# Presentation: 521635

## Spacecraft

***Mike Cully***
***Swales***
***January 22, 1999***

## EO-1 Launch -11 Month Launch Readiness ReviewSpacecraft Schedule & IssuesJanuary 22, 1999

***Agenda***
*Spacecraft Bus I&T Organization & System**	**	**M. Cully*
*Spacecraft Bus I&T Status**	**	**	**	**M. Cully*
*Hyperion Accommodation Status**	**	**	**M. Cully*
*Risk Mitigation**	**	**	**	**	**M. Cully*
*Software Status**	**	**	**	**W. Roher/K. Rehm*
*Post Hyperion Modifications S/C Bus I&T **	**	**E. Moyer*
*Overview of Environmental Program & Planning**	**	**E. Moyer*
*CPT Planning**	**	**	**	**	**M. Perry*
*Launch Site Processing & Status**	**      M. Perry/M. McMcullough*
*Summary**	**	**	**	**	**	**M. Perry*

## Spacecraft Schedule & IssuesI&T Status

***Agenda***
*I&T Organization*
*Team*
*Staffing**	*
*Work Order Authorization System*
*WOA Structure*
*Problem Reporting System*
*Problem Test Reports*
*Problem Action Reports*
*Overall I&T Flow Status*
*Flow Chart*
*Integration Status Prior to Hyperion Modifications**	*
*WOA Statistics*
*Problem Report Status*
*Problem Action Reports **	**	**	**	**	**	*

## Spacecraft Schedule & IssuesI&T Status

***Agenda ******(CONTINUED)***
*Hyperion Spacecraft Bus Modifications Status**	*
*Hyperion Structures*
*Louver/Battery Panel Mods*
*Solar Array*
*S/C Harness*
*Power Supply Electronics*
*ACS Analysis*
*Flight Software*
*Mechanical Support Equipment*
*Risk Mitigation*
*Interfaces Verified**	**	**	**	**	**	**	*

## EO-1 Core I&T Team

## I&T Staffing Overview

***Will typically run 2 shifts a day, 5 Days a week during the remaining Spacecraft Bus integration***
***Staffing for Spacecraft Bus Integration***
*Two Test Conductors per Shift*
*Two Electrical Techs per Electrical Shift*
*Two Mechanical Techs per Mechanical Shift*
*One Electrical Lead per Electrical Shift*
*One Subsystem Lead per Shift with S/S backup as required*
*One Mechanical Lead per Mechanical Shift*
*All Shifts covered by I&T Mgr, Systems, QA*
*Software on call- Software development Lab in same general area*
*Shift meetings scheduled at 7:30 & 15:30 to review previous shifts performance and upcoming shifts plan activities*

## Work Order Authorization (WOA) System

## Work Order Authorization (WOA) System

***I & T Plan (SAI-PLAN-130) provides full description of WOA System***
***The WOA System controls all work performed on the Spacecraft***
*Initiated typically by Subsystem Lead or Test Conductor*
*Includes detail work description *
*WOA will only be authorized after the following*
*Referenced Procedure released through CM*
*Signature of Systems Mgr., Subsystem Lead, Mech. & Elec. Leads, I&T Mgr & QA Mgr.*
*Following successful completion of work WOA will be closed after approval from I&T Mgr & QA*
*Original WOA with supporting information will then be entered into S/C logbook*
*If a Problem Report is issued the WOA remains open until PR is disposition & closed *
*WOA System uses an ACCESS 97 database developed specifically for EO-1*
*Provides statistics on WOAs, Problem Records, & Problem Action Reports*
*Onsite GSFC representative has full access to database at anytime & is invited to attend all meetings*
*It is located on I&T network which will be portable to GSFC & Launch Site *

## Problem Records (PRs)Problem Test Reports (PTRs)

***PRs are anomalous events inconsistent with what was anticipated or predicted***
***PRs are entered on PR forms in the ACCESS database system and are assigned numbers by the ACCESS database system consistent with WOA number under which the work was being performed***
***PRs are entered into the database system as they occur***
***PRs must be dispositioned, corrective action taken and closed before WOAs can be closed***
***Closure of PRs requires approval from responsible subsystem lead & QA***
***PR meeting held typically every two weeks or as required to review status & develop corrective action plan ***
***QA responsible to follow through with Subsystem Leads on closure***
***The PAR commences with the electrical integration of the PSE. Prior to this point MRBs instituted.***
***PTRs are analogous to PRs in Software environment ***
***Software Lead administers under Litton CM auspices***

## Problem Action Reports (PARs)

***PRs can be elevated to a Problem Action Report (PAR) if form, fit or function is affected.  Elevation to PAR requires agreement by Swales PM, I&T Mgr., QA, Systems, and appropriate Subsystem Lead.***
***PRs are held open pending PAR resolution***
***The PAR form used during spacecraft I&T replaces the Material Review Board Report form used during hardware development as referenced in the CERT Log***

