CarbonCarbon Radiator CCR

1
Carbon-Carbon Radiator (CCR)
2
Carbon-Carbon Radiator (CCR)

• Equipment panel composed of carbon-carbon
  facesheets and an aluminum honeycomb core
• Flight unit and spare
• No changes since CDR

3
Qualification Testing (Completed)

• Thermal Vacuum/Balance
• Vibration
• Mass Properties (Flight unit only)
• Non-destructive examination (radiography)
  conducted before start of qualification testing
  and after completion of thermal testing and of
  vibration testing

4
Thermal Vacuum / Balance Testing(TV / TB)

• Test Frame simulated S/C
• Mockups of LEISA and PSE baseplates
• Two strain gauges on the test frame
• Four thermal cycles with four-hour soaks at 50C
  and -10C
• Thermal balance testing for (8) various
  conditions
• Survival heaters tested with four different
  voltages
• Thermal cycling loads were half those predicted,
  indicating that finite element model (FEM)
  results are conservative
• Non destructive examination (NDE) indicated no
  structural damage

5
Vibration Testing

• Test frame simulated S/C
• Mass mockups of LEISA and PSE
• Two tri-axial accelerometers
• Sine burst to 1.25 x limit load (15g) in each
  axis
• Low-level sine sweep before and after each sine
  burst test
• Sine sweep tests and NDE indicated no structural
  damage
• First frequency 89 Hz, less than 5 below the 93
  Hz predicted (indicating that the FEM is reliable)

6
Mass Properties Testing

• Conducted with TRIDYNE model 200
• Measured weight and cg in x- and y-axes
• Calculated cg in z-axis and moi about x-, y-, and
  z-axes
• Weight 6.87 lb. (3.12 kg)
• STRUCTURAL ANALYSIS
• Report completed June 2, 1998
• All margins of safety positive (inertial and
  thermal loading)
• First frequency predicted to be 112 Hz, above the
  100 Hz requirement

7
Status/Issues

• Flight unit damaged during integration with S/C
• Flight unit will be replaced with spare before
  Observatory-level environmental testing
• Spare unit meets all subsystem-level
  environmental requirements
• Ready for Observatory-level integration and
  testing

8
GPS
9
GPS Subsystem

• Off the shelf GPS receiver, pre-amp and antennas
  from Loral Tensor
• In-house power conditioning unit built in-house
• Provides orbital navigation and time information
  for CDH and ACS/EFF applications.

10
GPS -- Scope of Box-Level Testing

• Contract Acceptance Testing
• Random vibration, thermal vacuum, EMI/EMC and
  acceptance tests on receiver, preamp and antennas
  performed by Loral Tensor
• PCU Environmental testing
• Random vibration and temperature cycling on
  in-house built power conditioning unit. EMI/EMC
  waived..
• Detailed Characterization at GSFC
• Performed three month characterization of entire
  GPS subsystem using GPS constellation simulator
  to understand operation and optimize operational
  configuration.
• Provided results of all above in detailed
  acceptance package to Swales before handover of
  unit.

11
Lightweight Flexible Solar Array (LFSA)
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Lightweight Flexible Solar Array (LFSA)
Functional Testing

• Launch Restraint Release and Deployment
• Verifies working of shape memory release
  mechanism and panel hinges
• CIS Solar Panel I-V Curve Sweep
• Verifies working of photovoltaic arry

13
LFSA Test Flow
14
X-Band Phased Array Antenna (XPAA)
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X-Band Phased Array Antenna (XPAA)

• Designed and built by Boeing for NMP
  Communications IPDT under fixed price contract
  with GSFC.
• Validates electronically scanned antenna
  technology for future missions.
• Provides 105 Mbps QPSK primary science downlink.

16
XPAA Hardware Changes Since Delivery

• Change
• Replaced 1773 interface connector (1 of 4).
• Reason
• During pre-integration inspection and test this
  connector was found to have an internal ceramic
  sleeve which was broken.
• Action
• Antenna was partially disassembled and connector
  was replaced at GSFC FOIL.
• Result of the Modification
• After repair and workmanship vibration,
  end-to-end 1773 and RF performance was verified
  with GSE and Near-Field Scanner at Swales.

