# Presentation: 033986

## Section 17

_***Section 17***_
***Thermal***

*** ******Nicholas M. Teti***
*EO-1 Thermal Systems Lead, Swales Aerospace*

## Contents

***Contents***

***To Do List***
***Thermal Design Verification***
***Special Topic: Comparison of Results of T/V I and II ***
***PR Status***
***Report Status***
***Thermal Subsystem Status***
***Residual Risk Items***
***Readiness Statement***

## Thermal Design “As Run” Verification Matrix

## To Do List

***To Do List***

***Verify Bay #4 (CC Radiator) & Bay 6 Thermistor Locations***
***DONE***
***Verify Solar Array Damper Heater/Thermostat Circuits***
***DONE***
*** ******Complete Thermal Balance / Thermal Vacuum Final Report***
***DONE***
***Complete Launch Site Battery Cooling Analysis and Distribute***
***DONE***
***Complete and Distribute Thermal Design and Analysis Report (FINAL)***
***DONE***
*** ******Fabricate and Install MLI Blankets for Bay #1 based on TB Results***
***DONE***
*** ******Fabricate and Install MLI Blankets for New AST Design***
***DONE***
***Install & Verify New Heater Circuits for Nadir Deck & Bay 6***
***DONE***
*** ******Install Battery Flight MLI Enclosure***
***At Launch Site***

## Thermal Analytical Models

- Flight Thermal Model

- T/V II Thermal Model

## Thermal Subsystem Verification

***Thermal Subsystem Verification***

## Thermal Design Verification

***Thermal Design Verification***

- TC = Thermocouple

- DCE Orbit - Hot Case

- Predictions vs. Design Maximum

- Model Correlation

## Thermal Design Verification (continued)

***Thermal Design Verification ****(continued)*

- TC = Thermocouple

- SAFEHOLD - Cold Case

- Predictions vs. Design Minimum

- Model Correlation

## Slide 9

## Special Topic:

***Comparison of Results from T/V I and II***

*** ******Nicholas M. Teti***
*EO-1 Thermal Systems Lead, Swales Aerospace*

## T/V I versus T/V II

***First T/V Test (Oct ‘99) also included a Spacecraft Level Thermal Balance Test***
***Cryo and Heater Panels placed around spacecraft and instruments to simulate on-orbit conditions***
***Flux Controllers vs. Temperature Controllers***
***T/V I Test used flux controllers to set control panel temperatures (important for thermal balance and thermal model verification)***
***T/V II Test used temperature controllers. GSE heaters and temperature sensors work together to maintain control settings.***
***New Nadir Deck Heater Wiring ***
***Reduced WARP & Star Tracker Radiator Sizes in T/V II***
***GPS Antenna’s, Calorimeters and Thrusters covered with GSE MLI ***
***Comparison of Results***
***Spacecraft Performed as Expected***

## Heater Verification Results

**Note: Solar Array Damper Heaters Checked During Solar Array Installation, using CO****2**** cold spray.**

## T/V Test Anomaly

***T/V Test Anomaly***

***X-Band Phased Array Cold Temperature Anomaly***
***The XPAA was turned on at a temperature of -20 C on 186:04:49. It operated until 186:05:02 before it was turned off. A PR was generated.***
***Reason for Anomaly***
*The first is that the X-band hat coupler was less than an inch away from the chamber shroud. Therefore, when the chamber was driven cold by reducing the temperature of the shroud, the X-band was driven very cold. The second problem was that the test heater applied to the hat coupler was not driven hot enough to overcome the shroud cold sink due to a GSE controller problem.*
***Corrective Action***
*The XPAA survival heaters were enabled to raise the XPAA to its operational temperature. In addition, the voltage applied to the GSE heaters was increased to provide additional wattage to the X-Band Hat Coupler. This anomaly was not repeated. The X-Band appeared to operate nominally throughout the T/V Test.*

## T/V Test Anomaly

***T/V Test Anomaly***

***The GSE heaters appeared to transition the spacecraft at an excessive rate.***
***Reason for Anomaly***
*Thermocouple data provided to the EO-1 shift lead during T/V II cold to hot transition appeared to indicate that the spacecraft structure was temperature transitioned at an excess rate.*
***Corrective Action***
*Thermocouple data did not represent actual spacecraft component heating. The  thermocouples were highly influenced by local heating from the GSE heaters. The thermistor data (Flight Data) shows that the spacecraft components were heated at a nominal rate. This anomaly is typical of temperature controllers. Lesson learned and incremental temperature settings were used on subsequent transitions to hot and cold plateaus.  Flux controllers were used in T/V Test #1 which allowed test conductors to set the power density.*

## PR & Report Status

***No Open PR’s***

***Thermal Balance / Thermal Vacuum Final Report***
***Done***
***Thermal Design and Analysis Final Report***
***Done***
*** ******Thermal Interface Control Document – Rev B***
***8/11/00***

## Thermal Blanket Status

***Flight Blanket Fabrication Completed Prior to T/V Test II***
***Bay 1 Modification ***
***Purge Fitting blankets***
***Flight Blankets Installed for T/V Test II, Except for:***
***Thruster Blankets (GSE Blankets used)***
***X-band Blanket (Hat Coupler Interference)***
***Calorimeter Blanket (GSE Blankets used)***
***GPS Antenna Blanket (GSE Blankets used)***
***Final Blanket Installation shall be performed at Launch Site***
***Blankets installed for Mass Properties, but removed for shipment because of interference with Red Tag Covers, Lifting GSE and S-band Transponder Installation (Bay 1 & Bay 6).***

## Readiness Statement

***No Residual Risk Items***
***No Redbook Candidates***
***On-Orbit thermal model updated based on results of TB Testing***
***Flight Heaters & Radiator Sizes Verified***
***Thermal Analysis Complete***
***Launch/Ascent***
***DCE ***
***Standby***
***Safemode***
***Blanket closeouts are to be completed at Launch Site***
***Documents scheduled for completion prior to shipment***
***THERMAL SUBSYSTEM IS READY FOR SHIPMENT !***