THEMIS INSTRUMENT SUITE FM 2FM 3 PRESHIP REVIEW

THEMIS INSTRUMENT SUITE FM 2/FM 3 PRE-SHIP REVIEW FM 4/FM 5 PRE-ENVIRONMENTAL REVIEW Electric Field Instrument (EFI) John Bonnell EFI, IDPU, and II&T Teams University of California - Berkeley FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-1 UCB, November 10, 2005

Outline • Summary of EFI Status at FM 2/3 PSR and FM 4/5 PER • Instrument Configuration by SN • Summary of End-Item Data Package • Final Test and Cal Results vs. Requirement Fulfillment • PFRs • Open Items • Bonus Content: • EIDP Table of Contents • Vibration Testing Summary • TVAC Testing Summary FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-2 UCB, November 10, 2005

EFI Status at FM 1 PSR • Requirements and Design: – – • Procurement: – • No major changes to Requirements or Design since M-CDR (see Changes Since M-CDR and PFR Status for details). All RFAs from previous reviews closed out. All procurement is complete. Personnel, Assembly and Test: – Team has done an amazing job. – – 5 full FLT complements of SPBs and AXBs have completed functional and environmental testing, and either delivered to II&T or have completed II&T by the end of Aug ’ 05 (roughly 8 weeks per set). BEB assembly complete in Dec ’ 04; bench testing through FM 6 complete. DFB assembly complete in Feb ’ 05; bench testing through FM 5 complete. Reduction in Force complete, Jun ‘ 05. – Final EFI team includes one half-time Scientist (Instrument Lead), one half-time Mech. E (shared with Probe I&T) and one half-time Elect. E (shared with Probe I&T). FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-3 UCB, November 10, 2005

Instrument Configuration FM SPB 1 SPB 2 SPB 3 SPB 4 AXB 1 AXB 2 BEB DFB Harness SPB Flight Enable Plugs AXB Flight Enable Plugs 1 904 903 902 901 002 004, v 8 002, v 7, v 4 001 To be serialized 2 908 905 906 907 003 004 012 004 002 3 912 909 910 911 005 006 007 003 4 916 913 914 915 007 008 014 005 004 5 920 917 919 918 009 010 013 007 005 6 922 924 011 012 FM 2/FM 3 IPSR AND FM 4/FM 5 IPER 006 EFI-4 UCB, November 10, 2005

FM 2/3 End-Item Data Package (EIDP) • Same great content as FM 1 EIDP, but now double the fun! • See Bonus Materials for Table of Contents. • Delivered Instruments: ~ 13. 1 kg (x 2). • End-Item Data Package: FM 2/FM 3 IPSR AND FM 4/FM 5 IPER ~ 22. 5 kg (x 2; 72% margin!). EFI-5 UCB, November 10, 2005

EFI Mission Requirements Fulfillment: • FM 2 -FM 4 MR fulfillment noted in THEMIS Verification Matrix (see MSE Presentation). • Integrated EFI and component parts compliant with mission requirements. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-6 UCB, November 10, 2005

Results of FM 1 -FM 5 Testing • • DC and AC Transfer functions agree within Flight sets to better than 1 % on non-critical functions (USHER, GUARD, AC SENSOR gain, etc. ), and better than 0. 2 % on critical, matched functions (BIAS, DC SENSOR gain). Full 16 -bit control of all bias functions demonstrated (control to better than 1 part in 1000, as per MRD). V- and E-channel gains on DFB as per specification. DFB Spectral (Filter Bank, FFT, and AKR) and Derived Quantities data products as per specification. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-7 UCB, November 10, 2005

EFI PFR Status FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-8 UCB, November 10, 2005

PFR Status (1) • New PFRs since FM 2/3 PER and FM 1 PSR: 103, 105, 115. • Update on open PFR relevant to FM 1 PSR: PFR-096. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-9 UCB, November 10, 2005

