Rafael Space Propulsion Catalogue

Summary

This catalogue provides an overview and technical specifications of Rafael Advanced Defense Systems’ space propulsion solutions. It details heritage flight programs, complete satellite and launcher propulsion systems, positive expulsion propellant tanks (PEPT), monopropellant hydrazine and electric Hall-effect thrusters, propulsion system valves, and manufacturing, testing, and quality assurance capabilities.

Cover Page

RAFAEL ADVANCED DEFENSE SYSTEMS LTD. Rafael Space Propulsion CATALOGUE

Sections: A - Heritage B - Satellite Propulsion Systems C - Propellant Tanks D - Propulsion Thrusters (Satellites / Launchers) E - Propulsion System Valves F - Space Production Capabilities G - Quality Management

Proprietary Notice: This document includes data proprietary to Rafael Ltd. and shall not be duplicated, used, or disclosed, in whole or in part, for any purpose without written authorization from Rafael Ltd.

Table of Contents / Overview

RAFAEL - SMART AND TO THE POINT Rafael Space Propulsion

INTRODUCTION AND OVERVIEW PART A: HERITAGE PART B: SATELLITE PROPULSION SYSTEMS PART C: PROPELLANT TANKS PART D: PROPULSION THRUSTERS (Satellites / Launchers) PART E: PROPULSION SYSTEM VALVES PART F: SPACE PRODUCTION CAPABILITIES PART G: QUALITY MANAGEMENT

RAFAEL SPACE PROPULSION CATALOG | 2024

PART A: Heritage - Cover

PART A: Heritage 0

PART A: Rafael Introduction and Overview

PART A - Heritage (Page 1)

Rafael Introduction and Overview

Rafael Advanced Defense Systems Ltd. designs, develops, manufactures and supplies a wide range of high-tech systems for air, land, sea and space applications.

Rafael was established as part of the Ministry of Defense more than 70 years ago and was incorporated in 2002. Currently, 7% of its sales are re-invested in R&D. Rafael’s know-how is embedded in almost every operational Israel Defense Forces (IDF) system; the company has a special relationship with the IDF.

Rafael has formed partnerships with companies with leading aerospace and defense companies worldwide to develop applications based on its proprietary technologies. Offset activities and industrial co-operations have been set-up with more than 20 countries world-wide. Over the last decade, international business activities have been steadily expanding across the globe, with Rafael acting as either prime-contractor or subcontractor, capitalizing on its strengths at both system and sub-system levels.

Rafael’s highly skilled and dedicated workforce tackles complex projects, from initial development phases, through prototype, production and acceptance tests. Rafael offers a full range of customer service and support, from upgrading of existing systems up to turnkey projects, from transfer of basic technologies to complete production facilities.

Rafael’s quality management system is certified to AS9100C (AS9100D in process), ISO9001, ISO14001, ISO27001, ISO90003, OHSAS 18001. The environmental tests facilities, metallurgy laboratory and calibration laboratory are certified to ISO17025.

Rafael aims to enhance its acclaim as a world-class provider of quality defense products and excellent customer service. It will continue to predict future aerospace requirements worldwide and provide the technologies and systems required by our customers.

PART A: Manor Advanced Defense Technology Division

PART A - Heritage (Page 2)

Manor Advanced Defense Technology Division

The Manor Advanced Defense Technologies Division develops and manufactures propulsion systems, composite materials, and pyrotechnic devices for all Rafael’s systems, as well as for domestic and international customers.

Manor Division is engaged in every aspect of product development and manufacturing, from specification and design to manufacturing and integrated logistics support.

Comprehensive analytic tools and facilities are available in-house, covering all aspects of research, design, development, manufacturing and testing of solid and liquid propellant rocket motors, hydrazine mono-propellant space propulsion systems electric space propulsion systems as well as propellant reservoir tanks.

Manor Division possesses the infrastructure necessary for the research, development and production of solid and liquid propellant rocket motors, their components and, in some cases, the raw materials. Modern computerized laboratories have been set up for synthesis and characterization of advanced binders, bonding agents, burning rate catalysts and other propellant ingredients.

Manor’s testing facilities include a variety of computerized static firing cells, including a high-altitude and space simulation cells, as well as environmental testing facilities.

PART A: Rafael’s Space Capabilities

PART A - Heritage (Page 3)

Rafael’s Space Capabilities

Rafael’s space activities are focused on Space Propulsion, Composite materials, Micro-Satellite technologies and airborne launchers.

Rafael has gained extensive experience in developing, qualifying and producing controllable propulsion and reaction control systems, based on both hot gas (gas generators, solid rocket motors and hydrazine thrusters) and cold gas (mainly nitrogen) for space applications.

Rafael propulsion modules or components are integrated in over seventy in-orbit satellites. Rafael complete propulsion modules are on board the OFEQ, EROS, TecSAR and other satellites. Rafael furnished the propellant tanks and hydrazine thrusters for the Galileo IOV, Globalstar-2 constellations, O3B constellations, SENTINEL-1 constellations, NEOSAT, SAC-D, IXV, EXOMARS 2016 and 2020, COSMO SG, CERES, SAOCOM and others.

Rafael joint CNES\ISA dual mission (Scientific / Technological) Venµs satellite, successfully launched in 2017, incorporates Rafael’s qualified Electric Propulsion system.

All Rafael propulsion systems and components in space have demonstrated 100% mission success, with no system or component failures, or loss of redundancy.

As part of its long-term strategy, Rafael invests in micro-satellite-related technologies and concepts, for improved mission solutions. Rafael intends to introduce missile technologies in terms of miniaturization and performance.

Rafael is studying the concept of mission-on-demand, for micro-satellite application, and intends to develop a dedicated airborne launcher that enables using a fighter-aircraft or a jet-liner as launching platform, to enable affordable, flexible mission-on-demand implementation.

PART A: Satellite Propulsion Systems Heritage (Table)

PART A - Heritage (Pages 4-6)

Satellite Propulsion Systems (PS): Hydrazine (HPS), Cold Gas, Electric Hall Effect

OFEQ (OFEQ 3, OFEQ 5, OFEQ 7, OFEQ 9, OFEQ 10, OFEQ 11, OFEQ 16)

Product Name: Hydrazine Propulsion systems (HPS)
Customer: IAI/MBT, Israel
Comments:
1. OFEQ 3, launched in 1995; fully operational in-orbit
2. OFEQ 5, launched in 2002; fully operational in-orbit
3. OFEQ 7, launched in 2007; fully operational in-orbit
4. OFEQ 9, launched in 2010; fully operational in-orbit
5. OFEQ 10, launched in 2014; fully operational in-orbit
6. OFEQ 11, launched in 2016; fully operational in-orbit
7. OFEQ 16, launched in 2020; fully operational in-orbit Their RAFAEL propulsion systems consist of:
- 5N / 1N thrusters - 12 or 8
- 25N thrusters - 2
- 30 liters hydrazine tank - 1 (PEPT-420)
- Latch valves - 2
- Filters - 2
- Pressure transducers - 2
- Fill and drain/vent valves - 2
- Manifolds, brackets & wiring

EROS (EROS A1, EROS B)

Product Name: HPS
Customer: IAI/MBT, Israel
Comments:
1. EROS A1, launched in 2000; fully operational in-orbit
2. EROS B, launched in 2006; fully operational in-orbit Their RAFAEL propulsion systems consist of:
- 5N / 1N thrusters - 12
- 25N thrusters - 2
- 30 liters hydrazine tank - 1 (PEPT-420)
- Latch valves - 2
- Filters - 2
- Pressure transducers - 2
- Fill and drain/vent valves - 2
- Manifolds, brackets & wiring

TECSAR

Product Name: HPS
Customer: IAI/MBT, Israel
Comments: TECSAR, launched in 2008; fully operational in-orbit. The RAFAEL propulsion systems consists of: 5N thrusters, 25N thrusters, 30 liters hydrazine tank (PEPT-420), Latch valves, Filters, Pressure transducers, Fill and drain/vent valves, Manifolds, brackets & wiring.

