
TITLE PAGE
Al GENERAL 11*
11.1 Scope Al*

A2 APPLICABLE DOCUMENTS Al*

A2.1 General Hi
A2.2 Documents Al*
A2.2.1 McDonnell Documents 11*
A2.2.2 Process Specifications A5
A2.3 Supersedence A5

A3 DESCRIPTION A6
A3.1 General A6
A3. 1.1 Power Source A6
A3. 1.2 AC Power A6
A3. 1.3 Wiring and Connectors A6
A3. 2 Power Distribution A6
A3. 2.1 Main Bus Subsystem A6
A3. 2. 2 Isolated Bus Subsystem A6
A3 .3 System Monitoring A6
A3. 3.1 Visual Indicators A6
A3. 3. 1.1 Ammeter A?
A3. 3- 1.2 Voltmeter A7
A3. 3. 2 Switches A7
A3.3.2.1 Main Battery Switch. A7
A3. 3. 2. 2 Squib Battery Switch A?
A3.3.2.3 Voltmeter Selector Switch A?
13.1* Circuit Protection A?
A3. 5 Components A?
13.5-1 Batteries A?
A3.5.2 Batteries A7
A3. 5. 2.1 Main Silver-Zinc Batteries A7
A3.5.2.2 Squib Batteries A8
A3. $.3 Relays A8
13.5.1* Switches A8
13.5.1*.! Toggle Switches A8
A3. 5.1*. 2 Rotary Switches A8
13.5-1*«3 Limit Switches A8
13.5.1*.!* Telelight/Switches A8
A3.5.5 External Power Connections A9
A3.5.6 Connectors A9
A3. 5. 7 Circuit Breakers A9
A3. 6 Fabrication A9
A3. 7 Installation A9
 MGDOJVJVJE
DATE _J November 1962 ST. LOUIS. MISSOURI PAGE A3
REVISED 8636 - Add. A
REVISED MODEL flonri r><

TABLE OF CONTENTS - (Continued)

Paragraph Title Page
AJ< ENVIRONMENTAL CONDITIONS A10
Ali.l General AID
A$ . QUALITY ASSURANCE A10
A5.1 General A10 N
E
A6 RELIABILITY A10 V
A6.1 General A10
A7 DATA REQUIREMENTS AID
A7.1 General A10
A8 TESTING A10
A8.1 General A10
A8.1.2 Electrical Power System A10
A8.1.2.1 Environmental Tests A10
A9 . DEFINITIONS A10
A9.1 General A10
DATE 15 November 1962 ST. LOUIS, MISSOURI PAGE A.U
REVISED REPORT. 8638 - Add> A
REVISED MODEL . Gemini

Al GENERA!
Al.l SCOPE.- Addendum A, which is the same as the basic specification
except as specified, defines the technical requirements for design,
development and testing of the Electrical System for Spacecraft No. 1 of Project
Gemini to be constructed by McDonnell Aircraft Corporation under Contract NAS
9-170 for National Aeronautics and Space Administration (NASA). This document
is not to be construed as, or used for ai inspection guide.
A2 APPLICABLE DOCUMENTS
A2.1 GENERAL.- Sane as basic specification.
A2.2 DOCUMENTS.- Same as basic specification.
A2.2.1 MCDONNELL DOCUMENTS.- The following McDonnell documents are
applicable to this addendum insofar as their content concerns the
system described herein:
Report 8357 "Gemini Spacecraft Applicable
Documents"
Report 8518 "Electrical and E3e ctronic Equipment
Design Requirements for Model 133P"
Report 8080-3 "Project Gemini Reliability Plan"
Report 8580-5 "Project Gemini Test Plai"
Report 8580-7 "Quality Assurance Provisions (Plan)
for Project Gemini Space System"
Report 8580-8 "Model 133P Gemini Program
Documentation Plan"
Report 8610 "Gemini Spacecraft Environmental
Criteria Specification
Report 8611 "Gemini Spacecraft Performance
Spe ci f ica ti on"
Drawing 52-79702 Battery, Storage
Drawing 52-79703 Relays, Control and Power
Drawing 52-79701* Relays, Electronic Time Delay
 MCDONNELL
DATE _J« November 1962 ST. LOUIS, MISSOURI PAGE

