1. FIELDS V1234 Thermal Vacuum & Balance Tests iPER Draft
Gayle K. Martin
Sasha Siy
Jose Fermin
David Glaser
Paul Turin
Brent Mochizuki
John Bonnell
Steve Marker
April 25, 2017

2. Contents Thermal Design Thermal Balance Test Completed Thermal Testing
Thermal Vacuum Test
Objectives and Summary
Mechanical Test Configuration
Test Cases and Parameters
Electrical Test Configuration
Thermocouple Locations
Test Profile and Parameters
Status

3. V1234 Thermal Design
Note: old graphics

4. V1234 Thermal Design
-77
-82
Note: old graphics

5. V1234 Flight Unit Flight unit pictures as of 4/21/16
Note: V3 radiator is larger than V124 due to radiative heating from SPC

6. Mission Phases and Distances from the Sun
Hot MP#
Cold #MP
Mission Phase
Instrument Operation
SPP - Sun Distance (AU)
SC Orientation
y-axis 1
101
Launch Aphelion 1
Off
1.02
Varies 2
102
Heat Radiators 1 & 4 (slew)
~90° 3
103
Recharge and cruise
45° 4
104
Launch error correction 5
105 6F
106F
Fields Deployment On
0.97 0° 7
107
Heat radiators 2 & 3 (slew)
0.9
90° 8
108
Cruise, thermal slew 9
109
Cruise, instrument checkout, fanbeam/SSR playback
0.82 10
110
HGA commission and SSR playbacks
0.75 11
111
Venus warm-ip, eclipse recharge
0.72 12
112
communication downlink (slew up to 45° +margin)
0.7
0° - 45° 13
113
Science turn on/off
0.25 14
114
Science perihelion 1, 34.9 Rs
0.162 15
115
Science perihelion 1, 27.4 Rs
0.127 16
116
Science perihelion 1, 19.9 Rs
0.093 17
117
Science perihelion 1, 15.5 Rs
0.072 18
118
Science perihelion 1, 12.9 Rs
0.06 19
119
Science perihelion 1, 11.1 Rs
0.052 20
120
Science perihelion 1, 9.86 Rs
0.046 21
121
Science with two 4hr Xband and recharge, 20 Rs
MP104 worst case cold, MP6 and MP106 deployment, and MP20 worst case hot
Spacecraft power sensitive cases: MP103, 112, 113

7. V1234 Completed Thermal Tests
Description
Date
Location
Optical Properties
Thermal properties of Nb C103 and Moly-TZM at high temperatures
2012
Odeillo, France
Choke Thermal Design
Verified the thermal design of the choke with TTM1 & 2
Outgassing Nb-C103
Verified low outgassing of Nb-C103; no mass losses seen under 1405°C
NASA Glenn, Cleveland OH
Material Compatibility
Verified that all materials are compatible at high temperatures (no eutectics)
VPE, Sacramento CA
Thermal Distortion
Verified low thermal distortion of antenna
2013
SRI, Menlo Park CA
Electrical Verification
Verified electrical design at flight temps (sapphire, alumina, NbC103)
2014
Shield & Stub Thermal Design
Verified thermal design with balance test using 4 light sources
SAO, Cambridge MA
Hinge deployment
Verified hinge deployment temperatures
SSL, Berkeley CA
Thermal Design
Verified thermal design with balance test at flight temperatures
2015
ORNL, Oak Ridge TN
ETU Test
Thermal balance test at operational and survival temperatures on hinge and harness
ITVT
Verified flight harness electrical connectivity and heat transfer from harness & TPS to the preamp
2017
GSFC, Greenbelt MD

8. Thermal Vacuum
V1234 Flight Units

9. V1234 TV Objectives and Summary
Test Objectives
Qualify the flight model of the FIELDS V1234
Verify that the V1234 preamps can bear the temperatures
Provide workmanship and performance verification by stressing the components to flight allowable temperatures
Test Summary
All 4 flight units will be tested together
Component temperatures will be tested to 10°C beyond flight model predicts (to flight allowable temperatures of electronics)
1 survival and 6 operational thermal cycles will be complete in vacuum
Functionals complete during every operational soak
2 hot and cold starts
2 deployments (hot and cold)

10. V1234 TV Mechanical Test Configuration
The V1234 flight unit will be tested in the UCB/SSL Bayside thermal vacuum chamber
There are two temperature zones for the TV test
Chamber baseplate (heating & cooling)
Chamber shroud (heating & cooling)
Bayside chamber at UCB/SSL feedthrough port and thermal control rack
Bayside chamber at UCB/SSL with aluminum baseplate and shroud