GOKTURK-2

Product Name: HPS
Customer: International customer
Comments: GOKTURK-2, launched in 2012; fully operational in-orbit. The RAFAEL propulsion systems consists of: 1N thrusters, Latch valves, Filters, Pressure transducers, Fill and drain/vent valves, Manifolds, brackets & wiring.

PRISMA

Product Name: HPS
Customer: OHB-I
Comments: PRISMA, launched in 2019; fully operational in-orbit. The RAFAEL propulsion systems consists of: 1N thrusters, 590 liters hydrazine tank (PEPT-420 [correction: PEPT-590/compatible]), Latch valves, Filters, Pressure transducers, Fill and drain/vent valves, Manifolds and brackets.

Venµs

Product Name: HPS
Customer: ISA/CNES
Comments: Venµs Satellite, launched in 2017; fully operational in-orbit. The RAFAEL Hydrazine Propulsion system consists of: 1N thrusters - 8, PEPT-260 hydrazine tank - 1, Latch valves - 2, Filters - 1, Pressure transducer - 2, Fill and Drain/Vent valves - 2, Manifolds, brackets & wiring.

Venµs

Product Name: Electric Hall Effect
Customer: ISA/CNES
Comments: Venµs Satellite, launched in 2017; fully operational in-orbit. The RAFAEL Electric Propulsion consists of: HET-300 thrusters (15 mN @ 300W anodic) - 2, PPU: 250W to 600W, Xenon tank: 9 liters, DXFC: Digital Xenon Flow Controller, Pressure reduction system and valves.

PART A: Launcher Propulsion Systems Heritage (Table)

PART A - Heritage (Page 7)

Launcher Propulsion Systems

Israeli Satellite Launcher

Product Name: RACS 25N Thruster Cluster | Customer: IAI/MLM | Comments: Successfully launched. Each RACS cluster consists of the following components: 25N thrusters, Valves, Pressure transducer, Manifold, Electronic driver.
Product Name: RACS 200N Thruster Cluster | Customer: IAI/MLM | Comments: Successfully launched. Each RACS cluster consists of the following components: 200N thrusters, Valves, Pressure transducer, Manifold, Electronic driver.
Product Name: Anti-Nutation Clusters | Customer: IAI/MLM | Comments: Successfully launched. Each cluster consists of the following components: 25N thrusters, Valves, Fill - drain valve, Pressure transducer, Manifold, Electronic driver.

PART A: Propellant Tanks Heritage (Table)

PART A - Heritage (Pages 8-9)

Propellant Tanks Heritage

PEPT-230

Customer: CNES, SNECMA, Astrium-ST | Sat. Program: Myriade/AS100 family: Demeter (x1), Parasol (x1), ESSAIM (x4), Spirale (x2), Elisa (x4), SSTO (X1), Future proj. (x4) | Comments: Demeter, in orbit since 2004; Parasol, in orbit since 2004; ESSAIM, in orbit since 2004; Spirale, in orbit since 2009; Elisa, in orbit since 2011; SSTO, in orbit since 2011.
Customer: SSC | Sat. Program: Prisma | Comments: Qualified and delivered to the customer, launched 6/2010.
Customer: International customer | Sat. Program: GOKTURK-2 | Comments: Delivered to the customer (part of Rafael HPS), operational in-orbit, launched 12/2012.

PEPT-260

Customer: International customer | Sat. Program: Satellite launcher | Comments: Qualified and delivered to the customer.
Customer: IAI/MBT | Sat. Program: Venµs | Comments: Qualified and delivered to the customer, launched 9/2017.

PEPT-330

Customer: TAS-F | Sat. Program: EXOMARS 2016 | Comments: Qualified and delivered to the customer, launched 3/2016.

PEPT-420

Customer: Thales Alenia Space (TAS), France | Sat. Program: PROTEUS (Jason-1, CALIPSO, COROT, OSTM / Jason-2, SMOS) | Comments: PROTEUS family: Jason-1 (12/2001), CALIPSO (4/2006), COROT (12/2006), OSTM/Jason-2 (6/2008), SMOS (11/2009). Fully operational in-orbit.
Customer: Astrium-ST, Germany | Sat. Program: Giove-B | Comments: Operational in orbit (launched 4/2008).
Customer: IAI/MBT | Sat. Program: OFEQ | Comments: OFEQ - 3, 5, 7, 9, 10, 11, 16 (launched 4/95, 5/02, 7/07, 6/10, 4/14, 9/16, 07/20), Eros (12/00, 4/06).
Customer: IAI/MBT | Sat. Program: TecSAR | Comments: TecSAR (1/08).
Customer: TAS-F | Sat. Program: CERES | Comments: 3x PEPT-420N type (silica-free diaphragm), delivered to the customer.
Customer: AIRBUS | Sat. Program: MYRIADE EVOLUTION | Comments: 2x PEPT-420 type and 4x PEPT-420N type (silica-free diaphragm), delivered to the customer, 1 unit PEPT-420 operational in-orbit.
Customer: TAS-UK | Sat. Program: NEOSAT | Comments: PEPT-420N type (silica-free diaphragm), 5 tanks were delivered to the customer (1 unit operational in-orbit), 1 tank in AIT process.

PEPT-590

Customer: Astrium-ST | Sat. Program: Galileo IOV (x5) | Comments: Qualified and delivered to the customer, 4 tanks were launched (10/2011 and 10/2012).
Customer: TAS-F | Sat. Program: IXV | Comments: Delivered to the customer, launched (2/2015).
Customer: OHB-I | Sat. Program: PRISMA | Comments: Delivered to the customer, launched (3/2019).
Customer: TAS-UK | Sat. Program: EXOMARS 2020 | Comments: Delivered to the customer (x2).

PEPT-590 GB

Customer: TAS-F | Sat. Program: Globalstar-2 | Comments: Qualified and delivered to the customer (x24), launched between 2010 - 2013.
Customer: TAS-F | Sat. Program: O3B | Comments: Qualified and delivered to the customer (x20), 16 tanks were launched between 2013 - 2018.
Customer: TAS-I | Sat. Program: Sentinel-1 | Comments: ST1 A and B delivered to the customer, launched 4/14 and 4/16, respectively. ST1 C and D.
Customer: TAS-I | Sat. Program: COSMO-SG | Comments: COSMO-SG 1 and 2 delivered to the customer, COSMO-SG 1 operational in-orbit.

GSU-1L

Customer: NRL | Sat. Program: Slosh-Sat | Comments: Operated in orbit (2/2005), 0.97 Liters (700 bar) – Cold Gas Tank.

XPV-260

Customer: CNES/IAI | Sat. Program: Venµs | Comments: Electric Propulsion Tank, Qualified and delivered to the customer, launched 8/2017.

