18-1MAVEN IPER May 22-23, 2012

Particles and Fields PackagePre-Environmental Review

May 22 -23, 201218 - Package

Dave Curtis, PFP Package Manager

Mars Atmosphere and Volatile EvolutioN (MAVEN) Mission

18-2MAVEN IPER May 22-23, 2012

EM Package Level Integration

• The EM package was integrated successfully in March-May 2011– All EM instruments successfully integrated with the EM PFDPU– Build 1 operational software verified hardware functionality,

compatibility– 26 EM anomalies discovered in various levels of test, all closed.

18-3MAVEN IPER May 22-23, 2012

EM Anomalies [1]

Issue # Subsystem Date Identified Identified by Date Resolved Issue Description Resolution Status1 MAG

/PFDPU4/26/2011 MAG/PFDPU

EM Interafce Test

9/6/2011 MAG EM PFDPU I&T timing test error (proc MAVEN-PF-TP-MAG step 8). Test run 5 times; on one occasion the time tag was correct, on 4 occasions it was 1 second early

Determined to be a GSE problem. Passed second test. Note the LPW also passed timing test.

CLOSED

2 STATIC/ SWIA SWEEP

6/1/2011 Chris Tiu 7/12/2011 1V, 4ms glitch would occur at the housekeeping outputs (VMONs) when integrated with the digital board and programmed to output a DC level on the HV outputs.

The glitch is diminished with close to 9k ohm series resistance at the housekeeping output. 20k ohm is placed and replaces the original 1k ohm resistor.

CLOSED

3 IIB 7/8/2011 Chris Tiu Aug-11 Temperature rise of two LTC1877s (U306, U308) are at 18C during peak load, room temperature, open frame, thermal image measurement.

Resolution - Lowering Vin will reduce the dissipation of the LTC1877s. This was accomplished by adjusting the duty cycle of the primary converter.

CLOSED

4 IIB 7/8/2011 Chris Tiu Aug-11 Temperature of the first stage filter resistor to the output of the +90V output on the LPW runs warmer than expected. Switching spikes out of the rectifier are adding to the dissipation. Increasing the resistance or adding an inductor causes the PIV of the rectifiers to fail derating.

Resolution - The power rating of the first stage filter resistors were increased from 1206 to RWR80.

CLOSED

5 IIB 7/8/2011 Chris Tiu 7/11/2011 10k ohm base resistors of the start-up 5V transistors run warm according to thermal images.

10k ohm is necessary to maintain a low hfe for proper operation, considering transistor effects during radiation.

CLOSED

6 LPW 4/1/2011 J. McCauley Aug-11 Black Coating for the Stacer must be applied and tested. Black Nickel changed the mechanical properties of the coil. Other plating options are forecast to produce a similar effect.

DAG coating demonstarted CLOSED

7 LPW J. McCauley Apr-12 Whip Coating must be tested and accepted for science application.

We have determined that there is no damage to the whip coating resulting from vibration. Our Swedish colleagues assure us that the micro-cracks we see are a normal part of the coating process. So we have no reason to believe that the coating is compromised in any way. All available data and tests indicate this is the best coating we have for the MAVEN LPW whip. AO testing still to be completed on flight whips

CLOSED

8 LPW / PFDPU

3/23/2011 LPW/PFDPU EM Interafce Test

Aug-11 A large 28v supply side inrush occurs upon LPW power-up for 3.5s

Problem with REG; Fixed on EM2 CLOSED

9 EUV/ PFDPU

3/23/2011 Will Apr-11 Picket Fence noise on 2 EUV channels. Repetition rate on order of second(s).

Fixed on EM CLOSED

10 PFDPU 8/18/2011 Gordon Sep-11 Interaction between SEP and MAG telemetry data during system test - see SPR-001

Software fix - see SPR-001 CLOSED

11 GSEOS 9/1/2011 Harvey 9/1/2011 UDP Checksum errors - see SPR-002 GSEOS fix - see SPR-002 CLOSED12 STATIC Mar-11 Dalton Aug-11 START Foil frames displaced during vibration Redesign START frame forn better clamping. Passed

Instrumenmt EM vibe/accousticsCLOSED

13 STATIC Mar-11 Dalton Aug-11 HV connections broken in vibration of EM TOF system redesign connections for more compliance. Passed vibration of full EM with redesigned connections

CLOSED

14 STATIC Aug-11 Dalton Aug-11 One foild showed significant damage during EM STATIC vibration. Appeared to be poor adhesion to grid.

