GLAST Large Area Telescope:

1
GLAST Large Area Telescope Integration and
Test Two Tower Integration Readiness
Review Integration, Facilities, Configuration
and Test (IFCT) Department Ken Fouts / Brian
Grist
2
IFCT Outline

1. Operations Readiness
2. EGSE
3. Integration Facility

3
IFCT Part I. Operations Readiness

1. Summary of 2 tower IT Operations and AIDS
2. Mapping of AIDS to schedule / PMCS
3. AIDS and Time Estimates Overview
4. Grid Installation and Survey
5. Calorimeter Receiving and Post-Ship Test
6. TEM/TPS Receiving
7. Tracker Receiving and Post-Ship Test
8. Calorimeter and TEM/TPS IT
9. Test Bay IT
10. Grid Bay IT
11. Bays 8 9 IT

4
Two Tower IT Operations
Receive Tracker Flight Unit A
Receive Calorimeter, TEM/TEM PS Flight Units A
Receive and assemble Grid
Receive Calorimeter, TEM/TEM PS Flight Units B
Receive Tracker Flight Unit B
Install in Metrology Bay for Shimming Assembly
Integrate Grid onto Rotation Stand
Install in Metrology Bay for Shimming Assembly
Install tower in Test Bay
Test CAL A TEM/TEM PS A
Grid Optical Survey
Install tower in Test Bay
Test CAL B TEM/TEM PS B
Test Single Bay Tower
Test Single Bay Tower
De-Install Tower from test bay
De-Install Tower from test bay
Integrate Tracker A into Grid
Integrate CAL/TEM/TPS A into Grid
Single Tower Test in Grid
Integrate Tracker B into Grid
Integrate Cal/TEM/TEM-PS B into Grid
Single Tower Test in Grid
Two Tower IT
Optical Survey
5
Assembly and Inspection Data Sheet
6
Assembly and Inspection Data Sheet
7
Assembly and Inspection Data Sheet
8
Mapping of AIDS to schedule / PMCS

• Strategy
• AIDS line items tracked in MS Project
• Line items are groups of work which take gt1hr
• Status
• AIDS drafts delivered to scheduler data input in
  process ECD Dec. 18

9
AIDS and Time Estimates Overview
10
Grid Installation and Survey

• Notes
• Mechanical Systems (Martin Nordby) is working
  with SLAC metrology to define the Grid survey
  requirements.
• Risk Mitigation
• Plan for completing a Grid to Grid Perimeter Ring
  fit check in work ECD 12/1.

11
Calorimeter Receiving and Post-Ship Test

• Notes
• Calorimeter post-ship test performed by
  Calorimeter Subsystem using subsystem GSE and
  staff.
• Calorimeter TEM/TPS safe-to-mate performed by IT
  for TEM-GASU and TPS-PDU connectors only
• Calorimeter IT receiving test performed by IT
• Risk Mitigation
• ELX will complete acceptance testing on EGSE Test
  Stand

12
TEM/TPS Receiving

• Notes
• TEM/TPS manufacturing is completed in Room 103
• Safe-to-mate is performed on all TEM/TPS
  connectors (14)

13
Tracker Receiving and Post-Ship Test

• Notes
• Tracker receiving inspection yet to be defined
• Tracker post-ship test performed by tracker
  subsystem
• Risk Mitigation
• IT working closely with TKR subsystem to develop
  processes.
• Plan is to use the TKR Mock Up with Flight-like
  Cables delivered in December to dry run receiving
  procedures.
• ELX will complete acceptance testing on EGSE Test
  Stand

14
Calorimeter and TEM/TPS IT

• Notes
• IT is considering requirements for relocating
  this process from room 104 (current baseline) to
  room 103 to relieve floor space usage in room 104
• Risk Mitigation
• ELX will complete acceptance testing on EGSE Test
  Stand

15
Test Bay IT

• Notes
• Tracker installation procedures not finalized at
  this time
• Tower survey is managed by Martin Nordby and
  staffed from SLAC Metrology
• Tower trigger test procedures and software not
  finalized at this time
• E2E test software not finalized at this time
• SVAC test software not finalized at this time
• Risk Mitigation
• Plan is to use the TKR Mock Up with Flight-like
  Cables delivered in December to dry run receiving
  procedures
• ELX will complete acceptance testing on EGSE Test
  Stand