PART A: Hydrazine Thrusters Heritage (Table)

PART A - Heritage (Pages 10-11)

Hydrazine Thrusters Heritage

1N Thruster

Astrium-ST | Galileo IOV | 32 units operational in-orbit
TAS-F | Globalstar-2 | 96 units operational in-orbit
TAS-F | O3B | 128 units (of 160) operational in-orbit
TAS-F | NEOSAT | 48 units Delivery to the customer in-process, 8 units operational in-orbit
TAS-I | Sentinel-1 | 28 units operational in-orbit (ST1 A & B), 28 units (ST1 C & D) were delivered to the customer
TAS-I | COSMO-SG | 12 units were delivered to the customer (COSMO-SG 1 & 2, COSMO-SG 1 units operational in-orbit), 12 units in AIT process (COSMO-SG 3 & 4)
IAI | Venµs | 8 units operational in-orbit (part of Rafael HPS)
OHB-I | PRISMA | 2 units delivered to the customer (part of Rafael HPS), operational in-orbit
International customer | GOKTURK-2 | Delivered to the customer (part of Rafael HPS), operational in-orbit
OHB-I | KOREASAT | 32 units in AIT process
CONAE | SABIA-MAR | 10 units in AIT process
CONAE | SAC-D | 8 units were delivered to the customer

5N Thrusters

IAI/MBT, Israel | OFEQ, EROS, TECSAR | More than 100 units were supplied, Fully operational in-orbit
CONAE | SAOCOM | 44 units delivered to the customer (part of Rafael Dual Thruster Module - DTM), operational in-orbit

25N Thrusters

IAI/MBT, Israel | OFEQ, EROS, TECSAR | More than 27 units were supplied, Fully operational in-orbit

25N RACS Thruster Cluster

IAI/MLM | Israeli Satellite launcher | Operational in-orbit

45N Thrusters

International customer | Satellite launcher | Qualified and delivered to the customer

200N RACS Thrusters Cluster

IAI/MLM | Israeli Satellite launcher | Operational in-orbit

PART A: Propulsion System Valves Heritage (Table)

PART A - Heritage (Page 12)

Propulsion System Valves Heritage

Latch valves

IAI | OFEQ, EROS, TECSAR | Delivered to the customer (part of Rafael HPS), operational in-orbit
International customer | Satellite | Qualified and delivered to the customer
International customer | GOKTURK-2 | Delivered to the customer (part of Rafael HPS), operational in-orbit
OHB-I | PRISMA | Delivered to the customer (part of Rafael HPS), operational in-orbit

FDV (Fill and Drain valve)

IAI | OFEQ, EROS, TECSAR | Delivered to the customer (part of Rafael HPS), operational in-orbit
International customer | Satellite | Qualified and delivered to the customer
International customer | GOKTURK-2 | Delivered to the customer (part of Rafael HPS), operational in-orbit
OHB-I | PRISMA | 3-barriers FDV type, Delivered to the customer (part of Rafael HPS), operational in-orbit

FVV (Fill and Vent valve)

IAI | OFEQ, EROS, TECSAR | Delivered to the customer (part of Rafael HPS), operational in-orbit
International customer | Satellite | Qualified and delivered to the customer
International customer | GOKTURK-2 | Delivered to the customer (part of Rafael HPS), operational in-orbit
OHB-I | PRISMA | Delivered to the customer (part of Rafael HPS), operational in-orbit

PART B: Satellite Propulsion Systems - Overview

PART B - Satellite Propulsion Systems (Pages 13-14)

Satellite Propulsion Systems:

Hydrazine
EPS - Electrical Propulsion System - Medium Power

Hydrazine Propulsion System - Satellite Propulsion Systems: The Satellites Space Propulsion Systems are typically used for correction of orbit insertion errors and for orbit maintenance. The monopropellant propulsion systems may typically use one of the following main architectural concepts:

Single branch propulsion, versus dual-branch (redundant) propulsion.
Low-thrust thrusters (5N or 1N), or high-thrust thrusters (25N).

Architectures shown:

Four thrusters, single-branch propulsion system architecture
Four thrusters, dual-branch (redundant) propulsion system architecture
Dual-Tank & dual branch propulsion (redundant) architecture with eight thrusters
Dual-branch (redundant) propulsion architecture with thrusters and PTs at branch-level

PART B: Hydrazine Propulsion System Architecture

PART B - Satellite Propulsion Systems (Page 15)

Hydrazine Propulsion System - Architecture

The Propellant is loaded into the tank through a fill and drain valve (FDV).
The pressurant gas is filled into the opposite side of the tank through a fill and vent valve (FVV).
A flexible EPDM diaphragm separates between the propellant and the pressurant Inside the Tank.
The tank maintains a gas pressure ratio of 4:1 (BOL/EOL).
A pressure transducer installed on the propellant line enables monitoring the propellant pressure which indicates the residual propellant quantity during the mission.
The latching valves (LV), provide an additional mechanical barrier for the hydrazine to meet the launch safety requirements and enables the option to disconnect the relative branch in case one of the thrusters fails throughout the mission.
Once the latch valve is switched to OPEN, the pressurized propellant may be expelled towards the thrusters. Integral dual-seat dual-coil normally-closed flow control valves (FCV) control the propellant flow into the thrusters; thus the design satisfies the common three-barriers requirement.
The pressure transducer is used throughout the service life of the satellite to estimate the residual hydrazine level; the pressure level is used by the control system as a parameter for estimating the available thrust.
The system architecture is selected according to mission and reliability considerations.
The use of redundant twin-branches propulsion significantly increases the system reliability.
The system can include two types of thrusters, High Thrust (HT) or Low Thrust (LT), according to mission requirements. The thrust of the high thrust level thrusters may be chosen as 25N or 5N. The thrust level of the low thrust thruster may be chosen as 5N or 1N.
Differences between the chosen system architectures are derived from the mission and satellite requirements for reliability, lifetime, weight and number of thrusters.
All Rafael propulsion systems and components flown have demonstrated 100% mission success, with no system or component failures or loss of redundancy.

PART B: Mass Budget of a Typical Propulsion Module

PART B - Satellite Propulsion Systems (Page 16)

Mass Budget of a Typical Propulsion Module (Dry mass) [Dual (redundant) branch propulsion with eight thrusters]

Propellant Tank (PEPT-590): Qty 1, Unit 7.5 kg, Total 7.5 kg
Thrusters: LT - 1N thruster, Qty 8, Unit 0.32 kg, Total 2.56 kg
Propellant Distribution Pipework:
- F – propellant Filter: Qty 1, Unit 0.08 kg, Total 0.08 kg
- PT – Pressure Transducers: Qty 1, Unit 0.25 kg, Total 0.25 kg
- LV – Latch Valve: Qty 2, Unit 0.4 kg, Total 0.8 kg
- FDV – Fill & Drain Valve: Qty 1, Unit 0.1 kg, Total 0.1 kg
- FVV – Fill & Vent Valve: Qty 1, Unit 0.06 kg, Total 0.06 kg
- Tubing (1/4”) /manifolds: Qty 1 set, Unit 0.6 kg, Total 0.6 kg
Brackets and Thermal Elements: Thruster brackets, component and piping brackets, fasteners and clamps, active thermal blankets, thermostats, thermistors & MLI: Qty 1 set, Unit 2.5 kg, Total 2.5 kg
Electrical Harness: Wire & connectors: Qty 1 set, Unit 1 kg, Total 1 kg
Total Dry Mass: ≈ 16kg

Photos shown: TECSAR Propulsion System, OFEQ / EROS Propulsion System.

PART B: Design Considerations, ICD, Mechanical, Electrical, and Thermal Interfaces

PART B - Satellite Propulsion Systems (Pages 17-18)

Design Considerations and ICD: During the design phase of the Propulsion System (PS) all the relevant considerations related to the satellite are taken into account, such as:

Mechanical interfaces and mass budget
Electrical interfaces, power consumption and control commands
Thermal control, heat dissipation and radiation budget.

