1. RBSP Radiation Belt Storm Probes RBSP Radiation Belt Storm Probes RBSP/EFW I-PER 21 January 2011 71 EFW Instrument Testing to Date Michael Ludlam for EFW Team Space Sciences Laboratory University of California, Berkeley

2. RBSP/EFW I-PER 21 January 2011Michael Ludlam 72 Overview IDPU Board Testing –DCB & FSW –LVPS –BEB –DFB Boom Qualification –AXB –SPB Instrument Testing –IDPU Integration –Boom Deployments –AC Test / BEB sensor control –Noise, Timing, Phasing –Calibration

3. RBSP/EFW I-PER 21 January 2011Michael Ludlam 73 DCB Testing Both FM DCB boards have completed & passed their board functional test – (RBSP_EFW_DCB_009) Boards have been integrated into IDPU and function correctly with other boards and booms. FSW v3.00 burned into PROMs. Installed on boards. Initially some problems, but failure analysis is pointing towards lead bending procedure. New parts bent correctly both work on flight units. Limited thermal testing was conducted & passed to verify no thermal issues. Other DCB modifications –Flash FET switches layout reversed. Rework fix. –Addition of inductor to suppress SEE induced transients from MSK regulators. –Flight board termination was different than ETU requiring a number of resistor changes.

4. RBSP/EFW I-PER 21 January 2011Michael Ludlam 74 DCB Photo

5. RBSP/EFW I-PER 21 January 2011Michael Ludlam 75 FSW Status FSW complete. Burned in PROMs after completion of CPT on ETU. All Analyses completed : RBSP_EFW_FSW_004_Analyses.xls Comprehensive Test Report : RBSP_EFW_FSW_020C_CPT_20101212.pdf Code Inspection Report : RBSP_EFW_FSW_021_Inspection.pdf Long Duration Stress Test Report : RBSP_EFW_FSW_022B_LDS_Report.pdf

6. RBSP/EFW I-PER 21 January 2011Michael Ludlam 76 Summary FSW Development –PROM Software Contains all Required Functions –EEPROM is empty at this point On-Board Scripts –Room Available in PROM –No Scripts Defined Verification at the Box & Instrument levels (Not FSW-level) –GSE/SOC Flash Memory “MET-to-Block” data management –Boom Door Opening & Wire Deployment –Real Data Compression (Requires Signals In, SOC to decode) –EEPROM test in TVAC

7. RBSP/EFW I-PER 21 January 2011Michael Ludlam 77 RBSP LVPS Testing (1) LVPS Testing completed on both boards. All functions passed. LVPS Testing is divided into sections 1- BEB Digital and Analog 2- IDPU Digital 3- IDPU Analog 4- BEB 225V These four sections have the same topology. The following tests were performed to verify their function individually: Frequency Adjustment to 187KHz FET Gate and Drain Waveform Check Verify Output Voltages Load Test (half load/ full load/no load) Output Ripple Measurement Line Test where S/C Voltage is varied from 24V to 35V Short Circuit Protection Test where a 1 Ohm resistor load is applied and the circuit recovers from this large load.

8. RBSP/EFW I-PER 21 January 2011Michael Ludlam 78 RBSP LVPS Testing (2) LVPS Testing completed on both boards. All functions passed. LVPS Testing is divided into sections - section 5: 5- Floaters Output Voltage Range Load tests Output Ripple Measurement Line Voltage Test Short Circuit Protection Test SYNC test Verified that all sections are operating at 200KHz when the internal clock is activated Verified that when an external Clock is applied all sections are synchronized Verified that internal crystal is turned off when an external clock is applied Housekeeping Inrush Current 40V Survival test

9. RBSP/EFW I-PER 21 January 2011Michael Ludlam 79 RBSP LVPS testing (3) Power Control Board Testing –Reference Voltage is verified –Housekeeping Monitor values are verified. –Motors, Doors and Stacers Activation verified using a tester that consists of resistors and LEDs Each command was sent separately and the current consumption is recorded.