16
Tracker Installation

• Basic Procedure complete
• New inputs from Tracker Group to be incorporated
• Cone assembly process (done)
• Cable bonding process (still in work)
• Some Project decisions pending
• Adjustment of Tower lean
• Measurement of Tower location
• Procedures and documentation for Lifting need
  approval after procedure release

17
IT Test Definitions

• Single Bay Test (in EM single bay) 54 hrs total
  (40 hrs w/o E2E/SVAC/VDG)
• Aliveness Test (15 min)
• Calorimeter CPT (2 hrs)
• Tracker Pass/fail tests (2hrs)
• Trigger Module internal timing, GEM timing
  alignment, subsystem TACK delays (36 hours)
• End-to-end Test, 6 hrs
• SVAC Data Collection (Bay 9 only, includes VDG) 8
  hrs
• Single Bay Test (in flight grid) 44 hrs total (4
  hrs w/o SVAC)
• Aliveness Test (15 min)
• Calorimeter CPT (2 hrs)
• Tracker Pass/fail tests (2hrs)
• SVAC Data Collection (Bay 9 only, no VDG) Day
  116 hrs, Day 2 24 hrs
• Two Bay Test (in flight grid) 104 hrs total
• Aliveness Test (15 min)
• Calorimeter CPT (4 hours)
• Tracker Pass/fail tests (4hrs)
• End-to-end Test, 40 hrs
• SVAC Data Collection (includes VDG) Day 116 hrs,
  Day 2 24 hrs, VDG16 hrs

18
Grid Bay IT

• Notes
• Same as for test bay IT, except no trigger nor
  E2E tests
• Risk Mitigation
• Plan is to use the TKR Mock Up with Flight-like
  Cables delivered in December to dry run receiving
  procedures
• ELX will complete acceptance testing on EGSE Test
  Stand

19
Bays 89 IT

• Notes
• Flight mates are performed on DAQ cables to bays
  8 9
• Subsystem tests are executed module by module
• E2E test software not finalized at this time
• SVAC test software not finalized at this time
• Risk Mitigation
• ELX will complete acceptance testing on EGSE Test
  Stand
• Test definition in process with Systems
  Engineering

20
IFCT Part II. EGSE Preparation

1. Acceptance and validation process
2. COTS
3. BOBs
4. Connector savers
5. PDU
6. GASU
7. TEM/TPS
8. BPU
9. Test Stands
10. Test Procedures

21
EGSE Process Design to Use
Integration and Test (IT) Subsystem Electrical
Ground Support Equipment (EGSE) Plan
LAT-MD-01533 Just released for review.
22
Break Out Boxes are Ready

• Breakout boxes facilitate interface verification
  without significant risk to flight hardware.
  Note that the LAT electronics design does not
  easily permit measurements of LVDS signaling
  characteristics at data rate. Four boxes are
  required
• 26 pin interface
• 44 pin interface
• 78 pin interface
• 104 pin interface
• Adapter cables adapt between different pin outs,
  connector styles and sizes. Examples of breakout
  boxes are shown in the following picture

23
Configuration Block Diagram, Tracker Test
EGSE
TKR
24
Equipment List, Tracker Test
Type Manufacturer/Model/ID Number
VME Crate Dawn VME Products, 11-1011777-2119
VME, TST-STP Trans card LAT-DS-00999
VME SBC MVME2304 card Motorola PN MVME2304-0123
VME LCB Mezzanine card LAT-TD-00860
LCB Transition board cable LAT-DS-03247
DC Power supply BK Precision MN1786A
Uninterruptible Power Supply Tripp-Lite SU1000 or equivalent
28 Volt supply cable LAT-DS-03246
PS Control cable LAT-DS-02095-20
TEM to GASU cable LAT-DS-02106
CAT5 Ethernet cable TRD855PL-50
CAT5 Ethernet cable.RS-232 TDC003-7 (RECO98M connectors)
Local PC DELL, Model
Golden TEM/TPS
25
Configuration Block Diagram, Two Tower Test
26
Equipment List, Two Tower Test
27
EGSE IN SINGLE TOWER ASSY FLOW
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EGSE IN TWO TOWER ASSY
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EGSE TEST REQUIREMENTS MD-00408