## EO-1 I&T Schedule Flow  (S/C Vibration with Flight ALI)

## I&T Flow Overview & Major Changes from Confirmation Review (11/98)

***Integration Schedule Features***
*Hyperion Spacecraft Modification time was extended due to a larger effort than anticipated for re-integration of components and power testing of PSE after re-work (requires sending EGSE back to Litton)*
*Additional effort allocated to complete Sband I&T*
*Inserted time to resolve GPS issues and included time for regression testing following new software loads. *
*Re-integration of LFSA inserted*
*PAF fit check moved to right due to delay in fit check stand and later delivery of flight PAF*
*S/C Bus Contingency Period (4/22 - 5/18) currently has Flight Software Verification & MOC testing planned. This effort will be inserted into the I&T schedule prior to this period as opportunities arise.*
*Flight ALI remains on throughout environmental testing. *

## EO-1 Bus Integration StatusPrior to Start Of Hyperion Modifications 1/04/99

***Spacecraft in Swales 5015 Cleanroom***
*Structure, Harness, & Propulsion systems completed & integrated *
*Solar Array delivered & tested which includes full deployment test (Hyperion Mod)*
*All EGSE received at Swales with exception to X-Band Rack which is in use at Litton for exciter board screening*
*Electrical Integration of following components was completed or in process at time of Hyperion Modification initiation*
*Test Battery & Battery Relay Box**	**– IRU*
*GPS with Antennas (PRs)**	**	**– Star Couplers*
*RWA & Electronics**	**	**	**– Solar Array Drive & Electronics*
*TAM**	**	**	**	**– S-Band Transponder & RF Coupler*
*Torque Bars **	**	**	**– C/C Radiator*
*Power Supply Electronics (PSE) (PRs)**	**- Attitude Control & Data System-ACDS*
*LFSA (PRs)**	**	**	**- Pulse Plasma Thruster (off structure)*
*Coarse Sun Sensor I/F Verified**	**- Propulsion System*
*X-Band Phased Array Antenna delivered and tested at Litton to verify interface*

## EO-1 Bus Integration Status

***ACDS delivery on 10/30/98 initiated intensive I&T effort to maximize testing on the spacecraft prior to start of Hyperion modifications. Approximately 137 procedures have been performed on the Spacecraft since the start of I&T ***
*Fully integrated & tested Power subsystem with exception to solar array (tested separately)*
*Integrated and tested RCS subsystem*
*Completed compressed functional test on C&DH Subsystem*
*Ninety percent of command and telemetry database has been verified*
*Successfully operated all the ACS components that have been delivered & performed limited phasing tests*
*MTB-TAM coupling calibration*
*IRU verification*
*Modified flight software based on testing on the Spacecraft*
*Have demonstrated full integration of MOC personnel into I&T team*
*Demonstrated MOC can receive Spacecraft telemetry *

## EO-1 Bus Integration Status (CONTINUED)

***In seven weeks a large percentage of the S/C interfaces have been verified. This is exceptional performance since a number of components are of new design (PSE, ACDS, PPT, LFSA, EGSE)***
***Collocation of S/W lab in 5015 has facilitated flight H/W & S/W troubleshooting***
***All components that have been delivered to Swales have been tested to some extent on the S/C with the exception to X-Band Phased Array which requires WARP***
***Overall, have completed integration of the spacecraft bus and tested through basic functionality***
*Some performance testing also accomplished: ACS, PSE, RCS*
*Some NMP payloads also integrated and tested: PPT, LFSA*
*A few problems as noted above (GPS, LFSA)*

## EO-1 Bus Integration Status (CONTINUED)

***Hyperion Modification stand down time provides opportunity to incorporate redlines captured during Phase 1 integration & work off problem reports in the following areas:***
*PSE Control loop*
*Have held meetings with MAP Engineers to resolve PWM oscillations*
- Held meetings with MAP program personnel to share information & S/W approaches
*GPS Interfaces has not been fully characterized*
*GPS H/W seems fine. Problem limited to ACDS Housekeeping  RSN I/F & S/W *
*LFSA bent pin during blind mate and thermostat wiring*
*Procedure released, approved by GSFC and Lockheed Martin, and corrective action to be started this week*
*EGSE modifications *
*Umbilical rack Solar Array Simulator (SAS) upgrade*
*Umbilical rack Power supply upgrade*
*Umbilical rack strip recorder fixes and re-calibration*
*APTS rack hardware and software upgrade*

## WOA Status

***WOA Statistics ***
*Total number generated as of 1/19/99 = 179*
*Number Closed out = 163 (91% closure rate)*
*Number open due to PRs = 20*
*GPS*
*PSE*
*LFSA*
*Number open due to WIP = 7*

## Problem Report StatusProblem Action Report Status

***PRs Statistics ***
*Total number generated as of 1/19/99 = 212*
*Number Closed out = 192 (91% closure rate)*
*Number open  =20*
*GPS*
*PSE*
*LFSA*
***Total Number of PARs = 1***
*Multiple GPS PRs have been elevated to PAR status*
*GPS interface on Housekeeping Card was not built to print one wire incorrectly placed on board*
*Flow control issue being worked by Swales and Litton *
*ACDS has been de-integrated from S/C & delivered back to Litton for re-work*
*Software Lab evaluating changes on breadboard*