17
XPAA -- Scope of Box-Level Testing

• Contract Acceptance Testing
• Random vibration, thermal vacuum, EMI/EMC, 1773,
  and RF functional tests using hat coupler,
  near-field scanner and anechoic chamber. Levels
  determined by Swales. Provided results of all
  above in detailed acceptance package to Swales
  before hand over of unit. No technical issues.
• Bench Testing
• RF and 1773 functional tests using a hat coupler
  to absorb and sample the RF output. Results
  compared with contractor supplied acceptance
  data.
• Near-Field Scanning
• Verifies antenna beam characteristics and
  pointing performance, does not require an
  anechoic chamber. Results compared with
  contractor supplied acceptance data.

18
XPAA Test Flow
19
Pulse Plasma Thruster (PPT)
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PPT Testing

• Qualification/Acceptance Tests
• Benchtop Functional
• Verified internal charging functionality
• Verified command and telemetry
• Vacuum Functional
• Verified discharge of PPT in vacuum
• Both sides operated at levels encompassing
  on-orbit commanding
• Charge/Discharge characteristics verified
• Vibration
• Random vibration of PPT to proto-qualification
  levels in three axis
• Performance
• Measurement of Impulse bit as a function of
  commanded charge time
• Measurement of Off-Axis thrust to determine
  thrust vector
• Thermal Vacuum
• Four thermal cycles
• Verified functionality at high and low
  temperature plateaus
• EMI
• Verified conducted and radiated susceptibility
  requirements
• Measure conducted and radiated emissions per S/C
  specifications

21
PPT Testing (Continued)

• Spacecraft Level Tests
• Functional Testing (Firing through Load Box)
• Verified PPT charging characteristics and
  sparkplug discharge
• Verify PPT command polarity and telemetry
• Close loop ACS control of PPT can be verified
  during CPTs
• Firing in Bell Jar Vacuum Integration Test
• Verified PPT discharge functionality with s/c
  commands
• Verified benign effect of PPT discharge on s/c
  bus (without instruments)
• Proposed Additional S/C Level Tests
• PPT Thermal Vacuum Firing
• To verify begin PPT discharge interaction with
  entire integrated s/c
• Plume covers over PPT horns to be used to prevent
  plume contamination of s/c

22
PPT Test Flow
23
PPT Test Flow
24
NMP / EO-1 PRE-ENVIRONMENTAL REVIEW
Atmospheric Corrector (AC)
Mark Matsumura LEISA AC Lead Engineer, NASA/GSFC
Code 553
25
Pre-Environmental Functional Testing

• Performance tests/Operations at ambient
  conditions
• Housekeeping mode
• Science Modes (30 Hz/60 Hz)
• ThermoElectric Coolers were disabled.
• GSE limited the amount of science data collected.

26
Vibration Test Status

• Modal Frequency Verification (Low Level Sine
  Sweep)
• Strength Tests (Sine Burst, Protoflight levels)
• Random Vibration (Protoflight levels)
• Performed on 3 orthogonal axes, one normal to
  mounting surface
• Tests were performed on each box separately.
• Harness was connected to the optics module.
• Due to NCRs LAC 002, and 003, the Optics Module
  was fully vibration tested a second time to
  protoflight levels.
• Due to NCR LAC 001, the Electronics Box was
  random vibration tested a second time to
  acceptance levels.

27
Mass Properties Test Status

• Measured weight of instrument.
• Measured center of gravity of Optics Module and
  Electronics box (No moment of inertia
  measurement).
• Mass properties were measured in the Code 549
  Mass Properties Test Facility

28
Thermal Vacuum Test Plan

• Overall Plan
• -10C to 50C survival range
• 0C to 30C operating range
• 4 cycles/ 25 Degrees per hour maximum
• Minimum 2-hour soak times
• Demonstrate turn on at both operational
  temperature extremes
• Demonstrate operation through temperature
  transitions
• Demonstration of ThermoElectric Coolers
• Thermal testing was performed in the B7 Code 549
  Thermal Vacuum Facility, Chamber 281 as per EO-1
  Spacecraft to LEISA AC ICD, SAI-ICD-021, and
  EO-1 Verification Plan and Environmental
  Specification, SAI-SPEC-158.
• Window in chamber provided for detector
  testing/calibration tests

