# Presentation: 476251

## Spacecraft Status:

***Integration and Test***

*** ******Earl Moyer***
***EO-1 I&T Manager***
***Swales Aerospace***

## Agenda

***Agenda***

***I&T Accomplishments to Date***
*Milestone Chart*
***I&T Schedule Challenges***
*I&T Schedule Flow*
***Verification Matrix***
***Configuration of S/C during 1******st****** CPT***
***Summary of Solved Problems that Caused Delays***
***I&T Activities at GSFC Prior to Environmental Test***
*Top-Level Test Flow at GSFC*
***Environmental Test Summary***
*with Hyperion STM*
*with Flight Hyperion*
***Environmental Test***
***Daily I&T Schedule***
***Work Order Authorization Status***
***Problem Record Status***

## I&T Accomplishments to Date

***I&T Accomplishments to Date***

***Completed structure assembly and buildup***
*Completed payload attach fitting (PAF) fit check*
*Thorough checkout of all spacecraft lifting and handling procedures*
***Completed harness build, ringout and installation (including F/O cables)***
***Completed most subsystem & NMP hardware integrations (exception AST & Omni’s).  WARP and XPAA was later removed for rework***
***Additional special testing included:***
*ACS phasing test and ACS magnetic coupling characterization and safehold*
*GPS Constellation testing*
*PPT firing test in Bell Jar*
*X-Band Phased Array Near Field RF performance test*
*LFSA bench deployment demonstration, mechanically integrated with S/C*

## I&T Accomplishments to Date (CONTINUED)

***I&T Accomplishments to Date ******(CONTINUED)***

***Completed ALI and LAC instrument integration (LAC later removed for box tests)***
***Completed solar array & S/A drive integration 8 full deployments at Swales and TECSTAR***
***Performed Flight S/W load and test and regression testing of new builds (5 RSNs and M5 CDH/ACS)***
***Performed a limited comprehensive performance test (CPT)***
***Supported MOC data and command testing***
***End-to-End Science data flow and  quick-look data processing (ALI thru WARP and X-Band and DPS)***
***Full EFF test (including executing *********V *****maneuvers)***

## Slide 5

## Slide 6

## I&T Schedule Challenges

***I&T Schedule Challenges***

***Accommodated delays in ACDS, PSE and M5 S/W***
*EO-1 became path finder as it moved ahead of MAP*
***Deleted FlatSat avionics testing (bench integration) at Litton***
*Once ACDS was delivered, the core avionics and ground I&T system (ASIST/EGSE) were integrated in the S/C in 7 weeks (great team effort)*
***The addition of the Hyperion Instrument required significant re-planning***
*S/C structure modifications for Hyperion required de-integration and re-integration of the S/C subsystems (8 weeks)*
*5 weeks of in-line schedule to re-integrate and get back to the first integration level*
***Six weeks was added in parallel for PSE and ACDS mods/rework and re-qual tests***
***Added schedule time for a second integration of the WARP, LAC and XPAA***

## I&T Schedule Challenges (CONTINUED)

***I&T Schedule Challenges ******(CONTINUED)***

***The additional schedule delay allowed for ALI integration to occur at Swales instead of GSFC.  This eliminated the need for an ALI STM integration but requires the flight ALI to go through a second vibration (notched to flight limits)***
***Deleted the early EMC and Thermal Vac from the flow to compensate for the additional integration activities and on time delivery of Hyperion***
***Added schedule time for integration of the Hyperion STM & flight units***

## EO-1 I&T Schedule Flow

## Slide 10

## Configuration of S/C During 1st CPT

***Configuration of S/C During 1******st****** CPT***

## Summary of Solved Problemsthat Caused Delays

***Summary of Solved Problems******that Caused Delays***

***Rework of 1773 connector I/Fs and replacement of Transceivers***
***GPS data flow***
***LFSA Connector pin damage***
***LFSA current draw exceeded requirement***
***LAC 1773 bus packet and control error ***
***ACDS liens requiring rework and retest***
***PSE battery charge control (H/W, S/W and GSE)***
***ALI/ALICE to WARP data interface (Chip replaced on circuit board)***
***XPAA 1773 connector sleeve crack***
***Hyperion/VNIR to ALI/ALICE interference (found during STM mounting)***
***Hyperion STM mounting hole alignment error***
***CCR panel crack (stress damage possibly due to trapped wire when closing panel)***
***Flight S/W testing due to RSN and M5 S/W anomalies/upgrades***

## Work Order Authorization (WOA) Systemand Problem Report Status

***Work Order Authorization (WOA) System******and Problem Report Status***

***WOA system is documented in Swales I&T Plan.  All Problem Reports are linked to a WOA number***
***Problem Test Reports are strictly related to software testing and are reported under the Hammers Company’s CM system***
***WOA system due to the transition from Swales to GSFC the WOA/ Problem Reporting System had to be shut down prior to move to GSFC (June 3******rd****** 1999).  The system will be fully functional by Wednesday, June 9******th***

## WOA System andProblem Report Status (CONTINUED)

***WOA System and******Problem Report Status ******(CONTINUED)***

***For the purpose of the Pre-Environmental Review and to focus in on the real issues Swales has placed all open Problem Reports and PTRs into the following categories:***
*Category “A”  This is a Procedural problem and/or a well understood problem which corrective action has taken place, however has not been verified on the S/C*
*Category “B”  This is a well understood problem that corrective action has been planned but not yet implemented.  Verification of problem will be performed at a later point*
*Category “C”  This type of problem is not well understood and further study, such as S/C level testing or software testing, is required to resolve.  This category of a problem will be elevated to a Problem Action Report if not resolved prior to the Baseline CPT*
***Subsystem Leads will only discuss Category “C” Problem Reports in this review.  WOA statistics, Problem Report database and PTR database are available for review***

## WOA Status

***WOA Status***

***WOA Statistics ***
*Total number generated from 7/1/98 through 6/3/99 = 392*
*Number Closed out = 322 (82.1% closure rate)*
*Number open = 70*
***Statistics on Open WOAs***
*Open work orders associated with PRs = 32*
*Open work orders associated with WIP = 7*
*Not started WOAs (in future) = 4*
*Work orders “ready to be closed” = 27**pending subsystem lead signoff*
*Adjusted closure rate = 89.0%**(includes “ready close”)*