REVISED REPORT 86^8 - Add. A

REVISED
A ¥ MODEL Gemini

A2.2.1 MCDONNELL DOCUMENTS.- (Continued)

Drawing 52-7970$ Switches, Control

Drawing 52-79707 Switches, limit

Drawing 52-79708 Ground Umbilical

Drawing 52-79709 Staging Umbilical

Drawing 52-79710 Telelights and Telelight Switches

Drawing 52-79711 Floodlight

Drawing 52-79715 Relay, Voltage Sensing N

E
Drawing 52-79720 Fuse/Fuse Resistor "W

Drawing 52-79721 Circuit Breaker

Drawing 52-90000 Finish Specification

A2.2.2 PROCESS SPECIFICATIONS.- Same as basic specification.

A2.3 SUPERSEDENCE.- Same as basic specification.

DATE -i November 1962 ST. LOUIS, MISSOURI PAGE A6
REVISED REPORT. 8638 - Add. A
REVISED MODEL . Gemini

A3 DESCRIPTION
A3.1 GENERAL.- The function of the Gemini spacecraft electrical system
is to supply and distribute electrical power of the proper voltage
to all spacecraft devices requiring electrical power for operation, with a
minimum of interference between the various subsystems and devices.
A3.1.1 POWER SOURCE.- The electrical system is a 2-wire, grounded system
utilizing silver-zinc batteries as sources of DC power. The
batteries shall be located in the re-entry module of the spacecraft, outside
the pressurized area.
A3.1.2 AC POWER.- Devices utilizing AC power are supplied by self-
contained inverters within the individual subsystems. These in-
verters are not considered a part of the electrical system, but are treated as
inherent elements of the subsystem which they serve.
A3.1.3 WIRING AND CONNECTORS.- For purposes of this specification, the
wiring and connectors which interconnect components of systems N
other than the electrical system are considered a part of the electrical system E
and shall meet all applicable requirements specified herein.
A3.2 POWER DISTRIBUTION.- DC power distribution to the utilizing systems
is accomplished through a main bus subsystem and an isolated bus
subsystem, each of which is independent of the other.
A3.2.1 MAIN BUS SUBSYSTEM.- The main bus subsystem consists of a main
bus energized by four silver-zinc batteries.
A3.2.2 ISOLATED BUS SUBSYSTEM.- The isolated bus subsystem consists of
two squib buses and a control bus energized by three isolated
silver-zinc batteries throughout the mission. The functions of this subsystem
are to supply power to the pyrotechnic ignition devices through redundant,
isolated, parallel circuits from power source to igniter and to supply power
to solenoids and control relays. The control bus is energized by both squib
buses and a separate battery, but isolated from each by diodes. In the interest
of launch site, and in-flight safety, provisions are incorporated for disarming
the pyrotechnic circuits. Redundant pyrotechnic control is provided.
A3.3 SYSTEM MONITORING.- Provisions are incorporated on the instrument
panel for monitoring the power sources. Monitoring of the system
will be followed throughout the mission by camera and recorders.
A3.3.1 VISUAL INDICATORS.- Visual indications of electrical system events,
conditions, outputs and malfunctions are provided, consisting of
warning and indicator lights and single and multiple reading meters.
DATE November 1962 ST. LOUIS. MISSOURI PAGE

