FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 1 UCB, November 10, 2005 THEMIS INSTRUMENT SUITE FM2/FM3 PRE-SHIP REVIEW FM4/FM5 PRE-ENVIRONMENTAL REVIEW SYSTEM OVERVIEW Ellen Taylor University of California - Berkeley

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 2 UCB, November 10, 2005 Requirement Verification Status Performance Requirements - FM1/2/3/4/5 MRD Verification Status Environmental Test Requirements - FM1/2/3/4/5 ETM Verification Status Performance Verification Tests and Operating Hours Resource Requirements - Instrument Payload History and Status Instrument Suite Test Flows FM2/3 Environmental Test Flow FM4 Integration Flow FM5 Integration Flow Problem Failure Reports (PFRs) PFR Statistics and Status Open Items and Residual Risk FM1 Open Items Closure FM2/3 Open Items Back-Up: System FM1 PSR RFA Response (FM1 IPSR RFA #04) Open PFR Summary Pending and Waived Requirements Overview

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 3 UCB, November 10, 2005 Performance Verification Mission Requirements Document (MRD) Verification Matrix MRD Verification Matrix is available on-line at: ftp://apollo.ssl.berkeley.edu/pub/THEMIS/1 Management/1.3 Systems Engineering/1. Requirements/thm_sys_001G.3_MRD.xlsftp://apollo.ssl.berkeley.edu/pub/THEMIS/1 Management/1.3 Systems Engineering/1. Requirements/thm_sys_001G.3_MRD.xls 05/19/05 MRD Rev G: Released Verification Matrix for FM1 Instrument Suite PER 08/25/05 MRD Rev G.1: Released Verification Matrix for FM2/FM3 Instrument Suite PER 09/20/05 MRD Rev G.2: Released Verification Matrix for FM1 Instrument Suite PSR 11/10/05 MRD Rev G.3: Released Verification Matrix for FM2/FM3 Instrument Suite PSR and FM4/FM5 Instrument Suite PER MRD Status Statistics 142 Instrument Specific Requirements 129 Requirements for FM1/2/3, 125 Requirements for FM4/5 have been verified (GREEN) 10 Requirements for FM1/2/3, 14 Requirements for FM4/5 are pending (YELLOW) 3 Requirements have been waived (GREY) 0 Requirements have not been met (RED) Pending and Waived Requirements No pending requirements are considered liens to Probe-FM2 Instrument Suite Integration Verification activities have been planned for all pending requirements as part of normal course for Probe-level I&T List of pending and waived requirements provided in back-up slides

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 4 UCB, November 10, 2005 Environmental Test Verification Environmental Test Matrix (ETM) ETM is available on-line at: ftp://apollo.ssl.berkeley.edu/pub/THEMIS/1 Management/1.3 Systems Engineering/1. Requirements/ETM_TestRecord_9.xls 05/19/05 ETM_TestRecord_5: Released Test Record after FM1 Instrument Suite PER 06/29/05 ETM_TestRecord_6: Updated Test Record at FM2/FM3 Instrument Deliveries 08/25/05 ETM_TestRecord_7: Released Test Record for FM2/FM3 Instrument Suite PER 09/20/05 ETM_TestRecord_8: Released Test Record for FM1 Instrument Suite PSR 11/10/05 ETM_TestRecord_9: Released Test Record for FM2/3 Instrument Suite PSR and FM3/4 Instrument Suite PER ETM Status Vibration Testing: Over 100 Vibration Tests have been completed Only FM4/5 IDPU/ESA Vibration Test remains to be done, scheduled for next week Thermal Vacuum Testing: Over 120 Thermal Vac Tests have been completed, over 250 cycles and >3000 hours FM4/5 SST (2 cycles), FM3 SST Re-Test (1 cycle), FM4/5 IDPU/ESA (2 cycles) and FM4/5 Instrument Suite (6 cycles) Thermal Vac Tests remain to be done SPARES: Spare FGM and EFI Y-axis SPBs (6 cycles)

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 5 UCB, November 10, 2005 Performance Tests Instrument Suites have gone through numerous CPTs/LPTs. Over 60 CPTs/LPTs have been completed on FM1, FM2 and FM3. THM-SYS-PROC-005 Instrument CPTs (3-4 per Suite): Initial Run, Pre-EMC (FM1 Only), Pre-Vibe, Post-Vibe, Post-TV THM-SYS-PROC-006 Instrument LPTs (over 15 per Suite): Pre-TV, 2 Cycles every Hot/Cold ESA/IDPU TV, 6 Cycles every Hot/Cold Suite TV, Post-TV CPTs/LPTs are also performed as necessary pre- and post- workmanship vibes, thermal re-tests, rework, etc. Performance Tests through ITOS CPT/LPT procedures have been converted to ITOS STOL scripts Procedures and ITOS data base have been reviewed for conversions, limits and logic Automated command checking ensures GSE/ITOS scripts are exactly the same FM3 LPT was successfully run through ITOS Performance Tests