## Problem Report StatusProblem Action Report Status

***Problem Report Status******Problem Action Report Status***

***PRs Statistics ***
*Total number generated from 7/01/98 through 6/03/99  = 478*
*Number Closed out = 364 **	**	**	**+ 11 **(pending subsystem lead signoff)** = 375 (78.5% closure rate)*
*Number open  = 103*

## Spacecraft Status:

***Mechanical Subsystem***

*** ******Pete Alea***
***EO-1 Lead Mechanical Engineer***
***Swales Aerospace***

## Agenda

***Agenda***

***Spacecraft Changes since Hyperion Delta CDR***
***Current Mechanical Configuration***
***Verification***
*Alignment*
*Strength*
*Mechanisms*
*DPAF Fitcheck*
*Mass Properties*
***Problems***
***Issues***
***Appendix A***
*Critical Stress Margins*

## Spacecraft Changes since Hyperion Delta CDR

***Spacecraft Changes since Hyperion Delta CDR***

***Hyperion Support Structure has been added to spacecraft nadir deck.***
*HSA mounting plate drilled with TRW supplied template in Dec ‘98 and hole pattern re-verified on 5/30/99*
*Electronics baseplate re-manfactured due to change in HEA hole pattern*
***XPAA and nadir S-Band mast height increased to provide clear FOV and new base fittings fabricated to accommodate increased loads.***
***Star tracker mounting plate was changed to allow 30 degree inclination to X-Y plane***
***Battery panel replaced with spare unit to accommodate thermal louver***
***Swales/GSFC calorimeter is being added to the exterior of the Bay 4 equipment panel***

## Current Mechanical Configuration

***As of 6/5/99, the following flight hardware has not been mechanically integrated:***
*WARP, XPAA, S-Band, Hyperion, Star Tracker, Thermal Louver*

## Current Configuration Photo

- EO-1 Satellite in Swales Cleanroom

## Alignment Verification

***Mechanical Alignment measurements have been performed at the subsystem & system level***
*A secondary reference optical cube has added to the IRU to provide for mapping of the gyro to the spacecraft primary axes. The IRU SRC was mapped to the PRC prior to installation in the spacecraft.*
*A view port was placed in the Bay 2 equipment panel to allow alignment measurements to be performed while closed*
*A spacecraft master and secondary reference optical cubes were installed on the nadir deck to facilitate measurements of the ALI, ACI & HSA. Initial mapping has been performed of the MRC & SRC, however, repeat measurements will be performed when all flight subsystems have been integrated.*

## Flight Load Verification

***The addition of the Hyperion instrument has resulted in a decrease of the spacecraft fundamental bending mode frequency from 20 to 18 Hz***
***There was a corresponding increase in the spacecraft flight loads as a result of dynamic coupling into launch vehicle modes***

## Strength Verification

***A waiver was requested and granted to reduce the factors of safety from 2.6/2.0 to 2.0/1.6 for strength qualification by analysis only. This waiver applies only to pre-Hyperion structure***
***All Hyperion specific structure will comply with 2.6/2.0 FOS***
***Static Testing***
*All post-fab bonded inserts have been qualified with coupon testing preformed at SAI facility. All pullout strengths meet or exceed the minimum design requirements*
*The Hyperion support structure strut assembly was qualified by static load test at SAI to 644 lbs*
***A summary of the final spacecraft structure margins of safety are given in Appendix A***

## Mechanisms Verification

***The spacecraft mechanisms support deployment and operation of the solar array***
*Solar Array Drive, GFE from GSFC*
*Panel hinges, launch restraints, deployment hinge & cable wrap are derived from legacy programs such as XTE, TRMM, COBE, ...*
*Launch restraint was qualified by thermal and vibration testing of engineering test unit. The table below summarizes the actuation results*
*The solar array assembly has been deployed a total of eight times to date with all results nominal*

## Solar Array Deployment Sequence

## Payload Attach Fitting Fitcheck

***A fitcheck was performed between the spacecraft and the Dual Payload Attach Fitting on 3-10-99***
*Overall interface form acceptable*
*Umbilical connector brackets and kickoff spring brackets correctly placed to mate with launch vehicle*
***During fitcheck, however, significant gaps were measured at the separation ******plane ******between the ******S/C & DPAF***

## DPAF Gap Resolution

## Payload Attach Fitting Fitcheck

## Satellite Mass Properties Summary

***Subsystem hardware weight is measured prior to installation on the spacecraft***
***Solid model is updated based on latest measured weights***
***Inertia properties are calculated from solid model***

## MGSE

***All Mechanical Ground Support Equipment (MGSE) has been design and proof tested IAW NSS/GO-1740.9B, NASA Safety Standard for Lifting Devices and Equipment***
***In addition, the transportation******dolly also has a dynamic******isolation system ******(Aeroflex isolators)***

## Open Problem Reports

***WOA-213,PR: Wrong length bolts; CA: New bolts obtained and replaced, WOA closure pending final review***
***WOA-234,PR: Excessive gapping found during DPAF Fitcheck; Cause: Incorrect preload applied; CA: Remove preload and re-torque, WOA closure pending final evaluation & review***
***WOA-290,PR: Ground resistance measurements exceed 2.5 milli-ohm; CA: Apply copper film tape to connector cover to provide better contact, WOA closure pending task completion & final review***
***WOA-377,PR: Inadequate HSA to ALI connector clearance; DSP: ALICE box position modeled incorrectly, connector changed, and spacer added; CA: Move HSA VNIR Electronics by .5” in Z.***
***WOA-370,PR: Damage noticed on CCR panel at interface with zenith deck; DSP: Elevate to PAR for further investigation. Second CCR panel in process of being prepared for changeout.***

## Remaining Issue

***Sufficient HSA to ALI clearance will be provided by TRW design change of VNIR mounting brackets. Clip brackets will be bonded and fastened to the exterior of the box to allow for an additional .5” clearance.***

## Appendix A:Critical Stress Margins

## Primary StructureStrength Margins of Safety

***Primary Structure******Strength Margins of Safety***

***All Margins of Safety (MS) are positive for the EO-1 primary structure as summarized in the tables below.  Safety Factor used is listed under.***
***Zenith Deck***