REVISED REPORT. 8638 - Add- A

REVISED MODEL . Gemini

A3.3.1.1 AMMETER.- A dual-reading ammeter is installed on the instrument

panel for monitoring current flow of the main batteries. Batteries
1 and 2 are indicated on one scale with 3 and k on the other scale.
A3.3.1.2 VOLTMETER.- A voltmeter is provided on the instrument panel for
monitoring individual voltages at the main bus, squib buses and
the control bus.
A3.3.2 SWITCHES
A3.3.2.1 MAIN BATTERY SWITCH.- Four 2-position (ON-QFF) switches are pro-
vided, one for each main battery. These switches permit connection
to or removal of any main silver-zinc battery from the main bus circuit.
A3.3.2.2 SQUIB BATTERY SWITCH.- Individual 2-position (ON-OFF) switches are
provided for control of the squib batteries. The common control
bus is activated by throwing any one of the squib battery switches. Squib
buses 1 and 2 are activated by their respective control switches.
N
A3.3.2.3 VOLTMETER SELECTOR SfclTCH.- A multiple-position switch is pro- E
vided for applying the voltages obtained at various points in the V
electrical system circuits to the voltmeter.
A3.il CIRCUIT PROTECTION.- Electrical circuit protection is provided for
the purpose of fire protection and/or prevention of system wiring
damage due to insulation failure. Protection is limited to areas in which
input power is capable of producing current which is sufficient to damage the
wire. Circuit protection is accomplished through the use of sequence switching,
fuses and/or circuit breakers, and reverse-current coils.

A3.5 COMPONENTS
A3.5.1 REQUIREMENTS.- The general design requirements for electrical
equipment used in the Gemini spacecraft are set forth in McDonnell
Report 8518.
A3.5.2 BATTERIES
A3.5.2.1 MAIN SILVER-ZINC BATTERIES.- Four UO.O ampere-hour 16 cell
main batteries of the silver-zinc type are provided. Open circuit
potential of these batteries is 29.6 volts maximum, with a plateau voltage of
approximately 25.3 volts. Each battery is activated and sealed at sea level
pressure. Battery cases are vented to permit escape of gases and are provided
with suitable pressure relief valves. Cases are designed and constructed to
withstand an interior-to-exterior differential pressure equal to 1.5 times the
maximum relief pressure setting without permanent deformation or deformation
adversely affecting battery operation. Venting provisions are designed to pre-
clude electrolyte loss. The vent fitting and electrical connector are mounted

MAC 231CM ( R E V 14 JUN 62!

DATE -Jt November 1962 ST. LOUIS, MISSOURI PAGE A8
REVISED REPORT 8638 - Add. A
REVISED BlfTIAL MODEL Gemini

A3.5.2.1 MAIN SILVER-ZINC BATTERIES.- (Continued)

as an integral part of the battery. Batteries are capable of operating in a
weightless state, in any attitude except with cells upside down while under any
acceleration force within the limits specified in Table II.

A3.$.2.2 SQUIB BATTERIES.- Three separate high-discharge rate 16-cell

silver-zinc batteries are provided for supplying power to the
isolated bus system. These batteries are isolated, both electrically and
mechanically, from the main silver-zinc batteries and will maintain 16.0 volts
at the terminal under a 100-ampere load for one second.

A3.5.3 RELAYS.- The electrical relays used on the spacecraft are of

sufficiently rugged construction to withstand the mechanical
stresses, shocks, and vibrations characteristic of the planned mission. The
switching mechanism is completely enclosed in a hermetically sealed cover, and
is capable of operation in any position. Contact bounce is minimized to the
best value obtainable consistent with closure-time requirements. Relays shall
be of the immediate-closing, time-delay or slow dropout type, dependent on the
function performed in the individual circuit.

A3.5.U SWITCHES N
E
A3.5.1ul TOGGLE SWITCHES.- Toggle switches used in the spacecraft W
are sealed so as not to constitute a fire or explosion hazard, and
are constructed to withstand mechanical stresses imposed during the mission.

A3.5.U.2 ROTARY SWITCHES.- The rotary switches used in the spacecraft in-
corporate housings which completely enclose the switching
mechanism. The switches are sealed so as not to constitute a fire or explosion
hazard. All terminals are solder-type, located on the back of the housing. A
positive detent mechanism is provided, and contact arrangement is permanently
marked on the switch housing. Switches are constructed to withstand temperature,
pressure, and acceleration variables encountered during the course of the
mission.
A3 •£•!*.3 LIMIT SWITCHES.- Limit switches used in the spacecraft are sealed
to eliminate fire or explosion hazards in an oxygen atmosphere as
encountered in the pressurized cabin of the spacecraft. The limit switches are
capable of functioning under pressure values and extreme temperature variations
as dictated by the mission.