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 6 UCB, November 10, 2005 Power Log Hours by Flight Model: Hours shown have been accumulated as Integrated Instrument Suite, additional hours were accumulated during board level tests and integration Approximately 2/3 of hours accumulated are in Instrument Suite Thermal Vacuum Operating Hours

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 7 UCB, November 10, 2005 Mass Status and History Mass Status Probe Dry Mass is limiting mass resource Probe Dry Mass Current Best Estimate (CBE): 77.1 kg Probe Dry Mass Not to Exceed (NTE): 81.8 kg Probe Dry Mass Margin: 6.1% Margin with >95% components weighed

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 8 UCB, November 10, 2005 Power Status and History Power Status Probe Total Power Current Best Estimate (CBE): 33.6 W Probe Capability - Daylight Power, Nominal Science Operations: 37 W Probe Power Margin: 10% Margin with most flight components measured

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 9 UCB, November 10, 2005 FM2/FM3 As-Run Test Flow FM2/3 PER: 08/29/05 FM2/3 IDPU/ESA TV Test FM2/3 Instrument Payload TV Test thm-sys-proc-004 Instrument TV: 10/03-14/05 6 cycles, +55C to -40C Op, +55C to -60C Non-Op PFR 097: SST Noise – CLOSED PFR 108,109,110: FSW Problems – OPENED PFR 114: FM2 P10V Imon Temp Dependency – OPENED PFR 115: FM3 EFI V1 Failure – OPENED FM2 thm-esa-proc-007 IDPU/ESA Vibe: 08/30/05 FM3 thm-esa-proc-007 IDPU/ESA Vibe: 09/01/05 SAI-TM-2430-RevD (Acc), 7.09Grms FM2 thm-sys-proc-005 LPT: 08/31/05 FM3 thm-sys-proc-005 LPT: 09/02/05 thm-esa-proc-016 IDPU/ESA TV: 09/07-13/05 2 cycles, +65C to -60C Survival, +55C to -40C Op PFR 097: SST Noise – OPENED thm-sys-proc-006 LPT: 10/14-20/05 2 cycle re-create, 1 cycle re-test PFR 115: EFI V1 Failure – CLOSED ESA/IDPU Workmanship Vib FM3 EFI V1 DeBug FM2/3 ESA/IDPU Vibration Test FM2/3 PER PFR 114: FM2 P10V Imon Temp Dependency – CLOSED FM2/3 Instrument Payload LPT thm-esa-proc-007 IDPU/ESA Vib: 11/04/05 Workmanship, 1 Axis 7.09 Grms FM2 thm-sys-proc-006 Instrument LPT: 11/03/05 FM3 thm-sys-proc-006 Instrument LPT: 11/03/05 (through ITOS) PFR 116: ESA FSW Table Load – OPENED IDPU Modifications (PCB, LVPS) FM2/3 Instrument Payload CPT FM2 thm-sys-proc-005 CPT: 11/08/05 FM3 thm-sys-proc-005 CPT: TBDone PFR 116: ESA FSW Table Load – CLOSED FM2/3 Instrument Payload LPT FM2 PCB DeBug

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 10 UCB, November 10, 2005 FM4 As-Run I&T Flow IDPU Integration Coating/Staking Board (LVPS, PCB)/SPB Mech Mods Board (LVPS, PCB)/SPB Mech Re-Tests EFI Integration SPB Deploy SCM Integration thm-idpu-proc-007 DCB Integration: 07/09/05 thm-idpu-proc-001 PCB Integration: 07/13/05 thm-idpu-proc-005 DAP Integration: 07/14/05 thm-idpu-proc-004 DFB Integration: 07/28/05 thm-idpu-proc-003 BEB Integration: 08/03/05 thm-idpu-proc-006 LVPS Integration: 08/19/05 thm-int-proc-001 SCM Integration: 09/29/05 thm-int-proc-003 EFI Integration: 09/30/05 thm-int-proc-004 SPB Deploy: 10/06/05 PFR 105: SPB Turns Count - OPENED thm-int-proc-005 EFI Intercalibration: 10/07/05 PFR 103: SPB Pin Retention - OPENED thm-int-proc-006 SST Integration: 10/17/05 thm-int-proc-007 ESA Integration: 10/18/05 thm-int-proc-008 MAG Boom Integration: 10/12/05 thm-int-proc-013 Instrument SCT: TBDone Fields Phasing Test MAG Boom Integration Instrument Payload Self-Compatibility Instrument Payload CPT FGM Integration thm-int-proc-002 FGM Integration: 08/10/05 thm-sys-proc-005 Instrument CPT: TBDone SST Integration ESA Integration PFR 103: SPB Pin Retention - CLOSED PFR 105: SPB Turns Count - CLOSED

