Wendell H. Booth

ZIN Technologies, Incorporated, Middleburg Heights, Ohio

Boiling Experiment Facility (BXF):

Post Flight Assessment

Anomaly Investigation Report

NASA/CR—2012-216036

December 2012

60081–RPT–0402
http://www.sti.nasa.gov

help@sti.nasa.gov
Wendell H. Booth

ZIN Technologies, Incorporated, Middleburg Heights, Ohio

Boiling Experiment Facility (BXF):

Post Flight Assessment

Anomaly Investigation Report

NASA/CR—2012-216036

December 2012

60081–RPT–0402
Level of Review
NASA/CR—2012-216036 iii

Contents

1.0 Introduction ........................................................................................................................................... 1

1.1 Background ................................................................................................................................. 1

1.2 Purpose ........................................................................................................................................ 2

1.3 Scope ........................................................................................................................................... 2

2.0 Documents ............................................................................................................................................ 2

3.0 Investigation Results ............................................................................................................................. 2

3.1 Exterior Visual Inspection and Packing at KSC ......................................................................... 3

3.2 Unpacking and Exterior Visual Inspection at ZIN ...................................................................... 3

3.3 Voltage Bus Resistance Check ................................................................................................... 3

3.4 Functional Check ........................................................................................................................ 4

3.5 Dissolved Gas Concentration Measurement ............................................................................... 4

3.6 High Speed Camera Alignment Check ....................................................................................... 4

3.7 24 Vdc Bus 1 Anomaly Check .................................................................................................... 4

3.8 Containment Vessel Gas Sampling ............................................................................................. 5

3.9 Containment Vessel Disassembly: Inspect Interior and Install CV Legs ................................... 5

3.10 24 Vdc Bus 1 Component Resistance Check .............................................................................. 5

3.11 Pre-Drain Fluid Sampling and Analysis ..................................................................................... 6

3.12 Flight Hardware Drain/Fluid Disposal ........................................................................................ 6

3.13 Pressure and Temperature Measurement Accuracy Check ......................................................... 7

3.14 Containment Vessel Disassembly: Uninstall CV Top Plate/CV Fan Visual Inspection

and Touch Test ............................................................................................................................ 7

3.15 Room Temperature Leak Test ..................................................................................................... 8

3.16 Elevated Temperature Leak Test ................................................................................................ 8

3.17 BXF Embedded Controller Inspection and Bench Test .............................................................. 8

4.0 Conditional/Optional Investigation ....................................................................................................... 9

4.1 2.7 mm MABE Embedded Controller Inspection ....................................................................... 9

4.2 7.0 mm MABE Embedded Controller Inspection ....................................................................... 9

4.3 Avionics Box Output Voltage Test ........................................................................................... 10

4.4 Avionics Box Interior Visual Inspection .................................................................................. 10

4.5 Bulk Fluid Heater Extraction and Inspection ............................................................................ 10

4.5.1 Extraction and Visual Inspection (Section 3.1 of PLAN–0394) ..................................... 10

4.5.2 Post-Extraction Resistance Check (Section 3.2 of PLAN–0394) ................................... 11

4.5.3 X-Ray Inspection (Section 3.3 of PLAN–0394) ............................................................. 11

4.5.4 Heater Wiring Dissection (Section 3.4 of PLAN–0394)................................................. 11

4.6 FOD Analysis ............................................................................................................................ 12

5.0 Conclusions ......................................................................................................................................... 12

5.1 High Speed Camera Misalignment ........................................................................................... 12

5.2 Dissolved Gas Concentration .................................................................................................... 12

5.3 On-Orbit Anomaly .................................................................................................................... 12

Appendix A.—Acronyms and Abbreviations ............................................................................................. 15

Appendix B.—Functional Check Details .................................................................................................... 17

Appendix C.—HSC Alignment Check Images ........................................................................................... 35

Appendix D.—Extraction and Visual Inspection Photos ............................................................................ 37

Appendix E.—X-Ray Inspection Photos .................................................................................................... 79

Appendix F.—Approvals .......................................................................................................................... 141

Appendix G.—Revisions .......................................................................................................................... 143

Reference .................................................................................................................................................. 144

NASA/CR—2012-216036 1

Boiling Experiment Facility (BXF): Post Flight Assessment

Anomaly Investigation Report

Wendell H. Booth

ZIN Technologies, Inc.

Middleburg Heights, Ohio 44130

1.0 Introduction

The Boiling eXperiment Facility (BXF) is an experiment package designed for the Microgravity

Science Glovebox (MSG) located on the International Space Station (ISS). Two experiments operate in

this facility, the Microheater Array Boiling Experiment (MABE) and the Nucleate Pool Boiling

Experiment (NPBX). The working fluid used by the facility is perfluoro-n-hexane.

MABE utilizes two arrays of microheaters along with measurement circuitry to record the local heat

transfer characteristics on the surface of the heaters during boiling in a microgravity environment. Each

heater is individually controlled to operate at a constant temperature.

NPBX consists of an array of five microcavities, or nucleation sites, on the surface of a polished

aluminum wafer. The heat applied to each nucleation site is individually controlled, and the data obtained

will be used to further the understanding of the heat transfer associated with nucleate boiling heat flux.

1.1 Background

BXF was turned over to NASA and packaged for launch aboard space shuttle flight ULF-5 in October

2010. After a lengthy delay, ULF-5 launched on February 24, 2011. BXF was installed into MSG and

began Flight operations on March 22, 2011 (GMT 2011/081). BXF operated successfully for the next

3 weeks with the exception of five problems. The High Speed Camera image of the 7 mm MABE Array

was out of alignment such that one row and one column of the array could not be seen in the image.

During Week 2, the dissolved gas concentration was measured at 299 ppm, which exceeded the

requirement of < 100 ppm. The Space Acceleration Measurement System (SAMS) unit that was to

provide acceleration data for BXF was inoperable. Data from another unit was used instead. The

connector from MSG video recorder 4 to the downlinking system was disconnected for a short period,

and there were problems with the MSG laptop computer (MLC) that prevented file transfer from BXF

during the calibration activities.

On April 11, 2011 (GMT 2011/101), the dissolved gas concentration was measured at 712 ppm, and

on that day a major anomaly occurred. The voltage on 24 Vdc Bus 1 dropped unexpectedly to about 6 V,

and an off-nominal current was drawn from MSG. This condition went unnoticed for approximately

8 min at which point a fluid loop pressure warning occurred. The BXF system entered into safe mode and

tripped the safety circuit to remove power from the heaters and motors. It was observed that all pressure

readings and some temperature readings were off-nominal. Attempts were made to recover by resetting

the embedded controllers (ECs), restarting the BXF software, and cycling power to BXF. All attempts

failed. The system was shutdown.

Over the next couple of weeks, multiple meetings and an Engineering Review Board (ERB) were

held to study the data collected, propose possible root causes, determine methods for troubleshooting onorbit, and put together a plan and procedure for carrying out troubleshooting on-orbit. Reference the

Anomaly Troubleshooting ERB Presentation slides in Appendix E of the Mission Summary Report,

60081-RPT-0404. On April 27, 2011 (GMT 2011/117), the on-orbit troubleshooting was performed. The

results of the troubleshooting indicated a possible electrical short on 24 Vdc Bus 1. It was also determined

that with the 24 Vdc Bus 1 circuit breaker open, some NPBX science could still be obtained. One more

week of operations with modified procedures was performed to obtain some limited NPBX science.
NASA/CR—2012-216036 2

BXF was returned on space shuttle flight ULF-7, and Post-Flight troubleshooting activities were

performed in accordance with the BXF Post-Flight Assessment Anomaly Investigation Plan, 60081-

PLAN-0383.

1.2 Purpose

This document serves as the report for presenting the results and conclusions of investigation

activities that were performed to determine the root causes of the anomaly, camera misalignment, and

dissolved gas concentration issues and to verify the calibration and accuracy of the pressure and

temperature measurements.

1.3 Scope

This report covers the results of Post-Flight Assessment (PFA) investigation activities that were

performed on the BXF Flight hardware per 60081-PLAN-0383.

2.0 Documents

The following documents are applicable to this report.

Document Number Document Title

60081–PLAN–0383 Post-Flight Assessment Anomaly Investigation Plan

60081–PROC–0390 Post-Flight Assessment Hardware Visual Inspection at KSC

60081–PROC–0368 Packing and Shipping Procedure

60081–PROC–0384 Voltage Bus Resistance Check for Anomaly Investigation

60081–PROC–0378 Flight Operations Anomaly Troubleshooting Procedure

60081–PROC–0379 NPBX Background Heaters Only Flight Operations Procedure

MGUEMSGBXFN001 BXF Setup Crew Procedure

60081–PROC–0391 Containment Vessel Gas Sampling Procedure

60081–PROC–0304 Containment Vessel Assembly Procedure, 60081M01A205

60081–PROC–0385 24Vdc Bus 1 Component Resistance Check for Anomaly Investigation

60081–PROC–0392 Pre-Drain Fluid Sampling and Analysis Procedure

60081–PROC–0397 Fluid Vapor Pressure Determination, FOD Collection, and Fluid Transfer Procedure

60081–RPT–0399 Post-Flight Pressure Measurement Verification Report

60081–RPT–0400 Post-Flight Temperature Measurement Verification Report

60081–PROC–0300 Fluids System Leak Test Procedure

60081–PROC–0393 Fluids System Leak Test at Elevated Temperature

60081–RPT–0401 Post-Flight Assessment BXF EC Engineering Checkout Report

60081–PROC–0075 Avionics Box Test Procedure

60081–PLAN–0394 Post-Flight Assessment Cartridge Heater Inspection Plan

60081–PROC–0395 Cartridge Heater Post-Extraction Resistance Check

60081–PROC–0396 Cartridge Heater Wiring Dissection

60081–PROC–0389 Post-Flight FOD Collection Procedure

3.0 Investigation Results

The following subsections give brief summaries of the results for each investigation activity that was

conducted on the BXF Flight hardware. Only brief summaries are given. Detailed results are documented

in individual reports, as-run procedures, attachments to the as-run plans, or appendices of this report as
NASA/CR—2012-216036 3

specified in each subsection. Only results of activities are presented. For detailed information on each

activity itself, reference 60081–PLAN–0383.

3.1 Exterior Visual Inspection and Packing at KSC

At the beginning of the visual inspection at Kennedy Space Center (KSC), it was observed that the

BXF Flight hardware components were positioned and oriented in a disorganized manner. The

Containment Vessel (CV) was located on a cart, and the remaining components were located on a table in

the center of the lab. A few Non-BXF Flight components were mixed in with those of BXF.