Mechanical Interfaces: The propulsion system components (e.g. tank, thrusters, LV, FDV/FVV, Manifolds, etc.) are installed on the satellite structure. Two basic concepts of a PS components installation are available:

On a dedicated base plate (Plug-In Propulsion System)
Dispersed at various locations in the satellite. In the case of using a dedicated base plate concept, the base plate itself may be supplied by Rafael, or by the Customer. The PS, together with the base plate, is installed as a plug-in module to the satellite. The tank can be installed, held at the equator or poles, on the base plate or struts, subject to project requirements.

Electric Interfaces: Rafael provides full electric interface for the Propulsion Systems. A typical PS electrical design includes the electrical harnesses which perform the link of command lines between the satellite and the active elements of the PS. Electric wires, in accordance with space standards, are routed to on-board electrical devices. All splices, shrinks, crimps, lacing and soldering comply with ECSS-Q-70-08A. Typical PS uses regulated (28±4 VDC typical) and unregulated voltage (25 to 45 VDC). The regulated voltage is supplied to the PS valves (FCV’s, LV). The unregulated voltage may be used for the subsystem heaters. Rafael performs overall electrical tests and provides a ready-to-connect plug-in module to the Satellite.

Thermal Control: Rafael is capable of delivering an all-around full thermal control solution as an integral part of the propulsion system. Rafael’s expertise is available for tanks as well as for thruster FCVs and for pipes; the capabilities include thermal analysis, thermal control design with redundancy options, specification of heating requirements, determining locations for heating elements (thermostats, thermistors) and use of thermocouples for heat measurement of thruster TCAs. The heating controllers are governed by the satellite’s main control unit.

PART B: Electric Propulsion System

PART B - Satellite Propulsion Systems (Pages 19-20)

Electric Propulsion System: Rafael designs, develops and manufactures Electric Propulsion Systems (EPS). The Venµs satellite (a CNES & ISA cooperation) was launched in 2017. Rafael supplied its EPS, which is successfully operating since and gaining heritage. The Rafael EPS for the Venµs satellite is designed to support and operate two IHET-300 Hall-Effect thrusters (HET), designed for low-power operation. Venµs EPS’s main components are the 2 Hall-Effect Thrusters, Propellant Management Assembly (PMA), Digital Xenon Flow Controller (DXFC), Power Processing Unit (PPU), and 2 Filter Units (FU). The PMA is composed of a tank, storing up to 16kg of high pressurized Xenon, and of a set of valves, pressure reducers and manifolds to transport the gas. The PPU comprises the power supplies and the sequencer command logic to operate the thrusters. The FU’s function is to filter and to mitigate the thruster oscillations. For missions requiring thrust flexibility, a variable thrust mechanism is incorporated. The Rafael EPS incorporates a DXFC that serves as the “throttling” device for the xenon flow rate through the HET-300 anode.

R-800 EPS Electric Propulsion System: The R-800 EPS is an electric propulsion system operating in the 450-900 W power range. The system consists of a Hall thruster unit, Power Processing Unit (PPU) and Propellant Management Assembly (PMA). The propulsion system is based on Rafael’s R-800 Hall Effect Thruster. The R-800 EPS is Rafael’s second-generation EPS system following the Space-Qualified R-400 EPS (Venµs EPS) success. The R-800 thruster has recently completed its qualification. Lessons learned during its initial development led to many improvements that were implemented with the purpose of producing a lighter-weight, electrically and mechanically robust thruster capable of operating in the expected environment of space. The thruster, including its corresponding low current heaterless hollow cathode completed the qualification process during which it underwent a full performance test, shock and vibration test and was operated in an endurance (lifetime) experiment. In addition, the thruster’s operational envelope was tested at power levels from 450 W and up to 1350 W, to verify operation robustness. The thruster was operated both on Xenon and Krypton propellants. Typical mission applications of the R-800 EPS include:

Orbit keeping and drag compensation for LEO, down to altitudes below 350 km.
Enabling formation-flying missions of small-satellites.
Accurate and precise final orbit insertion after separation from launcher.
Mission orbit change and disposal deorbit at end of life.

PART C: Propellant Tanks - Overview & General Description

PART C - Propellant Tanks (Pages 21-23)

Propellant Tanks Summary Table:

PEPT-200: Tank Nominal Volume 3.55 [Liter], Qualified Propellant Capacity 3.3 [Liter]
PEPT-230: Tank Nominal Volume 6 [Liter], Qualified Propellant Capacity 4.5 [Liter]
PEPT-260: Tank Nominal Volume 9.3 [Liter], Qualified Propellant Capacity 7 [Liter]
PEPT-330: Tank Nominal Volume 17.5 [Liter], Qualified Propellant Capacity 15.4 [Liter]
PEPT-420N: Tank Nominal Volume 37.5 [Liter], Qualified Propellant Capacity 30 [Liter]
PEPT-590: Tank Nominal Volume 102.5 [Liter], Qualified Propellant Capacity 75 [Liter]
PEPT-590GB: Tank Nominal Volume 204 [Liter], Qualified Propellant Capacity 154 [Liter] Note: The tanks can be partly filled in all configurations up to the full propellant capacity due to the use of a diaphragm as propellant management device.

Positive Expulsion Propellant Tank – General Description: Rafael’s Positive Expulsion Propellant Tank (PEPT) is made of 2 6Al-4V titanium alloy thin-walled hemispheres (optionally with a cylindrical mid-section extension). Positive fuel expulsion is provided by an EPDM-based rubber diaphragm retained between welded parts inside the tanks. Pressurant and propellant ports are weldable, 1/4” titanium tubes. The Propellant Tank is made of the following segments:

Lower hemisphere
Upper hemisphere
Cylindrical extension section – optional
EPDM-based, silica-free rubber diaphragm Integration to a complete tank is accomplished through peripheral Electron Beam Welding (EBW). The hemispheres are hot-formed and machined to final dimensions. The design of the hemispheres enables the incorporation of integral pressurant and propellant ports. The diaphragm has a 15 years life expectancy with hydrazine inside and has been qualified for various missions and satellite busses, such as Globalstar2, Myriade, Proteus, Galileo, Exomars, Neosat, OFEQ and others. The diaphragm has been qualified for use with ADN-based “green” propellant.

Diaphragm Propellant Management Device: The diaphragm allows active and efficient propellant management throughout the satellite’s lifetime. It allows multiple cycles of filling and emptying, simulation tests, as well as system integration and other tests. In contrast to a surface tension-based propellant management device, a tank equipped with a diaphragm does not limit the degree of filling in any of the operational stages. The tank may be partially filled to any degree, including prior to horizontal transportation on the launch pad, and the necessary gas-free propellant feed is assured for any subsequent demand. Another advantage is superior control over liquid sloshing. This superior propellant management by diaphragm prevents undue sloshing loads which might adversely affect satellite stability during launch and maneuvers in space, as well as propellant feed which is made free of any limitations caused by satellite orientation, movement, or acceleration. Positive expulsion by the diaphragm prevents excessive center-of-gravity shift as caused by propellant movements in surface tension or bladder type tanks during satellite maneuvers, thus preventing excessive attitude-control system requirements. Rafael’s diaphragm material is silica free (no SiO2) enabling better performances of the PS thruster.

