THEMIS FM 1 INSTRUMENT SUITE PRESHIP REVIEW PSR

THEMIS FM 1 INSTRUMENT SUITE PRE-SHIP REVIEW (PSR) THERMAL Chris Smith University of California - Berkeley FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-1 UCB, September 21, 2005

Open Issues • Two RFAs from the F 1 Instrument Suite PER are still open. – – – • One RFA from Mission CDR is open. – – • Responses submitted: 05/20/05 FM 1 PER RFA 02: Thermal Verification Test Summary FM 1 PER RFA 03: Provide Instrument Level Thermal Balance Test Plan Response Submitted: 01/10/05 MCDR RFA 05: Adhesive Temperature Limits One PFR opened on 09/16/05 – – – PFR 095: Thermal Radiator Tape Adhesive Failure Status: Under Investigation Needs to be resolved before Instrument Integration but not before “delivery” FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-2 UCB, September 21, 2005

FM 1 PER RFA #2 DATE SUBMITTED: 05/20/05 TITLE: Thermal Verification Test Summary RFA CODE: IN#1. PER. RFA 02 REQUESTED BY: L. Fantano SPECIFIC REQUEST: Provide summary table(s) (spreadsheet? ) that summarizes pertinent information associated with the THEMIS thermal verification test program. Include at minimum the following fields: Temp Sensitive Component ID, Cold operational Predict/Case, Hot Op Predict/Case, Op Cold Test Temp, Op Hot Test Temp, # of cycles, plateau duration, Cold non-operational Predict/Case, Hot non -op Predict/Case, Non-Op Cold Test Temp, Non-Op Hot Test Temp, # of cycles, plateau duration, test date, test facility, and test procedure/report reference. Also identify temperature sensitive components that have not been tested to limits plus appropriate margin and indicate future test plans for these items. SUPPORTING RATIONALE (ISSUE/PROBLEM): Project needs to book keep a consolidated accounting of thermal verification test program that is maintained by thermal engineer to assure that all thermal verification test requirements are satisfied. RESPONSE BY: Chris Smith All of the summary information requested is contained in the "Thermal As-Run" worksheet of the Engineering test matrix, which is included below. Double click icon to view table Themis ETM_Test. Record_5. xls FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-3 UCB, September 21, 2005

FM 1 PER RFA #3 DATE SUBMITTED: 05/20/05 TITLE: Provide Instrument Level Thermal Balance Test Plan RFA CODE: IN#1. PER. RFA 03 REQUESTED BY: L. Fantano SPECIFIC REQUEST: Provide instrument level thermal balance test plan. The test plan needs to describe thermal balance test strategy, test configuration, and test procedure for each test article. The results of in-chamber thermal analyses needs to be documented that provides thermal vacuum test temperature predictions. SUPPORTING RATIONALE (ISSUE/PROBLEM): Inadequate discussion was provided regarding instrument level thermal vacuum test plans. RESPONSE BY: Chris Smith FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-4 UCB, September 21, 2005

FM 1 PER RFA #3 Response Per phone conversations on 5/12, here is a sketch of thermal balance plans for the instruments. AXB: The AXB will be placed in a sheet metal thermal control box with three zones to simulate the top deck, bottom deck, and spacecraft interior. The chamber will be used to provide the environmental fluxes for the portions of the AXB that project outside the spacecraft simulation box. The goal of this test is general model correlation by helping determine the isolation at the top and bottom deck interfaces, to determine thermal conductivity of the carbon fiber tube, and to determine the effectiveness of the blanket. SPB: The SPB will be placed in a sheet metal thermal control box with four zones to simulate the top deck, bottom deck, side solar panel and spacecraft interior. The chamber will be used to provide the environmental fluxes for the portions of the SPB that project outside the spacecraft simulation box. The goal of this test is general model correlation by helping determine the isolation to the spacecraft deck, the effectiveness of the MLI insulation, and to determine the heat leak through the open SPB doors. IDPU/ESA/SCM Preamp: These will be placed in a sheet metal thermal control box with four zones to simulate the top deck, bottom deck, side solar panel and spacecraft interior. The chamber will be used to provide the environmental fluxes for the portions of the ESA that project outside the spacecraft simulation box. The goal of this test is general model correlation by helping determine the isolation to the spacecraft deck, radiative coupling to a simulated spacecraft interior and the total emissivity of the ESA to the chamber. FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-5 UCB, September 21, 2005

