1. RBSP Radiation Belt Storm Probes RBSP Radiation Belt Storm Probes RBSP/EFW I-PER 21 January 2011 149 EFW Test Plan Michael Ludlam Space Sciences Laboratory University of California, Berkeley

2. RBSP/EFW I-PER 21 January 2011Michael Ludlam 150 Introduction Test Flow ETM Test Objectives Functional Testing EMC Vibration Thermal Vacuum

3. RBSP/EFW I-PER 21 January 2011Michael Ludlam 151 Instrument Test Flow

4. RBSP/EFW I-PER 21 January 2011Michael Ludlam 152 ETM Mechanical notes: (*)"AXB less whip" is the AXB Deployment mechanisim less the Cage/whip/preamp A1Analysis to show saftey margins per 7417-9019 A2Units follow design rule of 1 sq in vent area/ft^3 of volume as per Waiver EFW-008 T1Per 7417-9019 T2Test conducted as part of Spacecraft Structure verification. T3 Per 7417-9019 Section 5.4.5 for protoflight hardware. Test is done unpowered and no functional between axes as per waivers EFW-005 & EFW-003 T4 Cable assemblies on EFW Booms undergo static load test T5 EMFISIS Interface test done with simulators, plus an ETU to ETU test, and finally on the spacecraft T6Safe-to-Mate and compliance to ICD prior to Integration T7Per 7417-9018, full testing on F1, CE testing on ETU, F2 T9Total Dose and SEE Testing at part level as needed T1060C for 48 hours prior to TV w/ integrated payload T11Contamination Verification w/ TQCM T12 Deployments occur at start of test sequence (ETU and FM) and in thermal vac at temperature extremes; tests self-shock; T13 Whip deployment test after AXB vibration; then Whip removed and deployed again in thermal vac, stacer deployment in "AXB less Whip" thermal vac separately T14 SPB partial deploy during Spacecraft EMC test.AXB Whip deploy test after S/C Vib & Deployment service testing with actuator simulators as agreed per Waiver EFW-004 T15 AXB runout measured during horizontal deploy testing T16 Instrument level thermal vac test excludes the AXB Tube M1Mass, CG, MOI measured stowed; deployed by analysis M2DC Magnetics measured prior to Instrument Payload integration M3Mass only measured for the harness, no CG or MOI AAnalysis TTest M Measurement No changes to ETM since last review. Items in green are complete. Items in white are still to do.

5. RBSP/EFW I-PER 21 January 2011Michael Ludlam 153 ETM Electrical notes: (*)"AXB less whip" is the AXB Deployment mechanisim less the Cage/whip/preamp A1Analysis to show saftey margins per 7417-9019 A2Units follow design rule of 1 sq in vent area/ft^3 of volume as per Waiver EFW-008 T1Per 7417-9019 T2Test conducted as part of Spacecraft Structure verification. T3 Per 7417-9019 Section 5.4.5 for protoflight hardware. Test is done unpowered and no functional between axes as per waivers EFW-005 & EFW-003 T4 Cable assemblies on EFW Booms undergo static load test T5 EMFISIS Interface test done with simulators, plus an ETU to ETU test, and finally on the spacecraft T6Safe-to-Mate and compliance to ICD prior to Integration T7Per 7417-9018, full testing on F1, CE testing on ETU, F2 T9Total Dose and SEE Testing at part level as needed T1060C for 48 hours prior to TV w/ integrated payload T11Contamination Verification w/ TQCM T12 Deployments occur at start of test sequence (ETU and FM) and in thermal vac at temperature extremes; tests self-shock; T13 Whip deployment test after AXB vibration; then Whip removed and deployed again in thermal vac, stacer deployment in "AXB less Whip" thermal vac separately T14 SPB partial deploy during Spacecraft EMC test.AXB Whip deploy test after S/C Vib & Deployment service testing with actuator simulators as agreed per Waiver EFW-004 T15 AXB runout measured during horizontal deploy testing T16 Instrument level thermal vac test excludes the AXB Tube M1Mass, CG, MOI measured stowed; deployed by analysis M2DC Magnetics measured prior to Instrument Payload integration M3Mass only measured for the harness, no CG or MOI AAnalysis TTest M Measurement

