# Presentation: 252531

## Section 16

_***Section 16***_
***Thermal***

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

## Contents

***Contents***

***Thermal Control System***
***Performance Summary***
***Thermal Analysis***
***Thermal Balance & Thermal Vacuum Testing***
***Verification Matrix***
***Configuration Changes***
***RFA Status***
***PR Status***
***Report Status***
***Residual Risk Items***
***Readiness Statement***

## Thermal Control System

***Thermal Control System***

***Passive Radiators***
***Used on Spacecraft Equipment Panels 1, 2, 4 and 6 to radiate excess heat to space and maintain overall bulk temperature of spacecraft***
***REGULATED CONDUCTIVE PATHS***
***G-10 Isolators between Equipment (Battery) Panel 3 and S/C Structure***
* **Maintain Battery 18±5°C*
***G-10 Isolators between PPT Mounting Plate and Panel 6***
***Louvers***
***Used to Regulate Battery Equipment Panel #3 Temperature***
***TRMM spare with 10°C Design (5°-15°C) - calibrated by OSC***

## Thermal Control System

***Thermal Control System***

***Multi-Layer Insulation (MLI)***
*** ******Built by Swales Aerospace***
* **3 mil on Zenith Deck & Equipment Panels*
* **2 mil on Nadir Deck and HEA/CEA boxes*
* **Black Kapton on Nadir Deck below ALI FPA Radiator*
* **Battery Bay Enclosure - Aluminized Kapton*
* **Propulsion Tank*
*** ******Thermal Coatings***
*** ******Aeroglaze A276 White Paint***
* **Zenith Deck S-Band Antenna and SADA Actuator Cover*
*** ******Aeroglaze Z306 Black Paint***
* **Used on Nadir Deck S-Band Antenna*

## Thermal Control System

***Thermal Control System***

***Carbon Carbon Radiator (CCR)***
*** ******Six Thermistors***
*** ******PSE and LEISA Electronics***
*** ******Pulse Plasma Thruster (PPT)***
*** ******G-10 Isolators between PPT Mounting Plate and Panel 6***
***Lightweight Flexible Solar Array (LFSA)***
***G-10 Isolators between LFSA Electronics Box and Zenith Deck***
*** ******2-mil Kapton on External LFSA Electronics Box***
*** ******Autonomous Star Tracker (AST)***
***Design Verification during TB Testing***
*Reduced Radiator Size w/ MLI added to Sun Shade and AST Body*
*** ***

## Thermal Control System

***Thermal Control System***

***Thermostatically Controlled Survival Heaters***
***Used to maintain components above cold survival limits***
*Primary and Secondary Circuits*
*Redundant Thermostats*
*Heater Sizing*
* **Science Mode: < 5 watts*
* **SafeHold Mode:  < 20 watts*
***CHOTHERM between electronic boxes and S/C Equipment Panels***
***High emissivity coatings are used to enhance internal radiation***

## Thermal Control System

***Thermal Control System***

***Calorimeters***
***Bracket mounted with mass simulators for TB and TV Testing***
***Flight units not available for TB / TV Test***
*Flight units delivered to project 3/8/00*
* **Z93 White Paint (GSFC)*
* **LA-II White Paint (AZ Technology)*
***Propulsion Tank***
*** ******MLI blanket fabricated and installed***
*** ******Heater Verification completed during TV testing***

## Thermal Control System

***Thermal Control System***

***ALI***
*** ******Maintain 200K Passive Radiator for Focal Plane Assembly ***
* **Black Kapton On Nadir Deck in Front of FPA Radiator*
*** ******Passive Radiator for Focal Plane Electronics***
*** ******ALICE Box conductively coupled to Instrument Pallet which is conductively coupled to the EO-1 Nadir Deck***
*** ******Hyperion***
*** ******HSA Conductively Isolated from Spacecraft Nadir Deck***
*** ******CEA/HEA are Thermally Coupled to the Spacecraft Nadir Deck***
*** ******Atmospheric Corrector***
*** ******MLI Blanket Provided by Swales***
*** ******Conductively mounted to Spacecraft Nadir Deck***