FM 1 PER RFA #3 Response FGM Sensor: The FGM sensor will be tested on its boom to determine the effectiveness of the instrument MLI and mounting isolation. A test heater will provide the flux through the MLI and interface. SCM Sensor: The SCM sensor will be tested on its boom to determine the effectiveness of the instrument MLI and mounting isolation. A test heater will provide the flux through the MLI and interface. FGM and SCM Boom Assemblies: The full SCM and FGM boom assemblies will be tested to determine their conductive and radiative coupling to the top deck when in the stowed position. The chamber base plate will simulate the flux from the top deck and the chamber will provide the space environment. SST: The SST will be placed on the chamber base plate that will simulate the spacecraft corner panel. The chamber walls will provide the space environment. The goal of this test is general model correlation by helping determine the isolation to the spacecraft corner panel, the effective emissivity of the SST, and the isolation between the internal Amp. Tek pre-amps and the external casing. FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-6 UCB, September 21, 2005

Mission CDR RFA #5 DATE SUBMITTED: 01/10/05 TITLE: Adhesive Temperature Limits RFA CODE: MCDR. RFA 05 REQUESTED BY: L. Fantano SPECIFIC REQUEST: Identify all adhesives employed in the various instrument designs. Determine temperature requirements associated with each. Verify that adhesive temperature limits are not violated and that appropriate adhesives have been chosen by the instrument leads. SUPPORTING RATIONALE (ISSUE/PROBLEM): Adhesive temperature limits need to be satisfied. RESPONSE BY: Christopher Smith / Paul Turin FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-7 UCB, September 21, 2005

Mission CDR RFA #5 Response Project Response: The adhesives used are listed in the table below. The table shows the manufacturers listed temps and the temps the adhesives will see in service. Many of the epoxies used will see temperatures lower than those shown in manufacturers data. However, this data simply lists the extremes they have been tested to by the manufacturer and do not indicate possible failure at other temperatures. All Structural epoxies have been qualified by UCB to function at the predicted temperatures +/- 15 Deg C margin. FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-8 UCB, September 21, 2005

PFR 095 DATE OPENED: 09/16/05 TITLE: Thermal Radiator Tape Adhesive Failure UNITS AFFECTED : SST, ESA, FGB, SCB, AXB PROBES AFFECTED: F 1, F 2, F 3, F 4, F 5 ORIGINATOR: Christopher Smith PROBLEM DESCRIPTION: The ITO coated silver Teflon tape samples with 3 M 9703 adhesive failed to remain adhered to its substrate in its third thermal vacuum test. First a testing history is required to understand the development of this problem. Before deciding to use this tape and adhesive for THEMIS we tested a sample of similar tape that was being used for the STEREO project. The tape used on THEMIS differs from the STEREO sample by manufacture date, perforation pattern, and method of adhesive application. The STEREO tape sample was thermal cycled 5 times from – 135 to +80 ºC and examined. All tape samples remained adhered to their substrate and the tape’s surface conductivity remained within specification. We then ordered the THEMIS specific tape from Dunmore Corp. The STEREO tape was also ordered from Dunmore but came without the adhesive. APL personnel applied the 9703 adhesive manually on site. For THEMIS we had Dunmore apply the adhesive in their factory. FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-9 UCB, September 21, 2005