A3.5.U.1* TELELIGHT/SWITCHES.- The telelight/switches used for functional

indication on the spacecraft incorporate opaque legends on
translucent backgrounds and an integral switching capability. The dual
parallel-connected lamps are red, amber, or green as dictated by telelight
usage. Coloration is effected by the installation of filters on the lamps.

MAC 231CM ( R E V 14 JUN 62!

 MGDOJVAm.4.
DATE -JL November 1962 ST. LOUIS, MISSOURI PAGE A9

REVISED 8638 - Add. A

REVISED OOJiriDEirTIAL MODEL ; Gemini

A3.5.U.U TELELIGHT/SWTTCHES.- (Continued)

Test terminals are provided, with an internal diode arrangement to prevent
energizing the input circuit when test voltage is applied. The positive-break
switch is housed in a hermetically sealed case and actuated when the telelight
display is pressed. Switches are of the momentary-contact type, which auto-
matically return to normal position upon release and alternate-contact type in
which each successive actuation results in repositioning to the alternate set
of contacts.
A3.5.5 EXTERNAL POwER CONNECTIONS.- Prior to launch,, external power is
supplied to the adapter and re-entry modules "to prevent undue
depletion of the spacecraft power supply. This is accomplished by means of an
electrical disconnect assembly in each module. These assemblies also contain
electrical connections for monitoring spacecraft parameters during prelaunch
checkout. Each disconnect assembly consists of a plug and receptacle assembly
and a coupling device for securely retaining these components in the engaged
position. The disconnect assembly is capable of positive disengagement/separa-
tion both electrically by a solenoid device and manually by a lanyard-initiated
mechanism. The re-entry module disconnect is normally released at approximately
T-30 seconds. The adapter module disconnect is normally released at T+3 to
T+5 seconds, with the backup device actuated by movement of the launch vehicle.
A3.5.6 CONNECTORS.- Miniature bayonet (Bendix Pygmy) type connectors are
used throughout the electrical subsystem except at external power
and interface connections. (See McDonnell Report 8612 for interface connector
specifications.)
A3.5.7 CIRCUIT BREAKERS.- The circuit breaker/switches used in the
spacecraft are of the magnetic type. Choice of this type is
predicated on its relative insensitivity to thermal changes, which enhances
stability characteristics through temperature variations encountered in orbital
missions. Hermetically-sealed integral switches are incorporated which provide
capability of complete deactivation of selected circuits.
A3.6 FABRICATION.- Same as basic specification.
A3.7 INSTALLATION.- Same as basic specification.

MAC 23ICM (REV 14 JUN 62!

DATE 15 November 1962 ST. LOUIS. MISSOURI PAGE A10
REVISED REPORT. 8638 - Add, A
REVISED MODEL . Gemini

AU ENVIRONMENTAL CONDITIONS

AU.l GENERAL.- This system and its components will be capable of

acceptable performance when subjected to the environmental con-
ditions as specified in Tables I, II and III, as applicable.

AS QUALITY ASSURANCE

A5.1 GENERAL.- Same as basic specification.

A6 RELIABILITY

A6.1 GENERAL.- Same as basic specification. N

E
A7 DATA REQUIREMENTS W
A7.1 GENERAL.- Same as basic specification.
A8 TESTING
A8.1 GENERAL.- Same as basic specification.
A8.1.2 ELECTRICAL POWER SYSTEM.- The electrical power system will be
tested with simulated dynamic loads and with spacecraft system
loads.
A8.1.2.1 ENVIRONMENTAL TESTS.- Wire, fuses, circuit breakers, connectors,
insulating materials, electrical panels and other electrical
components will be subjected in sufficient quantity to space environments,
vibration shock, and acceleration representative of the Gemini mission to assure
proper and adequate performance and operation.

A9 DEFINITIONS

A9.1 GENERAL.- Same as basic specification.

MAC 2 3 I C M ( R E V 14 JUN 62!