## Nadir Deck

***Nadir Deck***

## Radials and Struts

***Radials and Struts***

## Equipment Panels

***Equipment Panels***

## Transition Ring

Hyperion Support Structure
Margin of  Safety Summary

***Hyperion Support Structure***
*Margin of  Safety Summary*

## Spacecraft Status:

***Electrical / Power Subsystem***

*** ******Bruce Zink***
***EO-1 I&T Lead Electrical Engineer***
***Swales Aerospace***

## Agenda

***System Block Diagrams***
***Maximum Orbit Average Power***
***S/C Bus Power Budget***
***Changes Since CDR***
***PSE Functions***
***PSE System Stability Issue History***
***PSE Spacecraft Level Testing***
***Solar Array Verification***
***Battery / Battery Enable Relay Box (BERB) Status***

***Solar Array Drive Electronic Control Unit***
***Spacecraft Harness Status***
***Power System Electrical Ground Support Equipment (EGSE)***
***Issues / Problem Reports***

## EO-1 Electronic Architecture Implementation

## Power System Block Diagram

## Maximum Orbit Average Power vs Time

- Degrading Battery (with taper)

***(Pre-Hyperion Solar Array Assumed)***

## Spacecraft Bus Power Budget

***Rack up of “as measured” powers for total system power for DCE and Standby orbits***

## Changes Since CDR

***Additional power requirements for Hyperion***
*Moved RWA’s to one output module service, providing Hyperion with two services*
*Interface fully tested during integration of RWA’s*
*Added four P2/GaAs/Ge strings of solar cells to solar array outboard panel*
*Cells fully tested at manufacturer (TECSTAR) using LAPSS*
*Cells tested after solar array integration using flood lamp illumination*
***Change in survival heater implementation by ALI***
*Focal Plane outgassing heaters took place of one survival heater service*
*Fully tested during ALI integration (and again following FPE repair)*
***Changing power requirements for various components***
*Transition from predicted values to actuals (measured)*

## PSE Qualification Test Flow

## PSE Functions

***Battery Management (Primary Task of the PSE)***
*VT Control *
*Command to VT levels per NASA Voltage-Temperature limits for 22-Cell NiCd battery*
*Flight Software shall Shunt or Open SA Segments(Coarse Control) to provide more/less current thus increasing/decreasing Battery Voltage until selected VT Curve is met*
*Flight Software shall adjust PWM circuit for fine control of battery charge current*
*Flight Software shall maintain VT level and battery current shall taper off until battery is fully charged*
*SA Segments and PWM shall compensate for loads turning on/off to maintain proper VT level*
*Trickle Charge Control*
*Battery Fully Charged (Indicated when BSOC =100%, FSW transition into trickle charge and remain at trickle charge until orbit night*
***Switched Services (SSPC; Solid State Power Controllers)***
*Provide power to the instruments and bus electronics*
*Indicates Status of its output*
*Instant trip protection*

## PSE System Stability Issue History

***System Stability (History)***
*Originally, software did not have VT Controller...one since designed*
*Oscillations occurred*
*EGSE Problem: Umbilical rack slow response in turning on SAS.  Since has been rectified using Current Limit Box in-line with umbilical*
*HW Problem: Stability Analysis was run and results were to reduce the dc gain  to increase stability margins.  (Hardware changeout....resistors)*
*SW Errors: Introduced due to lack of understanding of PSE hardware and during massive clean-up of the PSE code*
*Clean-up of aforementioned HW/SW problems resulted in stable PSE*
*VT Control verified working properly...(Battery Voltage could control more tightly to selected VT level)*
*Control loop changed from 4ms to 100ms to accommodate EGSE problem.  (May be changed back for Umbilical Current Limit Box since installed)*
*Incorporated MAP changes/suggestions*
- Allow VT loop to reduce battery current below trickle charge level
- Use Unfiltered battery current signal versus filtered signal
- Filtering LSB toggling in the control loop

## PSE Spacecraft Level Testing

***Performed Load Step Testing (results good)***
*Verified Stability and Duration Software/Hardware takes to correct changes in loads*
***Pre-CPT tests of entire S/C characterized several orbits at different VT levels***
***Further Testing of the PSE ***
_*Test FDC  functions:*_*  (Load Shedding FDC, Output Monitor FDC, Battery Backup thermistor FDC, Differential Voltage FDC)*
_*Test Battery PRT:*_*  Addition of parallel resistor with battery PRT needed.  RDL data base and PSE FSW calibration coefficients need modified*
_*Partial Power tests:*_*  Test system with less current from solar arrays.  (EOL, Eclipse)*
***Hardware/Software Model of PSE***
*Used to validate tests or changes in PSE code before actual PSE  tested*
*Model  needs to incorporate recent proportional control changes*

## Solar Array Verification

***Solar Cells***
*Full testing performed at TECSTAR*
*cell level*
*panel level electrical testing (LAPSS and isolation) and thermal vacuum cycling*
*array level LAPSS testing and flood lamp testing*
*Isolation checks as part of array electrical integration*
*Illumination test following spacecraft integration and deployment*
***Deployment Potentiometers***
*Integrated to array prior to deployment*
*Tested and monitored during deployment.*
*RDL modifications will be performed using measured data.*
***Hinge Damper Heaters***
*Integrated and tested*
*Utilized during final deployment*

## Solar Array Verification (CONTINUED)

***Temperature Sensors***
*Integrated to panel at solar cell manufacturer (TECSTAR)*
*Verified during solar array integration and deployment*
*RDL calibrations required (3 degree C error)*
***Coarse Sun Sensors***
*Integrated prior to array deployment*
*Tested using stim lamps and flashlight in both the stowed and deployed configuration*
***Harness***
*Integrated fully less the following items:*
*Potting / Staking of cable wrap interface connectors*
*Potting / Staking of hinge pot terminals*
*TC-105 installation on yoke*

## Battery / BERB

***Spacecraft currently using “I&T” battery***
*50 AH Super NiCd identical to flight battery, SN:001*
***Battery is fully integrated, including environmental closeouts***
***Battery Enable Relay Box (BERB) fully integrated***
*Thermal cycling and vibration testing done at box level prior to integration*
***Fuse plugs installed on primary power and signal connectors***
*Will be removed at launch site when flight battery is installed*