PART C: PEPT-200 Specifications

PART C - Propellant Tanks (Pages 24-25)

PEPT-200 Main Characteristics:

Configuration: Spherical, ~200 mm OD
Fluid Media Compatibility: Hydrazine, IPA, distilled water, GN2, GHe
Nominal Volume: >3.55 [L] Unpressurized
Max Propellant Capacity: 3.3 [kg]
Volumetric Expulsion Efficiency: ≥ 99.1 [%]
Internal Pressure:
- MEOP: 32 [bar] @ 50 [°C]
- Proof: 48 [bar]
- Required burst: > 64 [bar]
Internal Leakage: ≤ 4.0 x 10^-3 [Scc/sec GHe]
External Leakage: ≤ 1.0 x 10^-6 [Scc/sec GHe]
Materials:
- Tank’s shell: Ti-6Al-4V, Annealed
- Diaphragm Material: EPN-40, Silica free elastomer
Ports:
- Pressurant Port: Ti per AMS4942, 0.25” OD tube for butt welding
- Propellant Port: Ti-6Al-4V screwed connection per AS4395-02
Mass (dry): 0.91 [kg] ± 0.05 [kg]
Temperatures Qualification: +5°C / + 50°C
Service Life: Storage 5 years, Flight 15 years
Mounting: Equatorial, 6 x Ø5.2 [mm] clearance holes, located on a diameter of Ø216 [mm], equally distributed
Status: Under Qualification

PART C: PEPT-230 Specifications

PART C - Propellant Tanks (Pages 26-27)

PEPT-230 Main Characteristics:

Configuration: Spherical; nominal Ø230 mm
Fluid Media Compatibility: Hydrazine, IPA, distilled water, GN2, GHe.
Pressurant: GN2, GHe, inert gases
Nominal Volume: 6 liters
Propellant Nominal Capacity: 4.5 liters max @ 4:1 blow-down ratio
Liquid Volumetric Expulsion: >99%
Pressure:
- Operating: 24 to 5.5 bars. approved for SSC requirement of 400 psi
- Proof: 36 bars
- Burst: 48 bars (actual rupture >110 bar)
Leakage:
- Internal Leakage: <10^-2 Scc/sec (GN2)
- External Leakage: <1x10^-6 Scc/s (GHe) at 24 bars
Material:
- Tank Material: Ti- 6 Al-4V
- Diaphragm Material: EPZ-63
Ports: ø 1/4” titanium tubes
Weight: <1.3 kg
Temperature: Operating 10°C to 50°C; Qualification 4°C to 60°C
Service Life: Storage 7 years, Flight 15 years
Mounting: 4 lugs at tank’s equator with ø6.5 mm clearance holes (90° distribution)
Heritage: Qualified for space applications. (Myriade, Prisma) flight heritage with Myriade and Gokturk-2 satellites in orbit

PART C: PEPT-260 Specifications

PART C - Propellant Tanks (Pages 28-29)

PEPT-260 Main Characteristics:

Configuration: Spherical, nominal Ø260 mm
Fluid Media Compatibility: Hydrazine, IPA, distilled water, GN2, GHe.
Pressurant: GN2, GHe, inert gases
Nominal Volume: 9.3 liters
Hydrazine Nominal Capacity: 7 liters max @ 4:1 blow-down ratio
Liquid Volumetric Expulsion: > 99%
Pressure:
- Operating: 24 to 5.5 bar
- Proof: 36 bars
- Burst: 48 bars
Leakage:
- Internal Leakage: <1x10^-2 Scc/s (GN2)
- External Leakage: <1x10^-6 Scc/s (GHe) @ 24 bar
Material:
- Tank Material: Ti-6Al-4V
- Diaphragm Material: EPN-40 (Silica Free)
Ports: Ø1/4” Ti per AMS4942 tubes, 5” Length
Weight: <1.7 kg
Temperature: Operating +10°C to +50°C; Qualification +4°C to +60°C
Service Life: Storage 7 years, Flight 15 years
Mounting: 4 lugs at tank’s equator with ø6.5 mm clearance holes (90° distribution)
Heritage: Qualified for space applications satellite Launcher (international), flight heritage with Venus satellite in orbit

PART C: PEPT-330 Specifications

PART C - Propellant Tanks (Pages 30-32)

PEPT-330 Main Characteristics:

Configuration: Spherical, nominal Ø327 mm
Fluid Media Compatibility: Hydrazine, de-ionized water, IPA, GN2, GHe
Pressurant: GN2, GHe, inert gases
Nominal Volume: 17.5 liter
Hydrazine Maximal Capacity: 15.4 kg.
Liquid Volumetric Expulsion: ≥ 99.1%
Pressure:
- Operating: 29 bars (MEOP)
- Proof: 36.25 bar
- Burst: 43.5 bar
Leakage:
- Internal Leakage: <1x10^-2 Scc/s (GHe)
- External Leakage: <1x10^-6 Scc/s (GHe)
Material:
- Tank Material: Ti-6Al-4V
- Diaphragm Material: EPN-40 - Silica Free
- Tank tubes: Ti3Al2.5V
Tubing Interface:
- Pressuring Tube: Ti-3Al-2.5V, 0.5” OD, 0.026” WT
- Propellant Tube: Ti-3Al-2.5V, 0.75” OD, 0.035” WT
Weight: ≤ 3.1 kg
Temperature:
- Operating (Qualification): +4°C to +50°C
- Non-Operating (Qualification): -20°C to +60°C
Service Life: Storage 7 years, Flight 15 years
Mounting: Pedestal mounting
Heritage: EXOMARS RCS DM

PART C: PEPT-420N Specifications

PART C - Propellant Tanks (Pages 33-35)

PEPT-420N Main Characteristics:

Configuration: Spherical, nominal Ø420 mm
Fluid Media Compatibility: Hydrazine, distilled water, IPA, GN2, GHe
Pressurant: GN2, GHe
Nominal Volume: 37.5 liter
Hydrazine Nominal Capacity: 30 kg max., 28 kg @ 4:1 blow-down ratio
Liquid Volumetric Expulsion: ≥ 99.0%
Pressure:
- Operating: 25.4 to 5.5 bar
- Proof: 38.1 bar
- Burst: 58.2 bar
Leakage:
- Internal Leakage: <1x10^-2 Scc/s (GHe)
- External Leakage: <1x10^-6 Scc/s (GHe)
Material:
- Tank Material: Ti-6Al-4V
- Diaphragm Material: EPN-40: EPDM type silica-free rubber
Ports: ø 1/4” weldable Ti tube or MS 33656-4 connections
Weight (kg): 3.9
Temperature:
- Operating (Qualification): +4°C to +55°C
- Non-Operating (Qualification): -20°C to +60°C
Service Life: Storage 7 years, Flight 15 years
Mounting: Pedestal mounting
Heritage: Delivered for CERES, Myriade Evolution, NEOSAT

PART C: PEPT-590 Specifications

PART C - Propellant Tanks (Pages 36-38)

PEPT-590 Main Characteristics:

Configuration: Spherical, 586 mm OD
Fluid Media Compatibility: Hydrazine, IPA, distilled water, GN2, GHe
Pressurant: GN2, GHe
Minimal Net Volume: 102.5 liter
Propellant Nominal Capacity: 75 kg
Liquid Volumetric Expulsion: > 99.1 %
Pressure:
- Operating: 24.6 to 5.5 bar
- Proof: 36.9 bar
- Burst: 49.2 bar
Leakage:
- Internal Leakage: <5.6x10^-3 Scc/s (GHe)
- External Leakage: <1.0x10^-6 Scc/s (GHe) at 24.6 bar
Material:
- Tank Material: Ti-6Al-4V
- Diaphragm Material: EPN-40: EPDM type silica-free rubber
Ports: ø 1/4” tube weldable connections for both gas and hydrazine ports, made of Ti-6Al-4V
Weight: 7.5 kg
Temperature:
- Operating (Qualification): 4°C to 60°C
- Non-Operating (Qualification): -20°C to 60°C
Service Life: Storage 7 years, Flight 15 years
Mounting: Polar mounting
Heritage: Designed and qualified for Galileo IOV, flight heritage with IXV, delivered for Exomars 2020, PRISMA

PART C: PEPT-590GB Specifications

PART C - Propellant Tanks (Pages 39-41)