## Instrument Thermal Requirements

***Instrument Thermal Requirements***

***Advanced Land Imager (ALI) Interface***
***No thermal isolation between Instrument Shroud & Instrument Pallet***
***No thermal isolation between Instrument Pallet and S/C Nadir Deck***
*Bolted Interface *
*DeltaT  10°C to 20°C between Nadir Deck and Instrument Interface*
***Hyperion Interface***
***Energy transferred from Hyperion Instrument Mounting Plate to the Nadir Deck shall be regulated to maintain the Nadir Deck upper limit temperature below 40°C during all phases of the mission.***
***NMP Technology Interface***
***Energy Transfer at Spacecraft Interface:******	******+/- 5 watts***

## Thermal Analysis

***Thermal Analysis***

- Louver

- Bay 4 Radiator

- ALI FPA Radiator

- Thermal Models updated and correlated based on spacecraft Thermal Balance Test Results. No significant changes required.

## 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

## Thermal Design Verification Summary

***Thermal Design Verification Summary***

- TC = Thermocouple

***Thermal Balance Test***
***Critical spacecraft components within 5°C of thermal model predictions***
***Thermal design goals met with margin***
***Radiator areas verified***
***NiCd Battery thermal design verified***
***Autonomous Star Tracker thermal design verified***
***ALI instrument performed as designed***
***Hyperion instrument performed as designed***
***Atmospheric Corrector instrument performed a designed***
***NMP Technologies performed as designed***

## Thermal Verification Plan

***Thermal Verification Plan***

***Thermal-vacuum testing of protoflight and flight components and spares shall be performed to demonstrate satisfactory operation in representative functional modes at mission operating temperatures, at temperatures in excess of the extremes predicted for the mission, and during temperature transitions.  Protoflight components shall be tested in a non-operational mode at cold and hot limits to demonstrate that permanent degradation will not result from exposure to survival mode temperatures defined for the EO-1 mission.  In addition, for components able to be powered at low temperature survival heater settings, the protoflight and flight units shall be tested in a powered mode to demonstrate operation without degradation, although the component need not meet its performance specification until the operational test limit is reached.***
***Components shall be subjected to a minimum of 4 hot-cold cycles with the hot temperature at 10°C above the maximum operating predictions and the cold temperature 10°C below the minimum operating predictions. Where the temperature of an area is controlled by a verified active thermal control system (such as thermostatically controlled heaters), the margin may be reduced to 5°C.***
***The test duration shall be based on the time required to perform performance/functional testing of the component at each hot and cold temperature plateau but, as a minimum, two-hour soak periods shall be conducted.  Components shall be operated during the transition times and turn-on demonstrations shall be made at both cold and hot extremes.***
***Components that are powered during the Delta II vehicle launch phase shall be operated during test chamber pump down and venting to ambient to verify performance.***

***EO-1 Verification Plan (SAI-SPEC-158) and Environmental Specification***

## Spacecraft Level Testing

***Spacecraft Level Testing***

***Spacecraft Level***
***Four cycles of Thermal Vacuum Testing***
***Thermal Balance Test***
*Hot Balance (Data Collection Event)*
*Cold Balance (Safe Hold)*
*Cold Balance (Standby)*
***Spacecraft thermal control system performed nominally***
*Post Test Correlation within 5°C*
***Spacecraft Hardware***
***Thermal Louver calibrated by OSC ***
***Heaters are NASA Standard Parts (S-311-79)***
***Thermostats are NASA Standard Parts (S-311-429)***
***Thermistors are NASA Standard Parts (S-311-P18)***
***Heater/Thermostat Circuits***
* **Verified using CO**2** cold spray during I&T*
*Verified during Thermal Vacuum Testing*

## Thermal Requirements

- Flight Prediction/Design Range

- Acceptance Test Limits

- Qualification Test Limits (Operating)