11. V1234 TV Mechanical Test Configuration
The flight units will be fully assembled up to the stub (no whip)
The units will be mounted on aluminum standoffs, the interface for the flight titanium spacers
A shelf will be used to accommodate the harness
The radiators will be thermally coupled with thermal straps to the baseplate to help increase transition time

12. V1234 TV Electrical Test Configuration
Electrical configuration
Stimulus clamps for each shield
Stimulus clamps for each stub
Stimulus “stub”
The flight units will be controlled via the EM MEP
Thermal control
Thermocouples and temperature zones controlled and monitored via AnaWin2

13. V1234 TV Thermocouple Locations
Thermocouples will be mounted along the flight unit and instruments internal to the chamber to verify temperatures during thermal cycling
The internal thermistor will verify that the temperatures have stabilized during instrument operation (not available during survival)
TC #
Location 1 
Door Shroud  2
Main Shroud  3
Baseplate  4
V1 Arm  5
V2 Arm  6
V3 Arm  7
V4 Arm  8
V1 Pin puller  9
V2 Pin puller
 10
V3 Pin puller
 11
V4 Pin puller
 12
n/a broken channel
 13
V1 Preamp box lid
 14
V2 Preamp box lid
 15
V3 Preamp box lid
 16
V4 Preamp box lid 6 10 15

14. V1234 TV Test Profile and Parameters
The test duration for the combined thermal cycling test will take ~14 days (with 4 hour soaks)
Duration includes set-up, chamber break, and disassembly
Instrument functions
Pre-test functional
Hot and cold operation CPTs
Post-test functional
Instrument deployments: Hot and cold deployment of all units
Cold deployment, all 4 at minimum bus voltage of 26V
Hot deployment, 2 units at each at bus min and max voltage of 26V and 35V, respectively
Test parameters
The transition rate of the instrument is not to exceed 3°C per minute
Start of soak is defined when the control temperature is within 1°C of the test temperature
Soak is defined as a minimum of four hour at case temperatures with a change in temperature of ±1°C
Temperature set-points for each case
Survival = -77°C to 90°C
Operational = -77°C to 90°C
Temperature profile on following slide
TQCM measurement will be made at the end of the test
Future vacuum testing
Additional vacuum exposure will occur on the flight hardware during Observatory level S/C test

15. V1234 TV Test Profile
Hot
start
Cold start
Cold

16. V1234 TV Heater Verification
Heater duty cycle will be verified during TB test
Heater circuit (thermostatically controlled) will be tested to verify that each thermostat and heater works as planned
Single heater circuit for operational and survival controlled through S/C service

17. V1234 TV Status 4/25/2017 Mounting hardware Thermal hardware Harness
Mounting plate, spacer posts, shelf and hardware ready for cleaning
Stub and shield stimulus clamps are in fab
Clickbonds and Teflon tubing ready for cleaning
Thermal hardware
Straps are ready for cleaning
Thermal mounting hardware for straps are needed
Thermocouples are ready
Harness
Flight harness included on units
Test harness in fab
Harness needs cleaning
All hardware in the chamber has been verified for vacuum compatibility and temperature limits

18. Thermal Balance
V1234 Flight Unit

19. V1234 TB Objectives and Summary
Test Objectives
Maintain temperatures within survival limits while in non-operating mode and operational limits while in operating mode
Demonstrate proper function of survival and operational heaters, including duty cycle
Measure the isolation scheme resistance including bracket, bolts, ground straps, harness between the flight instrument and spacecraft
Collect enough data to correlate thermal model
Test Summary
A single flight unit (spare) will be tested in the UCB/SSL SNOUT1 thermal vacuum chamber
Thermocouples will be mounted along the flight unit, shroud and baseplate to verify temperatures during thermal balance
The flight unit will be fully assembled including MLI
The heaters will be operational for the heater verification portion of the test

20. V1234 TB Mechanical Test Configuration
Flight hardware configuration
No whip
V124 unit
Deployed
Simulated conductive and radiative interface
SNOUT1 thermal vacuum chamber at UCB/SSL
Mounted to the baseplate via spacer posts (required for clearance)
Flight harness, ground straps and spacer are included
Fully blanketed
Radiative view to shroud and heater plate (black)
Baseplate blanketed
Temperature zones for the TB test
Three temperature zones to create a gradient for correlation
Shroud, baseplate, and heater plate (located at MLI shield side)
Shroud and baseplate are enabled with heating and cooling capability
Door opening will be blanketed (no thermal control)
Baseplate
Shroud
Test Unit
Heater Plate
Door MLI
End Shroud & heater plate MLI