## Hyperion Spacecraft Bus Modifications Status

***Hyperion Structures***
*S/C Nadir Deck drilled for base plate & Instrument Shelf (HSA)*
*Updated Base Plate design fabricated and due in 1/22/99*
*Instrument Shelf pre assembly completed this week *
*Both roll and pitch angles verified on S/C*
*Component Structural testing due to be completed next week*
*Overall schedule is several days ahead of original schedule*
***Louver/Battery Panel Modifications***
*Spare Battery panel modifications completed*
*Heater installation is in process*
*Louver re-conditioned and ready for installation*
*Louver mounting H/W completed (fitcheck w/ panel completed on 1/19/99)*
*Reintegration of test battery on panel next week*
*On schedule*

## Hyperion Spacecraft Bus Modifications Status

***Solar Array***
*Received upgraded outboard panel with GA Multi-junction cells*
*Efficiency of new circuits at 22%*
*Procedure for Re-integration of outboard panel completed and issued*
*To begin outboard panel re-integration later in January *
*Not critical path*
***S/C Harness***
*Designs completed and drawings released*
*All parts in stock*
*Will begin fabrication on flight structure following completion of mechanical modifications next week*
*Not critical path at this time*

## Hyperion Spacecraft Bus Modifications Status

***Power Supply Electronics (as of Tuesday 1/19/99)***
*LVPC completed*
*Output Modules completed (2)*
*RSN in test*
*Solar Array Module in manufacturing*
*ATP scheduled to start on Saturday the 24**th*
*At least six days behind schedule and is critical path*
*Will go to third shift during thermal cycle to reduce schedule*
***ACS Analysis***
*Held delta CDR at GSFC on December 11, 1998*
*2 of 5 action items closed (other three are informational in nature - no risk)*
*Working towards end of February closure, including new ACS FSW parameter updates*
*Not on critical path*

## Hyperion Spacecraft Bus Modifications Status

***Flight Software***
***M5***
*C&DH Changes Incorporated into Build 3.1*
*ACS Changes Delivery to C&DH Mid February 99*
*Final C&DH/ACS Hyperion Build 4.0 delivery (post ACS delivery)*
***PSE***
*PSE OM Changes Incorporated into PSE Build 6.00*
***RDL***
*RDL Changes Delivery 2/5/99 with MV Build 3.1 RDL delivery*
*Requires Special ASIST directives due to size of Cooler Command C&DH completed all data base changes and will be part of next C&DH load*
***Not on critical path***

## Hyperion Spacecraft Bus Modifications Status

***Mechanical Support Equipment ***
*Completed fabrication of new outriggers*
*Completed all sling modifications *
*Proof testing to be completed next week*
*Mechanical Ground Support hinges (2) delivered*
*Proof testing to be completed in early February ‘99*
*Not Critical Path*

## I&T Team Effort during Hyperion Mods

***Current activities that are in parallel to Mechanical/Harness rework for Hyperion and PSE work 1/99***
*Modify existing Integration PROCS to eliminate re-integration tests that are redundant*
*Developing the CPT and other systems tests*
*Working EGSE issues that affected the first integration*
*Incorporating software changes from first phase of Integration (and making Hyperion changes)*
*Working off all problem reports and completing documentation*
*Developing additional subsystem performance procedures and tests*

## Risk Mitigation

***Mechanical Area***
*Performed WARP panel I/F check*
*ALI I/F check completed between pallet and Nadir deck*
*Hyperion HSA I/F drilled from same template*
*Solar Array deployed several times at Swales and TECSTAR*
*PAF fit check to be performed in first quarter of 1999 pending fit check stand completion and availability of PAF*
*Two sets of GSE hinges have been fabricated to reduce need of panel carts. This will facilitate I&T reducing schedule risk.*

## Risk Mitigation

***Electrical***
*X-Band Phase Array Antenna I/F with RF Exciter Card verified at Litton*
*X-Band Phase Array near field test being planned for I&T*
*RF exciter Card integrated with WARP and interfaces verified*
*AST simulator being pursued by Swales and LMC*
*ALI & Hyperion 1773 interface testing was performed at GSFC to verify data interfaces*
*Atmospheric Corrector (AC) cabling was fit check on spacecraft resulting in changes to cable. Second fit check to be performed shortly.*
*PPT bell jar testing was performed to verify EMC compatibility with S/C*
***MOC personnel fully integrated with I&T team. ***
*This will facilitate future EO-1 Ground Operations and affords more reliable ground testing of the Spacecraft *

## Software Status

***Presented by ***
***Wayne Roher - Deputy I&T Manager***
***Ken Rehm - Lead Software Engineer***

## ACDS Flight Software Status

***Flight Software Review held 12/15/98***
*All Problem/Trouble Reports (PTRs) reviewed*
*Current S/W statused*
*Build plan schedule reviewed, on schedule to maintain I&T Plan*
***M5 Software - Build 3.0 (current)***
*Loaded 9/9/98*
*Includes ACS from 9/1/98*
*Includes EFF from 9/1/98*
*In place during S/C integration*
*Issues*
*FPU exception*
- Problem resolved last week