- 5°C

- 30°C

- 10°C

- 35°C

- 5°C

- 40°C

- Heater Controlled

- - Set to 5°C for primary heater circuits having >75% duty cycle

- Operational Heater Control (includes safehold)

## Slide 17

## Box Level Testing

***Box Level Testing***

**Safehold**

## Instrument Level Testing

***Instrument Level Testing***

***Advanced Land Imager***
***Four operating cycles + One survival cycle of TV Testing***
***Thermal Balance Test Analysis for ALICE Box***
***Hyperion***
***Four operating cycles + One survival cycle of TV Testing***
***Thermal Balance Test at nominal hot and cold operating temperatures***
***Atmospheric Corrector***
***Four survival cycles of TV Testing***
***Four operating cycles***

## Verification Matrix

***Verification Matrix***

## Accumulated Power On Time for EO-1 S/C & Components

## Post TV/TB Test Configuration Changes

***Equipment Panel #1 Radiator***
***Reduced radiator size to decrease heater power duty cycle***
***Replaced Nadir Deck Heaters***
***Autonomous Star Tracker***
***Prior to TB/TV spacecraft testing, radiator size was modified to correct error in vendor modeling and design***
***Added Multi-Layer Insulating blankets around entire AST shade***

## Technical Peer Reviews

***Technical Peer Reviews***

***PDR, CDR, Confirmation Review***
***Thermal Peer Review  (6/98)***
***Delta-Thermal Critical Design Review (10/21/98)***
***Thermal Subsystem Readiness Review (9/24/99)***
***Pre-Environmental Review (10/1/99)***
***Pre-Ship Review (12/15/99)***
***No Open RFAs as a result of Reviews***

## Mission CDR RFAs

***Mission CDR RFAs***

***RFA #4.31***
***Perform transient spacecraft thermal analysis for all EO-1 mission modes. ***
*Thermal Analysis Complete for Launch, Ascent, DCE, Standby and Safemode*
***RFA #4.33***
***Perform thermal design and analysis of solar array deployment mechanisms, including HOP restraint/release, dampers and hinges.***
*Thermal analysis completed for HOPS and Dampers. The HOPS are contained in an MLI enclosure. The dampers have thermostatically controlled heaters and are enclosed with MLI.*
***RFA #4.34***
***Integrate reduced thermal mathematical model of the ALI in SINDA format into the spaceraft mathematical model and perform integrated analysis.***
*The ALI, Hyperion, Atmospheric Corrector and NMP technologies have been integrated with the spacecraft models and analyzed.*

## S/C CDR RFA 4.36

***S/C CDR RFA 4.36***

***Consider providing a breadboard to the IRU vendor for demonstration of the 1/4 C temperature control stability***
***Background***
***At the time of the S/C CDR, the temperature control of the gyro internal platform was to be hosted on the S/C side of the interface***
***Within a month later, Litton G&C, the IRU vendor, accepted an ICD change in this regard since an internal heater control module had been developed for another program and was already to be included in the SIRU design used by EO-1***
***Response to RFA***
***Due to the change an the IRU ICD, the concern raised by the RFA was retired and no breadboard was needed by Litton G&C***
***IRU temperature stability based on the input bus voltage only was verified during IRU Acceptance Testing and continues to be verified during S/C I&T as part of IRU performance tests***

## PSR RFA Status

***PSR RFA Status***

***RFA #14.22***
***Completed***
***RFA #14.23***
***Completed***
***RFA #14.24***
***Completed***

## RFA #14.22

_***SPECIFIC REQUEST***_***:  Provide or include in the January PSR a temperature sensitive component tabular listing which included the following information:***
***Thermal design minimum / maximum power dissipation range***
***Actual measured/derived  power dissipation***
***Hot / Cold /Safehold thermal correlation temperature differences***
***Demonstrated heater margins******	***
_***SUPPORTING RATIONALE***_***:  This information is normally contained in a Pre-Ship Review Package.******	***
_***PROJECT RESPONSE***_***:***
***A chart was presented showing the thermal design min/max power dissipations provided by the EO-1 spacecraft systems. ***
***A spreadsheet showing the transient measured power for the EO-1 electronics that was verified during thermal balance and thermal vacuum testing. The only change was for the SADA during Safehold. The SADA dissipation remains 11.86 during safehold. In addition, 1 watt power loss was added to the cable wrap during the sunlit portions of the mission***
***Correlated Data was provided for Hot DCE Orbit, Cold Standby and Safehold Cold Thermal Balance***
***Heater Duty Cycles provided.***