In general, there were no findings that could be readily associated with the anomaly during the KSC

visual inspection. All components were in their packings. Some packings were open, and some had minor

tears and punctures. Some components were observed to have minor marks and scratches. Notable

observations were as follows.

Minor damage found on connector P108 of cable W301

Dirt and minor damage found on the HSC Mirror

Missing protective CCD cap of HSC S/N 001

Fingerprints and damaged thermal pad on AB Mounting Plate

HSC Processor S/N 001 appeared to be unused—ramification being that HSC Processor S/N 002

was the one used on orbit.

Details for the visual inspection and packing of the hardware are documented in the as-run procedures

60081–PROC–0390 and 60081–PROC–0368, respectively. Both are located in manufacturing work order

(MWO) 60081M01L123–01.

3.2 Unpacking and Exterior Visual Inspection at ZIN

Additional observations were made by the technicians during unpacking of the hardware after arrival

at ZIN.

Pin E of connector P302 was found to be slightly bent

Connector P8 of Cable W205 was not capped

Minor damage found on CV Mounting Plate

Debris found on outside of 2.5 mm MABE Lens

RTV was missing from a screw located on top of the Avionics Box near connector J1

None of the additional observations made could be readily associated with the on-orbit anomaly.

Details are documented in the as-run procedure 60081–PROC–0368 located in MWO

60081M01L123–01.

3.3 Voltage Bus Resistance Check

The Voltage Bus Resistance Check found a short between the 24Vdc Bus 1 voltage line and the J101

connector shell (CV structure). The resistance measured was 5.43 A bonding measurement between

connector J101 and the CV structure also failed. The bond resistance was 43 These results showed

that there was a problem located somewhere within the CV.

Details are documented in the as-run procedure 60081–PROC–0384 located in MWO

60081M01L123–01.
NASA/CR—2012-216036 4

3.4 Functional Check

The Functional Check successfully demonstrated that the BXF Flight hardware functional capability

was the same as it was just prior to being disassembled and stowed on orbit.

Some details are documented in the as-run procedure 60081–PROC–0378 located in MWO

60081M01L123–01. Remaining details are in electronic form located in Appendix B of this report.

3.5 Dissolved Gas Concentration Measurement

The Dissolved Gas Concentration, measured August 18, 2011, after return to ZIN, was found to be

603 ppm at a fluid temperature of 21.5°C and a fluid pressure of 0.36 atm. For comparison, the following

table shows a list of Dissolved Gas Concentration values over time during Flight operations.

Date Gas concentration,

ppm

Fluid temperature,

°C

Fluid pressure,

atm

March 21, 2011 (GMT Day 081) –46 30.3 0.35

March 31, 2011 (GMT Day 091) 299 33.1 0.46

April 3, 2011 (GMT Day 094) 261 23.1 0.31

April 10, 2011 (GMT Day 101) 712 24.8 0.42

April 26, 2011 (GMT Day 117) 737 23.6 0.41

May 8, 2011 (GMT Day 129) 589 23.1 0.37

May 11, 2011 (GMT Day 132) 543 30.1 0.46

Based on the measurements made Post-Flight and throughout operations, the gas contamination

leakage appears to have stopped when on-orbit testing ended in May 2011.

The PFA Dissolved Gas Concentration Measurement is documented in the as-run procedure 60081–

PROC–0379 located in MWO 60081M01L123–01.

3.6 High Speed Camera Alignment Check

Assembly of the BXF Flight hardware per MGUEMSGBXFN001 did not result in an HSC Camera

misalignment on the ground as severe as that observed on orbit. Troubleshooting found that a

misalignment more similar to that observed on orbit could be induced by unloading the HSC Mounting

Bracket and not fully seating the MABE lens against the HSC Alignment Bracket set screws.

These observations suggest that minor compliance in the camera mounting hardware, incomplete

seating of the lens on the set screws, or a combination of both of these factors could have caused the

image misalignment observed on-orbit. The one attempt that was made to correct the alignment during

Flight operations was unsuccessful. It is possible, with further opportunities to iterate, that proper

alignment could have been achieved during Flight operations. The potential for success, however, would

have been hindered by the following factors: crew time constraints; the inability to have the system

powered during alignment for image viewing; and the lack of a high fidelity Engineering Model to utilize

for guidance and assistance. These factors would have likely made future attempts similarly unsuccessful.

Details are documented in an attachment to the as-run BXF PFA plan, 60081–PLAN–0383, located in

MWO 60081M01L123–01. The HSC images acquired during the alignment check can be found in

Appendix C of this report.

3.7 24 Vdc Bus 1 Anomaly Check

In accordance with the BXF PFA plan, the 24 Vdc Bus 1 Anomaly Check was not performed,

because the BXF Flight hardware failed the Voltage Bus Resistance Check of section 3.3 of the plan.
NASA/CR—2012-216036 5

3.8 Containment Vessel Gas Sampling

This activity was not originally part of the BXF PFA plan but was added due to growing concern that

a Bulk Fluid Heater may have overheated and generated perfluoroisobutene (PFIB) from the BXF Fluid.

PFIB is a hazardous gas and has an acceptable exposure limit of only 10 parts per billion. The intent of

the CV Gas Sampling was to determine whether any fluid, and possibly PFIB, might be present in the CV

interior space.

Two samples of gas were taken from the interior space of the CV, and both samples were analyzed

for hydrogen fluoride (HF), fluorine (F2), and perfluoro-n-hexane (PFnH). No HF or F2 were detected.

This greatly increased the confidence that no PFIB was present in the CV interior space. Some PFnH was

detected at very low levels, 334 and 437 ppm. This low level of PFnH was attributed to low diffusion

leakage through the BXF Test Chamber soft seals. If there had been a major leak of PFnH into the CV

interior space, the concentration would have been several orders of magnitude greater. It was, therefore,

concluded that the BXF Test Chamber was intact (first level of containment still in place) and that it was

okay to proceed with disassembly of the CV.

In addition to the results discussed above, the analysis also showed the presence of carbon byproducts in

the gas samples, suggesting that a combustion event may have taken place within the CV interior space.

Details are documented in the as-run procedure 60081–PROC–0391 located in MWO

60081M01A205–03.

3.9 Containment Vessel Disassembly: Inspect Interior and Install CV Legs

This activity was modified slightly to include monitoring of the short found on 24 Vdc Bus 1. The

intent was to determine the nature of the short, whether it was intermittent or stable, and isolate its

location.

Disassembly of the CV revealed the presence of burnt/melted wiring. The wiring leading to Cartridge

Heater Assembly S/N 010, utilized for Bulk Fluid Heater 1, exhibited a dark black and brown

discoloration in and around connector J215. Some of the discoloration was observed on nearby wires. The

overall internal insulation sleeving of the cartridge heater wiring appeared to have melted and protruded

through the shield braid near connector J215. A red tie wrap that held the cartridge heater wiring in place

was damaged, melted, and fused to the shield braid.

There is clearly a problem associated with Bulk Fluid Heater 1.

Details of disassembly are documented in the as-run procedure 60081–PROC–0304 located in MWO

60081M01A205–03. Observations are noted in an attachment to the as-run BXF PFA plan, 60081–

PLAN–0383, located in MWO 60081M01L123–01.

3.10 24 Vdc Bus 1 Component Resistance Check

Cartridge Heater Assembly S/N 010 (Bulk Fluid Heater 1) failed the 24Vdc Bus 1 Component

Resistance Check. Heater 1 had multiple shorts as follows.

Cartridge Heater S/N 010

(Bulk Fluid Heater 1)

Location Resistance, Pass criteria

Between power and return 2.4

Between power and structure 6.26

Between return and structure 5.97
NASA/CR—2012-216036 6

Additional failures were found on Cartridge Heater Assembly S/N 012 (Bulk Fluid Heater 2) as

follows.

Cartridge Heater S/N 012

(Bulk Fluid Heater 2)

Location Resistance, Pass criteria

Between power and structure 35.6

Between return and structure 34.1

Cartridge Heater Assembly S/N 009 (Bulk Fluid Heater 3) passed the resistance check along with all

other components on 24 Vdc Bus 1.

These results confirmed a problem with Bulk Fluid Heater 1 and revealed a possible hidden

degradation of Bulk Fluid Heater 2.

Details are documented in the as-run procedure 60081–PROC–0385 located in MWO

60081M01A205–03.

3.11 Pre-Drain Fluid Sampling and Analysis

This activity was not originally part of the BXF PFA plan but was added due to stronger evidence that

one or more Bulk Fluid Heaters overheated, increasing concerns that PFIB was produced.

As a consequence of determining that Bulk Fluid Heaters 1 and 2 were shorted, two samples of the BXF

fluid were taken. One sample was sent out for analysis to determine whether PFIB was present or not. The

second sample was stored for possible analysis in-house. The analysis results confirmed the presence of

PFIB in the BXF Fluid at 90 parts per million. The acceptable exposure level (AEL) of PFIB is 10 parts

per billion.

Upon notification of this result, the BXF CV was reassembled back into the CV Housing to

reestablish three levels of containment. All BXF PFA activities were placed on hold until it was

determined how to proceed.

Details are documented in the as-run procedure 60081–PROC–0392 located in MWO

60081M01A205–03.

3.12 Flight Hardware Drain/Fluid Disposal

This activity was not originally part of the BXF PFA plan but was added due to the discovery of the

presence of hazardous PFIB in the BXF Fluid.

After weighing the pros and cons of several courses of action, it was finally determined that the BXF

Fluid would be removed from the BXF hardware and disposed of by the NASA Hazardous Waste

Management organization. The fluid was transferred into two disposal cylinders, and NASA Hazardous

Waste Management arranged for a disposal vendor to pick them up.

Just prior to the transfer process, a series of temperature and pressure measurements were taken to

determine the Dissolved Gas Concentration of the fluid, and during the transfer, the fluid was passed

through a filter to collect any foreign object debris (FOD) present in the fluid. The filter containing the

collected FOD was stored for future analysis.

The resulting Dissolved Gas Concentration value was 870 ppm at 20.7 °C and 0.40 atm. The

temperature and pressure measurements, however, were taken in a manner that differed greatly from the

method used for prior Dissolved Gas Concentration calculations. At the time these measurements were

taken, a GSE pressure transducer was used instead of the transducers of the BXF system, an external

fluids system was attached to the BXF hardware, and there was no bellows control of BXF Fluid pressure.

While it is possible that there was an increase in gas contamination at this time, due to the differences in

how the measurements were taken, the value of 870 ppm is likely not very meaningful.
NASA/CR—2012-216036 7

Details are documented in the as-run procedure 60081–PROC–0397 located in MWO

60081M01A205–03.