• Configuration of EGSE shall be controlled via
  released documentation
• EGSE shall be acceptance tested
• EGSE shall be validated before use if it has been
  moved, reconfigured, or repaired
• Validation shows that equipment is both ready for
  use and safe to use
• High degree of confidence that equipment in that
  configuration has full operating capabilities
• NASA guidance
• Perform an EICIT and an SVT to ensure electrical
  safety
• Trip points on circuit breakers, current limits
  in power supplies, shall be verified
• While everything is validated, the scope of
  validation is tailored for each piece equipment
  type

30
STATUS OF EGSE COTS

• Digital Multimeters (IT responsible for these)
• Calibrated Instrument
• Validation Tests
• Embedded within test procedure that calls them
• STATUS Meter purchased exceed maximum voltage
  for parts in some equipment, so we are
  re-procuring
• Borrowing Safe DMMs in the meantime
• Hand Tools
• Procured, cleaned, and placed in toolbox within
  cleanroom
• Automated Test Equipment for Safe to Mate
• All parts received - calibrated
• Interconnection harness designed in assembly
• Rack trays sent out for machining affected by
  safety stand down at SLAC

31
SCOPE OF EGSE TESTS BOBs ETC.

• Cables and break out boxes (IT is responsible
  for these)
• Design documentation complete and released
• Acceptance Tests include
• Configuration inspection to assembly drawing
• Interface integrity and cleanliness, inspection
• Electrical continuity isolation tests per
  LAT-TD-04325
• Labeling with test due date, operator, QA
• Validation Tests include
• Verify Acceptance Testing has been performed and
  is not due for re-test
• Configuration inspection
• Interface integrity and cleanliness, inspection
• Electrical continuity tests, manual
• Connector Savers
• Tests Interface integrity and cleanliness,
  inspection

32
STATUS OF BOBs ETC

• All BOBs designed, built, and tested
• Inspection remains to be completed
• Associated cables designed, built to shortage,
  and tested
• The backshells for the 100 pin cables were back
  ordered and just arrived. Estimate assembly
  complete 12/1
• Inspection remains to be completed
• Long versions of the Two Tower test cables for
  EGSE interconnections are awaiting the floor
  layout to determine lengths. Design, build, and
  test complete 12/31.
• Acceptance and Validation Test Procedures in sign
  off cycle

33
STATUS OF CONNECTOR SAVERS

• Determining connector saver needs
• Coordinating with subsystems
• All ELX boxes arrive with connector savers on
  each connector
• CAL delivers mated to an EM TEM, so they are not
  needed
• TKR towers arrive with connector savers that will
  be turned over to IT
• Determining who buys connector savers for the
  flight cables submitted lien to program office
  to fund procurement
• Complete determination by 11/24

34
SCOPE OF EGSE TESTS - PDU

• EM PDU
• Acceptance Tests include
• Configuration inspection to LAT-DS-01696
• Interface integrity and cleanliness, inspection
• EICIT and SVT tests
• Functional Tests in accordance with
  LAT-TD-02544-01
• Labeling with test due date, operator, QA
• Validation Tests include
• Verify Acceptance Testing has been performed and
  is not due for re-test
• Configuration inspection
• Interface integrity and cleanliness, inspection
• Electrical STM tests
• Further validation tests performed within the
  test stand using load box

35
SCOPE OF EGSE TESTS PDU LOAD

• EM PDU LOAD BOX
• Acceptance Tests include
• Configuration inspection to LAT-DS-03400
• Interface integrity and cleanliness, inspection
• EICIT and SVT tests
• Functional Tests in accordance with
  LAT-TD-04095-01
• Labeling with test due date, operator, QA
• Validation Tests include
• Verify Acceptance Testing has been performed and
  is not due for re-test
• Configuration inspection
• Interface integrity and cleanliness, inspection
• Electrical STM tests
• Further validation tests performed within the
  test stand