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 11 UCB, November 10, 2005 FM5 As-Run I&T Flow IDPU Integration ESA Integration FGM Integration Coating/Staking Board Mods Board Re-Tests thm-int-proc-001 SCM Integration: 10/26/05 thm-idpu-proc-007 DCB Integration: 09/08/05 thm-idpu-proc-001 PCB Integration: 09/12/05 thm-idpu-proc-003 BEB Integration: 09/14/05 thm-idpu-proc-004 DFB Integration: 09/14/05 thm-idpu-proc-005 DAP Integration: 09/20/05 thm-idpu-proc-006 LVPS Integration: 10/04/05 thm-int-proc-002 FGM Integration: 11/02/05 thm-int-proc-003 EFI Integration: 11/04/05 thm-int-proc-005 EFI Intercalibration: 11/07/05 thm-int-proc-006 SST Integration: 11/02/05 thm-int-proc-008 MAG Boom Integ.: 11/03/05 thm-int-proc-013 Instrument SCT: TBDone SST Integration Instrument Payload CPT EFI AKR Test Instrument Payload Self-Compatibility thm-sys-proc-005 Instrument CPT: TBDone EFI Integration SPB Deploy thm-int-proc-007 ESA Integration: 11/07/05 thm-int-proc-004 SPB Deploy: 11/04/05 MAG Boom Integration Fields Phasing Test SCM Integration thm-int-proc-019 DFB AKR: 11/08/05

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 12 UCB, November 10, 2005 PFR Summary PFR Statistics 21 PFRs logged since FM1 PSR (PFR 096 – PFR 116) 10 PFRs affected FM1: 8 Closed, 2 Open 11 PFRs affected FM2: 10 Closed, 1 Open 14 PFRs affected FM3: 12 Closed, 2 Open 8 PFRs affected FM4: 7 Closed, 1 Open 9 PFRs affected FM5: 7 Closed, 2 Open No PFRs are considered liens for FM2 Instrument Suite Integration to Probe

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 13 UCB, November 10, 2005 Blue type provides update since FM1 PSR and current status FGM Sensor Swap FGM Team to replace FM1 Sensor (SN 04) with Flight Spare (SN 12) CLOSED: FGM Team currently at UCB performing recalibration. No issues. ESA Re-Calibration ESA Team to perform short re-cal of ESA FM1 Sensor OPEN (PFR): Excessive MCP Noise discovered during Re-Cal. PFR 106 opened. SST Modification and Re-Calibration SST modification seemed to make sensor more susceptible to system noise CLOSED: Additional shielding added to make SST less susceptible to radiated noise. All sensors have been modified, workmanship vibes completed, and final calibrations on all flight units are in progress. FM1 PSR Open Items and Risk

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 14 UCB, November 10, 2005 Blue type provides update since FM1 PSR and current status SST Vibration SST FM1 required vibration test, was planned for week of Sept 26th CLOSED: All Flight Model (FM1-FM5) SSTs have completed vibration testing without issue. SCM Noise SCM showed susceptibility to power line noise, LDO regulator to be added to Pre-Amp OPEN: LDO Regulator was added to ETU Pre-Amp. System Test complete. All daughter boards have been assembled and inspected. SCM Team scheduled to be at UCB last week in November to provide final go-ahead for modification to flight units. FM1 PSR Open Items and Risk

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 15 UCB, November 10, 2005 ONE Open Item on FM2 Instrument Suite (to be integrated with 1 st Probe) SCM Noise Same issue as FM1 item THREE Additional Open Items on FM3 Instrument Suite ESA Re-Calibration ESA Team still to perform short re-cal of ESA FM3 Sensor Requires 1-2 days to de-integrate ESA from Suite and perform calibration Low Risk: FM2 ESA re-cal is completed. FM3 Sensor re-cal can be completed at any time prior to IDPU Probe Integration. ESA noise investigation is on-going. SST Final Calibration SST Team still to perform final calibration of SST FM3 Sensor Requires 1-2 days to perform calibration Low Risk: FM2 SST final calibration is completed. FM3 Sensor re-cal can be completed at any time prior to IDPU Probe Integration. EFI Final Re-Furbishment EFI Team still to complete final re-furb on EFI FM3 Spheres Requires approximately 1 week to re-coat spheres Low Risk: FM2 EFI spheres have been re-furbished. FM3 spheres can be completed at any time prior to IDPU Probe Integration. FM2/3 Open Items and Risk