PFR Status (2) • PFR-103 (Cracked SPB Retainer Tube): • • The SPB Door Retention Pin Retainer Tube on one FM 4 unit was found to be damaged after actuation; the material around a fastener had yielded. Analysis of the design showed that insufficient material was present to hold the fastener. A retention clip was added to all units to properly retain the pin mechanism. PFR-105 (FM 4 Turns Counter Switch Failure): • • • The SPB turns counter switch on one unit was found to actuate at half the rate of other units. It was found that the turns counter cam fastener sat proud of the cam surface on some of the units in a survey of all flight units, leading to unreliable switch actuation in the affected units. The turns counter cam was reworked to assure that the fastener head would be below the cam surface in all units, and actuation was tested in all flight units. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-10 UCB, November 10, 2005

PFR Status (2) • PFR-115 (FM 3 EFI V 1 Failing AC Functional Test in TVAC) • • • One FM 3 SPB unit displayed an anomalous response during AC Functional Testing during the cold soak portion of FM 2/3 TVAC. The anomalous response was traced to contact between the Sphere and Usher surfaces, which would affect pre-deployed testing of the sphere but would not affect deployed operation. The contact between the Sphere and Usher was traced to an out-ofspec gap between the two surfaces, arising from tolerance stack up on the Preamp Enclosure and Sphere. A 5 -mil insulating kapton spacer anchored to the SPB Sphere Holder via transfer adhesive was added to all flight SPBs to increase the gap and eliminate the possibility of contact between the Sphere and Usher. The gap under axial load and electrical isolation on all units was verified by measurement, and will be complete by F 5 TVAC. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-11 UCB, November 10, 2005

Open Items FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-12 UCB, November 10, 2005

Open Items • Instability of EFI Y IMON (PFR-096): • • • Source of 2 m. A current consumption instability traced to EFI Preamps on affected units. Suspect preamp boards swapped for Flight spares, and affected units re-integrated and re-calibrated. Spare units consume nominal, stable current. Suspect preamp PWBs subjected to bench tests to determine nature of current consumption instability. Suspect preamp PWBs reworked to isolate source of problem to particular components (power supply bypass caps replaced). Suspect parts sent for comparative DPA (suspect parts and parts from same lot and vendor); results pending (NOV 2005). FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-13 UCB, November 10, 2005

Bonus Materials: • • • EIDP Table of Contents (note FM identifier is not valid) Vibration Testing Summary TVAC Testing Summary FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-14 UCB, November 10, 2005

EIDP: Electrical • THEMIS EFI Preamp: F 1 PWB: • Assembly Records. • Special TVAC Acceptance Test Data. • THEMIS EFI F 1 Sci. Cal: • Sci. Cal Summary (calibration data summary). • DC Response Data (BIAS, SENSOR, FLGND, USHER, GUARD, BRAID). • AC Response Data (SENSOR, FLGND, USHER, GUARD, BRAID). • THEMIS BEB, S/N 004, FM 1 (BINDER 1): • SCHEMATIC, ASSEMBLY AND RE-WORK RECORDS, BOARD-LEVEL TESTING RESULTS, MATE/DEMATE AND POWER LOGS. • THEMIS DFB, S/N 02, FM 1 (BINDER 5): • SCHEMATIC, ASSEMBLY AND RE-WORK RECORDS, BOARD-LEVEL TESTING RESULTS, MATE/DEMATE AND POWER LOGS. • THEMIS Harness: EFI (F 1 -6; no Binder number assigned): • Schematic, assembly and re-work records. • THEMIS Harness: Enable Plugs, Coax Cables (F 1 -6; Binder 24): • Schematic, assembly and re-work records. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-15 UCB, November 10, 2005

EIDP: Misc. • THEMIS EFI Preamp PWB and Cable Loading Log (SPB and AXB): • CROSS-REFERENCED LIST BETWEEN BOOM UNIT, CABLE, AND PREAMP S/N. • THEMIS EFI: PA & Cable Drawings (Binder 35): • Mechanical Drawings of Preamp Enclosure and Cable Assembly fixtures. • Assembly and Re-Work records included in individual boom unit assembly records. • THEMIS EFI Deploy Data (F 1 -6): • Sphere/Fine Wire deploy data. • Duplicates of SPB Hi-Bay and TVAC Deploy Test Reports. • Duplicates of AXB Vertical and TVAC Deploy Test Reports. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-16 UCB, November 10, 2005