3.13 Pressure and Temperature Measurement Accuracy Check

A comparison between the Pre and Post-Flight results of pressure measurement testing found that

there was little to no deviation in data that could not be explained by the combined uncertainty of the

BXF system and the pressure calibrator used for testing. This suggested that the state of the BXF

electrical system, post-anomaly, had no effect on the output of the pressure transducers.

Post-Flight temperature measurement verifications were performed on the BXF Bulk Fluid, Cavity,

Surround, Background and Insulation (Rake) Thermistors with the BXF avionics in the post-anomaly

flight-like configuration. Unlike the pressure measurement verification, a complete end-to-end calibration

of the temperature measurement system could not be performed since the locations and configurations of

the thermistor elements made it impossible to do so without complete disassembly and possible damage

to the system and components of interest. Instead, the thermistors were disconnected from the rest of the

system as close to the element as possible and replaced with a variable load. The load on each

temperature circuit was varied to simulate each element’s output based on the Pre-Flight thermistor

calibration results and the temperature ranges of interest. Ambient temperature checks of the thermistor

elements were also performed to support the system verification results. All thermistor elements, except

the known non-conformance of Cavity Thermistor 5, showed good agreement with Pre-Flight calibration

results indicating that the elements themselves and associated cabling were in good working order.

In general, all of the random variation observed in the temperature measurement verification data

showed reasonable agreement with the Pre-Flight uncertainty analyses conducted. There were a number

of instances where data outliers were observed in the Post-Flight results, and these may be attributed to

experimental errors as identified and discussed in 60081–RPT–0400. Since the outliers generally occurred

only at the extremes of the temperature ranges tested (suggesting saturation of the measurement channel)

and the rest of the data followed expected trends, there appears to be no significant impact to the BXF

temperature measurements in the post-anomaly configuration of the system.

Details for the pressure and temperature measurement accuracy checks are documented in 60081–

RPT–0399 and 60081–RPT–0400, respectively.

3.14 Containment Vessel Disassembly: Uninstall CV Top Plate/CV Fan Visual Inspection

and Touch Test

This activity was modified to include a CV Fan Inspection and Touch Test to determine whether

“smoke” may have been generated that could have adversely affected the pressure sensors.

The Top Plate was uninstalled from the CV to prepare for subsequent PFA activities. After the Top

Plate was uninstalled, the fans located on it underwent a visual inspection and “white glove” touch test.

Reddish-brown FOD was found present on the leading edge of the fan blades and the inner surface of the

housing on both CV Fans. The material had a slight reddish appearance when adhered to the fans, but

took on more of a brownish appearance when transferred to the white cloth used for the touch test.

The substantial amount of FOD present on the CV Fans suggests that “smoke” may have been generated

within the CV interior space during the anomaly on-orbit.

Details for the disassembly are documented in the as-run procedure 60081–PROC–0304 located in

MWO 60081M01A205–03. Details for the CV Fan visual inspection and touch test are documented in an

attachment to the BXF PFA plan, 60081–PLAN–0383, located in MWO 60081M01L123–01.
NASA/CR—2012-216036 8

3.15 Room Temperature Leak Test

An overall instantaneous vacuum leak rate of 0.9×10–8 sccs helium (He) was measured, and a

permeation leak rate of 4.1×10–6 sccs He was measured over 2.7 hr. For pressure, a leak rate of 1.1×10–7

sccs He was measured over 1.5 hr, which was also the background rate.

During Pre-Flight leak testing, the results were as follows:

Vacuum Instantaneous Leak Rate: 7.0×10–7 sccs He

Vacuum Permeation Leak Rate: 5.4×10–6 sccs He, over 4.8 hr

Permeation Leak Rate: 1.3×10–7 sccs He, over 15 min (background rate)

As can be seen above, the Post-Flight leak rates are comparable to the Pre-Flight leak rates, which

suggests that there have been no new leaks since that time.

It should be noted that during individual component sniffing while under pressure, two Cartridge

Heater Assemblies, S/Ns 012 and 009 (Bulk Fluid Heaters 2 and 3, respectively) were found to have a

slightly higher localized leak rate of 1.7×10–7 sccs He. No leaks were found on any other components,

including the Cartridge Heater Assembly S/N 010 (Bulk Fluid Heater 1).

Details are documented in the as-run procedure 60081–PROC–0300 located in MWO

60081M01A206–02.

3.16 Elevated Temperature Leak Test

This activity was not originally part of the BXF PFA plan but was added to determine the credibility

of the presence of temperature-dependent leaks that may have been induced by the elevated temperatures

experienced by the BXF hardware on-orbit.

The Elevated Temperature Leak Test, which used the CV Housing and a thermal chamber set at

50 °C, produced an overall instantaneous vacuum leak rate of 1.0×10–7 sccs He and a permeation leak rate

of 1.7×10–5 sccs He over 2.8 hr. The test was repeated at room temperature, again using the CV Housing,

to produce an instantaneous leak rate of 1.1×10–8 sccs He and a permeation leak rate of 7.5×10–6 sccs He

over 4.3 hr. The room temperature results were comparable to those generated during the “bagged” Room

Temperature Leak Test (Section 3.15) and are an order of magnitude lower than the leak rates observed at

an elevated temperature of 50 °C.

Individual component spraying at elevated temperature inside the thermal chamber without the CV

Housing did not reveal any specific leak sources. In general, all components and seals appeared to share

in the increased leak rate at higher temperatures.

Details are documented in the as-run procedure 60081–PROC–0393 located in MWO

60081M01A206–02.

3.17 BXF Embedded Controller Inspection and Bench Test

Visual inspection of the BXF Embedded Controller (EC) found the same FOD that was found during

the CV Fan Visual Inspection. The reddish-brown FOD was located in areas of the board that were

exposed to the air flow of the fans.

The BXF EC passed bench testing with the exception of two failures. The Flow Meter Input failed,

because the worst case error of +15 counts exceeded the success criterion of ± 10 counts. The control

relays for Bulk Fluid Heaters 2 and 3 failed, because their on-state resistances

success criterion of <

It should be noted that the control relay for Bulk Fluid Heater 1 passed the success criterion.

The Flow Meter Input was not specified as a requirement for BXF. The success criterion was,

therefore, arbitrarily selected based on actual results achieved during development. The current worst case
NASA/CR—2012-216036 9

error of +15 counts is equivalent to a fluid flow measurement error of +0.006 L/min. This failure is likely

not related to the on-orbit anomaly.

The higher on-state resistance of each failing control relay reduced the amount of power delivered to

Bulk Fluid Heaters 2 and 3 resulting in less than nominal heating of the BXF Fluid with Bulk Fluid

Heater 1 carrying more of the burden. Consequently, the time required to achieve desired fluid

temperatures may have been longer than normal.

Details of the visual inspection are documented in the as-run process plan PP60081E01A520–3

located in MWO 60081M01A205–03. Details of the bench test are documented in 60081–RPT–0401.

4.0 Conditional/Optional Investigation

The following subsections give brief summaries of the results for each conditional/optional

investigation activity that was conducted on the BXF Flight hardware. The activities in this section were

either conditional or optional, being performed only when certain conditions were met, or at the discretion

of ZIN and NASA project management. Only brief summaries are given. Detailed results are documented

in individual reports, as-run procedures, attachments to the as-run plans, or appendices of this report as

specified in each subsection. Only the results of activities are presented. For detailed information on each

activity itself, reference 60081–PLAN–0383.

4.1 2.7 mm MABE Embedded Controller Inspection

The original BXF PFA plan specified this activity be an inspection and bench test, but the project

determined that a bench test was not necessary since the investigation results were pointing towards the

Bulk Fluid Heaters as the source of the failure. This activity was reduced in scope to a visual inspection

only.

The visual inspection of the 2.7 mm MABE EC found the same FOD that was found during the CV

Fan Visual Inspection. The reddish-brown FOD was located in areas of the board that were exposed to the

air flow of the fans. All other observations were nominal.

It is unlikely that the 2.7 mm MABE EC contributed to the on-orbit anomaly.

This visual inspection is documented in the as-run process plan PP60081E01A501–3 located in

MWO 60081M01A205–03.

4.2 7.0 mm MABE Embedded Controller Inspection

The original BXF PFA plan specified this activity be an inspection and bench test, but the project

determined that a bench test was not necessary since the investigation results were pointing towards the

Bulk Fluid Heaters as the source of the failure. This activity was reduced in scope to a visual inspection

only with extra attention paid to the circuit components for microheater 27.

The visual inspection of the 7.0 mm MABE EC found the same FOD that was found during the CV

Fan Visual Inspection. The reddish-brown FOD was located in areas of the board that were exposed to the

air flow of the fans. Additionally, attention was focused on the board components associated with control

of microheater 27, because it was noted during operations that this microheater had stopped functioning.

All components involved with microheater 27 appeared nominal. All other observations also appeared

nominal.

It is unlikely that the 7.0 mm MABE EC contributed to the on-orbit anomaly.

This visual inspection is documented in the as-run process plan PP60081E01A519–3 located in

MWO 60081M01A205–03.
NASA/CR—2012-216036 10

4.3 Avionics Box Output Voltage Test

The original BXF PFA plan specified this activity be a full-fledged bench test, but the project

determined that a full-fledged bench test was not necessary since the investigation results were pointing

towards the Bulk Fluid Heaters as the source of the failure. This activity was reduced in scope to an

output voltage test only.

All output voltages of the BXF Avionics Box (AB) passed the success criterion of ±10% of nominal.

The resulting voltages are listed below.

Voltage Bus Voltage,

V

12 Vdc Bus 11.952

24 Vdc Bus 1 23.971

24 Vdc Bus 2 23.943

It is unlikely that the BXF AB contributed to the on-orbit anomaly.

Details are documented in the as-run procedure 60081–PROC–0075 located in MWO

60081M01A438–04.

4.4 Avionics Box Interior Visual Inspection

Visual Inspection of the interior space of the BXF AB found everything to be nominal.

This inspection is documented in the as-run process plan PP60081M01A438–3 located in MWO

60081M01A438–04.

4.5 Bulk Fluid Heater Extraction and Inspection

The extraction and inspection investigation activities for the Bulk Fluid Heaters were conducted in

accordance with the Post-Flight Assessment Cartridge Heater Inspection Plan, 60081–PLAN–0394. The

following subsections discuss the results of each activity.

4.5.1 Extraction and Visual Inspection (Section 3.1 of PLAN–0394)

All three Cartridge Heaters Assemblies were removed from the BXF Test Chamber and visually

inspected. The metal sheaths of Cartridge Heaters S/Ns 012 and 009 (Bulk Fluid Heaters 2 and 3,

respectively) appeared discolored and blackened. Heater 2 appeared more blackened than Heater 3. Other

than the discoloration, however, no additional damage was observed.