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 16 UCB, November 10, 2005 BACK-UP: FM1 IPSR System RFA FM1 IPSR Closure of Open PFRs FM1/2/3/4/5 Open PFR Summary FM1/2/3/4/5 Pending and Waived Requirements

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 17 UCB, November 10, 2005 TITLE: Testing of Flight Spares RFA CODE: IN#1.PSR.RFA 04 REQUESTED BY: B. Keegan SPECIFIC REQUEST: Ensure that instrument hardware substituted as flight units after instrument suite testing are subjected to appropriate environmental testing that have been missed by not having been integrated during the instrument suite testing. SUPPORTING RATIONALE (ISSUE/PROBLEM): Instrument stand alone testing imposes only two thermal vacuum cycles. Instrument suite testing would impose an additional six. Spare units substituted after completion of suite testing must be subjected to equivalent testing. (e.g.: FGM on suite #1) RESPONSE: We have reviewed the spares and have taken action to expose the spares to additional TV cycling. When practical, the spares will tag along with the Instrument Suite TV tests already in progress. A specific 6-cycle test has been planned (but not completed) for FGM spare and EFI Y-axis SPB spares that will become part of the FM1 Suite. This test must be completed prior to FM1 Instrument Suite delivery to F1 Probe, which is the last probe delivered to UCB (need date April ’06). Back-up: FM1 PSR RFA #4

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 18 UCB, November 10, 2005 Back-Up: FM1 PSR Open PFRs Blue type provides update since FM1 PSR and current status Open PFRs PFR 045 PROBLEM: Non sequential sequence count in the packet header of ESA data RESOLUTION: FSW problem, investigation on-going. Analysis shows problem is most likely due to packet minimum set during test. Very little data affected. CLOSED: Solved by setting higher packet minimums during test. PFR 056 PROBLEM: SST tripped off & Actels reset as SPB cables were connected RESOLUTION: Occurred first during post-vibe CPT, moved to unverifiable failure, occurred again during pre-ship CPT. Procedural change required, additional analysis to be completed. CLOSED: Procedures have been changed to power down system any time test cables are connected/disconnected. All instruments were retested after the anomalies and behaved nominally. Analysis leads to a conclusion that plugging in the SPB motors can cause a spike on the PCB board that causes a number of supply switches to trip off and housekeeping to read anomalous readings. Latent damage is not a concern. PFR 065 PROBLEM: Bad, missing or out of order EFI data RESOLUTION: FSW problem, investigation on-going. Problem similar to PFR 045. CLOSED: Solved by setting higher packet minimums during test.

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 19 UCB, November 10, 2005 Back-Up: FM1 PSR Open PFRs Blue type provides update since FM1 PSR and current status Open PFRs PFR 095 PROBLEM: ITO coated silver Teflon tape samples failed thermal vacuum test RESOLUTION: Resolution on-going. Will be discussed further in Thermal. CLOSED: Tape was retested using flight aluminum alodine treated samples and with silver epoxy holding down corners and long edges. This technique resulted in a well-adhered tape that satisfies THEMIS requirements.. PFR 096 PROBLEM: EFI Y-axis floating supply current monitor drifts RESOLUTION: Investigation on-going. Will be discussed further in EFI. OPEN: See previous discussion.

FM2/FM3 IPSR AND FM4/FM5 IPERSYS - 20 UCB, November 10, 2005 Back-Up: Open PFRs PFR 096 PROBLEM: FM1 EFI Y-axis current monitor unstable RESOLUTION: Significant variation in the preamp current consumption was localized to a pair of tantalum power supply bypass capacitors (10%, 50-V, 0.1-uf, polarized tantalum capacitors, CWR06NH104KBB, VISHAY, Date Code: 0410). The original pair of capacitors was sent out for DPA to determine the physical damage present in the units. PFR 106 PROBLEM: FM1-FM5 ESA Noisy in one channel RESOLUTION: During re-cal of FM1 ESA, one of the channels was noisy with the MCP HV on. The analyzer was disassembled and examined. As the unit was disassembled, a pin used in the assembly fell out. FM1 MCP plates will be swapped with FM6 plates and the ESA will be re-calibrated. PFR 101 PROBLEM: FM3 SST nano-muscle was damaged during assembly RESOLUTION: During assembly of the FM3 SST, the resistance of the nano-muscle was found to be 100 Ohms instead of 5 Ohms. The nano-muscle was replaced and the actuator circuit was found to behave normally. The sensor requires 1 cycle of TV testing to verify actuator works over temperature extremes. PFR 115 PROBLEM: EFI V1 Sphere fails AC Functional Testing (all units fixed except FM5) RESOLUTION: It was found that EFI V1 Sphere was failing AC Functional Testing was due to a low impedance short existed between the Sphere and Usher surfaces. A Kapton spacer was added to FM1-FM4 units. The spacer has not been added to FM5 yet.