## Solar Array Drive ECUQualification Test Flow

***Solar Array Drive ECU******Qualification Test Flow***

## Solar Array DriveElectronic Control Unit

***ECU is a Schaeffer Magnetics (Moog) component to drive SADA***
***Component level testing performed by manufacturer***
***Fully integrated and tested***
***Additional testing performed during environmental closeout to ensure unit did not exhibit potential faults discovered in different units manufactured by Schaeffer (Moog)***

## Spacecraft Harness Status

***Harness verification accomplished prior to integration***
*Resistance check*
*Isolation check*
*Continuity check*
*Hi-Pot testing*
***Completed harness interface verification for all components***
*AST interface verified via simulator*
*Hyperion interface verified by TRW (harness fabricated by Swales)*
***Remaining closeout items to be completed within the next 3 weeks***

## Power System EGSE

***Battery Racks (used on TRMM)***
*Used to maintain and provide health status of the 50Ah, Super NiCd battery.**	*
*Charge, Discharge, Monitor Voltage, Current, Temperature, and Ind. Cell Info.*
*Biweekly “Top-off” -Charge until Voltage Rollover +30 minutes.*
*Periodically reconditioned.*
*Log Book and Data for Battery activities being kept.*
***Battery Cooling GSE***
*Air Conditioning Unit (provides cooling to maintain battery @ 18±5°C under normal operating conditions)*
*Battery Chiller and Cold Plate (provides additional cooling to Bay-3 Panel during overcharge periods such as reconditioning)*
***Umbilical Rack***
*Provides DPC and SAS Power to S/C.*
*Provides Signal to disable relay contacts to bring battery off the S/C bus.*
*Provides status signals (Temperatures, Sep Signals, Hardline Cmd and Telemetry)*

## Power System Problems/Issues

***Problem Records***
*7 open PRs that are category A or B  (Procedural / pending verification or corrective action planned)*
*Three category C Problem Reports*
*PR 361-20-2: Backup thermistor changes in value when PRT was open circuit.  After installation of PRT resistor, further testing will be required.  Change in value is slight and may only need to recalibrate this effect out.*
*PR 382-30-6: Day/Night flag toggled when battery current was ~2 amps.  PTR written and PSE FSW changed and tested.  Orbit_Constant2 parameter changed to match MAP code.  PR remains open because question concerning why there are two Orbit_Constant parameters.  Need further information*
*PR 391-20-1: Yellow limit observed battery module temperature.  (30.7deg C).  Limit may be set too low since on orbit temperatures will be greater than this.  Requested  further board level information so limit can be properly set*

## Spacecraft Status:

***ACDS (C&DH / ACE)***

*** ******Dave Speer***
***EO-1 ACE Electrical Engineer***
***Litton Amecom***

## Agenda

***ACDS Qualification Test Flow***
***ACDS Box Block Diagram***
***Changes Since CDR***
***Command & Data Handling (C&DH) Status***
***Attitude Control Electronics (ACE) Status***
***ACDS Problems/Issues***

## ACDS Qualification Test Flow(GSFC MIDEX Design, also used for MAP)

## ACDS Box Block Diagram

***ACDS Box Block Diagram***

## Changes Since CDR

***Modifications to HK RSN board ***
*Design changes and repairs for GPS data flow control and Sub-Second Timer Latch*
***1773 Type 3 changed to Type 4***
***Comm RSN special command changed from warm start to cold start***

## Command & Data Handling (C&DH) Status

***M5 processor interfaces to 1773 bus, Comm RSN (medium speed serial port), WARP science data recorder and APTS Rack are integrated***
***Comm RSN interfaces to PSE and for 1773 bus, Special Command Resets, S-band transponder status/commands/telemetry, Umbilical Rack and APTS Rack are integrated***
***HK RSN interfaces for 1773 bus, HOP Deployment, Solar Array Hinge ******	******Deployment potentiometers, GPS Receiver power/control/data/timing, ******	******numerous spacecraft temperature sensors, Lightweight Flexible Solar Array (LFSA), WARP PLS Command, Umbilical Rack (separation signals) and ******	******APTS Rack are integrated***
***C&DH LVPC interfaces to PSE and for GPS Power Unit, HOP Deployment power, Bay 1, 2, 3, 4, 5, 6 Heaters and Nadir Deck Secondary Heater are ******	******integrated***

## Attitude Control Electronics (ACE) Status

***ACE RSN interfaces to 1773 bus, Comm RSN, Three-Axis Magnetometer ******	******(TAM), Reaction Wheels (3x), Coarse Sun Sensors (4x) & APTS Rack are integrated***
***ACE LVPC interfaces to PSE, IRU, S/A Deployment Damper Heater, TAM, MTB converter, IRU relay converter, Latch Valve & Tank Pressure Sensor are integrated.  Power to AST & AST Heater have been tested with load simulator box, but not yet integrated with flight AST.  AST to be delivered this month.***
***PROP  I/O interfaces to PSE & for RCS temperatures & tank pressure, latch valve & thrusters are integrated.  Umbilical Rack & APTS Rack functions through ACDS J70 have not yet been integrated.  J70 integration to be completed as soon as practical at GSFC.***
***ACE  I/O interfaces for IRU, Magnetic Torquer Bars (3x), ECU & S/A Drive Actuator, S/A Yoke Deployment pot, MDE thermistor, PPT & APTS Rack are integrated.   Sync & Reset & baseplate temperature interfaces to AST have been tested with load simulator box, but not yet integrated with flight AST.   AST to be delivered this month.***

## ACDS Problems/Issues

***Problem Records***
*9 open PRs that are category B  (Procedural / pending verification or corrective action planned)*
*One category C Problem Report*
*PR 336-40-5: During CPT ACS8 with AST load box, ON command did not produce expected current delta. Careful look inside AST Load Box found no faults that could explain results.  ACE LVPC service for AST may have gone into current pulse oscillation mode for RC load.  MAP has seen similar pulses with real AST load.  Slow MOSFET switch under study for solution.*