Cartridge Heater S/N 010 (Bulk Fluid Heater 1) could not be extracted from its port fitting on the Test

Chamber. So, the entire fitting was removed from the chamber and left in place on the heater. Heater 1

showed extreme damage at two locations along the sheath. Melting of the Incoloy 800 is evident in both

locations. The brownish magnesium oxide (MgO) insulating material and greenish remains of the nickel

chromium (NiCr) wiring inside are also visible. Melting points of the various materials are listed below.

Material Melting Point,

°C

Incoloy 800 1385

Magnesium oxide 2800

Nickel chromium 1400

The damage observed on Bulk Fluid Heater 1 proves that temperatures in excess of 1400 °C were

achieved on-orbit.
NASA/CR—2012-216036 11

Details are documented in an attachment to the as-run PFA Cartridge Heater Inspection Plan, 60081–

PLAN–0394, located in MWO 60081M01A206–02. Photos taken during the inspection can be found in

Appendix D of this report.

4.5.2 Post-Extraction Resistance Check (Section 3.2 of PLAN–0394)

The Post-Extraction Resistance Check yielded similar results for Bulk Fluid Heaters 2 and 3 as those

obtained during the 24 Vdc Bus 1 Component Resistance Check. Heater 2 had partial shorts to the heater

sheath, but not the wiring shield. Heater 3 passed the check.

The results of Bulk Fluid Heater 1 were erratic. A few of the results technically passed, but the

resistance value was not stable. It was still evident in the recorded data that Heater 1 suffered a major

failure.

Details are documented in the as-run procedure 60081–PROC–0395 located in MWO

60081M01A206–02.

4.5.3 X-Ray Inspection (Section 3.3 of PLAN–0394)

X-rays of the Flight Cartridge Heater Assemblies showed the obvious damage of S/N 010 (Bulk Fluid

Heater 1). The two damaged areas are easily seen. When S/Ns 012 and 009 (Bulk Fluid Heaters 2 and 3,

respectively) are compared, there appears to be a subtle difference between them. The internal heater coil

of S/N 012 appears to be slightly unwound and irregular, but these observations are subjective.

Details are documented in an attachment to the as-run PFA Cartridge Heater Inspection Plan, 60081–

PLAN–0394, located in MWO 60081M01A206–02. Photos of the Cartridge Heater x-ray images can be

found in Appendix E of this report.

4.5.4 Heater Wiring Dissection (Section 3.4 of PLAN–0394)

Two heaters were dissected. Cartridge Heater S/N 012 (Bulk Fluid Heater 2) was dissected first

followed by Cartridge Heater S/N 010 (Bulk Fluid Heater 1).

Throughout all stages of dissection for Heater 2, observations were nominal, and the heater resistance

 The Post-Dissection Resistance Check of Heater 2 found two partial shorts, each

, between the heater sheath and both the power and return lines going into the sheath. This is in

agreement with prior investigation results.

Difficulties were encountered during the dissection of Heater 1. The wiring shield braid could not be

pulled back from the connector, because the shield was fused with the internal insulation sleeving.

Cutting open the shield braid proved to be a slow process, as it was found that the shield had been

hardened. After the shield was cut open, it was observed that the internal insulation sleeving was

carbonized near the connector. The sleeving crumbled apart easily as the dissection proceeded. The

insulation of the internal wiring appeared blackened overall, but whitened over the crimped area. The

wire insulation near the connector was melted away leaving bare exposed wire. When the insulation

sleeving was finally removed from around the connector, it was observed that the connector was melted

and completely encasing the internal contacts. The contacts could not be extracted. During the dissection,

the wiring separated from the heater sheath on its own without the need for cutting it, and the heater

sheath became bent at one of the damaged portions of the sheath. The heater resistance was unstable and

varied greatly as the assembly was handled.

Post-Dissection Resistance Check. nd both

power and return lines. The wiring that separated from the heater sheath failed continuity testing.

Details are documented in two copies, one for each heater, of the as-run procedure 60081–PROC–

0396 located in MWO 60081M01A206–02.
NASA/CR—2012-216036 12

4.6 FOD Analysis

The original BXF PFA plan included FOD collection along with the analysis, however, this was

before the discovery of PFIB in the BXF Fluid. When the Fluid was disposed of, the opportunity was

taken at that time to collect any FOD present. This activity was reduced in scope to an analysis only.

Also, originally this activity was for Fluid FOD only. When the CV Fan FOD was discovered, this

activity was expanded to include collection and analysis of the CV Fan FOD.

The filter containing FOD collected during the Flight Hardware Drain/Fluid Disposal activity was

analyzed by NASA GRC using a Field Emission Scanning Electron Microscope (FESEM). The analysis

found the presence of fluorine, magnesium, aluminum, silicon, chromium, and in some cases, iron and

nickel. Magnesium was consistently found in many of the particles analyzed. The following table lists the

most likely sources of the elements detected in the Fluid FOD.

Element(s) Source(s)

Magnesium MgO Insulation of Bulk Fluid Heater 1 Oxygen

Nickel Incoloy 800 and NiCr Resistance Wiring of Bulk Fluid Heater 1,

Stainless Steel (SS) Tubing of BXF Fluids System Chromium

Iron

Aluminum BXF Test Chamber

Fluorine Soft Goods and Insulating Materials throughout BXF System Silicon

A sample of the CV Fan FOD was collected and also sent for analysis by NASA GRC using a

FESEM. The analysis consistently found the presence of carbon, fluorine, silicon, and oxygen. Tin,

sodium, calcium, aluminum, and sulfur were also detected. Some of these elements, especially fluorine,

carbon, and oxygen, are likely the result of decomposition of materials making up the burned/melted

wiring of Bulk Fluid Heater 1. Some of these materials are Halar (tie wrap), Viton (insulation sleeving),

Teflon (wire insulation), and nylon (connector).

Collection of the CV Fan FOD is documented in the as-run procedure 60081–PROC–0389 located in

MWO 60081M01A205–03. The Fluid and CV Fan FOD analyses are documented in reports generated by

NASA GRC, and these reports are available in files maintained by the NASA Project Manager.

5.0 Conclusions

5.1 High Speed Camera Misalignment

Based on the results outlined in Section 3.6, it can be concluded that the high speed camera (HSC)

misalignment was due to compliance in the HSC hardware. It is possible that correct alignment could

have been achieved with more time and iteration.

5.2 Dissolved Gas Concentration

The results of Sections 3.5, 3.15, and 3.16 suggest that the overall leak rate of the BXF hardware

increased when the hardware was exposed to higher operating temperatures on-orbit. This was not

anticipated, and the hardware was leak tested only at room temperatures before Flight.

5.3 On-Orbit Anomaly

It can be concluded from the investigation results that Cartridge Heater S/N 010 (Bulk Fluid Heater 1)

overheated. The heater temperature had to have reached at least 1400 °C in order to melt the Incoloy 800

and NiCr materials of the heater. The heat that was generated probably transferred via thermal conduction

down the cartridge heater wiring causing the burn and melt damage observed near the connector. The
NASA/CR—2012-216036 13

burning and melting of the heater and its wiring led to the creation of an electrical short on 24 Vdc Bus 1.

This short would have caused the 24 Vdc Bus 1 DC/DC converter to go into current limiting mode,

reducing voltage output, while at the same time, causing higher than nominal current draw from MSG.

The investigation results also suggest that Cartridge Heater S/Ns 012 and 009 (Bulk Fluid Heaters 2

and 3, respectively) may have also overheated, or came close to doing so.

The manufacturers of the cartridge heaters and BXF Fluid (PFnH) were consulted to determine the

possible reasons why the heaters overheated. The following is a list of the most likely causes:

Lack of direct heater temperature monitoring and control allowed overheating to occur.

The dissipation heat flux of the cartridge heaters was within the range required for the onset of

boiling (4 W/cm2 versus 6 to 10 W/cm2) in normal gravity (Ref. 1).

Fluid flow rate may have been too low to carry heat away from the heaters.

Microgravity may have inhibited convective removal of heat from the heaters.

One or more of the factors above contributed to a scenario in which nucleation boiling of the fluid

may have been induced around the heaters. In the case of Heater 1, this nucleation boiling may have

progressed to film boiling, causing the heater to become completely enveloped in vapor. The vapor, in

turn, would have acted as a thermal insulator and significantly reduced heat transfer from the heater to the

fluid. This would have caused the heater to enter into a “runaway” condition in which the heater

temperature increases extremely rapidly. The Bulk Fluid temperature sensors throughout the Test

Chamber would not have detected this local temperature rise at the heater.

NASA/CR—2012-216036 15

Appendix A.—Acronyms and Abbreviations

AB Avionics Box

AEL Acceptable Exposure Limit

atm atmospheres

BXF Boiling eXperiment Facility

CCD Charged Coupled Device

CV Containment Vessel

dc or DC direct current

EC Embedded Controller

ERB Engineering Review Board

F2 fluorine

FESEM Field Emission Scanning Electron Microscope

FOD Foreign Object Debris

GMT Greenwich Mean Time

GRC NASA Glenn Research Center

GSE Ground Support Equipment

He helium

HF hydrogen fluoride

HSC high speed camera

ISS International Space Station

KSC NASA Kennedy Space Center

L/min liters per minute

MABE Microheater Array Boiling Experiment

MgO magnesium oxide

MSG Microgravity Science Glovebox

MWO Manufacturing Work Order

NASA National Aeronautics and Space Administration

NiCr nickel chromium

NPBX Nucleate Pool Boiling eXperiment

PFA Post-Flight Assessment

PFIB perfluoroisobutene

PFnH perfluoro-n-hexane

ppm parts per million

RTV Room Temperature Volatile

S/N serial number

sccs standard cubic centimeters per second

ULF Utilization and Logistics Flight

ZIN ZIN Technologies

NASA/CR—2012-216036 17

Appendix B.—Functional Check Details

This appendix contains the BXF Ops Display screenshots, acquired HSC images, Command Log file,

and Housekeeping Data files generated during the Functional Check. See Section 3.4.

Figure B.1.—Screen displays for RS-422 Communication test: Fluid System Tab for BXFOPSDisplay (top left) and for

Sidekick (top right), NPBX Experiment Tab for BXFOPSDisplay (bottom left) and for Sidekick (bottom right).if [[[ III •. ill Ii flH d ji II .!l! ! J id' !! II I n I I '.oj, I I i I, I L ij' III i I 'j'II!Jill!1 

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NASA/CR—2012-216036 18

Figure B.2.—Screen displays for RS-422 Communication test: MABE Experiment TAB for BXFOPSDisplay (top left)

and for Sidekick (top right), System Tab for BXFOPSDisplay (bottom left) and for Sidekick (bottom right).

