1. Tracker Thermal Control System 1 AMS Tracker Thermal Control System (TTCS) TTCS Design Description NLR-team: J. van Es, M.P.A.M. Brouwer, B. Verlaat (NIKHEF), A. Pauw, G. van Donk, T. Zwartbol, CAM. Rens, SM. Bardet Sun Yat-Sen University team: ZH. He, KH. Guo, JQ. Ni, SS. Lu, XZ. Wang, XM. Qi, TX. Li, YH Huang INFN-AMS-team: R. Batiston, M. Menichelli et al.

2. Tracker Thermal Control System 2 Wake heat pipe radiator Ram heat pipe radiator TTCS com- ponent box Condensers Evaporator Requirements summary System Lay-out & Operation Tube routing & condenser TTCS-Boxes Components –Pump –Heat exchanger –OHP Safety approach Design challenges Integration Contents

3. Tracker Thermal Control System 3 Requirements Summary

4. Tracker Thermal Control System 4 TTCS Fluid temperature ranges Operating Temperature loop (set-point): -15˚C / +15˚C Loop temperatures in the single-phase part can be -40˚C / +15˚C Survival temperature: -100 ˚C / +65˚C (also for internal pressure) Start-up temperature: -40 ˚C / + 20˚C (accumulator start-up temperature) Requirements Summary

5. Tracker Thermal Control System 5 TTCE (Electronics) in TTCS-boxes Operating temperature: -20˚C / +85˚C Survival temperature: -40˚C / +105˚C TTCS-box interface with USS Operating temperature: -40˚C / +55˚C Survival temperature: -40˚C / +55˚C Start-up temperature (driving requirement): -40 ˚C / 10 ˚C Requirements Summary

6. Tracker Thermal Control System 6 AMS- Tracker Thermal Control System MDP determination Constraint 1: max allowed system fill ratio=f (MDP, MDT) NASA : shuttle Earth Max Design Temp (MDT)= 65 °C Given the temperature, now FR SYSTEM is only a function of MDP AMS-team: MDP is set to 160 bar 160 bar, 65 °C, System Fill Ratio=density=r=580 kg/m 3 Carbon dioxide: enthalpy pressure diagram 160 Filling accuracy: ± 4%: FR SYSTEM,MAX = 580 kg/m 3 FR SYSTEM,MIN = 536 kg/m 3, this value to be used for further calculations

7. Tracker Thermal Control System 7 Requirements Summary

8. Tracker Thermal Control System 8 The overall leak tightness of the TTCS-loop is 1.0E-4 mbar.l/s CO2 at 33 bar. Leak tightness budget Remark1: This leak tightness requirement defines (in)directly the fill rate of the TTCS as overpressurizing the system has to be avoided. Remark2: Calculation of the equivalent He-leakrate at standard pressure and temperature should be carried out. Requirements Summary

9. Tracker Thermal Control System 9 Orbital data on the radiator is given in the following format: – MERAT temperatures of the RAM and Wake Tracker radiators. – View temperatures at the back side of the radiator – Orbital load (sun solar earth) on the RAM and Wake Tracker radiators – Orbital load at the back (inside) of the RAM and Wake radiators Requirements Summary: Environment RAM

10. Tracker Thermal Control System 10 Requirements Summary: Environment

11. Tracker Thermal Control System 11 Typical Operational Radiator Temperatures (BBM)

12. Tracker Thermal Control System 12

13. Tracker Thermal Control System 13

14. Tracker Thermal Control System 14 TTCS Functionality

15. Tracker Thermal Control System 15 TTCS Functionality

16. Tracker Thermal Control System 16 TTCS Operation AMS Payload Ops & Control TTCS Ground Ops & Monitoring System TTCS-SS CAN busses Primary Loop (PL) a equipment b Secondary Loop (SL) a equipment b TTCE-A aPaS TTCE-B bPbS TM TC JMDC-CAN I/F JMDC SW TTCE Manager Architectural overview

17. Tracker Thermal Control System 17 TTCS Operational modes

18. Tracker Thermal Control System 18 TTCS tube routing (schematic) WAKE RAM Primary TTCS Secondary TTCS Circular tube routing using outer cylinder generic hole pattern Condenser manifold Circular tube routing using former ACC/PMT mounting hole pattern Two tube support beams Condenser tubes supported by radiator diagonal strut Evaporator line Condenser line Welded connections made on site Hydraulic connectors Also at bottom evaporator branch not shown

19. Tracker Thermal Control System 19 Tube routing Dimensions All tubing D o = 4 mm, D i =2.6 mm 1 Tracker return line (combined part) D o = 6 mm, D i =2.6 mm (only in box) Additional integration issues Wire and start-up heaters are located at evaporator tubes from box to Tracker All tubing wrapped in MLI or located below Flange MLI. Two support beams from top to bottom at wake side

20. Tracker Thermal Control System 20 Tube routing (support beams)

21. Tracker Thermal Control System 21 Condenser tube routing Condenser design –14 capillary Inconel tubes (7 feed and 7 return lines) from each manifold to the condensers (D i = 1mm, D o =2-3 mm –Each capillary tube is wired with a wire heater to thaw the line after AMS02 complete power down. –Tubes are wrapped in MLI to minimise environmental heat leak. –Each radiator is equipped with 2 x 3 redundant Pt1000’s for switching. –Each radiator is also equipped with heater cabling A & B for health heaters. –Electrical connectors located on a bracket boxes at main radiators