29
Thermal Vacuum Testing - Profile

40OC
30OC
Ambient
0OC
-10OC
1st Cycle
2nd Cycle
3rd Cycle
4th Cycle
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Thermal Vacuum Testing(Individual Test
Descriptions)

• Cold Start Test
• Warm Start Test
• Housekeeping
• Science Operations/Calibration tests
• Detector Temperature set points
• Frame Rate Operations
• Calibration at varying temperatures and set
  points
• 1773 Fiber Optics Trending Test
• NCRs LAC 004 and 005 were from Thermal Vac
  testing.

31
EMI / EMC Test Status

• Conducted Emissions
• Steady-State (CE01, CE03)
• Radiated Emissions (RE01, RE02)
• Radiated Susceptibility (RS03)
• All EMI/EMC tests were performed in the B7 Code
  549 facility as per System Level Electrical
  Requirements, EO-1 AM-149-0002(155),
  SAI-SPEC-159.
• Tests were run during housekeeping and science
  modes.
• Thermoelectric Coolers were disabled during the
  tests.
• NCRs LAC 006 and 007 were from EMI Testing.

32
Interface Summary

• WARP interface tests
• Spacecraft interface (with Optics Module
  Simulator)
• Mechanical
• Power
• Fiber Optics/Commanding

33
Non-Conformance Records

• LAC 001 - Fiber optic ceramic connector feed
  through sleeve cracked during electronics
  vibration.
• Resolution Disassembled e-box and replaced
  connector which is on the digital board fiber
  optic bracket. Revibrated e-box to acceptance
  levels (Random). Status Closed
• LAC 002 - Detector 1 was saturated at post
  vibration functional test on the optics module
  (OM). Partially disassembled OM to investigate
  failure. Visual investigation showed that bond
  wires had sheared from the chip carrier of the
  detector.
• Resolution Fully disassembled OM and rebond the
  bond wires. Examined detector. Thoroughly
  checked the bond wires of the other detectors.
  Rebonded the detector bond wires and retested.
  Check all three detector assemblies for proper
  spacing. Fully Re-vib to Protoflight levels.
  Status Closed

34
Non-Conformance Records

• LAC 003 - Lens of the optics module rotated from
  its fixed position during vib. testing.
• Resolution Fully disassemble OM and uralane all
  three lens assemblies. Fully re-vib OM to
  Protoflight levels. Status Closed.
• LAC 004 - Instrument was not powering up properly
  during set-up for T/V testing.
• Resolution Replace GSE power supply with a power
  supply with greater capacity. Status Closed.
• LAC 005 - Detector 3 was not cooling down at the
  same rate as the other two detectors during T/V
  testing.
• Resolution Use as is. Does not pose a danger to
  mission success. Status Closed.

35
Non-Conformance Records

• LAC 006 - Current draw of the instrument did not
  ramp up as designed. Test set up for Conducted
  Susceptibility CS01 has a risk of damaging
  instruments. The audio power amp must be powered
  before any other equipment is powered up, or the
  power amp acts as an isolation transformer.
• Resolution Make strong recommendation to add a
  warning to the test procedure. Status Open
• LAC 007 - Instrument is not meeting conducted
  emissions or radiated emissions test
  requirements.
• Resolution Investigate options such as applying
  for a waiver. Status Open.