21. V1234 TB Thermocouple Locations
Thermocouples will be mounted along the flight unit and instruments internal to the chamber to verify temperatures during thermal cycling
The internal thermistor will verify that the temperatures have stabilized during instrument operation (not available during survival) 7 9 10 15 13
TC #
Location 1 
Baseplate  2
Shroud  3
Heater Plate  4
Door MLI  5
MLI on TPS shield  6
TPS shield  7
Hinge  8
Preamp box lid  9
Pin puller
 10
Arm Radiator
 11
Radiator near strut
 12
Harness saddle (near strut)
 13
Arm near connector
 14
Spacer (near spacer posts)
 15
Shield 1
 16
Shield 2 6 14 11 12 13 5

22. V1234 TB Test Cases and Parameters
Four balance cases will be completed, two survival and two operational cases plus heater verification
Test parameters
The transition rate of the instrument is not to exceed 3°C per minute
Start of soak is defined when the control temperature is within 1°C of the test temperature
Soak is defined as a minimum of 6 hours with a change in temperature of ±0.25°C per hour, as deemed by thermal engineer
The length of the cold soaks must be long enough to verify the duty cycle of the heater during heater test cases
Instrument will be powered on during operational cases
Case
Description
Instrument Status
Heater Status
Shroud T (°C)
Baseplate T (°C)
Heater T (°C) 1 
Non-operational 1
Off 75
-50
150 2
Operational 1 On 3a
Non-operational 2
-100 (cold as possible) 25 3b
Non-operational 2, surv heater 4a
Operational 2 4b
Operational 2, op heater

23. V1234 TB Status 4/25/2017 Mounting hardware Thermal hardware Harness
Spacer posts in build
Thermal hardware
Heater plate in design
Heaters and mounting hardware ready for integration
Thermocouples baked out and ready
Harness
Test harness in design
All hardware in the chamber has been verified for vacuum compatibility and temperature limits

24. V1234 Thermal Analysis Current actions
Incorporate Shawn’s comments to current model
Thermal balance predicts
Component
Cold Survival Temps (°C)
Hot Survival Temps (°C)
Limit
Predict
Margin
Antenna
-150
-42
108
1450
131
1319
Antenna Shield
-80 70
129
1321
MLI Shield
132
1318
Harness
-100
-72 28
300 96
204
Hinge
-140
-74 66
250 91
159
MLI
-79 71
400
315 85
Pin puller (pre deploy)
-81 19 75 64 11
Pin puller (post-deploy)
150
118 32
Preamp V1 (electronics)
-110
-67 43 90
-64
154
Preamp V2 (electronics)
-60
Preamp V3 (electronics)
-57
147
0Preamp V4 (electronics)
-66 44
-62
152
Component
Cold Operational Temps (°C)
Hot Operational Temps (°C)
Limit
Predict
Margin
Antenna
-150 22
172
1450
1323
127
Antenna Shield
-64 86
1295
155
MLI Shield
-80 70
300
228 72
Harness
-100
-66 34
217 83
Hinge
-79 71
290
232 58
MLI
390
331 59
Pin puller (deploy)
-67 33 50 36 14
Pin puller (post-deploy)
150
111 39
Preamp V1 (electronics)
-110 44 90 78 12
Preamp V2 (electronics) 20
Preamp V3 (electronics) 75 15
Preamp V4 (electronics) 69 21

25. Hail-man We build more than instruments!

26. Back-up

27. Handling & Contamination Control
All test articles and test hardware to be bagged and kept in clean room
Personnel are to handle only with appropriate gloves and contamination gowning
EMECP specifications shall be practiced during flight hardware handling, test set-up and test operations
Contamination control of the instrument must follow the specifications in the SPP-FIELDS Contamination Control Plan 

28. Test Abort, Real Time Activity Assessment and Success/Failure Criteria
Minor anomalies will be evaluated and fixed or alleviated in an attempt to continue testing
Examples of minor anomalies include temporary loss of thermocouple, minor problems with hardware (cable movement) or problems with vacuum facility
Response to minor anomalies will be made by Test Conductors at test site
Significant anomalies will result in abort of further testing
The UCB Test Engineer has the authority to stop testing if deemed damage may be occurring to the hardware, the test equipment functioning is suspect, output data is questionable, or test is not compatible with this procedure
All anomalies shall be reported as part of standard Project Problem/Failure Reporting.
Success/Failure Criteria
Adequate temperature data collected at steady state from all test cases
Meet all S/C requirements