1_a-I_ I ... _ ... I .. _ c-l(--' ... · Quouo Ia-1 ... _. - ...... -'''', .. ..-, I 

-r---~ 

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NASA/CR—2012-216036 19

Figure B.3.—Screen displays for Systems Initialization Test: Fluid System Tab for BXFOPSDisplay (top left) and for

Sidekick (top right), MABE Experiment Tab for BXFOPSDisplay (bottom left) and for Sidekick (bottom right). !. <Hi i II j!il ! jl 1/ !!! ! J illl! I! Ij Ii ii I "j < Iff 

11 L 

1 U i 

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NASA/CR—2012-216036 20

Figure B.4.—Screen displays for Systems Initialization Test: NPBX Experiment Tab for BXFOPSDisplay (top left) and

for Sidekick (top right), System Tab for BXFOPSDisplay (bottom left) and for Sidekick (bottom right).
NASA/CR—2012-216036 21

Figure B.5.—Screen displays for BXF EC I/O Test, NPBX Camera 1 Test: Fluid System Tab for BXFOPSDisplay (top

left) and for Sidekick (top right), MABE Experiment Tab for BXFOPSDisplay (bottom left) and for Sidekick (bottom

right).
NASA/CR—2012-216036 22

Figure B.6.—Screen displays for BXF EC I/O Test, NPBX Camera 1 Test: NPBX Experiment Tab for BXFOPSDisplay

(top left) and for Sidekick (top right), System Tab for BXFOPSDisplay (bottom left) and for Sidekick (bottom right).
NASA/CR—2012-216036 23

Figure B.7.—Screen displays for BXF EC I/O, NPBX Camera 2 Test: Fluid System Tab for BXFOPSDisplay (top left)

and for Sidekick (top right), MABE Experiment Tab for BXFOPSDisplay (bottom left) and for Sidekick (bottom right).
NASA/CR—2012-216036 24

Figure B.8.—Screen displays for BXF EC I/O Test, NPBX Camera 2 Test: NPBX Experiment Tab for BXFOPSDisplay

(top left) and for Sidekick (top right), System Tab for BXFOPSDisplay (bottom left) and for Sidekick (bottom right).
NASA/CR—2012-216036 25

Figure B.9.—Captured image of MABE 7.0 mm array with default exposure.
NASA/CR—2012-216036 26

Figure B.10.—Captured image of MABE 7.0 mm array with 1/13000 s exposure.
NASA/CR—2012-216036 27

Figure B.11.—Captured image of MABE 7.0 mm array with 1/13000 s exposure.
NASA/CR—2012-216036 28

Log Files During BXF Function Check:

2011_229_00.log

"2011/229/14:04:08","System","280","Changed system time","2011/229/14:04:08"

"2011/229/14:04:08","Debug","314","Sending file via

FTP","/bigdisk/2011_144/2011_144_00.log"

"2011/229/14:04:08","Debug","314","File sent via FTP","2011_144_00.log"

"2011/229/14:04:08","Debug","314","Sending file via

FTP","/bigdisk/2011_144/2011_144_18.hkp"

"2011/229/14:04:11","Debug","314","File sent via FTP","2011_144_18.hkp"

"2011/229/14:06:19","Command","210","Command Received","SystemNoOp()"

"2011/229/14:06:19","System","250","NoOp performed",""

"2011/229/14:06:19","Command","210","Command Completed","SystemNoOp()"

"2011/229/14:21:24","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(safety_reset,On)"

"2011/229/14:21:24","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(safety_reset,On)"

"2011/229/14:21:27","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(safety_reset,Off)"

"2011/229/14:21:27","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(safety_reset,Off)"

"2011/229/14:27:50","Command","210","Command Received","SystemInitialize()"

"2011/229/14:27:50","System","1003","BXFAvionicsController::Initialize","Initializing.

.."

"2011/229/14:27:54","System","1013","Initializing CrewInterfacePanel",""

"2011/229/14:27:54","System","1012","Initializing Video Recording System",""

"2011/229/14:27:54","System","1012","NOT Homing MABE Side View Camera focus",""

"2011/229/14:27:54","System","1012","Initialized Video Recording System",""

"2011/229/14:27:54","System","1014","Initializing Containment Vessel",""

"2011/229/14:27:54","System","1010","Initializing Pressure Control System",""

"2011/229/14:27:54","Debug","1010","...Reloading pressure control system

parameters","P=2.000, I=0.000, D=0.000"

"2011/229/14:27:54","Debug","1010","...Reloading pressure control system

parameters","Sensor=1(1-3), Poll Period=1000,InRange=25,Max Bellows Correct="

"2011/229/14:27:55","Debug","1010","Going to safe pressure 793=1.000 atm",""

"2011/229/14:27:55","System","1010","Initialized Pressure Control System",""

"2011/229/14:27:55","System","1011","Initializing Thermal Control System",""

"2011/229/14:27:55","Debug","1011","TCS parameters loaded","MABE Test Pump

Setpoint=600, Bulk Heating Pump Setpoint=600, Update period =2000 msec"

"2011/229/14:27:55","Debug","1011","TCS parameters loaded","Bulk Stability

Variation=175, Valid Sensor Variation=800, Bulk Temperature In Range Limit=25"

"2011/229/14:27:55","System","1011","Initialized Thermal Control System",""

"2011/229/14:27:55","System","1007","Initializing High Speed Video System",""

"2011/229/14:27:55","System","1008","Initializing MABE Heater Array",""

"2011/229/14:27:55","System","1008","Initialized MABE Heater Array",""

"2011/229/14:27:55","System","1009","Initializing NPBX Heater Array",""

"2011/229/14:27:57","System","1009","Initialized NPBX Heater Array",""

"2011/229/14:27:57","System","1028","Initializing Watchdog Timer",""

"2011/229/14:27:57","System","1003","BXFAvionicsController::Initialize","Initializatio

n complete"

"2011/229/14:27:57","Command","210","Command Completed","SystemInitialize()"

"2011/229/14:27:57","Debug","1028","Watchdog hardware reset enabled","10 secs"

"2011/229/15:00:00","Debug","314","Sending file via

FTP","/bigdisk/2011_229/2011_229_14.hkp"

"2011/229/15:00:28","Debug","314","File sent via FTP","2011_229_14.hkp"

"2011/229/15:35:40","Command","210","Command Received","SystemShutdown(Shutdown)"

"2011/229/15:35:52","Command","210","Command Completed","SystemShutdown(Shutdown)"

"2011/229/15:35:54","Debug","314","Sending file via

FTP","/bigdisk/2011_229/2011_229_15.hkp"

"2011/229/17:11:37","System","1001","Getting Version and Checksum...",""

"2011/229/17:11:37","System","1001","BXFAvionicsController","VER:60081-SW-F001-

1.10CS::Check Disabled"

"2011/229/17:11:37","System","1002","BXFAvionicsController","BXF Avionics Controller

started."
NASA/CR—2012-216036 29

"2011/229/17:11:36","System","280","Changed system time","2011/229/17:11:36"

"2011/229/17:13:30","Command","210","Command Received","SystemInitialize()"

"2011/229/17:13:30","System","1003","BXFAvionicsController::Initialize","Initializing.

.."

"2011/229/17:13:31","System","1013","Initializing CrewInterfacePanel",""

"2011/229/17:13:31","System","1012","Initializing Video Recording System",""

"2011/229/17:13:31","System","1012","NOT Homing MABE Side View Camera focus",""

"2011/229/17:13:31","System","1012","Initialized Video Recording System",""

"2011/229/17:13:31","System","1014","Initializing Containment Vessel",""

"2011/229/17:13:31","System","1010","Initializing Pressure Control System",""

"2011/229/17:13:31","Debug","1010","...Reloading pressure control system

parameters","P=2.000, I=0.000, D=0.000"

"2011/229/17:13:31","Debug","1010","...Reloading pressure control system

parameters","Sensor=1(1-3), Poll Period=1000,InRange=25,Max Bellows Correct="

"2011/229/17:13:31","Debug","1010","Going to safe pressure 793=1.000 atm",""

"2011/229/17:13:31","System","1010","Initialized Pressure Control System",""

"2011/229/17:13:31","System","1011","Initializing Thermal Control System",""

"2011/229/17:13:31","Debug","1011","TCS parameters loaded","MABE Test Pump

Setpoint=600, Bulk Heating Pump Setpoint=600, Update period =2000 msec"

"2011/229/17:13:31","Debug","1011","TCS parameters loaded","Bulk Stability

Variation=175, Valid Sensor Variation=800, Bulk Temperature In Range Limit=25"

"2011/229/17:13:31","System","1011","Initialized Thermal Control System",""

"2011/229/17:13:31","System","1007","Initializing High Speed Video System",""

"2011/229/17:13:31","System","1008","Initializing MABE Heater Array",""

"2011/229/17:13:31","System","1008","Initialized MABE Heater Array",""

"2011/229/17:13:31","System","1009","Initializing NPBX Heater Array",""

"2011/229/17:13:34","System","1009","Initialized NPBX Heater Array",""

"2011/229/17:13:34","System","1028","Initializing Watchdog Timer",""

"2011/229/17:13:34","System","1003","BXFAvionicsController::Initialize","Initializatio

n complete"

"2011/229/17:13:34","Command","210","Command Completed","SystemInitialize()"

"2011/229/17:13:34","Debug","1028","Watchdog hardware reset enabled","10 secs"

NPBX Camera 1 Test

"2011/229/17:16:16","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(npbx_camera_1_power,On)"

"2011/229/17:16:16","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(npbx_camera_1_power,On)"

"2011/229/17:16:25","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(npbx_camera_1_backlight,On)"

"2011/229/17:16:25","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(npbx_camera_1_backlight,On)"

"2011/229/17:19:36","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(npbx_camera_1_backlight,Off)"

"2011/229/17:19:36","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(npbx_camera_1_backlight,Off)"

"2011/229/17:19:39","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(npbx_camera_1_power,Off)"

"2011/229/17:19:39","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(npbx_camera_1_power,Off)"

NPBX Camera 2 Test

"2011/229/17:21:01","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(npbx_camera_2_power,On)"

"2011/229/17:21:01","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(npbx_camera_2_power,On)"

"2011/229/17:21:06","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(npbx_camera_2_backlight,On)"

"2011/229/17:21:06","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(npbx_camera_2_backlight,On)"

"2011/229/17:23:24","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(npbx_camera_2_backlight,Off)"

"2011/229/17:23:24","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(npbx_camera_2_backlight,Off)"

"2011/229/17:23:27","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(npbx_camera_2_power,Off)"

"2011/229/17:23:27","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(npbx_camera_2_power,Off)"
NASA/CR—2012-216036 30