10. RBSP/EFW I-PER 21 January 2011Michael Ludlam 80 LVPS Photo

11. RBSP/EFW I-PER 21 January 2011Michael Ludlam 81 All Digital Fields Boards Delivered All 3 DFBs delivered to Berkeley –All tested and qualified for flight DFBs meet or exceed all performance requirements –No known performance deficiencies

12. RBSP/EFW I-PER 21 January 2011Michael Ludlam 82 DFB Entrance Criteria – All Met All Requirements Verified –Release/signature process complete All RFAs closed Deviation or Waivers –Completing release/signature process on 1 remaining waiver for PCB bake-out recording. CCB approved 1/3/11. One Part issue in resolution –Op-Amp failure analysis in process by APL End-Item-Data Packages completing –FM-1 complete and delivered to Berkeley –FM-2 & FM-3 waiting on outstanding waiver

13. RBSP/EFW I-PER 21 January 2011Michael Ludlam 83 Extensive Testing on all DFBs All board-level testing complete on all DFBs per the test plan –Tested the full default configuration of each DFB Science data products including: Survey and Burst data from the digital filters, Trigger data, Spectral data, and Cross spectral data Synch to 1 PPS test, super-synch (long and 1sec) Full Analog section testing - 16K ADC sampling –Stimulated analog inputs create proper response on the appropriate digital outputs Verified that each digital data product can access all its commandable sources. –Obtained calibration data Gains, Offsets, Crosstalk and Noise Characteristics –Long duration testing ran on each board 3-4 days each –Thermal cycle testing between -25 to +55 on all DFBs No open work remaining on any DFB

14. RBSP/EFW I-PER 21 January 2011Michael Ludlam 84 DFB Tests Performed Register Read TestSpectral Dynamic Enable Test Spectral IDL CompareCross-Talk Test Full Default TestSpectral Bins TestCross-Spectral IDL Compare Noise Test ADC MUX Switching Test Cross-Spectral Bins Test FAP Initial Functionality Test Gain Test Waveform Verify Channel Test Spectral Dynamic Bins Test Spectral FAP TestThermal Test Trigger Vavg TestSpectral Cycle Ncad Test Super-synch Test IPower Draw Waveform Maximum Bandwidth Test Cross-spectral Cycle Ncad Test Super-synch Test IIFAP IDL Comparison Spectral Bandwidth Test Spectral Dynamic Ncad and Navg Test Trigger Frequency Response Test Invalid Configurations Test Trigger Cycle Sources Test Triggers Speed Select Test Waveform Frequency Response Test Digital Filter Delays Spectral Cycle Sources Test Waveform IDL Compare Test AC Common Mode Rejection Test Frequency Response Testing Cross-Spectral Cycle Sources Test Trigger IDL Compare Test DC Common Mode Rejection Test Signal Integrity and Timing Tests

15. RBSP/EFW I-PER 21 January 2011Michael Ludlam 85 BEB Testing The following tests were performed during bench testing of the BEB. –DC offset Test –DAC and MUX Setting Verification test –DC Gain Verification –Frequency Response Verification –EMFISIS Distortion Test –EMFISIS Frequency Response –AC Test Line Verification

16. RBSP/EFW I-PER 21 January 2011Michael Ludlam 86 BEB Example Results All measurements were in specification. More details in Calibration slides. Gain Frequency (Hz)

17. RBSP/EFW I-PER 21 January 2011Michael Ludlam 87 BEB Photo

18. RBSP/EFW I-PER 21 January 2011Ludlam 88 Boom Qualification All AXB and SPB units have completed qualification program

19. RBSP/EFW I-PER 21 January 2011Ludlam 89 Axial Booms (AXB) Jeremy McCauley Aerospace Engineer Space Sciences Laboratory, UCB jeremymc@ssl.berkeley.edu AXB Spacecraft +Z