Add vibration qualification step for flight foils prior to final assembly of FM STATIC

CLOSED

15 SWIA Aug-11 Dalton 9/16/2011 During vibration of EM circuit board stack fasteners became loose

fasteners not staked. NEED TO ENSURE FM FASTENERS ARE STAKED; INCLUDE ON ASSEMBLY INSTRUCTIONS. Re-test with staked fasteners passed

CLOSED

18-4MAVEN IPER May 22-23, 2012

EM Anomalies [2]

Issue # Subsystem Date Identified Identified by Date Resolved Issue Description Resolution Status16 SWIA Aug-11 Dalton 9/16/2011 During vibration of EM MCP transistor mounted on heat sync

broke off board at leads. May have been caused by aboveredesign heat sync for more compliance. Retest passed CLOSED

17 SWEA Jul-11 Mitchell Apr-12 Instrument response has significant settling time after change of anlyzer setting. Looks like charging deep in instrument. Tried removing NUFLON from top cap, problem persists. CESR sees the same issue on their STEREO EM

Do not see the issue on the MAVEN flight units CLOSED

18 SEP Aug-11 Larson Apr-12 EM SEP detector bond wires fail in vibration SEP EM detector mounting to flex poor, no bond pull, no double-bond wires. FM detectors have dual bonds and a bond pull test

CLOSED

19 SWIA 7/26/2011 Halekas 10/24/2011 High levels of noise counts during vacuum chamber calibration with ion source, observed on all but the first deflector step at each energy step. Suspected to be caused by poorly seated FPGA and/or lack of preamp shield during this test. Noise was not observed in subsequent benchtop testing with a partially loaded anode and a properly installed FPGA, suggesting FPGA as culprit.

Retest with shield board in place and properly installed FPGA. Issue seems to be grounding and is improved/solved by grouding the HV shields to chassis ground. Still not perfect - some noise correlated with digital board memory access. Problem traced to bad grounding of preamp board to chassis. Improved EM grounding, will be fixed for FM.

CLOSED

20 SWEA Aug-11 Heavner LVPS 5VD supply has inadequate drive for load. Change to an LTC1877 regulator CLOSED21 STATIC Aug-11 McFadden Apr-12 LVPS has >10mV 200KHz noise - needs filtering Added filter; CLOSED22 SWEA Aug-11 Mitchell Aug-11 EM SWEA inner grid is shorted, which shorts V0 Found short at grid, repaired CLOSED23 SEP Aug-11 Larson Apr-12 DAP FPGA does wake up properly occasionally. Needs power

cycle. Power on reset time increased to 100 msCLOSED

24 STATIC Aug 23 2011 McFadden Jan-12 Field emission in EM TOF section is causing high rates in MCP. Lengthend gap in TOF; also cleans up with op time CLOSED

25 LPW May-11 LASP Nov-11 DFB FPGA makes packets which do not conform to the 'multiple of 4 bytes' length restriction.

Fixed in next DFB FPGA rev, pending test CLOSED

26 STATIC Nov-11 McFadden Apr-12 High Voltage supply spike on 28V power-on Bias CTRL to keep supply off CLOSED

18-5MAVEN IPER May 22-23, 2012

EM PFP I&T

18-6MAVEN IPER May 22-23, 2012

FM Package Level Integration

• FM Package integration is just starting– 125 Clean Room facility– DCB, REG1, IIB, MAG, LPW delivered so far– SEP, SWEA, SWIA, STATIC integrated sequentially over the

next 6 weeks– Operational Flight Software Build 2 will be used

• Ready, but has an anomaly for SEP which is being worked– FM instruments have been or will have complete instrument CPT

prior to package integration• STATIC has not yet completed CPT• SWEA CPT done except spacecraft heater/thermistor

18-7MAVEN IPER May 22-23, 2012

Package Testing

• Starts with Initial Integration of each Instrument– Safe to Mate– Initial Power Turn-On– Inrush measurement

• Then a CPT for each instrument– Based on instrument CPT, modified for package-level (FSW interaction)– Biggest difference is the telemetry formats; PFDPU significantly reduces

the data volume to meet the allocation; new GSE displays for the new formats

– Also run the shorter LPT, subset of CPT• Then a Self Compatibility Test

– Verifies all the instruments work together and PFDPU can handle the load

– Includes ‘day in the life’ test• Flight Software Tests

– One-time test to verify software functionality on the flight hardware• Software previously verified by simulation, in the DVF, and on the EM

– Excludes things covered by CPT– Excludes tests that cannot be safely run on the bench for FM, such as

HV

18-8MAVEN IPER May 22-23, 2012

Package Configuration

IIB

APPOJ2

Command/Telemetry2

EUV-P3

PFDPU

SWIAThermal, Act.