MABE Side View Camera Test

"2011/229/17:25:29","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_side_view_camera_power,On)"

"2011/229/17:25:29","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_side_view_camera_power,On)"

"2011/229/17:25:32","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_side_view_camera_backlight,On)"

"2011/229/17:25:32","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_side_view_camera_backlight,On)"

"2011/229/17:28:28","Command","210","Command

Received","SetMabeSideViewCameraFocusPositionCommand(2.7mm)"

"2011/229/17:28:37","Command","210","Command

Completed","SetMabeSideViewCameraFocusPositionCommand(2.7mm)"

"2011/229/17:29:05","Command","210","Command

Received","SetMabeSideViewCameraFocusPositionCommand(7mm)"

"2011/229/17:29:14","Command","210","Command

Completed","SetMabeSideViewCameraFocusPositionCommand(7mm)"

"2011/229/17:29:37","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_side_view_camera_backlight,Off)"

"2011/229/17:29:37","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_side_view_camera_backlight,Off)"

"2011/229/17:29:41","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_side_view_camera_power,Off)"

"2011/229/17:29:41","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_side_view_camera_power,Off)"

"2011/229/17:33:56","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,On)"

"2011/229/17:33:56","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,On)"

"2011/229/17:35:23","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,Off)"

"2011/229/17:35:23","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,Off)"

Fluid Loop Test

"2011/229/17:37:08","Command","210","Command

Received","BXFEmbeddedControllerCoolingPumpSpeed(1,600)"

"2011/229/17:37:08","Command","210","Command

Completed","BXFEmbeddedControllerCoolingPumpSpeed(1,600)"

"2011/229/17:37:28","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(pump_enable,On)"

"2011/229/17:37:28","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(pump_enable,On)"

"2011/229/17:38:38","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(pump_enable,Off)"

"2011/229/17:38:38","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(pump_enable,Off)"

"2011/229/17:39:19","Command","210","Command

Received","BXFEmbeddedControllerCoolingPumpSpeed(2,600)"

"2011/229/17:39:19","Command","210","Command

Completed","BXFEmbeddedControllerCoolingPumpSpeed(2,600)"

"2011/229/17:39:32","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(pump_enable,On)"

"2011/229/17:39:32","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(pump_enable,On)"

"2011/229/17:40:39","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(pump_enable,Off)"

"2011/229/17:40:39","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(pump_enable,Off)"

"2011/229/17:43:25","Command","210","Command

Received","SystemManualSetChamberPressure(0)"

"2011/229/17:43:25","Command","210","Command

Completed","SystemManualSetChamberPressure(0)"

"2011/229/17:47:40","Command","210","Command

Received","SystemManualSendMotorCommand(3,-300)"

"2011/229/17:47:40","Command","210","Command

Completed","SystemManualSendMotorCommand(3,-300)"

"2011/229/17:48:49","Command","210","Command

Received","SystemManualSetChamberPressure(793)"

"2011/229/17:48:49","Command","210","Command
NASA/CR—2012-216036 31

Completed","SystemManualSetChamberPressure(793)"

"2011/229/17:49:36","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(primary_valve,On)"

"2011/229/17:49:36","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(primary_valve,On)"

"2011/229/17:50:42","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(primary_valve,Off)"

"2011/229/17:50:42","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(primary_valve,Off)"

"2011/229/17:51:18","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(secondary_valve,On)"

"2011/229/17:51:18","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(secondary_valve,On)"

"2011/229/17:52:23","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(secondary_valve,Off)"

"2011/229/17:52:23","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(secondary_valve,Off)"

"2011/229/17:58:27","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(npbx_camera_1_backlight,Off)"

"2011/229/17:58:27","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(npbx_camera_1_backlight,Off)"

"2011/229/17:58:31","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(npbx_camera_1_power,Off)"

"2011/229/17:58:32","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(npbx_camera_1_power,Off)"

"2011/229/18:00:00","Debug","314","Sending file via

FTP","/bigdisk/2011_229/2011_229_17.hkp"

MABE Bottom View Back Lights and Camera Test

"2011/229/18:00:19","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_2p7mm_leds,On)"

"2011/229/18:00:19","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_2p7mm_leds,On)"

"2011/229/18:00:23","Debug","314","File sent via FTP","2011_229_17.hkp"

"2011/229/18:00:29","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_2p7mm_leds,Off)"

"2011/229/18:00:30","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_2p7mm_leds,Off)"

"2011/229/18:00:35","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,On)"

"2011/229/18:00:35","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,On)"

"2011/229/18:00:41","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,Off)"

"2011/229/18:00:41","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,Off)"

"2011/229/18:00:47","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_2p7mm_leds,On)"

"2011/229/18:00:47","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_2p7mm_leds,On)"

"2011/229/18:00:49","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,On)"

"2011/229/18:00:49","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,On)

"2011/229/18:03:49","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,On)"

"2011/229/18:03:49","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,On)"

"2011/229/18:05:39","Command","210","Command Received","HighSpeedCameraPower(on)"

"2011/229/18:05:39","Command","210","Command Completed","HighSpeedCameraPower(on)"

"2011/229/18:05:44","System","1007","Initializing High Speed Camera...",""

"2011/229/18:05:59","System","1007","High Speed Camera number of Pixel Defects =

0",""

"2011/229/18:06:03","System","1007","High Speed Camera Initialized",""

"2011/229/18:09:05","Command","210","Command

Received","HighSpeedCameraCaptureImage(500,1,true)"

"2011/229/18:09:18","Command","210","Command

Completed","HighSpeedCameraCaptureImage(500,1,true)"

"2011/229/18:09:18","Debug","314","Sending file via
NASA/CR—2012-216036 32

FTP","/bigdisk/2011_229/MABEImages/0000_000/0000_000_00065345_0001.IMG"

"2011/229/18:09:23","Debug","314","File sent via FTP","0000_000_00065345_0001.IMG"

"2011/229/18:11:02","Command","210","Command

Received","HighSpeedCameraSetExposureTime(13000)"

"2011/229/18:11:03","Command","210","Command

Completed","HighSpeedCameraSetExposureTime(13000)"

"2011/229/18:12:41","Command","210","Command

Received","HighSpeedCameraCaptureImage(500,1,true)"

"2011/229/18:12:50","Command","210","Command

Completed","HighSpeedCameraCaptureImage(500,1,true)"

"2011/229/18:12:51","Debug","314","Sending file via

FTP","/bigdisk/2011_229/MABEImages/0000_000/0000_000_00065561_0001.IMG"

"2011/229/18:12:56","Debug","314","File sent via

FTP","0000_000_00065561_0001.IMG""2011/229/18:15:33","Command","210","Command

Received","HighSpeedCameraConfigure(0,500,0,0,13000,0)"

"2011/229/18:15:42","Command","210","Command

Completed","HighSpeedCameraConfigure(0,500,0,0,13000,0)"

"2011/229/18:15:59","Command","210","Command

Received","HighSpeedCameraCaptureImage(500,1,true)"

"2011/229/18:16:12","Command","210","Command

Completed","HighSpeedCameraCaptureImage(500,1,true)"

"2011/229/18:16:12","Debug","314","Sending file via

FTP","/bigdisk/2011_229/MABEImages/0000_000/0000_000_00065759_0001.IMG"

"2011/229/18:16:25","Debug","314","File sent via FTP","0000_000_00065759_0001.IMG"

"2011/229/18:17:06","Command","210","Command Received","SystemSelfTest(4096,1)"

"2011/229/18:17:07","System","1001","BXFAvionicsController::SelfTest","Setting mabe

sampling rate"

"2011/229/18:17:07","System","1004","BXFAvionicsController::SelfTest","Checkout

successful!"

"2011/229/18:17:07","System","1004","BXFAvionicsController::SelfTest","Checkout

successful!"

"2011/229/18:17:07","Command","210","Command Complete","SystemSelfTest(4096,1)"

"2011/229/18:17:55","Command","210","Command Received","HighSpeedCameraPower(off)"

"2011/229/18:17:56","Command","210","Command Completed","HighSpeedCameraPower(off)"

"2011/229/18:18:17","Command","210","Command Received","HighSpeedCameraPower(on)"

"2011/229/18:18:17","Command","210","Command Completed","HighSpeedCameraPower(on)"

"2011/229/18:18:23","System","1007","Initializing High Speed Camera...",""

"2011/229/18:18:37","System","1007","High Speed Camera number of Pixel Defects =

0",""

"2011/229/18:18:42","System","1007","High Speed Camera Initialized",""

"2011/229/18:19:29","Command","210","Command

Received","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,Off)"

"2011/229/18:19:29","Command","210","Command

Completed","BXFEmbeddedControllerSetOutput(mabe_7mm_leds,Off)"

"2011/229/18:19:37","Command","210","Command Received","HighSpeedCameraPower(off)"

"2011/229/18:19:38","Command","210","Command Completed","HighSpeedCameraPower(off)"

"2011/229/18:25:56","Command","210","Command

Received","SystemManualForceLogFileSend()"
NASA/CR—2012-216036 33

2011_229_01.log

Data Download

"2011/229/15:36:09","System","1001","Forcing log file transfer",""

"2011/229/15:36:11","Debug","314","File sent via FTP","2011_229_15.hkp"

"2011/229/15:36:11","Debug","314","Sending file via

FTP","/bigdisk/2011_229/2011_229_00.log"

"2011/229/15:36:11","Debug","314","File sent via FTP","2011_229_00.log"

"2011/229/18:25:56","Command","210","Command

Completed","SystemManualForceLogFileSend()"

"2011/229/18:25:56","Debug","314","Sending file via

FTP","/bigdisk/2011_229/2011_229_00.log"

"2011/229/18:25:57","Debug","314","File sent via FTP","2011_229_00.log"

"2011/229/18:26:04","Command","210","Command

Received","SystemManualForceHousekeepingSend()"

"2011/229/18:26:04","Command","210","Command

Completed","SystemManualForceHousekeepingSend()"

"2011/229/18:26:05","Debug","314","Sending file via

FTP","/bigdisk/2011_229/2011_229_18.hkp"

"2011/229/18:26:18","Debug","314","File sent via FTP","2011_229_18.hkp"

"2011/229/18:26:50","Command","210","Command Received","SystemShutdown(Shutdown)"

"2011/229/18:27:03","Command","210","Command Completed","SystemShutdown(Shutdown)"

"2011/229/18:27:05","Debug","314","Sending file via

FTP","/bigdisk/2011_229/2011_229_18_01.hkp"

"2011/229/18:27:06","Debug","314","File sent via FTP","2011_229_18_01.hkp"

NASA/CR—2012-216036 35

Appendix C.—HSC Alignment Check Images

This appendix contains the images acquired during the High Speed Camera Alignment Check

activity. See Section 3.6.