## Spacecraft Status:

***Attitude Control Subsystem***

*** ******Paul Sanneman***
***EO-1 Lead Attitude Control Engineer***
***Swales Aerospace***

## Agenda

***ACS Architecture Block Diagram***
***Changes Since Hyperion Delta-CDR 9/98***
***Inertial Reference Unit Qualification Test Flow***
*IRU Spacecraft Level Testing*
***GPS Qualification Test Flow***
*GPS Receiver Spacecraft Level Testing*
***Reaction Wheel Assemblies and Electronics Qualification Test Flow***
*RWA Spacecraft Level Testing*
***Three Axis Magnetometer Qualification Test Flow***

***Magnetic Torquer Bars Qualification Test Flow***
*TAM and MTB Spacecraft Level Testing*
***Coarse Sun Sensor Qualification Test Flow***
*CSS Spacecraft Level Testing*
***Autonomous Star Tracker Qualification Test Flow***
*AST Spacecraft Level Testing*
***ACS Verification***
***ACS Phasing Tests Summary***
***Magnetic Testing***
***ACS Problems/Issues***

## ACS Architecture Block Diagram

***ACS Architecture Block Diagram***

## Changes Since Hyperion Delta-CDR 9/98

***Autonomous Star Tracker mounting orientation******	***
*Rotated from 10 degrees to 30 degrees away from S/C XY plane toward zenith*
*Improves Pitch axis attitude determination*
*Provides further separation from Earth limb*
***Autonomous Star Tracker Transient Suppression Assembly***
*Required to suppress electrical current oscillations which may occur during AST turn-on*
*Problem could not be fixed inside AST*
*Flight interconnect box in fabrication*

## Inertial Reference UnitQualification Test Flow — Litton G&C SS-SIRU with three HRGs

## Inertial Reference UnitSpacecraft Level Testing

***Verified functionality and phasing via Earth rate measurements ***
***Verified internal heater control of gyro platform to 60 °C***
***Verified configuration relay drivers and sequence for fault recovery***
***Trending parametric drive voltage to HRGs and duration from power-up to data valid***
***Commanded stimulated rate capability used extensively during ACS control mode phasing tests***
***Additional optical cube added to unit prior to integration to support alignment measurements ***
**1553 connector terminators to be installed**

## GPS Qualification Test Flow Space Systems Loral - GPS Tensor/RPU, Pre-Amp, Ant

## GPS ReceiverSpacecraft Level Testing

***Integrated to ACDS H/K RSN card and Power Conditioning Unit***
***Roof-top antenna used to individually verify each of four Pre-Amp channels and then each of four flight antennas attached to Pre-Amp***
***Verified GPS Receiver acquisition of time and ground-location using roof-top antenna; supported parallel connection of GPS GSE***
***GPS Constellation simulator used for end-to-end system tests***
*Validated operation through Y2K and post-GPS epoch change*
*Validated GPS data interpretation by M5 ACS FSW*
*Identified H/K RSN software problems with warm-start command capability and telemetry packet processing*
*Scheduled retest with constellation simulator to validate changes in software*

## Reaction Wheel Assemblies andElectronics Qualification Test Flow Ithaco Space Systems, Type A Wheels

## Reaction Wheel Assemblies Spacecraft Level Testing

***Mechanically mounted along S/C control axes***
***Z-axis RWA has phase inversion due to mounting orientation***
***Verified bearing/lubricant health with run-up and coast-down tests***
***Verified no detrimental interaction with power system during wheel drive-down [i.e. “electrical generator” operation]; RWA internal provides shunting of generated current***
*** ******Verified torque command and tachometer direction phasing using simultaneous observations of voltage measurements on RWA harness, hub rotation direction via window in housing and flight telemetry from both the ACE and the M5 ACS FSW***
***Expect “friction” change during S/C T/V due to vacuum; plan to test overspeed protection circuit during T/V***

## Three Axis MagnetometerQualification Test Flow SAIC/Ideas, QFM-600 w/NanoTesla sensor

## Magnetic Torquer BarsQualification Test Flow Ithaco Space Systems, TR60CFR

## TAM and MTB Spacecraft Level Testing

***Three Axis Magnetometer [SAIC/Ideas, QFM-600 w/NanoTesla sensor]***
*Verified functional and phasing with Earth field measurements and hand-held bar magnet*
*Extensive use of electrical stimulation during control mode phasing*
***Magnetic Torquer Bars [Ithaco Space Systems, TR60CFR]***
*Verified functionality and phasing with using simultaneous observations of current measurements on MTB harness, field generation using handheld compass and flight telemetry from both the ACE and the M5 ACS FSW*
*Verified MTB field coupling to TAM measurements; compensation matrix updated following initial integration and further modified after ALI integration*
*Expect slight variation in coil resistance during S/C T/V due to temperature *

## Coarse Sun SensorQualification Test Flow Adcole Corporation, Part # 29450 

## Coarse Sun Sensors Spacecraft Level Testing

***Three CSS mounted on outboard solar array panel***
***One CSS mounted on +Y side of zenith deck***
***Non-flight CSS used initially to validate S/C harness***
***APTS provides both electrical stimulation directly to ACE and target lamp for flight CSS verification - both used during control mode phasing tests***
***Verified three solar array mounted CSS with SA wiring during tests with fully integrated array on 3-JUN-99***

## Autonomous Star Tracker Qualification Test Flow LMMS/ATC AST-201 w/1773 

## Autonomous Star Tracker

***Flight AST not yet delivered; expected by 6/14/99***
***High-fidelity AST 1773 telemetry simulator used in FSW lab***
***1773 Remote Terminal simulator with AST telemetry used on S/C***
***AST Electrical load box fabricated and used during S/C CPT***
***Mechanical mounting to be performed using Swales designed plate***
***Electrical current oscillations during turn-on evidenced on both IMAGE and MAP; EO-1 unable to develop fix within AST***
*AST Transient Suppression Assembly designed and in fabrication as an interconnect between ACE LVPC and AST*
***Star Field Stimulator will be used with flight AST for functional testing both at ambient and during S/C T/V testing ***