PFR 095 (cont) When the adhesive arrived it was attached to the sample of aluminum and thermal cycled 6 times from – 60 to +65 ºC. In this test all five tape samples failed to remain adhered to their substrate. After consultation with 3 M we modified our application method. The tape was applied as it was in the first test and then warmed to 50 ºC. While still warm it was rerolled and placed back in the oven for 12 Hours @ +50 ºC. These samples were then thermal cycled 6 times from – 65 to +75 ºC and all tape samples remained adhered to the substrate so the test was considered a success. However, after the tape sample sat on my desk for 21 days at room temperature, it was noticed that three of the tape edges, out of 24 edges on 6 tape samples, had pulled up. This tape is used on the AXB, FGB and SCB Hinge, ESA, and SST. Three flight AXB units have been delivered for spacecraft integration but they all used the STEREO tape which passed qualification. We have enough excess STEREO tape to complete the remaining AXBs and FGB/SCB hinges. Analyses Performed to Determine Cause: In Progress Corrective Action/ Resolution: In Progress FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-10 UCB, September 21, 2005

EFI Pre. Amp Thermal Testing Setup FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-11 UCB, September 21, 2005

Thermal Testing Outline Cycle Accumulation • • • 2 cycles at instrument level - constrained by schedule 6 cycles at instrument suite level 4 cycles at spacecraft level 12 cycles total for every flight instrument 4 hour soaks at hot and cold targets Every TVAC test is preceded by a PER where thermal engineer signs off on procedure Status • • Over 100 component TV Tests have been completed Over 3300 hours of TV testing to date All Flight units tested to meet GEVS requirements As run procedures and reports are available in the EIDP FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-12 UCB, September 21, 2005

ESA/IDPU Thermal Testing Status • F 1 retested following rework FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-13 UCB, September 21, 2005

FGM Thermal Testing Status • • • F 4 FGS was not conductively mounted correctly in first qualification test. Retest was done in air at limits shown All FGM sensors have completed thermal vac testing No changes since F 1 PER FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-14 UCB, September 21, 2005

SCM Thermal Testing Status • • • Thin crack in the potting for two antennas during first ETU test. Potting method reworked and retested All SCM Sensors have completed thermal vac testing No changes since F 1 PER FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-15 UCB, September 21, 2005

SCM/FGM Boom Thermal Testing Status • • F 1 booms re-named F 6 after anomalous vibration results F 1 SCM and FGM will get a total of 4 cycles at the instrument suite level instead of the normal 8 due to the swap of F 1 and F 6 F 1/F 2 retested twice due to test setup errors All FGM and SCM booms have completed thermal vac testing FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-16 UCB, September 21, 2005

SST Thermal Testing Status • • F 3 renamed F 4 and F 4 renamed F 3 F 1, F 2, and F 3 need to be recalibrated following mezzanine board rework FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-17 UCB, September 21, 2005

EFI Pre. Amp Thermal Testing Status • • ETU 1 Preamp had no problems but FR 4 board was switched to Thermount 85 NT for ETU 2 and flight Six ETU 2 Qual Units went through 24 cycles, Two of those units added an additional 14 cycles for a total of 38 All EFI Pre Amps have completed thermal vac testing No changes since F 1 PER FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-18 UCB, September 21, 2005

EFI SPB Thermal Testing Status • • • Qual ETU motor was a motor only stress test, no problems seen SPB design changed from flying with doors closed to flying with doors open. ETU was retested after the small modifications this required Calibration runs done with the sphere keyreels to determine release tension at hot and cold deployment conditions All SPB units have completed thermal vac testing No changes since F 1 PER FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-19 UCB, September 21, 2005

EFI AXB Thermal Testing Status • • Due to delivery schedules to Swales we were unable to include the AXBs in the suite testing. They accumulated the 6 suite cycles on their own All AXB units have completed thermal vac testing FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-20 UCB, September 21, 2005

Suite TV Testing TV Plan • F 2 and F 3 Suites Together • 6 Suite Level TV Cycles, Survival, Cold Start and Bake-out (TQCM Monitor) • Details contained in THM-SYS-PRC-004, THEMIS INSTRUMENT SUITE Thermal Vacuum Test Procedure , Rev. B (unchanged from F 1) FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-21 UCB, September 21, 2005

Instrument Suite Thermal Testing Status • • Due to an error F 1 Suite did not go to the cold survival temperature before turn on. All units have separately been turned on at their cold survival limit. F 2 -F 5 will be tested to the – 60 survival temperature FM 1 Instrument Suite Pre-Ship Review (PSR) Thermal-22 UCB, September 21, 2005