6. RBSP/EFW I-PER 21 January 2011Michael Ludlam 154 ETM Thermal, Contam & Other notes: (*)"AXB less whip" is the AXB Deployment mechanisim less the Cage/whip/preamp A1Analysis to show saftey margins per 7417-9019 A2Units follow design rule of 1 sq in vent area/ft^3 of volume as per Waiver EFW-008 T1Per 7417-9019 T2Test conducted as part of Spacecraft Structure verification. T3 Per 7417-9019 Section 5.4.5 for protoflight hardware. Test is done unpowered and no functional between axes as per waivers EFW-005 & EFW-003 T4 Cable assemblies on EFW Booms undergo static load test T5 EMFISIS Interface test done with simulators, plus an ETU to ETU test, and finally on the spacecraft T6Safe-to-Mate and compliance to ICD prior to Integration T7Per 7417-9018, full testing on F1, CE testing on ETU, F2 T9Total Dose and SEE Testing at part level as needed T1060C for 48 hours prior to TV w/ integrated payload T11Contamination Verification w/ TQCM T12 Deployments occur at start of test sequence (ETU and FM) and in thermal vac at temperature extremes; tests self-shock; T13 Whip deployment test after AXB vibration; then Whip removed and deployed again in thermal vac, stacer deployment in "AXB less Whip" thermal vac separately T14 SPB partial deploy during Spacecraft EMC test.AXB Whip deploy test after S/C Vib & Deployment service testing with actuator simulators as agreed per Waiver EFW-004 T15 AXB runout measured during horizontal deploy testing T16 Instrument level thermal vac test excludes the AXB Tube M1Mass, CG, MOI measured stowed; deployed by analysis M2DC Magnetics measured prior to Instrument Payload integration M3Mass only measured for the harness, no CG or MOI AAnalysis TTest M Measurement

7. RBSP/EFW I-PER 21 January 2011Michael Ludlam 155 Functional Testing All instrument functionality has been tested and verified. –Instrument performance is verified by calibration (discussed later by John Bonnell) –Other Instrument functionality verified by tests, such as boom deployments. –Future tests of functionality are now checked by running a CPT. –CPT’s occur before environmental tests start, after tests, and during thermal vacuum. –The CPT includes all functionality as can be tested using stowed booms. Deployments are simulated with GSE ‘Boom Loads Box’ that connects to the test/enable plugs on the SPB/AXBs. –Other tests are conducted at S/C I&T (whip deployment, SPB deployment, Usher and Guard test). These have already been verified at instrument level.

8. RBSP/EFW I-PER 21 January 2011Michael Ludlam 156 EMC EMC Testing levels and configurations set by EMECP (7419- 9018), based on MIL-STD-461C. Procedure (RBSP_EFW_INT_014) submitted for review by Carl Hermann, and signed off by EFW team. Test on one flight unit will be conducted in a semi anechoic chamber (CKC Labs in Fremont, CA) Test on second unit will only be CE measurements to verify units are the same. This will be done at SSL.

9. RBSP/EFW I-PER 21 January 2011Michael Ludlam 157 Vibration Instrument designed and tested to EDTRD rev A specification: –Limit Loads, Stiffness, Shock –Sine, Random vibration at component level As specified by EDTRD No acoustic test (no acoustically sensitive parts) Vibration Test Procedures –Written and signed off before run. –IDPU Vibration Procedure RBSP-IDP-PRO-200A

10. RBSP/EFW I-PER 21 January 2011Michael Ludlam 158 Vibration SSL uses Quanta Labs in San Jose for vibration testing. Standard Operating Procedure at SSL is to do verification run with empty shaker table to ensure equipment is performing within specification prior to actual runs with flight hardware. Functional Test is run on assemblies pre and post vibration, not between axes and assemblies are unpowered during vibration test. [Deviations EFW-003 & EFW-005] AXB and SPB vibration tests successfully run in Q3 and Q4 of 2010.

