1. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Integration and Test Marc Kaylor 301-902-4392 MKaylor@swales.com

2. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 I&T Focus on Major System Components to be Verified

3. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 I&T Approach Overview  Bottoms Up, Modular Approach -Component Level and Subsystem ETU Verification prior to Integration -System Integration Aliveness Test to verify functionality  System Level Tests -Aliveness Test - Verifies each probe operates including basic functionality and mechanical motion where applicable -Functional Test - Verify every interface, command, telemetry point, and function - Uses EGSE as stimulus to test systems more in depth than Aliveness -Comprehensive Performance Test - Measures performance on each subsystem - Demonstrates measurements of performance at a system level -Mission / Orbits Simulation Test -Verifies system from simulation test modes at steady state orbits -Environmental Tests - Verifies subsystem and system at design environment loads with margin

4. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04  Components are flight qualified prior to bus/probe installation –Instruments undergo thorough environmental testing individually and as a assembly at UCB –Bus components are qualified at vendor level and retested as part of the Bus integration and test process Battery AEA Technology Antenna PSL Transponder L3 Com S/A Cells & Laydown COI (CICs SpectroLab) Gyro’s Systron Donner (Swales does Module testing) Sun Sensor Adcole Tanks & RCS ARDE & Aerojet BAU Swales & General Dynamics Primary Structure with ClampbandSwales  Single instruments to spacecraft electrical interface through IDPU  Plan to verify BAU and IDPU (EDU) interfaces as early as possible for compatibility  EDU bus avionics and IDPU support early h/w and s/w development on the FlatSat system I&T Approach Component Qualification Program

5. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Test Personnel and Roles

6. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 I&T Organization

7. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Core Team Test Personnel and Roles  I&T Manager -Responsible for Integration and Test Activities -Directs Test Activities -Coordinates Integration and Test Team -Prepares Facility and Test Stimuli  Systems Engineers -Plans System Tests and creates input parameters to tests -Writes system level test plans / procedures such as Comprehensive Performance Test, Aliveness Test, and Orbits Simulation Test -Assist in the direction of test activities -Leads Verification Program and assures test objectives and requirements are verified and documented  Subsystem Leads / Engineers -Address technical issues regarding operation and design of subsystem -Works with Systems Engineering in verifying subsystem requirements through test  Quality Assurance Engineer -Cognizant of the execution of the test -Verifies quality of integration hardware, test data and equipment -Witness integration and sign-off of critical procedure steps  Spacecraft Test Conductors -In charge of operations to perform test procedure -Perform troubleshooting during test as required -Identify, report, and initiate corrective action for the flight hardware, database, or GSE -Disposition test anomalies -Conduct test briefings to the team

8. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Core Team Responsible Equipment Engineer (REE) / Subsystem Engineer  Responsible Equipment Engineer (REE) / Subsystem Engineer –The REE is the Subsystem Engineer who was responsible for the delivery of the test hardware to the l&T Team. –The REE is responsible for performing testing to verify delivered hardware is fully operational prior to approving the start of the l&T process. –The REE is required to attend the Test Readiness Review (TRR), Daily Test Coordination meetings and the Post Test Review (PTR). –The REE has signature authority on the procedures and Work Order Authorizations (WOAs) applicable to the REE's hardware. –Prior to signing the REE is to ensure that the testing activities are safe for the hardware, that the REE fully understands the testing activities as planned, and the expected results are accurate. –The REE's signature is required on any black or red lines made to the procedure. The signature is required before the black or red lines are to be performed. –The REE is required to be present and observing all Flight testing. The REE is an active participant in the test operations but only in an oversight and support role. The REE is responsible for ensuring the hardware is never at risk, understanding and approving any deviations and to aid in the investigation of any anomalies or out of tolerance readings

9. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Core Team Safety / Contamination  Safety Engineer –The Safety Engineer is required to attend the Test Readiness Review (TRR), Daily Test Coordination meetings and the Post Test Review (PTR) –This ensures that the Safety Engineer is cognizant of all testing operations  Contamination Engineer –The Contamination Engineer is required to attend the Test Readiness Review (TRR), Daily Test Coordination meetings and the Post Test Review (PTR) –This ensures that the Contamination Engineer is cognizant of all testing operations and potential impacts to the cleanliness of the spacecraft/instrument

10. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Facilities Plan

11. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Swales 5015  Primary Probe Integration facility and the epicenter of our flight system development  5015 1st floor layout attachment shows separate work areas and multiple workstations to support our parallel probe I&T flow, includes class 100/10K cleanrooms, Flatsat, and harness labs –Class 100K required in cleanrooms, Class 10K rules in effect when instrument interiors are exposed –When the spacecraft is outside of the class 100,000 cleanroom it must be double bagged. 65-75 F, 30-60% RH –No unique power requirements identified, standard 120VAC, 20A service should be adequate for each lab and zone. In addition zone 2 should be wired for 60A two phase service should we require a dedicated centralized UPS for sensitive GSE and grounding control –Connectivity to the intranet and Internet required in each lab and zone. Zones 2, 2 and Lab C must also be connected to the THEMIS test net –Existing portable crane required

12. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 5015 Layout

13. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Swales 5015 Mezzanine  Second floor mezzanine area (not shown) planned for I&T staff office area and conference rooms. Includes areas for I&T team, Hammers SW Team, and Instrument Support Team –Mezzanine must be wired to support phones Intranet, Internet and THEMIS test net connectivity –Power requirements limited to standard 120VAC, 20A service –Printer and photocopy machine available in lobby  Planned usage is as follows –First floor highbay, labs and office has already begun –First floor cleanroom 3Q04 –Second floor mezzanine 2Q04

14. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Network Security and Access

15. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Probe Carrier Integration Facility  High Bay in Swales Building 11310 –The probe carrier will be fully integrated in this facility. –There are no requirements to maintain the this hardware assembly in a cleanroom at a Class 100K –40’ x 40’ area needed for PC and shipping container –Same facility that we plan to use to manufacture the probe primary structure components (decks, side and quarter panels) –Has loading dock, clean areas, access control, bonded storage, machine shop, tooling, lots of staff etc –No facility modifications identified at this time, expect to use as is –First use is expected in the 3Q04

16. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Swales 5016 Highbay  ETU Clampband Requirements (Inside 5016) –25’ X 25’ area under beam crane –Overhead crane required – existing ½ ton beam is acceptable – need hoist –65-75 F, 30-60 % RH (TBR) –Standard 120VAC, 20 A service (6 outlets) –Phone and network access in clampband corner –Capability to partition work areas –2 work tables one with provisions for ESD ground –Secure cabinet and/or cage storage –Planned first use is 1 March 2004 for ETU clampband testing

17. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Facilities / Security Control  FACILITY ACCESS REQUIREMENTS –Personnel supporting the THEMIS activity will require authorization by the I&T Manager and/or the THEMIS Program Manager for access to the facilities where the activities occur. –Access to the Swales 5015 Building will be controlled by the use of a key card. QA will maintain a current access log of personnel working on or in the general area of the spacecraft. –Swales has current arrangements for off duty police patrols from 6PM- 6AM weekdays and 24/7 on weekend

18. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Cleanroom Support / Contamination  Mission level Contamination Control Plan from UCB Baselined –SST, and ESA instrument drive mission contamination requirements –ESA and SST Instruments arrive covered and remain that way except for TV testing and launch –GN2 purge required, 24 hour interruptions OK –Surface cleanliness levels of 500A specified  The general set of contamination critical surfaces identified in the Themis spacecraft and the instruments include –ESA Microchanel PlatesOSRs –ESA Gold-Black Surfaces –SST Detectors –Thermal control surfaces –Solar panels –Sun sensor

19. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Contamination Plan  The requirement is to maintain the cleanroom at a Class 100K –Historically, the facility has performed as a Class 10K –GN 2 purge lines and Flow Control for the ESA and SST –Cleanroom Supplies / Cleanroom Monitoring Equipment Cleanroom garmentsCleanroom gloves Cleanroom wipes Cleaning solvents Paper and report covers Portable vacuum equipment Witness plates, stainless steel Room air particle counter Tape-lift suppliesCleanroom bagging material High purity gaseous nitrogen (GN 2 ) bottles (UCB provided) GN 2 purge cart/lines/controls (UCB provided) –Probe shall be bagged when ever it is necessary to relocate the probe outside of the cleanroom for any reason

20. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Cleanroom Personnel Requirements

21. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 GSFC ENVIRONMENTAL TEST FACILITIES  A Class 100K, or better, area is required for staging and integrating the instrumentation suite to the spacecraft bus and after moving THEMIS to GSFC –Staging implies an area that can be used to open a bay and do rework, remove/install solar array, perform functional testing, and a place to move to between environmental tests. The cleanroom supplies listed earlier will also apply. This facility must accommodate a lifting crane to lift the spacecraft from the transport dolly to/from the work stand in preparation for environmental verification at GSFC  1000 sq. ft of floor space is anticipated for handling of all probes in Building 7  Office space with phone/copier/fax to support 10-12 people will also be needed  Each probe shall remain in the GSFC cleanroom until all five probes have completed their environmental tests  The cleanroom is required from June of ’05 till launch  The I&T test operations area of approximately 600 sq. ft. will contain the computer workstations, RF rack, Probe test rack, data interface equipment, and data/voice links to the other environmental facilities  Preliminary Meeting held at GSFC in May to discuss requirements and request for facility support

22. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 I&T Flow

23. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 I&T Flow Probe Instrument Activities

24. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Test Flow GSFC Environmentals

25. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Launch Site Processing Flow

26. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 INTEGRATION PROCESS

27. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Work Authorization  Manufacturing activities will begin when a Work Order Authorization (WOA) is received and accepted  Production operations shall be conducted in accordance with approved and released documentation (e.g. work instructions, drawings, specifications, standard operating procedures, bill of materials, etc.)  Applicable drawings (properly checked approved and issued through Configuration Management), specifications, and/or procedures must be available for all work requests  Any changes to the applicable documents reflected in work orders must be documented on an approved engineering change order, as a minimum

28. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 WOA Cont  Equipment –All special equipment (e.g. tooling, jigs, inspection fixtures, etc.) required by the production process shall be clearly specified in the work instructions. Any unique handling/use instructions shall also be identified

29. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 WOA Entry

30. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 WOA Entry

31. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 WOA Entry

32. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 WOA Review

33. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Reporting

34. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Problem Records

35. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Test Flow

36. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Typical Electrical I&T Flow Electrical Interface Continuity and Isolation Test (EICIT) Interface Verification Test (IVT) Aliveness Test (AT) Safe To Mate (STM) (only as required) Limited Performance Test (LPT) Comprehensive Performance Tests (CPT)

37. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 I&T Test Documentation Summary  Test Procedure –Document which details the prerequisites, test configuration, requirements and steps to demonstrate a set of requirements  WOA –A document which details in incremental steps an operation to be completed or references a Test Procedure  Test Summary Report –A memo which documents the completion of a test, detailing any anomalies  Final Test Report –A formal document which details the results of the test, details the analysis of the data collected during the test, details the status of the procedure, details the rationale for requirements being satisfied, and publishes for the record the complete as run test procedure and data

38. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Test Procedures  The I&T test procedures will be prepared in accordance with the approved I&T Test Plan  The test procedures are developed by the I&T Engineering Group and submitted to the project for review and approval. Once approved all procedures will be under CM control. The basic I&T test procedures that will be developed for each test article are as follows –Electrical Interface Continuity and Isolation Test (EICIT) –Interface Verification Test (IVT) –Aliveness Test (AT) –Safe To Mate (STM) (only as required) –Limited Performance Test (LPT) –Comprehensive Performance Tests (CPT)

39. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Functional Tests  Aliveness Test (AT) –The AT is a short test in which the test article(s) is powered on for health and status checks. Telemetry is then verified to be within acceptable ranges  Limited Performance Tests (LPT) –A demonstration that the primary hardware and software meet their performance requirements within allowable tolerances. The test shall demonstrate operation of primary circuitry and satisfactory performance in the primary operational mode  Comprehensive Performance Tests (CPT) –A detailed demonstration that the hardware and software meet their performance requirements within allowable tolerances. The test shall demonstrate operation of all redundant circuitry and satisfactory performance in all operational modes

40. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Verification Test Configuration Control  Configuration control shall be maintained for each test conducted  At a minimum the following data shall be captured –Revision level of all EGSE software and databases –Revision level of all FSW –Revision level / serial no. of EGSE hardware –Revision level of Flight Hardware System/Subsystem components

41. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Verification Plans Verification Plan and Envr. Test Spec  THEMIS Verification Plan and Environmental Test Specification Document Number SAI-SPEC-1164  Objectives of the Verification Program –Provide assurance that specified mission objectives are met –Provide assurance that hardware will meet specific functional / performance, interface and safety requirements –Provide confidence that the probes will survive the environments imposed during the launch and mission sequence –Determine operating and performance characteristics from simulated mission environments  Verification Planning of the Instruments –Documented in the THEMIS Instrument Payload Verification Plan and Environmental Test Specification Document No. THM-SYS-005  Written by UCB

42. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Verification Plans Summary of Required Tests  THEMIS Verification Plan and Environmental Test Specification Document Number SAI-SPEC-1164  Tests are conducted at the Component Level, Subsystem Level, Integrated Probe System Level, and Integrated Probe Carrier Level  Summary of Tests and Analysis for the applicable Components / Systems include –Comprehensive Performance Test (CPT) –Functional / Performance Test –Electromagnetic Compatibility Test –Mission Simulation Test –Thermal Balance Test –Thermal Vacuum Test –Alignment Demonstration –Sine Sweep Vibration Test –Separation Shock Test –Magnetic Properties Demonstration –Mass Properties Measurement –Acoustic Test –Radiation Susceptibility Analysis –Pressure Profile Verification Analysis

43. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 ENVIRONMENTAL TEST USING GSFC The GSFC facilities have been selected as the baseline approach to be used for environmental testing. The environmental test facilities will consist of  Magnetics  EMC/ EMI  Mass Properties, Weight, Center-of-Gravity (C.G.), Moment-of- Inertia (MOI)  Vibration  Thermal Vacuum / Thermal Balance (TV/TB)  RF Compatibility  Acoustics GSFC Facilities within 7 miles & Swales staff has worked with GSFC team for many years

44. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Magnetics Testing  Component testing previously identified and evaluated by UCLA  Probe level self compatibility with onboard FGM and SCM augmented by external magnetometer GSE in a quiet lab here at Swales baseline  Test program designed to verify magnetics requirements specification and guidelines document issued by UCB –Draft document under UCB review  High fidelity testing at GSFC Magnetics test facility base lined for first probe with the possibility of running two probe for signature comparison –Visit to the mag test site facility was very informative and generated the possibility of additional test configurations and EGSE needed –The implementation and impacts of adding compensations magnets to be discussed with Swales mechanical

45. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 ELECTROMAGNETIC TESTING  The THEMIS Satellite will be tested for EMC/EMI compatibility in the EMC facility at GSFC Building 7  A self compatibility functional test matrix will be used to exercise each electronic box or function in a noise generation mode while all others are setup in their quiet modes  The objective is to determine if any box or component is sensitive to external RF or electromagnetic emissions, either conducted or radiated  Another objective is to plot an electromagnetic signature of the satellite in its various operating modes  These RF sources will be run based on requirements given in the MIL- STD-461C/462C and will be modified to test any elevated RF emissions (above the levels in the MIL-STD) to simulate transmitters at the launch site

46. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Spin Balancing of Probes  Miller table at GSFC will be used to test and iterate to final static and dynamic balance point  UCB has been tasked to make magnetometer booms self balancing when deployed  Swales evaluating the possibility to obtain spin balance of booms both in stowed and deployed configurations prior boom integration onto probe  Masses/washers made of tungsten will be used  Mass properties for the probe (fueled) and stacked PCA shall be performed at AstroTech

47. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Vibration  Vibration and shock testing shall be perform at GSFC test facilities  Probes shall be secured to the table via a payload attachment flange  EGSE and racks to be located Upstairs  The tests shall be conducted with the probe “ON”  Probe #1 to be tested to protoflight durations  Shock testing to be conducted via separation firing of the clamp band  Post “Pop and Catch” of the booms was a review question raised during preliminary conformation meetings

48. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Separation System Acceptance Testing  Single firing functional test (Probe 1 twice) –Performed at Separation System Assembly level  Single firing functional test (performed after delivery to Probes) –Performed after each flight Probe vibration

49. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Thermal Vacuum Testing  Probe #1 to be tested alone  Evaluate the ability to test two Probes in the same chamber –Thermal balance / stability with having two probes –Number of environments to be supported –Cold plate / TCUs needed to support environment –Thermal test fixture design  Hot biased thermal design depends on solar heat absorbed on top deck VDG. The hot case thermal balance needs to be conducted using a solar simulator to create the hot top deck boundary condition. Using a heater controlled elevated deck temperature does not validate this design condition  Multiple thermal balance cases need to be run to develop correlated thermal model – at least 6 cases for Probe #1  Thermal balance case for Probes #2-5 to be reduced with in correlated results of Probe #1  Thermocouple instrumentation to be removed after TV test… –This implies that solar arrays will need to be removed prior to test and after test for removal  Hot / Cold case performance with CTV to be evaluated so as not to impact test durations

50. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 RF COMPATIBILITY  The RF Compatibility Test Van (CTV) will be used at GSFC to test the RF compatibility of THEMIS RF subsystems with the Ground Network (GN) and the Space Network (SN)/Tracking and Data Relay Satellite System (TDRSS)  The CTV test will consist of testing the S-Band transponder at different data rates and different data coding modes for telemetry downlink, at 1 kbps for command uplink, and for ranging compatibility. Additional S-Band transponder testing will be done at multiple data rates with the TDRSS  UCB mission Ops has the lead to coordinate this testing  Its expected to support this test during probe thermal vacuum testing

51. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Schedule

52. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Manpower Plan thru Phase #1 Note: There is approximately and additional 11 subsystem staff that are not included in the I&T Team head count. In addition UCB Instrument Team & MOC staff support I&T An additional EGSE Rack has been added based on re-evaluation program goals & schedule

53. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Manpower Plan thru Phase #2

54. ITAR Restricted Data THEMIS Probe and PCA Overview Mission CDR 6/14 – 6/18/04 Manpower Plan thru Phase #3