36
WARP
37
WARP Design Changes Since Delta-CDR
38
Pre-Environmental Functional Testing

• Fiber-Optics Baseline Test
• Establishes Pre-Environmental Baseline for
  Transmitter Output Power and Receiver Sensitivity
• Power Variation Test
• Verifies WARP Operation (Record/Playback) at Bus
  Voltage Limits (35V, 24V)
• Limited Performance Test
• Briefly Verifies End-to-End WARP Data Flow
• Performs Record/Playback via X-Band and S-Band
• Memory Test
• Performs Memory Card Built-In Test to Verify All
  Memory Locations
• Record/Playback Test Pattern to Assess Memory
  EDAC Characteristics

39
Pre-Environmental Functional Testing

• Comprehensive Performance Test
• Provides Comprehensive Verification of All WARP
  Functions and Data Paths
• Record Large Data Set (Fill Memory) and Playback
  via X-Band
• Record Smaller Data Set and Playback via S-Band
• Verify WARP Processor Memory Scrubbing
• Verify WARP Processor and RSN Watchdog Operation
• Verify WARP Special Command Operation
• Normal Operations Test
• Emulates Typical On-Orbit WARP Operations
  (Multiple Record/Playback Iterations) Over an
  Extended Period

40
EMI / EMC Tests

• Performed Conducted Susceptibility Tests
• CS01/02 Steady-State Susceptibility
• CS06 Transient Susceptibility
• Will Perform Conducted Emissions Tests
• CE01/03 Steady-State Emissions
• Will Perform Radiated Emissions Tests
• RE01/03 Steady-State Emissions
• Radiated Susceptibility Tests are TBD
• Test Limits Defined As Per System Level
  Electrical Requirements, EO-1 AM 149-0020 (155)

41
Vibration Test

• Performed Sine-Sweep and Random Vibration in Each
  Axis
• Tested to Protoflight Levels As Per EO-1
  Verification Plan and Environmental
  Specification SAI-SPEC-158 Sections 3.7, 3.9
• WARP Was Not Powered During Vibration Testing

42
Mass Properties Test

• Mass Properties Test Shall Measure WARP Weight
  and Center of Gravity
• To Be Performed Immediately Prior to Delivery to
  Spacecraft

43
Thermal Cycling Test

• Survival Soaks (Powered Off) Performed at 60OC
  and -15OC
• Six Cycles from at 55OC and -15OC Performed at
  Ambient Pressure, As Per SAI-SPEC-158 Section
  3.11
• Functional Tests Performed During Cycling
• Power Variation Test
• Fiber-Optics Trending Test
• Limited Performance Test
• Comprehensive Performance Test
• Memory Test
• Long Duration Storage Test
• Normal Operations Test

44
Post-Environmental Functional Testing

• Final Fiber-Optics Test
• Verifies that 1773 Transceivers Were Not Damaged
  During Environmental Testing
• Will Perform Comprehensive Performance Test
• Verifies that WARP Record/Playback Was Not
  Degraded During Environmental Testing
• Will Perform Memory Test
• Verifies that Bulk Memory Was Not Damaged During
  Environmental Testing

45
WARP Test/Anomaly Status
46
WARP Test/Anomaly Status
47
Open Items

• WARP Thermistor Errors Due to RF Exciter
  Thermistors
• Characterize Thermistor Errors at Cold
  Temperatures (Where Errors are Worst)
• Possibly Install New WARP Harness Eliminating
  Connection to RF Exciter Thermistors
• WARP Std Ops Mode Transition Anomaly at Cold
  Temperatures
• Determine Via Testing the Coldest Temperature at
  Which Std Ops Mode Transition Reliably Occurs at
  a 24V Bus Voltage
• Determine Work-Around Approach, Possibilities
  Include
• Bias WARP Warm
• Remain in Std Ops Mode as the Default WARP Mode
• Perform Retries When Std Ops Mode Transition
  Fails
• Fully Document Anomaly and Submit a Request for
  Waiver

48
Open Items

• Conducted Susceptibility EMI/EMC Anomalies
• Compile List of Anomalies and Submit a Request
  for Waiver
• Conducted/Radiated Emissions Testing
• Perform Emissions Tests Prior to Delivery to
  Spacecraft
• Mass Properties Testing
• Perform Mass Properties Tests Prior to Delivery
  to Spacecraft
• Radiated Susceptibility Testing
• Perform Abbreviated Radiated Susceptibility Test
  If Spacecraft IT Schedule Permits
• Re-Integrate Onto Spacecraft