11. RBSP/EFW I-PER 21 January 2011Michael Ludlam 159 Thermal EFW interface temperature limits agreed upon between EFW and APL Thermal Engineers. –EFW components conductively coupled to spacecraft deck. –IDPU will be qualified to ‘standard’ RBSP limits; (operating +55  C to - 25  C). –EFW Instrument TVAC procedure has been submitted for approval to Bruce Williams at APL. Thermal Vacuum Procedures. –Spin Plane Boom RBSP-SPB-PRO-102 Completed –Axial Boom Stacer RBSP_EFW_AXB_022 Completed –Axial Boom Whip RBSP_EFW_AXB_026 Completed –Axial Boom Preamps RBSP_EFW_PRE_AXB_009B Completed. –Spin Plane Boom Preamps RBSP_EFW_PRE_SPB_010A Completed. –Instrument Thermal Vacuum Procedure RBSP_EFW_INT_016B

12. RBSP/EFW I-PER 21 January 2011Michael Ludlam 160 Thermal test matrix 7 total cycles per instrument total. No need for thermal balance as all units are conductively coupled to the spacecraft. 7

13. RBSP/EFW I-PER 21 January 2011Michael Ludlam 161 Thermal Test Values / Limits Instrument Science Operation Operation Out of Spec Non Operation ColdHotColdHotColdHot EFI PreAmp-5575-160105-160105 IDPU-2555 -3060 Instrument Pre Deployment Deployment Post Deployment ColdHotColdHotColdHot AXB Mechanical Units-3060-2555-30100 SPB Mechanical Units-3060-2555-3060 Boom Frangibolts-3070-2565 All values are interface temperatures provided by APL. They carry the margin in these numbers Except Preamp where values shown are based on UCB predict ±5 ˚C predict uncertainty ±10 ˚C margin, 15 ˚C total

14. RBSP/EFW I-PER 21 January 2011Michael Ludlam 162 Flight Thermal Vac Testing Cycles highlighted in green have already been completed Instrument Non Op Low ( ˚ C) Op Low (˚C) Deploy Low (˚C) Deploy High (˚C) Op High (˚C) Non Op High (˚C) # Cycles SPB Preamp-160 105 8 SPB-30-25 55 605 AXB Preamp-160 105 8 AXB Tube-35-25 55657 AXB Stacer Mech -30-25 55 605 AXB Cage / Whip -30-25 65 707 IDPU-30-25 55 605 Instrument Suite -30-25 55 602

15. RBSP/EFW I-PER 21 January 2011Michael Ludlam 163 Instrument Thermal Vacuum Profile

16. RBSP/EFW I-PER 21 January 2011Michael Ludlam 164 Thermal Vacuum Facilities Instrument Thermal Vacuum to be done in house. Chamber has been used for AXB and SPB Thermal Vacuum already. Flight Harnesses and internal cabling will be baked out for 48 Hours prior to test.

17. RBSP/EFW I-PER 21 January 2011Michael Ludlam 165 Conclusions Instrument test plans in place No significant changes to plan since CDR Procedures for EMC, Vibration and Thermal Vacuum testing are written and signed off Test GSE and software ready to support testing

18. RBSP/EFW I-PER 21 January 2011Michael Ludlam 166 Back Up Slides

19. RBSP/EFW I-PER 21 January 2011Michael Ludlam 167 Alignment EFW Boom unit alignment achieved by bolt-hole tolerance –Verified to meet IRD alignment requirements by EFW analysis –No observatory-level alignment measurement required EFW AXB run-out measurement –verifies deployed AXB meets straightness (alignment) requirement –at Component level testing (before delivery to APL)

20. RBSP/EFW I-PER 21 January 2011Michael Ludlam 168 This page intentionally almost blank