36
STATUS OF PDU LOAD BOX

• Documentation
• PDU Assy, LAT-DS-01696, released
• PDU Test Procedure, LAT-TD-02544-01, released
• PDU Load Box Assy, LAT-DS-03400, released
• PDU Load Test Procedure, LAT-TD-04095-01,
  released
• EICIT Procedure, PDU, LAT-TD-04332, released
• SVT Procedure, PDU, LAT-TD-04332, in work (12/1)
• Delivered to IT
• Inspection, acceptance test, validation pending
  development of flight documentation

37
SCOPE OF EGSE TESTS - GASU

• EM GASU
• Acceptance Tests include
• Configuration inspection to LAT-DS-01611-09
• Interface integrity and cleanliness, inspection
• EICIT and SVT tests
• Functional Tests in accordance with
  LAT-TD-04267-02
• Labeling with test due date, operator, QA
• Validation Tests include
• Verify Acceptance Testing has been performed and
  is not due for re-test
• Configuration inspection
• Interface integrity and cleanliness, inspection
• Electrical STM tests
• Further validation tests performed within the
  test stand

38
STATUS OF GASU

• Documentation
• GASU Assy, LAT-DS-01611-09, released
• GASU/Test Stand Test Procedure, LAT-TD-04267-02,
  released
• EICIT Procedure, GASU, LAT-TD-04260, released
• SVT Procedure, GASU, LAT-TD-04382, in work (12/1)
• Delivered to IT
• Inspection, acceptance test, validation pending
  development of flight documentation

39
SCOPE OF EGSE TESTS TEM/TPS

• EM TEM/TPS
• Acceptance Tests include
• Configuration inspection to LAT-DS-01643
• Interface integrity and cleanliness, inspection
• EICIT and SVT tests
• Functional Tests in accordance with
  LAT-TD-4085-01
• Labeling with test due date, operator, QA
• Validation Tests include
• Verify Acceptance Testing has been performed and
  is not due for re-test
• Configuration inspection
• Interface integrity and cleanliness, inspection
• Electrical STM tests
• Further validation tests performed within the
  test stand

40
STATUS OF TEM/TPS

• Documentation
• TEM/TPS Assy, LAT-DS-01643, released
• TEM/TPS Test Procedure, LAT-TD-4085-01, released
• EICIT Procedure, TEM, LAT-TD-03875-02, released
• SVT Procedure, TEM, LAT-TD-04097-02, released
• EICIT Procedure, TPS, LAT-TD-03875-02, released
• SVT Procedure, TPS, LAT-TD-04098-01, released
• Two delivered to IT
• Inspection, acceptance test, validation pending
  development of flight documentation

41
SCOPE OF EGSE TESTS BUS PROTECTOR

• Acceptance Tests include
• Configuration inspection to LAT-DS-
• Interface integrity and cleanliness, inspection
• EICIT and SVT tests
• Functional Tests in accordance with LAT-TD-
• Labeling with test due date, operator, QA
• Validation Tests include
• Verify Acceptance Testing has been performed and
  is not due for re-test
• Configuration inspection
• Interface integrity and cleanliness, inspection
• Electrical STM tests
• Validation tests performed in accordance with
  LAT-TD-

42
STATUS OF BUS PROTECTOR

• Requirements identified in EGSE Plan
• Design assigned within ELX
• Documentation needs be created
• Developing schedule with ELX to support Two Tower
  Test

43
TEM TEST STAND - CAL AND TKR TESTS

• Acceptance Tests include
• Configuration inspection
• LAT-DS-02861 CAL
• LAT-DS-03605 TKR
• Interface integrity and cleanliness, inspection
• EICIT and SVT tests
• Functional Tests in accordance with
  LAT-TD-4085-01
• Validation Tests include
• Verify Acceptance Testing has been performed and
  is not due for re-test
• Configuration inspection
• Interface integrity and cleanliness, inspection
• Electrical STM tests
• Perform tests described in LAT-TD-4085-01, Para.
  5.5.4, Basic Test

44
STATUS OF TEM TEST STAND

• Documentation
• CAL Test Stand set up procedure, LAT-DS-02861,
  released
• TKR Test Stand set up procedure, LAT-DS-03605,
  released
• TEM/TPS Test Procedure, LAT-TD-4085-01, released
• EICIT Procedure, TEM, LAT-TD-03875-02, released
• SVT Procedure, TEM, LAT-TD-04097-02, released
• EICIT Procedure, TPS, LAT-TD-03875-02, released
• SVT Procedure, TPS, LAT-TD-04098-01, released
• Two Test Stands delivered to IT
• Inspection, acceptance test, validation pending
  development of flight documentation