## Attitude Control Subsystem Verification

***ACS Component functional tests performed as part of integration***
***Verified Attitude Control Electronics interfaces as part of component integrations***
***M5 ACS FSW interfaces to ACE verified using both override command capability and as part of phasing tests [next slide]***
***M5 ACS FSW control mode transitions, algorithm performance, and software performance within M5 tested extensively in FSW Lab and with a selected subset on the flight M5 using VirtualSat simulator***
*Includes GPS data processing, X-Band antenna steering, Solar Array Drive control, and Pulsed Plasma Thruster commands*
***ACE RSN Safe Hold Mode control software verified using extensive command/telemetry test, SHM phasing tests, and entry/exit test***
***Detailed MTB-to-TAM magnetic coupling data collected three times***

## ACS Phasing Tests Summary

## ACS Problems/Issues

***Problem Records***
*13 open PRs that are category A or B  (Procedural / pending verification or corrective action planned)*
*One category C Problem Report*
*PR 333-20-4: SHM timeout incorrectly cleared.  Suspect initialization issue and plan to correct in ACE V. 2.11*
*AST Late Delivery*
*Interfaces verified with simulator*
*AST power interfaces require Spacecraft modifications to prevent turn-on oscillation*
*I/F box designed and in fabrication*

## Spacecraft Status:

***Communications***

*** ******Tom Spangler***
***EO-1 Communications Engineer***
***Swales Aerospace***

## Agenda

***Changes Since CDR***
***Communications Block Diagram***
***S-Band Transponder Status/Verification***
***S-Band System Status/Verification***
***X-Band System Status/Verification***
*Near Field Test*
***S-Band EGSE***
***X-Band EGSE***
***Communications Issues***

## Communications Block Diagram

***Communications Block Diagram***

## Changes Since CDR

***S-Band***
*Backup Science Downlink Rate reduced from 4 Mbps to 2 Mbps due to WARP limitations*
***X-Band***
*Flight Attenuator sized to 3.5dB based on actual measurements of RF Exciter output and X-Band Input Threshold*
*Added a Post-Environmental Near Field Test*

## S-Band TransponderStatus/Verification

***Lockheed Martin CSX-600***
*Heritage:  TRMM*
*Ninth Transponder in SMEX Order of Ten*
***Integration onto S/C Bus***
*Interface to COMM RSN (verified)*
*Interface to Hybrid/Coupler/Antenna Network (verified)*
***Functional Testing***
*Manufacturer performed extensive Box-Level Functional Testing*
*Component functions verified during system testing*

## S-Band SystemStatus/Verification (CONTINUED)

***Integration onto S/C Bus***
*COMM RSN Output, Transponder, 3dB Hybrid, 20dB Coupler (verified)*
***Functional Testing***
*Limited Functional testing performed*
*Full functional before RF Compatibility test*
***Performance Testing***
*RF Compatibility test verifies performance parameters*
*Best-Lock Frequency*
*Phase Modulation Index*
*Acquisition Threshold/Rate*
*Command Threshold*
***Overall Status***
*No outstanding hardware issues*
*Problems to date related to setup/GSE issues*

## X-Band System Status/Verification

***Integration onto S/C Bus***
*Power and 1773 interfaces (verified)*
***Functional Testing***
*Combined testing On and Off spacecraft*
*Command and Telemetry exercised (manual and ACS)*
*Limited Dataflow performed (WARP Fill Data)*
***Performance Testing***
*Performance parameters measured during NFT*
*Full Performance Test (with Orbit Simulation) in development*
*Second NFT (on spacecraft)*
*RF Compatibility Test will verify test data.*
***Overall Status***
*Characterization of system*

## X-Band Near Field Test

***Objectives***
*Provide a full characterization of the phased-array antenna*
*Each of 64 elements are verified as having nominal output*
*XPAA beam steering is verified*
*Transform to Far-Field indicates radiation pattern on orbit*
***Pre-Integration NFT***
*XPAA working nominally*
*All 64 elements radiating as expected*
*XPAA commands were verified prior to integration*
***Post-Environmental NFT***
*Necessary to validate XPAA prior to launch*
*Verify no elements were damaged during environments*
*XPAA cannot be characterized in any other way*
*Hat coupler on ACTIVE antenna does not provide enough information about health and safety of the antenna*
*Last Pre-Launch Verification other than aliveness*

## S-Band EGSE

***Main Components***
*Switching Unit (Hybrid, Couplers, Attenuators)*
*Microdyne TSS-2000 Signal Simulator*
*Microdyne Signal Receiver*
***Post-Shipment Verification (to GSFC)***
*EGSE checkout proved nominal operation*
***Issues***
*GSE Transmitter failed*
*Manufactures fixed problem and returned the unit operating as expected*

## X-Band EGSE

***Main Components***
*Scientific Atlanta Bit Sync/Signal Conditioner*
*Scientific Atlanta Demodulator*
***Issues***
*Equipment Operating Nominally*
*Currently In Use For WARP Testing*

## Communications Issues

***Outstanding PRs***
*The appropriate GN Amplitude must be determined for downlink rates*
*Issue to be resolved by S-Band Functional Test*
***Limits***
*X-Band and S-Band Limits*
***Software Changes***
*FDC Settings Changed in XPAA*
*Event Messages from XPAA*
*Requires new load of XPAA RSN software*

## Spacecraft Status:

***Software***

*** ******Gary Smith***
***EO-1 Lead Software Engineer***
***Litton Amecom***

## EO-1 Flight Software Overview

***Changes Since CDR ***
***Status of Software Revision Levels ****** ***
***FSW Testing Program ***
***Outstanding Problems ***

## EO-1 Context Diagram

## Mongoose V Applications

## Software Heritage

***Inherited the software design from MAP***
***90% reuse from MAP***
***The bulk of the effort involves developing and testing EO-1 specific schedule table***
***EO-1 tightly coupled to MAP’s Build testing at the task level ***
*Maps requirements testing and traceability is approximately 95% complete*

## MAP Inheritance

***Documentation***
*Development Plan*
*Test Plan*
*CM Plan*
*Design Review*
*Test Procedures*
*1773 ICD*
***RSN Software  and Specifications***
*Generic RSN*
*Transponder RSN*
*PSE*
*H/K*