22. Tracker Thermal Control System 22 Condenser tubing Manifold positions Location at upper trunnion bridges T>-40 in all cases –Condenser lines from manifold to box T > 40 C (no freezing) –Parallel condenser lines are installed together with condenser Manifold design Y:\Projects\AMS-Tracker\Technical\Components\condensers\CondenserManifold25feb05.pdf Y:\Projects\AMS-Tracker\Technical\Components\condensers\CondenserManifold25feb05.pdf –brazed and welded design –Manifold orientation should be convenient for tube routing. –the manifold has a stainless steel tube end attached on the box side –tube end is orbital welded to the tube routed to the box right after installation of the condenser

23. Tracker Thermal Control System 23 Condenser manifold locations

24. Tracker Thermal Control System 24 Condenser Manifold location (detail) Upper trunnion bridge

25. Tracker Thermal Control System 25 Condenser tube routing Electrical connectors (terminal blocks) are located on a bracket boxes at main radiators Picture CGS (Assenza)

26. Tracker Thermal Control System 26 Condenser Design & tube routing Tracker radiator Condenser inserts OHB Sept 2004

27. Tracker Thermal Control System 27 Condenser Design & tube routing

28. Tracker Thermal Control System 28 Condenser Design & tube routing (MGSE) Rod I/F Bracket Integration Bar 1 (temporary) Integration Bar 2 (temporary) TTCS Condensator Schematic OHB Sept 2004

29. Tracker Thermal Control System 29 TTCS Boxes

30. Tracker Thermal Control System 30 TTCS Boxes

31. Tracker Thermal Control System 31 TTCS Box lay-out

32. Tracker Thermal Control System 32 TTCS Box lay-out

33. Tracker Thermal Control System 33 Components: Pump

34. Tracker Thermal Control System 34 Components: Pump Initial Data Drop for PDR is performed Data only available for safety panel (export license agreement) B-field test set-up is being manufactured BBM model impeller test starting in May Electronics design EM and QM will start next week

35. Tracker Thermal Control System 35 Components: Heat Exchanger approx 68 approx 87 weld two-phase to single phase plate type heat exchanger welded housing soldered stack of plates

36. Tracker Thermal Control System 36 Components: Heat Exchanger soldered stack of plates Soldering tests will be performed as soon as solder is delivered bottom view

37. Tracker Thermal Control System 37 Components: Heat Exchanger Heat exchanger design is updated for box tubing Strength calculations show 4 mm wall thickness is required Material is stainless steel The weld cannot be done by orbital welding (4 mm) EM prototype is planned end of April –depends on a successful soldering test

38. Tracker Thermal Control System 38 Components: Oscillating Heat Pipe Working Fluid FC-87 (inert, non-toxic) Volume tubing: 2.3 ml Fill rate 70% (i.e. 1.6 ml FC-87) Heat supply by Minco foil heater Minco foil K5229 type 1 see specs below Cooling by two-phase line Operation only in cold orbits at set-points below 5 C Default disabled Construction needs to be ruggedized by a TBD frame

39. Tracker Thermal Control System 39 Safety Approach (thermal aspects) Safety requirement box -40 C <T < 65 C –hot case solved thermostats on power line (see lay-out) –cold case solved by USS worst case cold temperature and safety heaters as back-up (to avoid freezing and for electronics survival) Safety requirement radiator -40 C <T < 80 C –hot case shown by analysis (this afternoon) –cold case solved by health heaters

40. Tracker Thermal Control System 40 Safety Approach (thermal aspects) 9 parallel heater lines on PDS switch (redundant 9A and 9B) 5 parallel lines on radiator 4 parallel lines on condensers Switch control by TTCE –6 Pt1000’s (3A and 3B) Switch performed by PDS

41. Tracker Thermal Control System 41 Safety Approach (thermal aspects) Condenser heater lay-out 340 mm 460 mm

42. Tracker Thermal Control System 42 Design Challenges/Risks Interface temperature USS –Start-up at + 10 C USS is extreme –TEC coolers next to the pumps are foreseen in case margin is small Accumulator (design performed by CAST) –During launch temperatures above T(critical) can easily occur –Concern about bubbles in accumulator –CAST is investigating this issue by test Freezing –Freezing test to “measure” MDP –More in separate presentation

43. Tracker Thermal Control System 43 Integration aspects (welding/hydraulic connectors) Hydraulic connectors –Type: Dynatube fitting, Resistoflex Aerospace –Stainless Steel 15-5PH H1075 (-81 C to 343 C) –No leaks (MIL-F-85720) upto 8000 psi –Technical reply supplier (expected any moment) Micro-welding –Swagelock offers a “new” micro-welding technique –A meeting between AMS02 integration specialists and swagelock weld specialists is proposed to investigate the feasibility of this method

44. Tracker Thermal Control System 44 Electrical schematic and routing PDS thermostats