1 - ASP-05-STR1-263 M054-1 Tous droits réservés © Alcatel Space Industries All rights reserved Star One C1 - Insurance Presentation 8 - Satellite Test Plan and Philosophy

2 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space  The STAR ONE C1 satellite is a protoflight model and will be submitted to qualification environmental conditions as specified in the environmental specification  The objective is to demonstrate that the performances specified are met before, during and after the environmental tests Satellite Test Plan

3 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space AIT SEQUENCE  The AIT sequence in divided in phases:  SM Integration  Final integration  Initial performance test (SPT1A)  TV tests  Pre environmental tests (SPT1B)  Environmental tests  Post environmental tests (SPT2B)  Final performance tests (SPT2A)  MCI  Preparation for transport Satellite Test Plan

4 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space Satellite Test Plan

5 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space Assembly, Integration & Tests (AIT) Plan  Activities performed during AIT are detailed in the AIT plan which defines the scope of each phase  Each AIT phase is governed by reviews (Test Readiness Review - TRR and Test Review Board - TRB) and a leading procedure which calls modular tests execution.  The elementary tests which are performed all along the AIT Sequence are defined in the subsystem test matrices which summarize for each elementary test (defined by a test requirement) in which AIT phase it has to be performed. Satellite Test Plan

6 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space INITIAL SYSTEM PERFORMANCE TEST: SYSTEM PERFORMANCE TESTS 1 PART A SPT1A After SM/CM mechanical assembly, interface testing and S/C Final integration, the Satellite will be subjected to the reference system performance measurements. The SPT1A will be as follows:  Body alignments  Electrical performance tests  UPS tests  EMC CE/CS & ESD tests (can be postponed to SPT2A phase)  Antennas mounting and alignment  Flight batteries installation, connection and beginning of charge maintenance (ST3 option). Satellite Test Plan

7 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space THERMAL VACUUM TESTS  Those tests occur in the ALCATEL 550 m 3 thermal vacuum chamber and are composed of:  The Thermal Balance Test (TBT) applied to the PFM satellite  The Thermal Cycling Test (TCT) applied to all models.  Objectives:  To qualify the mathematical model in order to predict performances under flight condition (TBT)  To verify the validity of the thermal control concept chosen (TBT)  To verify the thermal behaviour (dissipation's, gradients) of units (TBT)  To verify the performances of units and Subsystems under environment representative of external conditions encountered during all spacecraft lifetime (vacuum, cold and hot temperature, CORONA effect) (TCT).  To serve as a complete spacecraft burn-in.  To perform eclipse discharge simulation.  To verify the spacecraft contamination criteria (TCT) Satellite Test Plan

8 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space THERMAL VACUUM TESTS  The hardware configuration of the satellite is similar to the flight configuration with the following exceptions:  The propellant tanks are empty, but are pressurised with about two bars of gaseous nitrogen  The Solar Arrays are not mounted  E/W reflectors are not mounted, but the Earth antenna is installed and both East/west feeds will be installed on test shim plates (ST8 option)  RF energy is dissipated into RF loads via non flight waveguides connected to input/output of the repeater  The flight PROM is not yet installed, replaced by an EM EEPROM (TBC) Satellite Test Plan

9 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space THERMAL VACUUM TESTS  The satellite is installed on the thermal adapter in the vacuum chamber. The adapter is superinsulated and is thermally isolated from the satellite by insulating washers. The dolly interface frame is temperature controlled during all the test. In addition, spacecraft horizontality is also controlled during the test in order to have heat pipes in operating conditions.  During the thermal vacuum tests, the satellite temperature is controlled using :  the cold shrouds & cryopanels,  thermocouples and S/C Telemetry (flight thermistors)  satellite heaters  test heaters installed on the satellite (if any)  IR heaters installed around the satellite when necessary. Each one is commanded and monitored independently in order to obtain the temperature required for the test. The massive quantity of thermocouples allows the temperature monitoring of all units dissipating more than 10 W as well as every units described in the STAR ONE C1 performance specification. Some additional thermocouples (direct channel) are used for the monitoring of extra spacecraft hardware: thermal test adapter, I/F with test equipment’s. Satellite Test Plan

10 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space Satellite Test Plan

11 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space THERMAL VACUUM TESTS  It is foreseen to submit the model to 3 cycles of thermal vacuum conditions and to perform all tests mentioned in the matrices. Tests are performed during the 2 first hot and cold plateaus. The third cycle will give opportunity to perform retest or investigation. For FM, a specific screening test will be performed (ST7 option).  The thermal cycling test is needed at system level but not specially for subsystem thermal control purpose. Nevertheless, the temperature level of the spacecraft during these tests is assured by thermal control subsystem, under his responsibility.  Contamination probes are installed in the vicinity of the satellite and analysed after test to determine outgazing products. After removal from the vacuum chamber, the satellite will be inspected. Satellite Test Plan