## RFA #14.22

***RFA #14.22***

## RFA #14.23

_***SPECIFIC REQUEST;***_*** Provide or include in the January PSR a component tabular listing which includes the following information:***
***Temperature requirements***
***Flight Cold and Hot temperature predicts***
***Qualification test history for each temperature sensitive component. ***
***Distinguish between subsystem and observatory testing and provide information in terms of temperatures achieved and number of cycles.******	***
_***SUPPORTING RATIONALE***_***:  This information is normally in a Pre-Ship Review Package.******	***
_***PROJECT RESPONSE TO PSR RFA #14.23:***_*** Charts provided with requested data.***

## RFA #14.23 (continued)

***RFA #14.23 ****(continued)*

- TC = Thermocouple

- DCE Orbit - Hot Case

- Predictions vs. Design Maximum

- Model Correlation

## RFA #14.23 (continued)

***RFA #14.23 ****(continued)*

- TC = Thermocouple

- SAFEHOLD - Cold Case

- Predictions vs. Design Minimum

- Model Correlation

## RFA #14.23 (continued)

***RFA #14.23 ****(continued)*

**Safehold**

## RFA #14.23 (continued)

***RFA #14.23 ****(continued)*

**Heater Duty Cycle for DCE  and Standby Cases - Cold Bias**

## RFA #14.23 (continued)

***RFA #14.23 ****(continued)*

**Heater Duty Cycle for Safehold Case - Cold Bias**

## RFA #14.24

_***SPECIFIC REQUEST***_***:  Assure that adequate launch site thermal subsystem inspections occur prior to launch.  Verify that the inspection process is sound.***
_***SUPPORTING RATIONALE***_***:  Pre-Thermal-Vacuum  Test inspections were not adequate since a test blanket hung up on the solar array actuator.******	***
_***PROJECT RESPONSE***_***: ***
***Nick Teti will be at launch site to perform final inspection of the thermal control subsystem. In addition to items identified in SAI-PROC-757, “EO-1 Satellite Red Tag Item Removal and Installation Procedure”, a Work Order Authorization (WOA) will be written to identify all remaining closeouts for the EO-1 thermal control systems, this includes but is not limited to, blanket closeouts, louver installation, final taping. WOA’s are reviewed and verified by the appropriate personnel.***
***The test blanket interference during thermal vacuum was a unique configuration that will NOT be part of the launch configuration. A camera was placed at the location of the solar array to monitor the movement within the blanket enclosure recognizing the possibility of interference. Several tests were run prior to the start of the thermal vacuum test to verify proper clearance. The camera provided an opportunity to monitor the solar array drive and if an anomaly were observed the solar array movement would be halted***

## Report Status

***Thermal Balance / Thermal Vacuum Final Report (SAI-RPT-319)***
***Completed***
***Thermal Design and Analysis Final Report (SAI-RPT-322)***
***3/31/00***
*** ******Thermal Interface Control Document - (SAI-ICD-048, Rev B)***
***4/15/00***

## Residual Risk Items

***None***
***No Redbook candidates***

***PR Status***

***No OPEN PRs***

## Readiness Statement

***On-Orbit thermal model updated based on results of TB Testing ***
***Thermal Analysis Complete***
***Launch/Ascent***
***DCE ***
***Standby***
***Safemode***
***No Open PRs ***
***Blanket closeouts are to be completed prior to shipment***
***Documents scheduled for completion prior to shipment***
***THERMAL SUBSYSTEM IS READY FOR SHIPMENT !***