PF-J15

LPW1-P1

SWE-P1SWEA

SAPYFJ4

APPIJ5

DCB 1

APPOP5

Power 2

SWEAThermal, Act.

PF-P15

LPW-J1

SWE-J1

STA-J1

PF-J01

SAPYFP4

SEPSensor 1

MAGSensor 2

PF-J11

HV Enable

PF-P25

LPW-J2

SWE-J2

STA-P1

PF-P02

SAMYFP4

LPW Boom 2

APPOJ5

SEP2-P2

SEP 1

HV Enable

PF-J16

LPW1-P2

PF-J02

SAMYFJ4

APPOP2

SEP-J2

SWI-J1

PURPLE = CESRHV Enable

LPW2-P1

PF-P18

SWI-P2

APPIJ2

PF-J21

SEP-J3

PF-J13

LPW-J2

PF-J26

PF-J18

SWI-P3

APPIP2

PF-J12

REG 1

SEP 2SEP2-P3

PF-J23

LPW2-P2

SWI-P1

PF-J17

MAG-P1

SWI-J2

PF-J22

SEP-J3

PF-P12

APPOJ3APPIP3

SWEA Analyzer

PF-J27

MAG-P1

SWI-J3

BOOMP1

EUV

BLUE = LM

SWI-P5

APPIJ2

Command/Telemetry1

PF-P26

MAG1-J1

SWI-J4

LPW-J1

DCB 2

SEP 1 Heater,Temp Sensor

STATIC

MAG 1

Power 1

PF-P16

MAG2-J1

STA-P2

PF-P21

SEP2-P1

GREEN = GSFC (MAG)

SEP 2 Heater,Temp Sensor

APPOP3

SWI-J5

LPW Boom 1PF-P27

EUV-J1

STA-P3

REG 2

PF-P11

SEP1-P2

ORANGE = LASP (LPW/EUVM)

MAG 2 Thermal

LPW DFB

MAGSensor 1

SWIA

APPIP4

EUV Act.

BOOMJ1

LPW Boom 2Thermal, Act.

PF-P17

STA-J2

PF-P22

SEP-J1

BLACK = SSL

MAG 1 ThermalAPPIJ4 APPOP4

BOOMP2

SEPSensor 2

PF-P07

STA-J3

PF-P23

EUV-J2

SEP-J1

RESPONSIBILITIES

EUV-J3

MAG 2

APPOJ4

BOOMJ2

PF-J07

STA-J4

LPW Boom 1Thermal, Act.

PF-P13

EUV-P1

SEP-J2

LPW BEB

SEP1-P1

EUV Heater,TempSensor

PF-P01

STATICThermal,Act.

PF-J25

EUV-P2

SEP1-P3

APPIP5

IRAP

18-9MAVEN IPER May 22-23, 2012

Package Integration GSE

• All GSE is ready to support• Commands and telemetry will use the spacecraft simulator

hardware and the GSEOS system– Plus ‘near real time’ science data analysis software

• Bench power supply and switch box used to provide primary power to PFDPU

• MAG Heater GSE simulates spacecraft, monitors MAG heaters• Instrument heater/temp sensor/actuator GSE simulates spacecraft,

monitors instruments temperatures• MAG shield can used for MAG functional

– Provides low field environment• Radiation source used for SEP functional

– Am241, 1mCi, ‘hand held’, will not go to KSC• LPW stimulus rack used for LPW functional• SWEA/SWIA/STATIC use internal test pulsers

– no external stimulus

18-10MAVEN IPER May 22-23, 2012

Package Testing, continued

• After package I&T, will perform power system test with ‘suitcase’ spacecraft power simulation provided by LM– Verify turn-on, inrush, full power capability

• Prior to proceeding to Environmental tests, all PFRs will be reviewed with Project to ensure adequate closure

• Following that the package goes to EMC test (as a package)

• Then the individual components go to environmental tests (and deferred / final calibrations)