EIDP: SPBs • THEMIS SPB: Vibration Acceptance Testing (FM 1 -2; Binder 12): • Acceptance Vibration Test Reports. • THEMIS SPB Flight Documents: Hi-Bay Full Deployment Testing (F 1 -5; Binder 13): • Deploy Testing Reports (current consumption, length measurement and calibration, deploy rate). • THEMIS EFI: SPB Procs & Schematics (all; Binder 14): • Vacuum Motor Burn-In Test Report. • THEMIS EFI: SPB Mass Properties (F 1 -6; Binder 15): • SPB Mass Properties and ICD Conformance Reports. • THEMIS: SPB Master Mechanical Drawings, FM 1 (Binder 27): • As-Built Mechanical Drawings. • SPB S 90 x: THEMIS (Assembly and Test Records; Binders 8, 9, 10, and 11): • Assembly and rework records for boom unit, preamp enclosure, and cable. • Electrical and mecahnical functional test records. • TVAC test records. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-17 UCB, November 10, 2005

EIDP: AXBs • THEMIS Axial Boom: Assembly Records, Flight 1 Upper and Lower Booms, THM-AXB-FLT-001, 002 (Binders 29 and 28): • Boom Wiring Diagram, Assembly and Re-Work Records. • THEMIS Axial Boom: Test Records, Flight 1 Upper and Lower Booms, THM-AXB-FLT-001, -002 (Binders 31 and 30): • Mechanical and Electrical Functional Test records. • Vibration Test Results. • TVAC test Results. • ICD Conformance and Mass Properties. • THEMIS Axial Boom: Vibration test Data, All Flight Units (no Binder number assigned): • Acceptance Vibration Test Data. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-18 UCB, November 10, 2005

SPB Acceptance Vibration Protocol Per UCB THEMIS Document THM-SPB-PRO-423 • • • All 3 Axes Sine Survey, . 25 G, 5 – 2000 Hz Sine Strength per Swales TM 2430 -Rev. D, 29 November 2004 Random – Per Swales Document TM 2430 -Rev. D – 7. 09 G RMS – 1 min duration All Vibration Testing Performed at Same Facility, Quanta Labs Retesting (if required) • • ‘Workmanship Shake’ – Validate any design changes following original Flight build shake – Validate rework of any failures on previous vibration test Entire vibration protocol, single axis only Acceptance Sine Strength Specification FM 2/FM 3 IPSR AND FM 4/FM 5 IPER 4 X SPB Flight Units on Vibration Plate EFI-19 Acceptance Random Specification UCB, November 10, 2005

SPB Acceptance Vibration Tests Run SPB Serial # Following First Build Retest #1 (Rework/Redesign) Retest #2 (Rework/Redesign) 901, 903 06 Dec 04 31 Jan 05 (Ferrule Redesign) 21 March 05 (Post-Release Springs Redesign) 902, 904 06 Dec 04 14 Dec 04 (Validate Retorquing of bolts that had backed out on first test) 31 Jan 05 (Post Ferrule Redesign) 21 March 05 (Post-Release Springs Redesign) 905, 906, 907, 908 01 Feb 04 04 March 04 (Post-Release Springs Redesign) - - 909, 910, 911 17 Mar 2005 - - - 21 March 05 (Validate failed wire in spool connector from previous test) - - 912 913, 914, 915, 916 17 Mar 2005 25 Apr 2005 FM 2/FM 3 IPSR AND FM 4/FM 5 IPER Retest #3 (Rework/Redesign) - EFI-20 UCB, November 10, 2005