## ACDS Flight Software Status (CONTINUED)

***M5 Software - Build 3.1***
*Delivery planned 2/5/99*
*Will include Hyperion accommodation software*
*Modified bus scheduler*
*Modified command handler*
*Will include FPU exception handling software*
*Will include ACS 3.01*
*Will include EFF 3.1*
*General clean up of problem reports*
*Build currently in test*
***M5 Software Build 4.0***
*Will include ACS 4.0 - support for Hyperion*
*Will include EFF 3.2*
*Work in progress, delivery date planned post ACS 4.0 delivery*

## ACDS Flight Software Status (CONTINUED)

***M5 ACS***
*Current Build 3.0*
*Build 3.1 complete, ready for S/C*
*No new functionality strictly problem cleanup*
*Build 4.0 - Hyperion*
*Hyperion table value updates*
*Work in progress, planned delivery mid February*
***M5 EFF***
*Current build 3.0 -  9/1/98*
*Build 3.1 - General Problem cleanup, ready for M5 build 3.001*
*Build 3.2 *
*Scheduled for ACDS build 4.0*
*Add smoother algorithm*
*JPL targeter algorithm*
- Removed from flight build due to memory constraints
- Plan to upload on orbit
- Testing this configuration, working process in place

## ACDS Flight Software Status (CONTINUED)

***Comm RSN***
*Build 4.4 current - loaded 9/3/98*
*Build 4.5 - delivered*
*Change default downlink rate to 2K*
***Housekeeping RSN***
*Build 3.8 current - loaded 12/19/98*
*Testing on S/C indicates GPS interface issues*
*Build 3.9*
*Will resolve GPS IF when S/C I&T continues in February*
***ACE RSN***
*Current build 1.8027 - 12/11/98*
*“**Final” build, covers all presently documented problem reports*
*Safehold Build*
*Initial build delivered October*
*Currently in test*
*Test bread board has memory limitations*
*Final testing to be performed on S/C when available*

## PSE Flight Software Status

***PSE RSN***
*Build 5.17 current 12/29/98*
*Testing indicates charge control loop stabilized within constraints of S/W*
*H/W of charge control loop being modified and calibrated per MAP*
*Expect retest and possible minor adjustments when re-integrated in February*
*Build 6.0*
*Planned delivery 2/5/99*
*Latest MAP PSE upgrade*
*Includes Hyperion power control modifications*

## Post Hyperion Modifications I&T

***Presented by ***
***Earl Moyer - I&T Manager***

## EO-1 I&T Schedule Flow (S/C Vibration with Flight ALI)

## L-11 Months I&T FlowBOX Re-Integration & S/W Tests

***Re-integration period 2/2-2/24/99***
*Goal is to get back to where we were before de-integration for Hyperion and PSE rework*
***Software Loads, regression test and short functionals - 2/24-3/8/99***
*Housekeeping RSN (HKRSN) software loads for GPS*
*PSE RSN software loads*
*ACDS/ACS software loads*
*ACE RSN Safe Hold Mode software*

## L-11 Months I&T FlowBox Re-Integration

***Re-Integration period 2/2-2/24/99***
***Box Re-Integration Flow******	******	******	******	***
*Complete Mounting of Hyperion Base Plate*
*Complete Mounting of Hyperion Instrument Shelf Pull harness back up & fasten to Nadir Deck*
*Mount Battery/BERB to Panel 3 on BAY 3 Cart & rotate vertical*
*Mount PSE to Panel 4*
*Install IRU**	*
*Install RWAs x, y, z*
*Install MTB x & y*
*Mount TAM Sensor*
*Secure Main Structure Harness at Panel hinge lines*
*Reconfigure/Certify UC and route Umbilical Cable**	*
*Reconfigure APTS Configuration 3/Certify and route APTS cable*

## L-11 Months I&T FlowBox Re-Integration (CONTINUED)

***Box Re-Integration Flow ******(CONTINUED)***
*Reconfigure & setup ASIST W/Ss, FEDS & Battery Conditioning Rack as needed*
*Move Panel 3 to Bay 3 & position/secure at hinge line rotated 50 degs*
*Route Bay 3 structure harness onto Panel 3*
*Electrically integrate Battery/BERB to Spacecraft harness*
*Electrically integrate Umbilical to S/C harness*
*Close Panel 3 and free up Panel Cart*
*Move PSE Panel 4 to Bay 4 & position/secure at hinge line rotated 50***
*Route Bay 4 structure harness onto Panel 4 *
*Electrical integrate PSE to harness (Safe to Mate) and to UC*
*Move Panel 6 to Bay 6 & position/secure at hinge line rotated 50 degs*
*Route Bay 6 structure harness onto Panel 6 *
*Move ACDS Panel 2 to Bay 2 & position/secure at hinge line rotated 50***
*Route Bay 2 structure harness onto Panel 2*