***M-V Software and Specifications***
*All M-V Applications*
***GSE***
*NT GSE*

## Major M5 Changes since CDR

***CPU Utilization reduced to approximately 38%***
***Optimized DRAM Memory settings to significantly reduce CPU utilization***
***Implemented Cold/Soft Power-on after predetermined number of Cold Restarts***
***Incorporated EFF S/W into standard M5 integrated build process***
***Updated TSM to 256 monitor points, 64 derived monitor point functions***
***MV FPU Exception Handling S/W to resolve major FPU underflow problem***
***Telemetry and Statistics Monitor Updates***
***Modified Software bus queue sizes to accomodated  EFF Software requirements***
***Incorporated changes for the Hyperion Interface***
***Implemented Critical Task Check-In Table***
***Modified MV S/W to use Virtual Channels (VC) 4 and 14 for Virtual Recorder (VR) 3 ***
***Added LFSA Telemetry Packet***
***Increased SC ATS Buffer size to provide 7 days of autonomous operations***
***HKRSN command length increase for GPS Almanac & ephemeris packets***
***Incorporated new TO and DS Filter Tables requirements***

## Changes Since CDR

***PSE RSN***
*Control Loop Stabilized*
*MAP’S V/T Control Algorithm incorporated*
*Hyperion updates incorporated*
***S-BAND Communications RSN***
*Maximum Playback limited to 2 Mbps*
*Default telemetry rate set to 2 Kbps*
***ACE RSN***
*Safe Hold Control Software implemented*
***HK RSN***
*HOPS Deployment Changes incorporated*
*GPS interface operational*
*LFSA commands and telemetry incorporated*

## EO-1 Software Status

## EO-1 Flight Software Integrationand Test Strategy

***EO-1 Flight Software Integration******and Test Strategy***

***Testing of EO-1 Flight Software modules occurs at three levels:***
*Build Testing*
*Spacecraft S/W Installation Checkout *
*Acceptance Testing*

## Build Test Process

***Build testing at the task level ***
*Test program relies on MAPS build test program*
*MAP Discrepancy Reports (DR) monitored for EO-1 impacts.*
***EO1 Specific requirements ***
*Verified and tracked through the PTR system*
*EO-1 unique traceability Matrix maintained for subsystems requiring significant modifications to MAP’s inherited S/W*
*Telemetry Output (TO), Command Ingest (CI), External Bus (XB), etc.*
***ACS, EFF, and C&DH Build tested separately in the S/W Lab before final integrated delivery***

## Spacecraft Software InstallationCheckout Testing

***Spacecraft Software Installation******Checkout Testing***

***Verifies the EO-1 MV Integrated software build***
***Includes a verification of the software load ***
***Verification of PTR fixes ***
***Regression tests from previous PTR fixes ***
***Performs an EFF basic test ***
***Performs an ACS basic test ***
***Executes the EEPROM version of the code***
***Also executes the PROM version of the code ***

## Acceptance Test Process Overview

***Focuses on testing the flight software from a mission operational perspective***
*The tests were designed to verify from an operational perspective that the EO1 Flight Software was capable of meeting its main objective of supporting the validation of the New Millennium technologies. *
***Performance and Stress tests***
*Normal and contingent operational scenario performance and stress tests were executed via STOL procedures by the test team. *

## Software Test Summary Report

***All test that were performed on the EO-1 spacecraft were reviewed and approved by the appropriate individuals***
***The test team included the software engineers who coded and build-tested the code, ACS analysts, Flight Operations Team Personnel, I&T Test Conductors, and Systems level support and engineering***
***Tests were performed in the Swales I&T environment using a combination of flight hardware and simulators***
***The EO-1 Spacecraft software testing performed continuously for 96 hours***
***No Major Deficiencies were identified as a result of the tests***

## ACS/ACE FSW Acceptance Testing

***ACS Software Acceptance Testing***
*40 Build 3.1 tests run on ACS software string**	*
*39 tests passed*
*1 failed test fixed with Build 4.0*
*20 Build 4.0 regression tests run on ACS software string*
*all 20 tests passed*
*16 Build 4.0 regression tests also run on SC*
*all 16 tests passed*
*Currently regression testing Build 4.1 on ACS software string*
*Open loop phasing tests have been successfully completed for Build 4.0*
***ACE Safehold Acceptance Testing***
*Will formally run closed-loop ACE safehold tests on a Vsat platform  (preliminary tests have been successful)*
*Open loop phasing tests have been successfully completed for Build 2.1*

## Open Problem / Trouble Reports (PTR)

***Problem Reports***
*Two Category C Problem Reports*
*PTR0602 Delay from Commanding to Receiving Telemetry. PTR still under investigation *
*PTR0586  Housekeeping RSN losing GPS packets. PTR still under investigation - expected to be closed in Build 4.8 *
***Software PTR Statistics******	***

## Spacecraft Status:

***Reaction Control System***

*** ******Mike McCullough***
***EO-1 Lead Propulsion Engineer***
***Swales Aerospace***

## Agenda

***EO-1 Reaction Control System***
***Component Verification***
*System Verification at PRIMEX*
*System Checks at Swales*
***Problem / Failures***
***Propellant Line Stand-Off Bond Failure***
***Inadvertent Catalyst Bed Heater Actuation***
***Open PR’s / Remaining Tests***

## EO-1 Reaction Control System

***EO-1 Reaction Control System***

***Propellant Tank***
*PSI P/N 80389-1*
***Thrusters***
*PRIMEX MR-103G*
***Latch Valve***
*Moog 51-204*
***Fill/Drain Valves***
*Moog 50-836/7*
***Filter ***
*Wintec 15241-772*
***Pressure Transducer***
*Paine 213-76-570-01*

## Component Verification

***Propellant Tank***
*Determination of Volume,*
*Proof Pressure Test*
*Internal and External Leakage Test*
*Radiographic/Penetrant Inspection*
*Visual Inspection and Cleanliness*
***Fill/Drain Valves***
*Inspection & Cleanliness*
*Proof Pressure*
*Internal and External Leakage*
*Operational Cycles *
***Filter***
*Proof Pressure*
*External Leakage*
*Bubble Point and D-P*
*Visual Inspection and Cleanliness*