45
GASU TEST STAND TESTS IN 1X1

• Acceptance Tests include
• Configuration inspection LAT-TD-04267-02
• Interface integrity and cleanliness, inspection
• EICIT and SVT tests
• Functional Tests in accordance with
  LAT-TD-04267-02
• Validation Tests include
• Verify Acceptance Testing has been performed and
  is not due for re-test
• Configuration inspection
• Interface integrity and cleanliness, inspection
• Electrical STM tests
• Perform tests described in LAT-TD-4085-01, Para.
  5.5.4, Basic Test

46
STATUS OF GASU TEST STAND

• Documentation
• Assembly and test procedure, LAT-TD-04267-02,
  released
• Validation test, run LAT-TD-4085-01, released
• EICIT Procedure, GASU, LAT-TD-04260, released
• SVT Procedure, GASU, LAT-TD-04382, in work (12/1)
• Delivered to IT
• Inspection, acceptance test, validation pending
  development of flight documentation

47
GASU/PDU TEST STAND TWO TOWER

• Acceptance Tests include
• Configuration inspection LAT-TD-04267-02
• Interface integrity and cleanliness, inspection
• EICIT and SVT tests
• Functional Tests in accordance with
  LAT-TD-04267-02
• Validation Tests include
• Verify Acceptance Testing has been performed and
  is not due for re-test
• Configuration inspection
• Interface integrity and cleanliness, inspection
• Electrical STM tests
• Perform tests described in
• LAT-TD-02544-01, Para. 5.3.6, PDU-GASU Interface
  and electrical load tests
• LAT-TD-4085-01, Para. 5.5.4, Basic Test

48
STATUS OF GASU/PDU TEST STAND

• Documentation
• Assembly and test procedure, LAT-TD-04267-02,
  released
• PDU Validation LAT-TD-02544, released
• Validation test, run LAT-TD-4085-01, released
• EICIT Procedure, PDU, LAT-TD-04332, released
• SVT Procedure, PDU, LAT-TD-04332, in work (12/1)
• EICIT Procedure, GASU, LAT-TD-04260, released
• SVT Procedure, GASU, LAT-TD-04382, in work (12/1)
• Delivered to IT
• Inspection, acceptance test, validation pending
  development of flight documentation

49
TEST PROCEDURE STATUS

• IT Test procedures are being written prior to
  completion of test plan.
• CAL Test Procedure
• Draft complete and in review
• Draft must be updated with new input from CAL
  subsystem (received after procedure completed)
• Complete one week after CAL final update
• TKR Test Procedure
• Draft was complete and in review three weeks ago
• Draft was updated with new input from TKR
  subsystem (received after procedure completed)
• Complete one week after TKR final update

50
TEST PROCEDURE STATUS (cont)

• Single Tower Test
• Draft in review in IT
• Affected by change to subordinate documents
• References to be updated and test descriptions
  re-written
• Complete 12/15
• Two Tower Test
• Draft begun
• Complete 12/31
• VG and CR Data Runs for LAT Integration

51
IFCT Part III. Integration Facility

1. Cleanroom
2. Computing

52
Cleanroom

• Building 33 Clean Rooms functional and occupied
• Monitoring system fully operational.
• Clean Rooms fully certified.
• All computers and oxygen sensors have battery
  back ups.
• Upgrades
• Grounding system for ESD and Multi-point ground
  to be installed. ECD 1/3/05
• 15 ton crane to get two speed option, after
  initial Grid handling. ECD 3/1/05 (TBR)
• Stand alone hot water boiler. ECD 3/1/05 (TBR)
• Upgrade environmental controls on clean room air
  handler. ECD 3/1/05 (TBR)
• Substation upgrade. ECD 3/31/05
• Extend back up generator lease thru Jun 05. ECD
  12/31/04

53
Computing

• Hardware and networking
• Online network / firewall fully operational
• SLAC centrally administered accounts (active
  directory) working
• Upgrades
• RAID5 servers in hand (3 unitsspare) and
  migration is in progress ECD Dec.18
• Environmental test computing infrastructure
  design in progress