12 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space PRE ENVIRONMENTAL TESTS SYSTEM PERFORMANCE TESTS 1 (part B) SPT1B The SPT1B will be sequenced as follows:  Body alignment verification  Antenna mounting, deployment and alignment verification  Solar arrays mounting, deployment, illumination & folding Satellite Test Plan

13 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space MECHANICAL ENVIRONMENTAL TESTS The aim of these tests is to demonstrate the ability of the Satellite to be submitted to the launch environment conditions (vibrations, acoustic noise and shock) with margins, without suffering performance degradation. The sequence of tests will be split as follows:  Tanks filling (simulation fluids)  Sine vibration test  Post sine vibration test  Acoustic noise test  Post acoustic verification  Adapter fit check and separation shock test (if required)  Tank draining. Satellite Test Plan

14 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space MECHANICAL ENVIRONMENTAL TESTS  Tank filling In order to reach a representative satellite mass and dynamical behaviour, the tanks will be filled with simulation liquids and pressurised to an adequate pressure. Satellite Test Plan

15 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space MECHANICAL ENVIRONMENTAL TESTS  Sine Vibration test The satellite, in its launch configuration, clamped upon test adapter, and with tanks filled with simulation fluid will be subjected to vibration test along each one of the three orthogonal X, Y and Z axes.The sequence of events for each vibration axis will be as follows:  initial no-notched very low level runs (entry 0.05g) Hz;  no-notched low-level run (entry 0.2g) Hz  intermediate level (entry half protoflight level and half notching level) Hz  STAR ONE protoflight level Hz  no-notched low-level verification sweep for comparison to initial satellite signature. Satellite Test Plan

16 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space Satellite Test Plan

17 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space Mechanical environmental tests  During the test, the satellite will be in electrical launch configuration and TM and TC RF links will be verified.  Post sine vibration test After the vibration tests a visual inspection will be performed on the satellite, then a short TM/TC verification will be carried out. Satellite Test Plan

18 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space MECHANICAL ENVIRONMENTAL TESTS  Acoustic noise test The Satellite will be installed into the chamber and submitted to the required acoustic environment as defined by arianespace. The spacecraft will be in electrical launch configuration and will be controlled through TM and TC video links.  Post acoustic noise test verification Before the first run and after each subsequent run, a visual inspection will be carefully performed on secondary structures, thermal insulation and on outside equipment such as Solar Array wings and antennas. Satellite Test Plan

19 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space Satellite Test Plan

20 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space MECHANICAL ENVIRONMENTAL TESTS  Adapter fit check and separation shock test (if required) The aim is to demonstrate the mechanical and electrical compatibility of the satellite with the adapter, and to verify that the separation shock does not damage the satellite. This test includes the pyrotechnic release of a flight representative clamp-band.  Tank draining The tanks will then be dried by flushing with hot and dry nitrogen. The heaters installed on the lower portion of the tanks are used. Dryness will be verified by gas chromatography. Satellite Test Plan

21 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space POST ENVIRONMENTAL VERIFICATION SYSTEM PERFORMANCE TESTS 2 (part B) SPT2B The SPT2B will be sequenced as follows:  Solar array verification  Antenna pyro deployment and alignment verification Satellite Test Plan

22 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space FINAL SYSTEM PERFORMANCE TEST SYSTEM PERFORMANCE TESTS 2 (part A) SPT2A The SPT2A will be basically similar to the SPT1A and the test results will be compared to verify continued satisfactory performances of the Satellite. SPT2A sequence is as follows:  Body alignments verification,  Electrical Performance Test,  UPS tests,  Ground Station compatibility  MCI Satellite Test Plan

23 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space Compact Antenna Test Range (CATR) Test  This phase includes all activities done in the CATR environment:  Antenna VSWR and Decoupling  EMC RE Launch compatibility  S/C Radiated Auto-compatibility  Antenna patterns, EIRP, IPFD  PIM’s (if necessary) A test of the fully assembled protoflight satellite, except Solar Arrays, is performed on the compact indoor antenna range as a part of the Final System Performance Test. The compact indoor antenna range is capable of evaluating the far field RF performance of the satellite. Satellite Test Plan

24 - ASP-05-STR1-263 All rights reserved © 2005-proprietary, Alcatel Space FINAL OPERATIONS The final operations will be sequenced as follows:  Solar array installation  Reference OMUX bandwith test  Final MCI (thruster’s adjustment)  Global leak test Satellite Test Plan