Figure C.1.—MABE 7.0 mm array imaged through HSC, lens correctly aligned.
NASA/CR—2012-216036 36

Figure C.2.—MABE 7.0 mm array imaged through HSC, incorrectly aligned, note translation to

right and top from Figure C.1.
NASA/CR—2012-216036 37

Appendix D.—Extraction and Visual Inspection Photos

This appendix contains the photos taken during the extraction and visual inspection of the cartridge

heaters. See Section 4.5.1.

Figure D.1.—Heater 1 power cable.

Figure D.2.—Heater 1 power cable.
NASA/CR—2012-216036 38

Figure D.3.—Heater 1 Molex connector, note

discoloration on wire braid.

Figure D.4.—Heater 1 Molex connector, strain relief sliced

open, note discoloration on wire braid.
NASA/CR—2012-216036 39

Figure D.5.—Heater 1 Molex connector, strain relief sliced open,

note discoloration on wire braid.

Figure D.6.—Heater 1 feedthrough into TC.
NASA/CR—2012-216036 40

Figure D.7.—Heater 1 feedthrough into TC.

Note melted shrink wrap.

Figure D.8.—Heater 1 feedthrough into TC.
NASA/CR—2012-216036 41

Figure D.9.—Heater 1 power cable, note

discoloration on wire braid by Molex connector

and melted ty-rap.

Figure D.10.—Heater 1 Feedthrough into TC.
NASA/CR—2012-216036 42

Figure D.11.—Heater 1, melted ty-rap.

Figure D.12.—Heater 1 Molex connector, note discoloration on

wire braid.
NASA/CR—2012-216036 43

Figure D.13.—Heater 1 extracted from tee to

maximum possible extent.

Figure D.14.—Heater 1 extracted with tee from TC, note

melted and blackened surface.
NASA/CR—2012-216036 44

Figure D.15.—Heater 1 extracted with tee from TC, note melted

and blackened surface.

Figure D.16.—Close-up of Heater 1 melted surface.
NASA/CR—2012-216036 45

Figure D.17.—Close-up of Heater 1 melted

surface near tip of heater.

Figure D.18.—Close-up of Heater 1 melted

surface.
NASA/CR—2012-216036 46

Figure D.19.—Close-up of Heater 1 melted surface.

Figure D.20.—Close-up of melted surface near Heater 1 tip.

Figure D.21.—Close-up of melted surface near Heater 1 tip.
NASA/CR—2012-216036 47

Figure D.22.—Close-up of Heater 1 melted surface.

Figure D.23.—Close-up of Heater 1 melted surface.

Figure D.24.—Close-up of Heater 1 melted surface.
NASA/CR—2012-216036 48

Figure D.25.—Close-up of Heater 1 melted surface.

Figure D.26.—Close-up of melted surface near Heater 1 tip.

Figure D.27.—Close-up of melted surface near Heater 1 tip.
NASA/CR—2012-216036 49

Figure D.28.—Close-up of melted surface near Heater 1 tip.

Figure D.29.—Heater 1 melted surface.

Figure D.30.—Close-up of Heater 1 melted surface.
NASA/CR—2012-216036 50

Figure D.31.—Fluid immersed portion of

Heater 1: Note two melted areas of Heater 1

Figure D.32.—Fluid immersed portion of Heater 1: Note two

melted areas of Heater 1.
NASA/CR—2012-216036 51

Figure D.33.—Feed through port for Heater 1.

Figure D.34.—Feed through port for Heater 1.
NASA/CR—2012-216036 52

Figure D.35.—Heater 1 assembly, note melted areas on heater and damage to power harness.

Figure D.36.—Heater 1 assembly, note melted areas on heater and damage to power harness.
NASA/CR—2012-216036 53

Figure D.37.—Fluid immersed portion of Heater 1: Note two melted areas.

Figure D.38.—Fluid immersed portion of Heater 1: Note two melted areas.
NASA/CR—2012-216036 54

Figure D.39.—Heater 1: Note melted area.

Figure D.40.—Heater 1: Note melted area.
NASA/CR—2012-216036 55

Figure D.41.—Heater 1: Note melted area.

Figure D.42.—Heater 1: Note melted area.
NASA/CR—2012-216036 56

Figure D.43.—Heater 1: Note melted area.

Figure D.44.— Heater 1: Note melted area
NASA/CR—2012-216036 57

Figure D.45.—Heater 1: Note melted areas.

Figure D.46.—Heater 1: Note melted areas.
NASA/CR—2012-216036 58

Figure D.47.—Heater 1 Molex connector, note discoloration on wire braid.
NASA/CR—2012-216036 59

Figure D.48.—Heater 1 Molex connector, note discoloration on wire braid.
NASA/CR—2012-216036 60

Figure D.49.—Heater 1 Molex connector, note discoloration on wire braid.

Figure D.50.—Wire harness for Heater 1: Note melted ty-rap.
NASA/CR—2012-216036 61

Figure D.51.—Wire harness for Heater 1: Note melted ty-rap.

Figure D.52.—Wire harness for Heater 1: Note melted ty-rap.
NASA/CR—2012-216036 62

Figure D.53.—Wire harness for Heater 1: Note melted ty-rap.

Figure D.54.—Wire harness for Heater 1: Note melted ty-rap and discoloration on wire braid.
NASA/CR—2012-216036 63

Figure D.55.—Heater 1 connection into TC.

Figure D.56.—Heater 2 label.
NASA/CR—2012-216036 64

Figure D.57.—Heater 2 connection into TC.

Figure D.58.—Heater 2 Molex connector.
NASA/CR—2012-216036 65

Figure D.59.—Heater 2 connection into TC.

Figure D.60.—Heater 2 connection into TC.
NASA/CR—2012-216036 66

Figure D.61.—Heater 2 connection into TC.

Figure D.62.— Heater 2 Molex connector.
NASA/CR—2012-216036 67

Figure D.63.— Heater 2 assembly: Note discoloration on fluid immersed portion.

Figure D.64.—Heater 2 fluid immersed portion: Note bluing and blackening.

Figure D.65.—Heater 2 fluid immersed portion: Note bluing and blackening.
NASA/CR—2012-216036 68

Figure D.66.—Heater 2 fluid immersed portion: Note bluing and blackening.

Figure D.67.—Heater 2 fluid immersed portion: Note blackening.

Figure D.68.—Heater 2 fluid immersed portion: Note bluing and blackening.
NASA/CR—2012-216036 69

Figure D.69.—Heater 2 assembly: Note bluing and blackening on fluid immersed portion.

Figure D.70.—Heater 2 assembly: Note bluing and blackening on fluid immersed portion.
NASA/CR—2012-216036 70

Figure D.71.—Heater 2 assembly: Note bluing and blackening on fluid immersed portion.

Figure D.72.—Heater 2 fluid immersed portion: Note bluing and blackening.
NASA/CR—2012-216036 71

Figure D.73.—Heater 3 label.

Figure D.74.—Heater 3 connection into TC.
NASA/CR—2012-216036 72

Figure D.75.—Heater 3 connection into TC.

Figure D.76.—Heater 3 connection into TC.

Figure D.77.—Heater 3 connection into TC.
NASA/CR—2012-216036 73

Figure D.78.—Heater 3 connection into TC.

Figure D.79.—Heater 3 Molex connector.
NASA/CR—2012-216036 74

Figure D.80.—Heater 3 connection into TC.

Figure D.81.—Heater 3 Molex connector.

Figure D.82.—Heater 3 assembly: Note bluing and blackening on fluid immersed portion.
NASA/CR—2012-216036 75

Figure D.83.—Heater 3 assembly: Note bluing and blackening on fluid immersed portion.

Figure D.84.—Heater 3 fluid immersed portion: Note bluing and blackening.

Figure D.85.—Heater 3 fluid immersed portion: Note bluing and blackening.
NASA/CR—2012-216036 76

Figure D.86.—Heater 3 fluid immersed portion: Note bluing and blackening.

Figure D.87.—Heater 3 fluid immersed portion: Note bluing and blackening.

Figure D.88.—Heater 3 fluid immersed portion: Note bluing and blackening.
NASA/CR—2012-216036 77

Figure D.89.—Heater 3 fluid immersed portion: Note bluing and blackening.

Figure D.90.—Heater 3 fluid immersed portion: Note bluing and blackening.
NASA/CR—2012-216036 78

Figure D.91.—Heater 3 assembly: Note bluing and blackening on fluid immersed portion.

Figure D.92.—Heater 3 fluid immersed portion: Note bluing and blackening.
NASA/CR—2012-216036 79

Appendix E.—X-Ray Inspection Photos

This appendix contains the photos of the cartridge heater x-ray images. See Section 4.5.3. For

Reference:

Bulk Fluid Heater 1 (S/N 010) = A

Bulk Fluid Heater 2 (S/N 012) = B

Bulk Fluid Heater 3 (S/N 009) = C

Figure E.1.—Planar view of heater assemblies bulk fluid heaters of 1, 2, and 3, respectively.

Note damage in heater 1.
NASA/CR—2012-216036 80

Figure E.2.—Planar view of heater assemblies bulk fluid heaters of 1, 2, and 3, respectively.

Note damage in heater 1.
NASA/CR—2012-216036 81

Figure E.3.—Rotated planar view of heater assemblies bulk fluid heaters of 1, 2, and 3,

respectively. Note damage in Heater 1.
NASA/CR—2012-216036 82

Figure E.4.—Close-up of Bulk Fluid Heater 1 damage at tip.
NASA/CR—2012-216036 83

Figure E.5.—Close-up of Bulk Fluid Heater 1 fitting.
NASA/CR—2012-216036 84

Figure E.6.—Close-up of Bulk Fluid Heater 1 damage along cartridge.

Figure E.7.—Close-up of Bulk Fluid Heater 1 damage along cartridge.
NASA/CR—2012-216036 85

Figure E.8.—Close-up of Bulk Fluid Heater 1 damage at tip.

Figure E.9.—Close-up of Bulk Fluid Heater 2 Tip.
NASA/CR—2012-216036 86

Figure E.10.—Wiring harness for Bulk Fluid Heater 2.

Figure E.11.—Close-up of Bulk Fluid Heater 2 along cartridge. Note irregularities in internal

heater wire.
NASA/CR—2012-216036 87

Figure E.12.—Close-up of Bulk Fluid Heater 2 along cartridge. Note irregularities in internal

heater wire.
NASA/CR—2012-216036 88

Figure E.13.—Close-up of Bulk Fluid Heater 2 along cartridge. Note irregularities in internal

heater wire.
NASA/CR—2012-216036 89

Figure E.14.—Close-up of Bulk Fluid 3 Tip.