20. RBSP/EFW I-PER 21 January 2011Ludlam 90 EFW AXB Environmental Testing Integrate Stacer, Whip and Cage Electrical Functional Test Science Calibration Whip and Cage Mechanical Functional Stacer Mech Functional, Length & Runout Measurement, Continuity Check PER Mass Properties Integrated Vibration Test Electrical Functional Test Dis-Integrate Stacer, Whip and Cage Stacer Mech TV Hot Deploy, Length & Runout Measurement, Continuity Check Integrate Stacer, Whip and Cage PSR Whip and Cage TV Hot Deploy Whip and Cage TV Cold Deploy

21. RBSP/EFW I-PER 21 January 2011Ludlam 91 EFW AXB I&T: Deployments Functional Deployments –Expected number of deployments on the instrument at launch: 5 Functional (MIP) Post Vibe Functional (“test as you fly” exception) Thermal Vacuum Hot Thermal Vacuum Cold INT Deployment with IDPU and Flight Harness Deployments of Whip and Cage at SC Level after Vibe All stacer deployments include: Frangibolt and Motor trending, EOT Switch verification, Continuity verification, Runout and Stiffness testing.

22. RBSP/EFW I-PER 21 January 2011Ludlam 92 EFW AXB I&T: Alignment Alignment Testing –Runout Requirement: <1° from spin axis

23. RBSP/EFW I-PER 21 January 2011Ludlam 93 EFW AXB I&T: Vibration Vibration Testing –Sine Vibration to flight levels per 7417-9019 Section 5.4.5 –Random to GEVS Workmanship Levels per 7417-9019 Section 5.4.5 –Self-shock survival from boom deployment actuations –ETU First Frequency: X, Y = 180 Hz, Z = 275 Hz –FM1 (SN_004) First Frequency: X, Y = 177 Hz, Z = 275 Hz –FM1 (SN_005) First Frequency: X, Y = 160 Hz, Z = 295 Hz –FM2 (SN_003) First Frequency: X, Y = 166 Hz, Z = 278 Hz –FM2 (SN_006) First Frequency: X, Y = 157 Hz, Z = 297 Hz

24. RBSP/EFW I-PER 21 January 2011Ludlam 94 EFW AXB I&T: TV Thermal Vacuum Testing –4(6) operational cycles plus 1 survival cycle, per the requirements and limits indicated in 7417-9019 section 5.3.2 –Deployment tests at hot and cold levels COLD DEPLOY HOT DEPLOY COMPONENT OPERA- TIONAL MIN OPERA- TIONAL MAX SUR- VIVAL MIN SUR- VIVAL MAX Whip & Caging Mechanism -2565-3070 Deploy Mechanism -2555-3060 HOT TURN ON COLD TURN ON N

25. RBSP/EFW I-PER 21 January 2011Ludlam 95 EFW AXB Mass Properties Testing –Mass: 2.97 predict, 3.40 NTE

26. RBSP/EFW I-PER 21 January 2011Ludlam 96 EFW AXB HYPOT Testing HYPOT Testing: –Connectors need testing for resistance to High Potential (HI POT) Not reasonable on a part by part basis Individual representative components passed –Harness tested in unit Sphere Whip Hinge Whip Harness

27. RBSP/EFW I-PER 21 January 2011Ludlam 97 EFW AXB Status Harness Passed HyPot Testing Mechanisms Passed Vibration Mechanisms Passed Thermal Vacuum Mass Properties Testing Completed INT Deploys completed –SN_004 will be tested again with updated Frangibolt AXB ready for INT Environments

28. RBSP/EFW I-PER 21 January 2011Michael Ludlam 98 EFW SPB

29. RBSP/EFW I-PER 21 January 2011Michael Ludlam 99 EFW SPB

30. RBSP/EFW I-PER 21 January 2011Michael Ludlam 100 EFW SPB

31. RBSP/EFW I-PER 21 January 2011Michael Ludlam 101 EFW SPB

32. RBSP/EFW I-PER 21 January 2011Michael Ludlam 102 EFW SPB

33. RBSP/EFW I-PER 21 January 2011Michael Ludlam 103 EFW SPB

34. RBSP/EFW I-PER 21 January 2011Michael Ludlam 104 Instrument Testing –All IDPU boards have been integrated into IDPU boxes. Functional testing mostly occurs at the instrument level. Most testing is to do with instrument performance. –Boom Deployments have been conducted with Flight IDPU/ Flight Boom Units on all booms. –AC Test / BEB sensor control tests complete. –Verification of HSK complete. –Noise, Timing, Phasing, ‘Full Up’, Calibration to be discussed by John Bonnell.