• The package is re-integrated for a final CPT prior to delivery to ATLO

18-11MAVEN IPER May 22-23, 2012

Open Items (before environments)

• STATIC instrument assembly, CPT, Preliminary Calibration

• SEP, SWEA, SWIA final preparations for package I&T– Conformal coat, final tests

• FM REG test• Package I&T completion• Deferred calibrations (after EMC)

– STATIC, SWIA, SEP

18-12MAVEN IPER May 22-23, 2012

Schedule Summary, PER to Delivery

18-13MAVEN IPER May 22-23, 2012

I&T Roles & Responsibilities

• Instrument Leads are responsible for organizing instrument testing• System Engineer responsible for Package testing (including EMC)• Support:

– Mechanical: Paul Turin plus instrument mechanical leads– Electrical: Subsystem leads– Flight Software: Peter Harvey– Thermal, Thermal Vac: Millan Diaz-Aguado– GSE, ITF: Tim Quinn– Test Conductor: Tony Mercer– Magnetics: Michael Ludlam– Contamination / Planetary protection: Jeremy McCauley– Lab Facilities Support: Steve Marker– QA, Safety: Jorg Fischer, Chris Scholz, William Whitehead (GSFC)– Operations: David Mitchell

18-14MAVEN IPER May 22-23, 2012

Shipping Plans

• Shipping & Handling Plan– MAVEN_PF_SYS_040 CDRL, delivered, approved

• PFP components are small enough for hand-carry– Purchased airline carry-on sized containers– Fitted with shock mounts, environmental monitors

• Dry run planned in near future– Instruments bagged in ESD material– Instruments shall be off purge for <8 hours.

• Bags back-filled with dry Nitrogen– Each container to be hand-carried by a team member to ATLO– TSA contacted to aid in getting through airport security

• NASA letter to be provided• Worked well with recent shipment of LPW whips to/from Sweden

• Most GSE to be shipped FedEx in advance

18-15MAVEN IPER May 22-23, 2012

PFP Shipping Containers

• All PFP instruments hand-carried by air

• Instruments bagged, purged, and shock-mounted in Pelican cases

• Shock, temperature, pressure, and humidity logged throughout shipment

• Isolator design: 30” drop to concrete less than limit load

Cable shock isolators

Data logger

Isolated mounting plate

18-16MAVEN IPER May 22-23, 2012

Post Delivery Support

• PFP ATLO team consists of:– Dave Curtis, Systems, Package Manager– William Thompson (LASP), Systems, LPW/EUV, Local– Tony Mercer, Test Conductor– Paul Turin and Instrument Mechanical leads for mechanical operations– Dorothy Gordon, PFDPU lead, for electrical integration– Millan Diaz-Aguado, Thermal (esp. Thermal Vac)– Tim Quinn, GSE– Jorg Fischer, Chris Scholz, QA– Instrument leads will support critical testing

• William Thompson is local and can be on the spot on short notice; the rest of the team will be available as needed– Will will be trained to operate the package during tests at Berkeley and

EMC• Telemetry data will be available in real time at Berkeley, reducing the

need for large numbers of team members at ATLO– PFP GSE supports this; test pending

• Critical tests (CPT, EMC, Thermal Vac) will have extra team support

18-17MAVEN IPER May 22-23, 2012

ATLO GSE

• Both MSA and SOC can display PFP housekeeping• GSEOS computer will be at LM for local display of data• Telemetry also available remotely in near real time for

extended team support• On-the-floor GSE includes (per ICD):

– LPW stimulus rack– SEP radiation source– EUV lamp– EUV hall effect sensor– MAG shield cans, test harness– MAG test magnetometers (for compatibility test, swing test)– Actuator reset tool, SEP flexure clamps, SEP handle– Red-tag covers, LPW deployment restraining pins

18-18MAVEN IPER May 22-23, 2012

Post Spacecraft Environment Test

• SWEA, SWIA, STATIC functionality cannot be assessed outside a calibration chamber– HV can’t be operated in air– Need electron/ion guns to verify detectors, electrostatic optics,

foils• There is a spot in the ATLO flow after environments for

SWEA, SWIA, STATIC to be removed from the spacecraft and returned to SSL for test– Need a few weeks at SSL to run the three instruments through

the calibration chambers.– A subset of the calibrations previously run– Use the same shipping arrangements used to get them to ATLO– Post-re-integration functional test

• This has been the baseline since the before PDR– Supported by LM ATLO planning