Figure E.15.—Close-up of Bulk Fluid Heater 3 along cartridge. Note irregularities in internal

heater wire.
NASA/CR—2012-216036 90

Figure E.16.—Wiring harness for Bulk Fluid Heater 3.

Figure E.17.—Wiring harness for Bulk Fluid Heater 3.
NASA/CR—2012-216036 91

Figure E.18.—Wiring harness for Bulk Fluid Heater 3.

Figure E.19.—Wiring harness for Bulk Fluid Heater 3.
NASA/CR—2012-216036 92

Figure E.20.—Wiring harness for Bulk Fluid Heater 3.

Figure E.21.—Wiring harness for Bulk Fluid Heater 3.
NASA/CR—2012-216036 93

Figure E.22.—Close-up of Bulk Fluid Heater 3 along cartridge. Note irregularities in internal

heater wire.

Figure E.23.—Close-up of Bulk Fluid Heater 3 along cartridge. Note irregularities in internal

heater wire.
NASA/CR—2012-216036 94

Figure E.24.—Close-up of Bulk Fluid Heater 3 along cartridge. Note irregularities in internal

heater wire.

Figure E.25.—Bulk Fluid Heater Assembly 1.
NASA/CR—2012-216036 95

Figure E.26.— Bulk Fluid Heater Assembly 1

Figure E.27.— Bulk Fluid Heater Assembly 1
NASA/CR—2012-216036 96

Figure E.28.— Bulk Fluid Heater Assembly 1

Figure E.29.—Bulk Fluid Heater Assembly 1.
NASA/CR—2012-216036 97

Figure E.30.—Wiring harness for Bulk Fluid Heater 1.

Figure E.31.—Wiring harness for Bulk Fluid Heater 1.
NASA/CR—2012-216036 98

Figure E.32.—Wiring harness for Bulk Fluid Heater 1.

Figure E.33.—Wiring harness for Bulk Fluid Heater 1.
NASA/CR—2012-216036 99

Figure E.34.—Wiring harness for Bulk Fluid Heater 1.

Figure E.35.—Wiring harness for Bulk Fluid Heater 1.
NASA/CR—2012-216036 100

Figure E.36.—Close-up of Bulk Fluid Heater 1 damage along cartridge.

Figure E.37.—Close-up of Bulk Fluid Heater 1 damage near cartridge tip.
NASA/CR—2012-216036 101

Figure E.38.—Close-up of Bulk Fluid Heater 1 damage along cartridge.

Figure E.39.—Close-up of Bulk Fluid Heater 1 damage along cartridge.
NASA/CR—2012-216036 102

Figure E.40.—Close-up of Bulk Fluid Heater 1 damage along cartridge.

Figure E.41.—Planar view of heater assembly for Bulk Fluid Heater 2.
NASA/CR—2012-216036 103

Figure E.42.—Planar view of heater assembly for Bulk Fluid Heater 2.

Figure E.43.—Planar view of heater assembly for Bulk Fluid Heater 2.
NASA/CR—2012-216036 104

Figure E.44.—Wiring harness for Bulk Fluid Heater 2.

Figure E.45.—Wiring harness for Bulk Fluid Heater 2.
NASA/CR—2012-216036 105

Figure E.46.—Connector for Bulk Fluid Heater 2.

Figure E.47.—Grounding strap for Bulk Fluid Heater 2.
NASA/CR—2012-216036 106

Figure E.48.—Heating element for Bulk Fluid Heater 2.

Figure E.49.—Close-up of heating element for Bulk Fluid Heater 2. Note irregularities.
NASA/CR—2012-216036 107

Figure E.50.—Close-up of heating element for Bulk Fluid Heater 2. Note irregularities.

Figure E.51.—Close-up of heating element for Bulk Fluid Heater 2. Note irregularities.
NASA/CR—2012-216036 108

Figure E.52.—Close-up of heating element for Bulk Fluid Heater 2. Note irregularities.

Figure E.53.—Close-up of heating element for Bulk Fluid Heater 2. Note irregularities.
NASA/CR—2012-216036 109

Figure E.54.—Close-up of heating element for Bulk Fluid Heater 2.

Figure E.55.—Close-up of heating element for Bulk Fluid Heater 2.
NASA/CR—2012-216036 110

Figure E.56.—Close-up of heating element for Bulk Fluid Heater 2. Note irregularities.

Figure E.57.—Close-up of heating element for Bulk Fluid Heater 2. Note irregularities.
NASA/CR—2012-216036 111

Figure E.58.—Connector for Bulk Fluid Heater 2.

Figure E.59.— Close-up of end of heating element for Bulk Fluid Heater 2.
NASA/CR—2012-216036 112

Figure E.60.—Close-up of heating element for Bulk Fluid Heater 2.

Figure E.61.—Close-up of heating element for Bulk Fluid Heater 2.
NASA/CR—2012-216036 113

Figure E.62.—Close-up of heating element for Bulk Fluid Heater 2.

Figure E.63.—Connection to heating element for Bulk Fluid Heater 2.
NASA/CR—2012-216036 114

Figure E.64.—Planar view of Bulk Fluid Heater 3.

Figure E.65.—Planar view of Bulk Fluid Heater 3.
NASA/CR—2012-216036 115

Figure E.66.—Planar view of Bulk Fluid Heater 3.

Figure E.67.—Planar view of Bulk Fluid Heater 3.
NASA/CR—2012-216036 116

Figure E.68.—Wiring harness for Bulk Fluid Heater 3.

Figure E.69.—Connector for Bulk Fluid Heater 3.
NASA/CR—2012-216036 117

Figure E.70.—Grounding connection for Bulk Fluid Heater 3.

Figure E.71.—Connection to heating element for Bulk Fluid Heater 3.
NASA/CR—2012-216036 118

Figure E.72.—Heating element for Bulk Fluid Heater 3. Note irregularities.

Figure E.73.—Heating element for Bulk Fluid Heater 3. Note irregularities.
NASA/CR—2012-216036 119

Figure E.74.—Heating element for Bulk Fluid Heater 3. Note irregularities.

Figure E.75.—Heating element for Bulk Fluid Heater 3. Note irregularities.
NASA/CR—2012-216036 120

Figure E.76.—Close-up of heating element for Bulk Fluid Heater 3. Note irregularities.

Figure E.77.—Close-up of heating element for Bulk Fluid Heater 3. Note irregularities.
NASA/CR—2012-216036 121

Figure E.78.—Close-up of heating element for Bulk Fluid Heater 3. Note irregularities.
NASA/CR—2012-216036 122

Figure E.79.—Close-up of heating element for Bulk Fluid Heater 3. Note irregularities.

Figure E.80.—Close-up of heating element for Bulk Fluid Heater 3. Note irregularities.
NASA/CR—2012-216036 123

Figure E.81.—Wiring harness for Bulk Fluid Heaters.
NASA/CR—2012-216036 124

Figure E.82.— Wiring harness for Bulk Fluid Heaters.
NASA/CR—2012-216036 125

Figure E.83.—Wiring harness for Bulk Fluid Heaters.
NASA/CR—2012-216036 126

Figure E.84.— Power connection to heating element for Bulk Fluid Heater 1.
NASA/CR—2012-216036 127

Figure E.85.—Power connection to heating element for Bulk Fluid Heater 1.
NASA/CR—2012-216036 128

Figure E.86.—Grounding connection for Bulk Fluid Heater 1.
NASA/CR—2012-216036 129

Figure E.87.—Power connectors for Bulk Fluid Heater 1.
NASA/CR—2012-216036 130

Figure E.88.—Harness connection for Bulk Fluid Heater 2.
NASA/CR—2012-216036 131

Figure E.89.—Power connection for Bulk Fluid Heater 2.
NASA/CR—2012-216036 132

Figure E.90.—Power connection for Bulk Fluid Heater 2.
NASA/CR—2012-216036 133

Figure E.91.—Wiring harness for Bulk Fluid Heater 2.
NASA/CR—2012-216036 134

Figure E.92.—Power connection to heating element for Bulk Fluid Heater 2.
NASA/CR—2012-216036 135

Figure E.93.—Power connection for Bulk Fluid Heater 3.
NASA/CR—2012-216036 136

Figure E.94.—Power connection for Bulk Fluid Heater 3.
NASA/CR—2012-216036 137

Figure E.95.—Grounding connection for Bulk Fluid Heater 3.
NASA/CR—2012-216036 138

Figure E.96.—Power connection to heating element for Bulk Fluid Heater 3.
NASA/CR—2012-216036 139

Figure E.97.—Grounding connection for Bulk Fluid Heater 3.
NASA/CR—2012-216036 140

Figure E.98.—Power connection to heating element for Bulk Fluid Heater 3.
NASA/CR—2012-216036 141

Appendix F.—Approvals

Prepared by: /s/ Wendell H. Booth Date: 04/05/12

Wendell H. Booth

ZIN Technologies, Inc.

BXF Lead Electrical Engineer

Reviewed by: /s/ Kevin S. Magee Date: 04/05/12

Kevin S. Magee

ZIN Technologies, Inc.

BXF Lead Mechanical Engineer

Reviewed by: /s/ Russell W. Valentine Date: 04/05/12

Russell W. Valentine

ZIN Technologies, Inc.

BXF Mechanical Engineer

Reviewed by: /s/ Craig A. Totman Date: 04/05/12

Craig A. Totman

ZIN Technologies, Inc.

Mechanical Engineer

Reviewed by: /s/ Christian T. Lant Date: 04/05/12

Christian T. Lant

ZIN Technologies, Inc.

BXF Optics Engineer

Reviewed by: /s/ Jim Bruewer Date: 04/06/12

Jim Bruewer

ZIN Technologies, Inc.

Manufacturing Manager

Reviewed by: /s/ Debra R. Lyden Date: 04/06/12

Debra R. Lyden

ZIN Technologies, Inc.

Quality/Safety Manager
NASA/CR—2012-216036 142

Approvals.—Continued

Approved by: /s/ Raymond K. Pavlik Date: 04/06/12

Raymond K. Pavlik

ZIN Technologies, Inc.

BXF Project Lead

Accepted by: /s/ William A. Sheredy Date: 04/11/12

William A. Sheredy

NASA Glenn Research Center

BXF Project Manager
NASA/CR—2012-216036 143

Appendix G.—Revisions

Revision

Letter

Publication

Date

Change Description Approval

- 04/2012 Baseline Release
NASA/CR—2012-216036 144

Reference

1. “Rainey, K. N. and You, S. M., “Boiling heat transfer phenomena from microporous and porous

surfaces in saturated FC-72,” International Journal of Heat and Mass Transfer, Vol. 40, pp. 4437–

4447, 1997,