## L-11 Months I&T FlowBox Re-Integration (CONTINUED)

***Box Re-Integration Flow ******(CONTINUED)***
*Perform CORE I&T (ACDS, PSE, EGSE, S-Band H/L Recvr, COMM RSN)*
*PSE S/W Load 5.18*
*Complete "core" PSE/BATT/ACDS/LVPC integration*
*ACE/LVPC Integration*
*Integrate APTS Rack with S/C*
*ACE RSN Test*
*ACE I/O Integration*
*TAM Integration*
*MTB Integration*
*RWA/RWE Integration*
*Latest CDH & ACS M5 S/w Load*
*IRU Integration*
*PROP I/O Integration*

## L-11 Months I&T FlowBox Re-Integration (CONTINUED)

***Box Re-Integration Flow ******(CONTINUED)***
*Run ACS B-dot Mag coupling PROC**	*
*ASC Component Phasing Verification PROC*
*Short Compressed functional*
*Move Panel 5 to Bay 5 and position/secure close to Bay 5*
*Route Bay 5 structure harness onto Panel 5*
*ECU Integration**	*
*SADA Integration*
*SADA Potentiometer, etc calibrate*
*Mount Zenith S-Band Antenna**	*
*Attach RF Load on Nadir S-Band antenna Position*
*Attach RF Hat Coupler to Zenith S-Band Antenna to S-Band RF Test Rack*
*S-Band RF Integration*
*Integrate GPS**	**	**	**	**	*
*GPS S/W Test**	**	**	**	*
*M5, PSE, ACS, SHM Flight Software tests*

## L-11 Months I&T FlowLFSA Integration

***LFSA Integration scheduled for3/2/99 - 3/3/99***
***LFSA has been mechanically mounted on spacecraft***
***Integration was started in December 98***
***Due to tight clearance of the electrical connector a pin was damaged and a repair was necessary***
***Procedure for mating this connector was modified***
***During this process it was discovered that a wrong thermistor interface was assumed and the ACDS/HKRSN interface was wrong.  A simple mod was proposed for the LFSA and incorporated.***
***LFSA has been deployed (unfolded) in the Swales electrical lab and the functionality is well understood***

## L-11 Months I&T FlowCompressed Functional

***Limited Functional and MOC testing following box re-integration   3/4/99 - 3/8/99***
*Establish a post re-integration baseline functional data set (not performance)*
*Verify telemetry parameters of health and aliveness*
*Run MOC command flow tests (this was not established before de-integration of boxes*
*Command testing from MOC required an I&T FEDS upgrade which has been done*

## Summary of Integration Activities at Swales (following Box Re-Integration)

***Rest of Integration at Swales  2.5 months (3/8/99 - 5/20/99):***
*PAF Fit Check -4 shifts*
*ALI Integration partial - 13 shifts*
*LEISA partial (Align to ALI) - 3 shifts*
*AST - 6 shifts*
*XPAA - 2 shifts*
*WARP (complete ALI, LEISA,and XPAA) - 12 shifts*
*1st Comprehensive Performance Test (CPT)/MOC Test - 10 days -24 hrs/d*
*XPAA Near Field RF Test - 2 shifts *
*Mechanical mount Hyperion STM - 2 shifts*
*Solar Array Integrate and Deployment - 4 shifts*
*Close out all Bays & Alignment Check - 8 shifts*
*Contingency - 26 calendar days*
*Pack & Ship to GSFC for environment test - 4 shifts (Mech/Elec in para)*

## L-11 Months I&T FlowPAF Fit Check

***PAF Fit Check  3/8/99 - 3/9/99***
*PAF fit check work stand available 2/15*
*Receive PAF & Clamp Band from Boeing after Mid Feb 99*
*S/A clearance measurement fixture will be used in place of actual S/A*
*Eliminated the need for a PAF harness installation at Swales since the PAF will now come with harness installed.  Although this was a parallel activity in previous schedule it required space, people and procedures*
*Perform electrical continunity test through umbilical cable & S/C umbilical connectors*

## L-11 Months I&T FlowALI Integration

***ALI Integration  3/10/99 - 3/18/99***
*Receive ALI at Swales 2/8 (date under review)*
*Move into clean room and perform post ship checkout with ALI EGSE (parallel to other S/C activities)*
*Move and mount ALI on spacecraft on 3/10*
*Will use ALI ASIST workstation with ALI STOL procedures for command and control of the ALI instrument (will be hooked into the spacecraft ASIST-FEDS network)*
*Continuous purge will utilize MIT/LL supplied Purge GSE*
*GN2 gas bottles will be supplied by a Swales contract*
*Activity precedes WARP integration therefore RS422 science data path will be checked with MIT/LL GSE*
*Schedule was adjusted based on a decision to leave ALI on for spacecraft vibration.  This eliminated the need for a ALI de-integration and re-integration, integration of Engineering test/structural units, and a CPT*

## L-11 Months I&T FlowAtmospheric Corrector (AC) Integration

***LEISA (AC) Integration  3/18/99 - 3/19/99***
*Mount and align AC Nadir instrument (if necessary) with ALI*
*Mount AC Electronics to Panel 4*
*Perform a safe-to-mate and  partial electrical integration (power and 1773 data bus)*
*Verify Command, Telemetry, RDL database/STOL procedure*