***Latch Valve***
*Internal and External Leakage*
*Visual Inspection and Cleanliness*
*Operating Cycles*
*Vibration*
***Thrusters***
*Hot Fire Performance*
*Decontamination & Cleaning*
*Proof Pressure, Vibration*
*Internal & External Leakage*
*Pull In / Drop Out Voltage*
***Pressure Transducer***
*Vibration*
*Proof Pressure*
*Calibration *
*Electrical Characteristics*

## System Verification at PRIMEX

***System Welds***
*Leak Checked, Dye Penetrant and Radiographic Inspection*
***Proof Pressure Checks***
*High Pressure Proof Pressure Test (820 psig) excl. Tank*
*Complete System Proof Pressure Test  (480 psig)*
***Internal Valve Leak Checks***
*Thruster and Latch Valve Seats Checked Individually*
***Electrical Component Resistance and Isolation Checks***
***System Level Functional Checks***
*Thrusters, Latch Valve, Pressure Transducer, Thermostats*

## System Checks at Swales

***Electrical Component Resistance and Isolation Checks***
***System Integration with Spacecraft***
***System Level Functional Checks***
*Pre- and Post Integration*
*Thrusters, Latch Valve, Pressure Transducer, Thermostats*
***Thruster Phasing***

## Problem / Failures

***Two Major Problems/Failures Encountered during RCS Integration and Test***
*Propellant Line Stand Off Bond Failure*
*Inadvertent Catalyst Bed Heater Activation*
***Both Problems Resolved***

## Propellant Line Stand-Off Bond Failure

***Propellant lines affixed to the zenith deck with composite glass epoxy stand-offs***
***3M 2216 (Grey) Adhesive Used by PRIMEX to speed assembly process***
***Clean separation of the bond observed under little or no stress***
***Suspected insufficient bond line thickness or contamination***
***Swales / PRIMEX team was unable to achieve adequate bond strength using a variety of adhesives and cleaning techniques***
***Ultimately standoffs were affixed using #4-40 hardware and a custom washer to distribute clamping loads***
***Solution demonstrated superior strength characteristics while retaining desired thermal isolation***

## Inadvertent Catalyst Bed Heater Actuation

***During Testing of Enhanced Formation Flying (EFF) Software Package***
***Uploaded RTS which exactly duplicated steps for EFF operation***
***RTS included two 31 minute catalyst bed heater actuation cycles***
***Concerns of Cat Bed Oxidation Discussed with PRIMEX***
***Thermal Analysis performed predicted Cat Bed temperatures ******approached 405F***
***PRIMEX performed thermal cycling to 405F which duplicated the EFF testing scenario***
***5 EFF test cycles (31 minutes on, 20 minutes off, 31 minutes on) resulted in no appreciable damage to the test catalyst material using H2 chemisorption testing***

## Open PR’s / Remaining Tests

***No Open Problem Records***
***Pressure Cycling Limited by Propellant Tank Fracture Mechanics Analysis***
*Post Vibration Pressure Cycle to MEOP*
*End to End Pressure Transducer Calibration*
*Thruster & Latch Valve Leak Checks*
*RCS Functional Demonstration at Launch Site*
*Upon Arrival at Range*
*Per EWR 127-1 Paragraph 3.12.2.11.3*
***FMA - 5 Cycles to Proof, 10 Cycles to MEOP***
***To Date - 2 Cycle to Proof, 4 Cycles to MEOP***

## Spacecraft Status:

***I&T GSE***

*** ******E.J. Bickley***
***EO-1 Lead Test Conductor***
***Jackson & Tull***

## Agenda

***Front End Data System (FEDS) Status***
***Umbilical Console Status***
***Advanced Spacecraft Interface for System Test (ASIST) Status***
***ACDS & PSE Test Set (APTS) Status***

## Front End Data System (FEDS) Status

***Functions:***
*Telemetry decoding and routing*
*Command Structure & Format*
***Hardware:***
*Time Code Generator*
*PSK Modulator*
*PCM Bit Synchronizer*
*DEC Alpha with serial board for command generation*
*	**Hard disk (RAID) array for telemetry archival (34 gigabyte storage capacity)*
***Software:***
*FEDS version 6.2 [in use since 4/99]*
***Liens***
*Final SW release not yet installed*

## Umbilical Console Status

***Functions:***
*Battery management using Solar Array Simulator (9 power supplies to simulate 10 Solar Array strings)*
*Battery OFF-LINE command capability*
*Provides analog data status for: battery current and voltage, S/C BUS voltage, battery temperature, RCS tank temperature, RCS tank pressure, S/C BUS current*
*Simulates separation function of PAF*
*Hardline command and telemetry interface*
*Trickle charge power and control for battery*
*	**Provides a TCP/IP link with ASIST for GSE commands and umbilical telemetry status*
*	**Provides capability to power spacecraft without battery*

## Umbilical Console Status (CONTINUED)

***Hardware:***
*Micron Pentium PC*
*9 Sorenson power supplies (SAS and DPC)*
*1 HP Solar Array Simulator Power Supply*
*Custom interface for analog signal processing*
*Internal battery for emergency power OFF of spacecraft battery*
*Emergency power OFF activated by push-button switch *
***Software:***
*NTGSE release 9/17/98.*
***Liens***
*None*

## Advanced Spacecraft Interface for System Test (ASIST) Status

***Functions:***
*Telemetry processing and display using RDL based database*
*Command distribution using RDL based database.*
*STOL procedure interface with spacecraft*
*GUI environment for telemetry page displays*
***Hardware:***
*4 IBM RS6000 based workstations (Power PC), 1 IBM RS6000, and 1 X-term*
***Software:***
*ASIST version 7.0.f [in use since 4/99]*
*Currently upgrading to version 7.0.g*
***Liens***
*Final I&T SW release expected to be 7.0.h. Installation on or about 6/7/99*

## ACDS & PSE Test Set (APTS) Status

***Functions:***
*GSE interface with ACE sub-system*
*GSE interface for EEPROM loads to flight hardware*
*Provides a TCP/IP link with ASIST for GSE commands and telemetry status*
*Labview environment for command and status displays*
***Hardware:***
*2 standard lab power supplies, VXI rack interface*
***Software:***
*3.1 *
***Liens***
*APTS ASIST link not fully functional more manual operation required*