35. RBSP/EFW I-PER 21 January 2011Michael Ludlam 105 Backup Slides

36. RBSP/EFW I-PER 21 January 2011Michael Ludlam 106 RBSP EFW LVPS LVPS Problem Failure Reports –There were 8 PFRs and 15 Engineering Change Notices. Problem Failure Reports –PFR 022: IC leads were cut to fit the pads. MRB approved –PFR 025: L4, L7 have pads that are too small for the magnetic wire. The wires are connected to the leads of capacitors. MRB approved –PFR 038: Floater Magnetics assembly error. The magnetic wire was connected to a via. No damage occurred. FM1 only. MRB approved –PFR 030: Floater Voltages were out of range. Magnetics are re-wound using ‘balanced winding’. ECN 047 is generated. MRB approved. –PFR 037: C59 reversed capacitor. No damage occurs. The capacitor is replaced. FM1 only. MRB approved. –PFR 040: Adjusting IDPU Analog Output Voltages. ECN 045 is generated. MRB approved. –PFR 049: On board crystal did not turn off when the external clock from DCB is applied. ECN 056 is generated. Added a diode in the SYNC circuit. MRB approved. –PFR 055: When an external clock is applied to LVPS the signal looked distorted. Changing the feedback transformer ratio fixed this distortion. As precaution we changed U30 (NOR gate IC). FM2 was fixed before turn on. U30 is not replaced on FM2. ECN 060 is generated.

37. RBSP/EFW I-PER 21 January 2011Michael Ludlam 107 RBSP EFW LVPS Engineering Change Notices –In order to capture BOM changes that did not cause any Problem Failure Reports we generated ECNs. Previous slide mentioned the ECNs that were generated for specific PFRs. LVPS ECNs –ECN 046: Changing the voltage housekeeping resistor dividers to have 2.0V at the output –ECN 054: Added 1K resistors between grounds per systems request –ECN 055: Assigning MSK resistor and capacitor values post systems tests. These were TBD items before. –ECN 057: Changing a resistor value to match ETU. –ECN 061: Decreasing BEB Digital output voltage. When an external clock is applied BEB digital output voltage increases. Systems decided that if it is easy to decrease the output voltage then it is better to have voltage less than 5.35V. –ECN 062: During Derating Analysis we found a 50V ceramic capacitor. It is changed to a 100V ceramic capacitor. –ECN 063: Requirements change on 3.6V Digital output. Increase 3.6V digital output voltage per systems engineering request.

38. RBSP/EFW I-PER 21 January 2011Michael Ludlam 108 DFB Changes Since CDR Requirements Clarifications –Added SuperPPS for synching low rate data FPGA Resource Constraints –Removed Solitary Wave Detector –Reduce spectral channels from 8 to 7 –All science requirements still met

39. RBSP/EFW I-PER 21 January 2011Michael Ludlam 109 DFB Waivers and Deviations status Doc #TypeDateSubjectLASPProject 115336 Deviation 4/30/10 Add parts to PCB for HV protection Approved 115338 Waiver 5/1/10 Stress Analysis Part Derating LT1604, OP262 - doc # 114799 Approved 116947 MUA 7/15/10 Material Usage Agreement for use of PFTE insulated wire on PWBA Approved 117858 Waiver 8/27/10 Solder Defects on FPGA Installation Approved 119429 Waiver 11/30/10 Demoisturization Bake-out Records, S/Ns 1,2,3 In review

40. RBSP/EFW I-PER 21 January 2011Michael Ludlam 110 This page intentionally almost blank