## L-11 Months I&T FlowAST Integration

***AST Integration  3/19/99 - 3/23/99***
*Delivery date of  Flight AST is questionable*
*If flight AST is not available and cannot be integrated before start of 1st CPT, the AST simulator will be electrically integrated*
*The AST simulator will allow testing of ACS software and to check the AST integration procedure, RDL database and STOL procedures*

## L-11 Months I&T FlowXPAA Integration

***X-Band Phased Array partial integration 3/23/99 - 3/25/99***
*The XPAA will be mounted to a mast on the Nadir deck*
*Electrically integrate XPAA with the 28 volt power and 1773 data bus*
*Verify Commands and Telemetry*
***A subsystem test has already been run with the WARP X-Band Exciter at Litton.***
***A 4 db Gain Compression question is under investigation, should be able to resolve during Near Field testing.***
***A complete RF test will be run as part of the WARP integration and the near field RF test.***

## L-11 Months I&T FlowWARP Integration

***WARP will be available in early March 99***
***Integration scheduled for twelve 8-hour shifts 3/25/99 - 4/2/99***
*WARP mechanical installation on Panel 1 is an off line activity*
*Position Panel 1 and route cables (1773 fiber, RS422, power and housekeeping) from S/C to Panel*
*Integrate WARP with GSFC-supplied GSE (includes instrument simulators)*
*Verify performance on spacecraft as observed in lab but with S/C power and S/C ACDS.*
*Interface with XPAA using XB RF GSE and WARP-provided GSE (X-Band front end) and repeat Instrument Simulator data.*
*Integrate ALI and AC & process data with MOC data capture system (Ampex TR and MOC FEDS).  Hyperion data simulator will be used.*
***Run Baseline WARP/Instrument functional test***
***WARP STOL procedures will be ported into a S/C ASIST workstation***

## L-11 Months I&T FlowCPT-MOC Test

***First CPT will not include Hyperion Instrument or Solar Array (S/A is considered a special test which is a follow-on to CPTs)***
***CPT and MOC test is scheduled for 96 hours over 6 work days (2 shifts per day).  We have staffing for 3 shifts a day (24-hour days) plus 4 extra weekend days if needed.***

## L-11 Months I&T FlowXPAA Near-Field Test

***Near-field measurement of the X-Band antenna mounted on the S/C scheduled for 4/12/99***
***Test time is approximately 4 hours after setup.  Some setup time in parallel with other activities.  Approximately 4 to 6 hours inline setup time.***
***Measurement consists of a moving probe antenna mounted on a square scanner( 2 x 2 feet)***
***Scanner assembly attached to s/c structure on a three point mount***
***Data output from the near-field tests are the far-field patterns and gains of the antenna for various beam scan positions***
***An inverse transform of the data will give diagnostics of the aperture distribution if needed***

## L-11 Months I&T FlowMount Hyperion STM

***Hyperion Structure/Thermal Model (STM) 2-shifts 4/12-4/13/99***
*The Hyperion STM will be installed at Swales for the spacecraft vibration and T/V tests to be done at GSFC.*

## L-11 Months I&T FlowSolar Array Integration

***Solar Array integration and Deployment test (4-shifts) 4/13/99 - 4/15/99***
*Mechanical installation in steps to allow electrical integration*
*Solar Array LAPPS test will not be performed*
*String illumination will be done to the extent to verify copper paths.*
*Electrical test includes :*
*Safe-to-mate (un-powered and powered)*
*Integrate three Coarse Sun Sensors*
*Thermal interfaces*
*Deployment/launch locks*
*Deploy S/A on air pad platform*
*Re-stow S/A in conjunction with final Bay closeouts*

## L-11 Months I&T FlowBay Close-Out & Align Measurement

***Bay closing will be done in conjunction with the planned contingency period and would be contingent with any Problem Record WOA activity.***
***Bay closing 4/15/99 - 4/22/99 scheduled prior to Contingency period:***
*Final dressing and tie-down of harness in each Bay*
*IRU alignment measurement*
*Interior Thermal Blanket dressing and secure*
*Visual inspection and picture taking*
*Close appropriate Bays for additional alignment measurements*
*Propulsion Leak test*
*Close all Bays and secure harnesses and blankets*
***Battery conditioning is a parallel and on-going activity***

## L-11 Months I&T FlowContingency

***Contingency 4/22/99 - 5/18/99***
*(weekends prior to this Contingency period are also considered additional contingency periods)*
***It is planned to use the contingency period (~26 calendar days) to get some more software and MOC testing***
***Software Testing would include further verification of the Mongoose 5 C&DH and ACS software***
***MOC testing would exercise MOC data and command procedures and provide more experience in MOC testing***