PEPT-590GB Main Characteristics:

Configuration: Cylindrically extended hemispheres, nominal Ø587 mm x 1,170 mm length
Fluid Media Compatibility: Hydrazine, IPA, distilled water, GN2, GHe
Pressurizing Media: GN2, GHe
Nominal Volume: 204 liters
Propellant Nominal Capacity: 154 kg @ 4:1 blow-down ratio
Liquid Volumetric Expulsion: > 99%
Pressure:
- Operating: 27.4 to 5.5 bar
- Proof: 41.1 bar
- Burst: 54.8 bar (actual rupture at 72 bar)
Leakage:
- Internal Leakage: <1x10^-2 Scc/s (GHe)
- External Leakage: <1x10^-6 Scc/s (GHe) at 27.4 bar
Material:
- Tank: Ti-6Al-4V
- Diaphragm: EPN-40 (silica free)
Ports: ø 1/4” weldable connections for both gas and hydrazine ports
Weight: 17.5 kg
Temperature:
- Operating (Qualification): 4°C to 50°C
- Non-Operating (Qualification): -20°C to 60°C
Service Life: Storage 7 years, Flight 15 years
Mounting: Polar mounting
Heritage: Designed and qualified for Globalstar-2, flight heritage with GB2, O3B and Sentinel-1 satellites in orbit, delivered for COSMO SG

PART D: Propulsion Thrusters Index

PART D - Thrusters (Page 42)

Satellite Thrusters - Chapter D1:

1N Thruster: LT - 1N - SP (Page 43)
5N Thruster: LT - 5N - SP (Page 47)
25N Thruster: HT - 25N - SP (Page 49)
IHET 300W: IHET-300 (Page 51)
HET 200W: R-200 (Page 52)
HET 800W: R-800 (Page 53)

Launcher Thrusters - Chapter D2:

25N Thruster/Pitch Yaw Cluster: AT - 25N (Page 53)
45N Thruster: ACT - 45N (Page 55)
200N Class Thruster / Roll Cluster: ST - 200N (Page 57)

PART D1: 1N Hydrazine Satellite Thruster

PART D1 - Satellite Thruster (Pages 43-46)

1N Thruster - General Description: The 1N hydrazine thruster generates the required thrust for maneuvering the satellite by means of a hot gas jet created by hydrazine decomposition and expansion through the exit nozzle. The thruster was designed and qualified for the OFEQ program. The Rafael 1N thruster was chosen for the following programs: Globalstar-2 (by TAS-F), O3B constellation (by TAS-F), NEOSAT Space bus (by TAS-UK), Cosmo SG (by TAS-I), Prisma (OHB-I) and for ESA programs: Galileo IOV (by EADS-ST), Sentinel-1 A, B, C & D (by TAS-I), Koreasat (by TAS-I) and Sabia-Mar (by CONAE). The 1N thruster is governed by a solenoid-operated, dual-coil, dual-seat normally-closed Flow Control Valve (FCV). Normally-closed position is maintained by springs for both seats. The FCV is equipped with an integral, 15 micron absolute filter, installed at the valve inlet. The normally-closed FCV is operated by its solenoid, opened when energized and shut-off by electric switch-off. The valve is an all-welded construction. The FCV consists of inlet port (filter included), valve body, coils (2), springs (2), seats (2), plungers (2) and a mounting flange. The all-welded FCV and the Thrust Chamber Assembly (TCA) are assembled together through a perforated, Hayness-alloy tubular element, which serves as a thermal barrier. The thermal barrier controls heat conduction from the TCA to the FCV throughout thruster operation and the heat soak-back period. A metallic seal provides leak tightness between FCV and TCA. The TCA incorporates a bell-shaped nozzle with expansion ratio ε=130 welded to the decomposition chamber. Rafael’s thrusters are free of ITAR restrictions. Equipped with electric catalyst bed heater (CBH) with two resistance coils. Recommended pre-heating temp is 180°C (~20 min from +25°C). Inlet connection: MS 33656-4 threaded connector, or optionally 1/4” or 3/8” welded inlet tube.

1N Thruster Main Characteristics:

Propellant: Hydrazine (N2H4)
Feed Pressure (bar abs): Type 1: 24.5 to 9; Type 2: 24.5 to 5.5
Thrust (BOL), Steady State (N): Type 1: 1.3 ÷ 1.4; Type 2: 1.0 ÷ 1.1
Thrust (EOL), Steady State (N): > 0.2
SSF Specific Impulse (sec): >214 @ 22 bar; >205 @ 5.5 bar
Minimum Impulse Bit (N-s): 0.008 @ 5.5 bar and D/C 0.02 sec/1 sec
Nominal Duty Cycle: 0.1 sec / 1 sec
Response Time (Hot Pulse): Rise Time < 200 ms @ nominal duty cycle; Decay Time < 300 ms @ nominal duty cycle
Total Delivered Impulse (N-s): Type 1: 100,000; Type 2: 60,000
Total Number of Pulses: Type 1: 100,000; Type 2: 58,000
Leakage: Internal < 1.0x10^-5 Scc/s GHe @ 5.5 bar and 24.5; External < 1.0x10^-6 Scc/s GHe @ 24.5
Temperature: Operating: +5°C to 90°C; Non Operating: -10°C to 95°C
Flow Control: FCV – dual-coil, dual seat, NC solenoid valve; Operating Voltage 23 to 36 Vdc; Power 9.2 W @ 28 Vdc
Heater – Dual Element: 23 to 36 Vdc; Resistance 257 ohms for each element
Nozzle Expansion Ratio: 130
Total Life (Storage and Flight): 15 years
Inlet Filtration: 15 micron absolute
Inlet Interface: MS 33656-4 or welded tube (1/4” or 3/8”)
Weight (gr.): ≤ 310 (1000 mm lead wire length)
Heritage: Qualified for OFEK, Globalstar-2, O3B, Neosat and GALILEO IOV. Flight heritage with Globalstar-2, O3B, Venus, GALILEO-IOV, Sentinel-1, Gokturk PS2, COSMO SG, Neosat SB and PRISMA.

PART D1: 5N Hydrazine Satellite Thruster

PART D1 - Satellite Thruster (Pages 47-48)

5N Thruster Main Characteristics:

Propellant: Hydrazine (N2H4)
Feed Pressure (bar abs): 24 to 5.5 (nominal), tested down to 4.5
Thrust, Steady State (N): 6.1 @ 22 bar to 1.8 @ 5.5 bar
SSF Specific Impulse (sec): >220 @ 22 bar; >210 @ 5.5 bar
Minimum Impulse Bit (N-s): <0.25 @ 5.5 bar & 0.1 sec / 1 sec; <0.012 @ 5.5 bar & 0.06 sec / 1000 sec
Nominal Duty Cycle: 0.1 sec / 1 sec
Response Time (Hot Pulse): Rise Time(ms) < 65 @ nominal duty cycle & 22 bar; Decay Time (ms) <100 @ nominal duty cycle & 22 bar
Total Delivered Impulse (N-s): 74,000
Total Number of Pulses: 42,000
Leakage: Internal <1.0x10^-4 Scc/s GHe @ 3.5 and 24 bar; External <2.6x10^-4 Scc/s GHe @ 24 bar
Temperature: Operating +4°C to 90°C; Non Operating -10°C to 90°C
Flow Control: FCV - single-coil, dual-seat, NC solenoid valve; Operating Voltage 23 to 36 Vdc; Power 9.2 W @ 28 Vdc
Heaters: 3x Single Heaters; Operating Voltage 24 to 32 VDC; Resistance 260 ohms per each heater
Nozzle Expansion Ratio: 50
Total Life (Storage and Flight): 15 years
Inlet Filtration: 15 micron absolute
Inlet Interface: MS 33656-4 or welded tube (1/4” or 3/8”)
Weight (gr.): ≤ 310 (2000 mm lead wires length)
Heritage: Flight heritage with OFEQ, EROS, SAOCOM and TECSAR programs