SPB Vibration Testing Overview • Deviations from Test Specification (Notching/Force Limiting/Aborts) - • • SPB First Natural Frequency: 144 Hz (Requirement: >75 Hz) Good Sine Sweep Consistency from Unit to Unit (within 15 Hz) Retesting due to Hardware Failure 1. Backing out of bolts (2 X Bolts not torqued correctly at Flight Build) 2. • Resolution: Bolts torqued and spot-bonded, single axis re-vibe completed Single Strand of Cable pulled out of connector at Spool (Assy error) • Resolution: Wire repaired, single axis re-vibe completed Retesting due to Hardware Redesign (FM 1 Only) 1. 2. • None Release Ring Spring Redesigned to Ensure Constant Force on Doors • Resolution: All springs Replaced in all units • Single Axis Retest Completed Preamp Ferrule Crimp Redesigned (Contact discovered to be inconsistent during testing) • Resolution: Ferrule material changed and recrimped • Single Axis Retest Completed Status • Flight Units F 1 -F 5 Vibration Acceptance Testing Completed FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-21 UCB, November 10, 2005

AXB Acceptance Vibration Protocol Per UCB THEMIS Document THM-AXB-PRC-302 • • • All 3 Axes Sine Survey, . 25 G, 5 – 2000 Hz, 2 octaves/minute Sine Strength per Swales TM 2430 -Rev. D, 29 November 2004 Random per Swales Document TM 2430 -Rev. D – Qualification: 13. 01 G RMS, 2 min duration – Acceptance: 9. 21 G RMS, 1 min duration All Vibration Testing Performed at Same Facility, Quanta Labs Retesting (if required) • • ‘Workmanship Shake’ – Validate any design/procedure changes following original Flight build shake – Validate rework of any failures on previous vibration test Entire vibration protocol, single axis only FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-22 UCB, November 10, 2005

AXB Acceptance Vibration Tests Run AXB Serial # Following First Build Retest #1 (Rework/Redesign) 001, 002 (Flight 1) 11 JAN 05 03 FEB 05 (Proper Accelerometer Location Retest) 003, 004 (Flight 2) 07 FEB 05 - 005, 006 (Flight 3) 25 FEB 05 15 MAR 05 (Sensor Door Mount/Axle Replacement) 007, 008 (Flight 4) 11 APR 05 - 009, 010 (Flight 5) 22 APR 05 - 011, 012 (Flight 6) SCHD. MAY 05 - AXB X Axis Note: Jan 11 2005 testing was to qualification levels due to design modifications relative to the engineering test unit. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-23 AXB Y Axis AXB Z Axis UCB, November 10, 2005

AXB Vibration Testing Overview • Deviations from Test Specification (Notching/Force Limiting/Aborts) - • • AXB Z First Natural Frequency: 300 Hz (Requirement: >75 Hz) Good Sine Sweep Consistency from Unit to Unit (within 15 Hz) AXB X & Y frequencies modeled fixture resonances, suggesting first natural frequency higher than 1800 Hz Retesting due to Improper Test Procedure 1. • Accelerometer was not located at the boom’s center of mass during vibration • Resolution: Accelerometer placed at center of mass and single axis test completed Retesting due to Hardware Failure 1. • Due to resonances in testing fixture, notching was required on the Y Axis to prevent overtesting of the booms • THM-AXB-FLT-001, 1570 Hz to 1670 Hz, input 0. 0016 g 2/Hz • THM-AXB-FLT-002, 1580 Hz to 1745 Hz, input 0. 0016 g 2/Hz Sensor door mount cracked during re-stow of boom (Assembly Error) • Resolution: Assembly replaced and single axis test completed Status • Flight Units F 1 -F 5 and Flight Spare F 6 Vibration Acceptance Testing Completed. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-24 UCB, November 10, 2005

EFI Pre. Amp Thermal Testing Status • NO CHANGE SINCE FM 1 I-PER. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-25 UCB, November 10, 2005

EFI SPB Thermal Testing Status Updates since FM 1 I-PER: • F 4 and F 5 SPB TVAC and Thermal Balance testing complete as of July 2005. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-26 UCB, November 10, 2005

EFI AXB Thermal Testing Status Updates since FM 1 I-PER: • • AXB F 3 thru F 6 received 6 Suite-level TVAC cycles en masse July 25 -28, ’ 05 in order to deliver AXB and AXT (tube) to Probe I&T. AXB F 2 and F 3 units delivered to Swales to support Probe RCS buildup, Aug and Sep 2005. FM 2/FM 3 IPSR AND FM 4/FM 5 IPER EFI-27 UCB, November 10, 2005