1. THEMIS FM4/FM5 INSTRUMENT SUITE
PRE-SHIP REVIEW (PSR)
INSTRUMENT DATA PROCESSING UNIT
Michael Ludlam
University of California - Berkeley

2. Outline Summary of IDPU Status at FM4&5 PSR FM Configuration by SN
End-Item Data Package, Summary
Environmental Tests Summary
FSW Status
PFR Status

3. IDPU Status Requirements and Design: Assembly and Test:
No major changes to Requirements or Design since M-CDR
Changes made to LVPS ESA supply and DCB board.
Assembly and Test:
All 5 IDPUs have been successfully integrated and have undergone final assembly, vibration, TVAC.
FM2, has been integrated on the FM2 probe.
FM3, FM4 and FM5 are ready to be integrated on the probes.
FM1 has undergone environments successfully. After modifications to the LVPS it has to undergo thermal vacuum after a workmanship vibration.
IDPU FM6 (spare) has been integrated, and the boards are currently undergoing staking and coating.

4. IDPU Configuration IDPU: DCB Software Version: Actel Revisions:
Version EEProm Code version 4.0
Actel Revisions:
Green box indicates part was programmed successfully

5. IDPU End-Item Data Package (EIDP)
The following items are part of the End Item Data Package for the IDPU
Stored in the Instrument Bookcases
Individual Boards – contains schematics, assembly instructions, bill of materials, test reports, connector mate/demate log, power log.
LVPS Binder #6
PCB/FGE Binder #4
DCB/ETC Binder #3
DFB Binder #5
BEB Binder #1
DAP Binder #2
Integrated IDPU – contains test reports for integration of IDPU.
IDPU Binder #17
Integrated Instrument Testing – contains test reports for instrument integration, connector mate/demate log for instrument integration and test, power log for instrument integration and test.
Integration Binder #16
Flight Software Binder #38
ICDs are stored on the Themis FTP site.
PFRs are stored on the Themis FTP site.
Full mechanical drawings are stored on the PDMWorks Server.

6. IDPU Vibration
FM4 & FM5
Vibration test carried out to specification SAI-TM-2430-RevD (Acc)
Acceptance level vibration carried out 12/9/05 and 4/12/06 to both units. Test report located in IDPU EIDP Binder. Test Passed – verified by visual inspection and Instrument LPT.
Rework on IDPU necessitated single axis Workmanship vibration on 11/04/05 for both FM2 and FM3.

7. IDPU Thermal Vacuum
Plan was 2 cycles of thermal vacuum run with IDPU/ESA Combination – including hot and cold non-operational soaks at +65°C and -60°C. Operational temperatures are between +55°C and -40°C. Actual run was disrupted after 1 cycle due to problem with a reset problem on the IDPU when the SST was powered at cold temperatures. (more details later). The second cycle was included in the instrument suite thermal vacuum testing.
Configuration includes SST sensors, FGM sensor, SCM preamp and EFI external EFI-GSE.
Test report and As-Run LPT Procedures stored in the Instrument Integration binder #16.

8. FSW Status Version 4.0 Version 4.0 is complete.
FSW Comprehensive Performance Test (FSW CPT) was performed on the ETU unit.
Instrument Limited Performance Test (LPT) has been run on FM5 Instrument Suite. Scripts need to be modified to run this version of FSW – particularly in how the FSW handles burst rate data. Once these scripts have been debugged on the FM5 suite platform we can transfer the changes to the ITOS scripts so version 4 can be run on the IDPUs integrated on the probes.
Version 2.13 is sufficient for instrument integration on to probes.

9. FSW Verification FSW Level 3 Requirement
All requirements met by test or analysis

10. Software Change Requests
Three new Software Change Requests implemented since last review :-
SCR31 – Change to ESA initialization script
SCR32 – CMD FIFO should detect full condition
SCR33 –TM FIFO increased to 64 packets

11. Ongoing FSW Testing
Some FSW functions cannot get data quality verification in the FSW CPT
The ETU IDPU does not have all sensors
These functions include
Compression
Science Trigger Calculations
Spin Fits
These portions of FSW are currently being verified on FM5 instrument.
Testing of FSW changes will be dealt with on a case by case basis.