PART D1: 25N Hydrazine Satellite Thruster

PART D1 - Satellite Thruster (Pages 49-50)

25N Thruster Main Characteristics:

Propellant: Hydrazine (N2H4)
Feed Pressure (bar abs.): 22 to 5.5
Thrust, Steady State (N): 28 to 9.5
SSF Specific Impulse (sec): > 220 @ 22 bar; > 205 @ 5.5 bar
Minimum Impulse Bit (N-s): 0.3
Nominal Duty Cycle: 0.24 sec / 1 sec
Response Time (Hot Pulse): Rise Time 65 ms @ nominal duty cycle & 22 bar; Decay Time 200 ms @ nominal duty cycle & 22 bar
Total Delivered Impulse (N-s): 100,000 (<5% Isp degradation)
Total Number of Pulses: 12,000
Leakage: Internal <1.0x10^-4 Scc/s GHe @ 3.5 & 24; External <1.0x10^-6 Scc/s GHe @ 24
Temperature: Operating +4°C to 90°C; Non-Operating -10°C to 90°C
Flow Control: FCV - single-coil, dual-seat, NC solenoid valve; Operating Voltage 23 to 36 Vdc; Power 15 W @ 28 Vdc
Heaters: 4x Single Heaters; Operating Voltage 24 to 32 Vdc; Resistance 260 ohms per each heater
Nozzle Expansion Ratio: 60
Total Life (Storage & Flight): 15 years
Inlet Filtration: 15 micron absolute
Inlet Interface: MS 33656-4 or welded tube (1/4” or 3/8”)
Weight (gr.): ≤ 530 (1000 mm lead wires length)
Heritage: Flight heritage with OFEQ and EROS programs

PART D1: IHET-300 Electric Thruster

PART D1 - Satellite Thruster (Page 51)

IHET-300 Thruster: The heart of the Venµs Electric Propulsion System (EPS) is the Israeli Hall-Effect Thruster (IHET), code named IHET-300. It operates on Xenon, which is ionized by electrons emitted from the cathode and accelerated as plasma using a high electric field. Ideal for onboard small and micro satellites, operating nominally on 300W anode power (useful range 250 to 600W).

IHET-300 Main Characteristics:

Thrust (@300W): > 14.3 mN
Specific impulse (@ 300W): > 1200 sec
Nominal anodic power: 300W
Power operation range: 250W to 600W
Total Impulse: >135 kN-s
Operating life: > 1000 hours
Number of operations cycles: > 2000
Mass: 1.6 kg
Dimensions: 170x120x90 mm
Heritage: Flight heritage – Venus Program

PART D1: R-200 and R-800 Electric Thrusters

PART D1 - Satellite Thruster (Pages 52-53)

R-200 Thruster: Low power Hall thruster designed to operate in the 100-300 W discharge power range, suitable for low to medium mass satellite platforms (<500 kg). Thrust levels 5-14 mN at Isp 800-1,300 sec. Features co-axial anodes and elongated discharge channel, low current heaterless hollow cathode. Characteristics:

Power: 100-300 W
Thrust (Xe): 5-14 mN
Specific impulse (Xe): 800-1300 sec
Propellant: Xe, Kr
Total Impulse: > 200 kNs
Mass: 2 kg

R-800 Thruster: Low power Hall thruster designed to operate in the 450-900 W discharge power range suitable for low to medium mass satellite platforms (<1,000 kg). Thrust levels 23-53 mN at specific impulse of 1,300-1,550 sec. Low mass and low volume footprint, permanent magnets and center-mounted cathode. Characteristics:

Power: 450-900 W
Thrust (Xe): 24-53 mN
Specific impulse (Xe): 1,300-1,550 sec
Propellant: Xe, Kr
Total Impulse: > 750 kNs
Mass: 1.5 kg

PART D2: Launcher Thrusters (25N, 45N, 200N)

PART D2 - Launcher Thrusters (Pages 52-63 [PDF internal pages 57-63])

25N Launcher Thruster (AT-25N): Integrated in Roll Attitude Control System (RACS) cluster including valves, pressure transducer and electronic driver. Characteristics:

Propellant: Hydrazine (N2H4)
Feed Pressure (bar abs.): 26.2
Thrust, Steady State (N): 24
SSF Specific Impulse (sec): >220 @ 24 bar; >210 @ 6 bar
Minimum Impulse Bit (N-s): 1.5
Weight (gr.): 310
Heritage: Israeli satellite launcher

45N Launcher Thruster (ACT-45N): Characteristics:

Propellant: Hydrazine (N2H4)
Feed Pressure (bar abs.): 24 to 6
Thrust, Steady State (N): 45 to 16
SSF Specific Impulse (sec): >208 @ 24 bar; >190 @ 6 bar
Total Impulse (N-s): SSF 60,000; PMF 15,000
Impulse Bit (N-s): 5.3 @ 24 bar & 100 msec. ON; 2.3 @ 6 bar & 100 msec. ON
Response Time (Hot Pulse): Rise Time 100 ms @ 24 bar; Decay Time 200 ms @ 24 bar
External Leakage (Scc/s GHe): <1 x 10^-4 @ 3.5 & 24 bar; <2.7 x 10^-4 @ 24 bar
Flow Control: FCV - single-coil, single-seat, N.C. solenoid valve
FCV Operating Voltage (Vdc): 24 - 32; FCV Power (Watt): 17 @ 28 VDV & 20°C
Inlet Filtration: 15 microns absolute; Inlet Interface: MS 33656-4; Nozzle Expansion Ratio: 50
Weight (gr.): 500 (500 mm lead wires length)
Heritage: Space Qualified

200N Launcher Thruster (ST-200N): Integrated in RACS cluster containing valves, pressure transducer and electronic driver. Characteristics:

Propellant: Hydrazine (N2H4)
Feed Pressure (bar abs.): 31 (nominal), down to 8
Thrust, Steady State (N): 200±5%
SSF Specific Impulse (sec): >220
QSS MIB (N-s): < 17.5 at D/C 0.08/2
Rise Time 90% (ms): <150; Decay Time 10% (ms): < 250
Flow Control: FCV - single-coil, single-seat, NC solenoid valve
Nozzle Expansion Ratio: 50; Weight (gr.): ≤ 1,250
Heritage: Israeli satellite launcher

PART E: Propulsion System Valves

PART E - Propulsion System Valves (Pages 59-70 [PDF internal pages 64-70])

Valves Index:

FDV (Fill and Drain Valve) - Page 60
FVV (Fill and Vent Valve) - Page 61
LV (Latch Valve) - Page 62
SMAV (Shape Memory Alloy Valve) - Page 64

FDV/FVV - Service Valves General Description: Each propulsion system contains Fill and Drain Valve (FDV) used for controlled loading or draining of propellant, and Fill and Vent Valve (FVV) used for pressurizing or venting of Nitrogen. Redundant sealing is provided by two seals in series; primary metal-to-metal seal tightly secured after loading by threaded retainer, secondary sealing implemented by hydrazine resistant O-ring gasket located within external cap. Ti welded interface at 1/4” diameter outlet.

Three Barriers FDV: Rafael P/N EFDV6000A is a fully-qualified updated 3-barriers version of the FDV.