## L-11 Months I&T FlowPack & Ship to GSFC

***The S/C and GSE will be moved to GSFC for environmental testing 5/18/99 - 5/20/99***
*Packing will commence in parallel for items that are not need to maintain the planned contingency period*
*Spacecraft will be placed on the transportation dolly with the transportation cover and loaded in a closed truck*
*Load GSE and move to Goddard by truck*
*Unload in Building 7 truck lock*
*Move Spacecraft to Building 15 Mass Properties Facility*
*Move EGSE to Building 7 Clean Room Area and adjacent raised floor area*

## L-11 Months I&T Flow Setup EGSE

***The Satellite GSE will be setup, powered and certified 5/20/99 - 5/25/99***
***Data and voice comm checks will be made and verified***
***This will start the Environmental Test Flow***
***A draft of the Environmental Test Facility Flow requirements is currently out for review***

## Environmental Test Summary(without Hyperion STM)

***Mass Properties ***
***Vibration (3-axis sine sweep)***
***Clamp Band Pyro Shock***
***Move to Clean Room (100K) for Solar Array (pop and catch)***
*Class 10K CR may be required at specified times*
***Alignment Measurement***
***Special ALI EMC Tests***
***Satellite EMI/EMC***
***RF Compatibility***
***Magnetic Survey (in Bldg 7/10 tbd area)***
***Thermal Balance (vertical orientation)***
***Thermal Vac (4 cycles) (vertical orientation)***

## Environmental Test Summary(with Flight Hyperion)

***Cleanroom (100K) for Hyperion Integration***
***Alignment Measurement***
***Pre-Environmental CPT***
***2nd Mass Properties***
***Acoustic Test***
***Clamp Band Pyro Shock***
***Satellite EMI/EMC***
***Magnetic Survey (in Bldg 7/10 tbd area)***
***Thermal Vac (2 cycles) (vertical orientation)***
***Radiometric Test (under vacuum vertical orientation)***
***Post Environmental CPT***
***Ambient Focal Plane End-to-End Test***
***Post Environmental Alignment Measurement***

## Environmental Test

***Supporting Documents***
*EO-1 I&T Plan (SAI-PLAN-130)*
*EO-1 Verification Plan & Environmental Specification (SAI-SPEC-158) *
*Draft Environmental Facility Flow (white paper) dated 1/12/99*
***Working closely with GSFC Project I&T Manager (Tom Gostomski)***
***Test Plans to be completed by end of Feb 1999***
*Mass Properties*
*Vibration*
*Acoustics*
*EMI/EMC*
*Magnetic Survey*
*Thermal Balance*
*Thermal Vac*
*Radiometric (TBD)*
*Ambient Focal Plane E-T-E Test (TBD)*

## Pack & Ship to WTR

***The Satellite will be shipped to WTR directly from GSFC (9/16/99)***
***The Satellite will be placed on the transportation dolly with the transportation cover installed and shipped in a closed truck***
*Transportation Plan (Draft mid Feb ‘99)*
***GSE will be shipped with the Satellite***
***Satellite will be shipped fully integrated, except with the “test” battery***
*Flight battery will be integrated at WTR*

## Comprehensive Performance TestforEarth Orbiter 1

***22 January 1999***
***Presented by***
***Mark Perry - Lead Systems Engineer***

## Systems Tests

***Aliveness***
*Verifies that each system operates, including basic functionality; mechanical motion, where possible*
*Used when system configuration prevents a full functional test*
*After each axis of vibration*
*During launch countdown and countdown simulations*
***Functional***
*Verify every interface, command, telemetry point, and function*
*Uses EGSE as stimulus & to test systems more fully than aliveness test*
*Performed post-ship to GSFC prior to thermal-vacuum tests, & on the LV*
***Comprehensive Performance Test (CPT)***
*Measures performance of each subsystem*
*Baseline CPT performed at Swales as pre-ship test*
*Four other CPTs: one in first thermal-vacuum test, one after each set of environmental tests and once at the launch site*
***Special tests. These tests need special support equipment or are conducted only a single time. Some FDC tests are special tests. ***
***Additional orbit cycles whenever time on the S/C is available***
***MOC will run real-time orbit simulations.***

## Development of the EO-1 CPT

***Preliminary CPT developed in the fall of 1997 by Earl Moyer***
***Holding a series of working-group meetings that began with the systems engineers & now  includes the subsystem leads***
*Each satellite subsystem has a lead that is responsible for fully testing that subsystem during the CPT*
***Based on Spacecraft Test & Operating Language (STOL) Procedures as much as possible***
*Automatic command verification and limit checking*
*Executes quickly*
*Can repeat with precision*
*Directly transportable to operations team*
*Already have more than 150 STOL procedures written*
*Can check out STOL procedures before running first CPT*
***Bottoms-up, modular approach***
*Using tests developed for box testing and integration*
*Some tests re-used from aliveness and functional tests*
***Where possible, conduct tests of different subsystems in parallel to shorten the duration of the CPT***
***TRMM and XTE CPTs used for reference***