12. No Open PFRs on FM4 or FM5 for IDPU.
FM4 & FM5 PFRs
List of PFR’s opened since last review:
No Open PFRs on FM4 or FM5 for IDPU.

13. PFRs Opened since FM2/3 PSR
PFRs opened (and subsequently closed) since last review
PFR 117 – When DAP board was layout was done, keep out zones for the edges were not implemented. Power and Ground planes go right to the edge of the boards. IDPU box has been taped to prevent shorting of these planes together. All boards modified.
PFR 127 – During probe testing, IDPU FM2 started to reset after being powered for several hours. A race condition on the DCB board was found that affected the unit only at slightly elevated temperatures from ambient. The two signals were synchronized to the DCB 20MHz clock and tested through the full temperature range and no resets were seen. No resets have been seen on IDPUs since the fix from hundreds of hours of testing. All DCB boards have been modified.
PFR 131 – Related to PFR 127.
PFR 135 – During IDPU Thermal Vacuum the IDPU reset on SST power on. Due to high inrush current on from the DAP the 5VD line on the DCB board was being pulled out of specification. The switches on the PCB board were modified to slow the voltage turn on and therefore reduce the drop on the 5VD line so that it was again in specification.

14. PFRs Opened since FM2/3 PSR
PFRs opened (and subsequently closed) since last review
PFR 136 – During IDPU Thermal Vacuum on the FM5 unit the actuator monitor on the PCB board was seen to have temperature dependence. The circuit was replaced, but still exhibited the same behavior. The monitor is redundant and it was decided further investigation was not merited. The monitor was characterized during subsequent TVAC cycles.
PFR 141 – During instrument suite thermal vacuum the ESA current monitor was seen to oscillate at cold temperatures. Improvement to efficiency of supply changed the characteristics of this supply leading it to oscillate under certain conditions. The topology of the supply was modified so that it would not oscillate under loaded conditions. During this time the ESA current draw was fully characterized and led to further changes being made to ensure the supply could handle short current spikes from the ESA sweep supply.
PFR 157 – FM4 LVPS Thermistor failed. Part sent for analysis.
PFR 158 – Pin bent on DCB FM4 board. Pin was replaced.

15. PFRs Opened since FM2/3 PSR
PFRs opened (and subsequently closed) since last review
PFR 164 – During probe thermal balance testing at JPL, it was noted that the ESA current monitor was jumping around in a short temperature window around 10 degrees C when the supply was unloaded (ESA off). The FM6 LVPS was characterized for these conditions and the supply was seen to oscillate. A fix for this has been worked out and is currently undergoing testing. However, it is not expected that this will be implemented and it is intended the supplies will be used as is. For the oscillation to occur the IDPU would need to be in a very narrow temperature window, and require the ESA off. It is not expected to see these conditions during flight. If the supply were to oscillate it has been analyzed that it does not cause any harm to the supply.

16. Backup
Backup Slides

17. FSW Resources PROM/EEPROM PROM Functions EEPROM/Uplink RESOURCE USAGE
EEPROM Load
Uplink Support
Deployments
EEPROM/Uplink
Compression
Burst/Triggering
Initialization Params
Science Upgrades
RESOURCE USAGE
96% PROM
48% RAM
50% EEPROM
21.3% CPU Data Collection/Playback
29.4% CPU Spin Fits of E and B
Compression Rate 4-6 Mb/minute

18. CMP Status Compression Module Status
Src: thm_fsw_001F Software Requirements Specification
CMP Huffman and Delta Modulation compression has been verified on the ETU with the IDPU GSE encoding the original waveforms.
CMP has been tested with Burst logic so that FSW can demonstrate compressing Bursts.
Test Procedures which are complete are Green, Incomplete are Yellow.

19. SCI Status Science Module Status
Src: thm_fsw_001F Software Requirements Specification
Test Procedures which are complete are Green, Incomplete are Yellow.

20. SCI Status Science Module Status
Src: thm_fsw_001F Software Requirements Specification
Test Procedures which are complete are Green, Incomplete are Yellow.