FDV/FVV Main Characteristics:

Fluid media compatibility: Hydrazine, IPA, distilled water, GN2, GHe
Operating pressure (bar): 0 to 24 (2 barriers’ FDV/FVV); 0 to 30 (3 barriers’ FDV)
Proof pressure (bar): 36 (2 barriers’ FDV/FVV); 45 (3 barriers’ FDV)
Burst pressure (bar): 112
External leakage (Scc/s GHe): <1x10^-6 at 24 bar (2 barriers’ FDV/FVV); <1x10^-6 at 30 bar (3 barriers’ FDV/FVV)
Close-open-close cycles: >100 per each barrier
Body material: Titanium (Ti)
Weight (g): 60 for FDV/FVV, 80 for 3 barriers’ FDV; Life: 15 years
Heritage: OFEQ, PRISMA (OHB-I)

Latch Valve (LV): Dual-coil, single-seat magnetically latched solenoid valve. Momentary electric input signal switches plunger between OPEN and CLOSED; permanent magnet maintains position. Employs 15-micron absolute integrated filter, equipped with reed-switch (magnetic type) position indicator. Characteristics:

Fluid Compatibility: Hydrazine, IPA, distilled water, GN2, GHe
Operating pressure: 0 to 24 bar; Proof: 36 bar; Burst: 96 bar
Pressure Drop: <1 bar @ 20 gr/sec hydrazine; Back Pressure Relief (Δbar): <14
Operating Voltage: 24 to 32 Vdc; Power: 25 W @ 28 Vdc for each coil; Min Actuation Time: ≥1 sec; Operating Response Time: < 50 ms @ 28 Vdc and 24 bar; Pull In Voltage: < 20 Vdc @ 24 bar
Leakage: Internal <1 x10^-4 Scc/s (GHe) @ 3.5 and 22 bar; External <1 x10^-6 Scc/s (GHe) @ 36 bar
Temp: Operating +5°C to 80°C; Non-Operating -10°C to 90°C
Storage Life: 7 years, Flight Life: 8 years, Cycle: >20,000
Inlet & Outlet Interface: MS 33656G-4 or 0.25” tubes; Weight: < 370 gr; Heritage: OFEQ and other foreign customers

Shape Memory Alloy Valve (SMAV): Inert one-shot device based on smart materials. Single-core cartridge heater testable pre-flight without damaging functionality. Hermetic device sealed with nipple sheared by SMA actuator. Inlet/outlet tubes: 1/4” Titanium. Characteristics:

Valve Type: NC, SMA operated
Fluid Compatibility: Xe, Kr, Ar, GN2, GHe, De-Ionized Water, IPA
Operating pressure: 0 to 330 bar; Proof: 495 bar; Burst: 1320 bar; Pressure Drop: negligible @ max pressure; Flow: 2 gr/min @ 186 bar
Operating Voltage: 28±1 Vdc; Power: 12W @ 28 Vdc; Response Time: <120 sec @ 28 Vdc & 330 bar
Leakage: Internal <1 x10^-6 Scc/s (GHe) @ 330 bar; External <1 x10^-6 Scc/s (GHe) @ 330 bar
Temp: Operating +12°C to 50°C; Non-Operating -20°C to 65°C
Storage: 7 years; Pre-Activation (Pressurized): 4 years; Flight (Post-Activation): 15 years; Cycle: 1
Interface: MS 33656G-4 or 0.25” tubes; Weight: 160 gr.

PART F: Space Production Capabilities

PART F - Space Production Capabilities (Pages 66-76 [PDF internal pages 71-81])

Clean Rooms: Components and subsystem assembly and integration carried out in special clean room facilities (US Fed. Std. 209B, Class 100,000 to Class 100). Equipped with ultra-sonic flushing benches, computerized particle counters (gas and liquid), UV light, hydraulic/pneumatic flow benches. Orbital welding used for tubing manifolds. New clean room (completed 2010) houses propulsion modules production and AIT sections (Rafael 1,000 m² Clean Room Site).

Hydrazine Thruster Test Firing: Hot-firing tests carried out at open air test stands and 4 vacuum chambers delivering 10^-3 torr. Includes spin table for functional tests under actual spin conditions. Automated, remotely operated data acquisition, RF glow discharge visualization.

Electric Thruster Test Firing: Hot-firing in vacuum chamber (2.5 m diameter), accommodating thrust measurements 5 to 120 mN, vacuum environment up to 5·10^-7 mbar. Continuously monitored by double set of pressure transducers, residual gas analyzer and video system. Additional small vacuum chambers for R&D.

Testing and Inspection Facilities: Dynamic, climatic, thermal, vacuum environmental tests; metallurgical, chemical, dimensional inspection (Automatic CMM), non-destructive testing (X-ray, dye penetrant, ultrasonic), vibration shaker.

Manufacturing: CAD/CAM, CNC machining (5 Axes CNC Center), electro-erosion, forming, hydro-spinning and deep hot- and cold-drawing, surface treatment, heat treatment, welding (EBW, GTAW, GMAW, plasma), brazing, cutting, bending/faring of titanium tubes, rubber roll mill and composite materials. Radiation testing at SOREQ Nuclear Research Center.

Analytic Resources & Structural/Thermal Analysis: Dynamic/static structural analyses (FEM, fracture mechanics, fatigue, PRODERA real-time modal analysis, CFD water hammer and sloshing). 3-D CAD software (SolidWorks). Heat and Mass Transfer Analysis Group uses SINDA/G, PATRAN, SINDARAD, FLUENT.

Ground Support Equipment (GSE): GSE for testing components, alignment method, propellant/pressurant/test fluid loading/unloading, vacuum leak checks, helium mass-spectrometers, hygrometer. GSE Propulsion Systems Electrical Tester automatically conducts response time, heater resistance, PT calibration, valve threshold voltage tests.

Propellant Loading – Launch Campaigns: Worldwide expertise and heritage in propellant loading (Hydrazine and Xenon) in Israel, Russia, French Guiana, and India.

PART G: Quality Management

PART G - Quality Management (Pages 77-80 [PDF internal pages 82-85])

Quality Management Standards & Policies:

Quality System certified to ISO 9001:2015 / AS9100D.
Environmental certified to ISO 14001:2015.
Safety certified to OHSAS 18001:2007.
Special activities NADCAP certified.
Testing/calibration laboratories ISO 17025 certified.

Space Quality Management:

Perception derived from Rafael quality policy aligned with common space quality standards (mainly ESA).
100% inspected from raw materials to final integration.
Full traceability integrated into ERP system from raw material to delivered item.
Dedicated Product Assurance (PA) manager assigned to every project/program, acting as POC to customer for assurance activities (reviews, audits, NCRs, RFDs).

Dedicated Quality Program Chapters include:

QA Plan: Setup, Objectives and Organizational Structure
Product Approval – Development and Qualification
Quality Records & Configuration Control
Failure Report, Corrective or Preventive Actions
Audit Program, Traceability, Marking, Calibration
Cleanliness and Contamination Control
Statistical Quality Control and Analysis, Handling and Storage
Materials, Mechanical Parts And Processes / Critical Items and Processes
Limited Life Items, Sub-Contractors, Personnel Training and Certification
Software Product Assurance, EEE Parts, Testing, Deliveries
End Item Data Package (EIDP), Program Reviews, Configuration & Data Management
Reliability Plan, RAMS, FRACAS, Customer Property, Alerts, Safety.

Contact Information / Back Cover

RAFAEL ADVANCED DEFENSE SYSTEMS LTD. Manor-Advanced Defense Technologies Division

Tel: +(972)73-335-7263 Email: [email protected]

HQ Tel: +(972)73-335-4714 Fax: +(972)73-335-4657 Email: [email protected] Website: www.rafael.co.il

Doc Reference: UNC.28503/0524/M5/01 ENG/ Studio | MSS