## Overview of the EO-1 CPT

***Three general phases with 11 sections***
*Begin with a launch, ascent, deployment, and sun-acquisition simulation to verify the most critical timelines on the mission and to stress the power system*
*Follow with a series of tests to verify all satellite functions and to measure system performance*
*End with several real-time, nominal orbit-cycle tests*
***The CPT is designed for ambient testing, with the solar arrays un-mounted and all the instruments and payloads integrated***
*Modified for first CPTs (without Hyperion)*
*Modified for thermal-vacuum testing (Hyperion cryocooler operations, PPT firing, and RCS pressurization will be different)*
*Modified for launch site (solar arrays will be mounted)*

## CPT Sections

***CPT0: Launch configuration. The S/C is turned on & configured as for launch. Nominal performance is verified through telemetry.***
***CPT1: Ascent through sun acquisition. From switch to internal power, through launch, ascent, separation, deployment, rate nulling, & sun acquisition following a worst-case timeline. Real time enables assessment of ACS timers & the power system. During the coast phase, additional subsystem tests gain experience in operating the S/C with 2kb/s telemetry.***
***CPT2: ACS & nominal S/C operations. Nominal configuration, execpt instruments, payloads, & WARP are off. Timeline driven by ACS tests: phasing, sensor stimulation, actuator operation, GPS, & coupling. Power, S-Band, & M5 tests conducted in parallel. S-Band requires some dedicated time.***
***CPT3: Instrument turnon, including payloads & WARP. Verify health of instrument & most functions excluding imaging.***

## CPT Sections (CONTINUED)

***CPT4: Comprehensive instrument & payload tests. Each payload performs exhaustive testing, including image data, where possible***
*CPT4A: ALI. Dark images, cal lamps, heater functions, FDC, mechanisms, processor loads, timers.*
*CPT4B: Hyperion. Dark images, cal lamps, heaters, cryocooler, mechanism, timers, FDC.*
*CPT4C: AC. Dark images, lab image, gain variations, temperature control*
*CPT4D: LFSA. Launch release, deploy, current/voltage*
*CPT4E: PPT. Single & multiple firings, both tubes, long & short pulses*
*CPT4F: EFF*
***CPT5: Comprehensive ACS testing. Complete performance testing of ACS S/W & component functions. RCS testing.***

## CPT Sections (CONTINUED)

***CPT6: Solar-array drive. Orbit rate, ramp up, ramp down, open loop test, blind acquisition of index, min/max travel limits, rewind, potentiometers, glitch test.***
***CPT7: WARP/RF. Correct image data through X-Band, correct data through MSSP to X-Band at 2 Mb/s (compare X- and S-Band data), correct pointing of X-Band.***
***CPT8: End-to-end tests & maximum rate. Correct data from instruments, through WARP & X-Band to ground storage. Test maximum data ingest: all instruments operating at the same time for 60 seconds.***
***CPT9: Safemode & load shed. Transition to safemode, ACS, all subsystems put into correct configuration. Safemode recovery***
***CPT10: Special command. Test each special command: reset processors & switch to alternate PROMs. ***
***CPT11: Orbit-cycles. As a minimum: data-collection orbit with downlink, lunar-calibration orbit, & delta-V orbit.***

## Status of System-Level Testing

***CPT architecture complete***
***Each of the subsystem leads provided a list of tests***
*Test number, title, and description*
*The CPT section to conduct the test and an estimate of the test duration*
*Subsystem configuration*
*Any special GSE requirements or differences from the nominal satellite configuration.*
*The set of tests must verify all subsystem functions and requirements. *
***The test conductors are revising and writing subsystem STOL procedures, and building top-level STOL procedure***
***The systems team has completed outlines of the aliveness and functional tests.***

## Near-Term Activities in Developing CPT

***Next week, each subsystem lead will provide***
*Test scripts (for writing STOL procedures) that describe, in detail, the actions accomplished in each test*
*A review of subsystem requirements*
*An assessment of the failure testing can be performed in the system configuration*
***By the end of February, additional information required from each subsystem lead:***
*A list of parameters that require trending analysis. The operations team will begin a long-term monitoring program for these parameters.*
*Red and yellow limits for parameters that have limits*
*Yellow limits are just outside nominal or expected operation and permit a controlled response by the TC*
*Red limits indicate impending damage to flight hardware and require immediate action*
*Input into the Command and Telemetry Handbook.** *
*Linking commands with the specific telemetry that they affect.*

## Launch Site Flow & I/F Status

***Presented by ***
***Mark Perry / Mike McCullough***

## Launch Site Processing

## Summary

***EO-1 I&T performance post ACDS delivery has been outstanding***
***PRs are being worked off or action plans are in place to resolve ***
***Open PAR related to GPS interface is in process of being resolved***
***Hyperion Modifications are in process and going well***
***Risk mitigation efforts are being pursued with rigor***
***Detail planning for re-integration and CPT is in place***
***Currently applying further resources to planning environmental testing at GSFC***
***Schedule***
*S/C Bus Contingency period is still holding, however, potential liens are AST, WARP and Atmospheric Corrector late deliveries. Weekends are reserve for problem resolution.*
*Program Contingency at Launch site is holding*
*I&T Team confident that the overall schedule is achievable without major problems developing.  Maximum resources will be applied to maintain schedule.*