1. FIELDS MEP & V5 Pre-Ship Review Thermal Summary
Gayle K. Martin
Brent Mochizuki
Alexander (Sasha) Siy
April 10, 2017

2. Contents Thermal Compliance
MEP Thermal Analysis and Environmental Testing
Action items, Deviations, Waivers
Thermal Vacuum Test Summary
Test set-up
Thermal Test Results
Thermal Model and Documents
Electrical and Performance Summary
Problems, Failures, Anomalies
V5 Thermal Analysis and Environmental Testing

3. Thermal Compliance EDTRD MEP Complete V5 Complete Description Artifact
0021
3/2017
2/2017
Performance tests CPT shall be conducted for all components during component level TV testing
MEP: ref [11], [12], [13]
V5: ref [11], [12], [13]
V1234: TBD
0052
Through 3/2017
Prior to and after environmental testing, components shall be kept in a controlled environment (i.e., laboratory) at room ambient barometric pressure at the temperature and humidity shown below in Table 4-‑2
Parts List
0066
Hardware shall be subjected to bake-out as required by SPP Contamination Control Plan
MEP: ref [16], [13]
V5: ref [16], [13]
0069
Component turn-on shall be demonstrated at the hot and cold plateaus of the first and last operational cycles
0079
Cold turn-on temperature (below operating temperature) and warm-up sequence shall be identified and defined for necessary components
0080
Thermal vacuum cycle testing shall be performed to the Operational Test Limits on all components in order to adequately stress internal parts and solder joints
0083
Component level thermal vacuum testing shall include a single survival cycle to demonstrate tolerance of the survival limits
0084
Flight model testing shall complete six operational and one survival cycle

4. Thermal Compliance EDTRD MEP Complete V5 Complete Description Artifact
0087
3/2017
2/2017
CPTs shall be conducted during component level TV testing
MEP: ref [11], [12], [13]
V5: ref [11], [12], [13]
V1234: TBD
0088
Minimal functional tests shall be performed at all remaining plateaus
Note: CPTs conducted at all plateaus.
0166
At the component level, components shall be tested over the range of 22 V to 35 V as measured at the input to each component
0179
Throughout thermal balance and thermal cycle testing, each instrument subsystem or instrument component shall be powered unless there is an identified potential for damage and a waiver has been obtained from APL
0186
Instruments shall be designed and tested to the thermal interfaces listed in Table 5-2
0187
Cold turn-on temperature and warm-up sequence shall be identified and defined for each instrument
0189
Instruments shall complete a successful thermal vacuum flight qualification testing program prior to delivery to the spacecraft
0190
Testing program shall consist of thermal vacuum balance and thermal vacuum cycle

5. Thermal Compliance EDTRD MEP Complete V5 Complete Description Artifact
0191
2/2017
1/2017
All instruments thermal test plans shall be provided to the SC thermal engineer for review and approval
MEP: ref [11], [12]
V5: ref [11], [12]
V1234: TBD
0195
3/2017
The thermal cycling that all thermal hardware works as expected hardware for these instruments forgoing the thermal balance test shall demonstrate in thermal vac
MEP: ref [11], [12], [13]
V5: ref [11], [12], [13]
0207
Instrument thermal vacuum cycle tests do not have to maintain the isolated coupling used during thermal balance. This should decrease transition time between cycles, thus total test time. Instrument component temperatures shall be based on flight model predictions if the isolation coupling is not flight-like
0208
Instrument component temperatures shall be tested to 10°C beyond flight model predictions
[to flight allowable limits]
0209
Flight model testing shall complete six operational and one survival cycle
0212
CPT’s shall be conducted during instrument level TV testing
0213
Minimal functional tests shall be performed at all remaining plateaus if no CPT performed
0337
Components, except the high gain antenna and the cooling system primary radiators, shall be tested with a rate of change of temperature no less than 5°C per minute

6. Thermal Compliance EDTRD MEP Complete V5 Complete Description Artifact
0182
5/2016
n/a
Instruments mounted internally to the spacecraft bus shall meet the thermal design requirements in section 4.3.1
MEP: ref [14], [15]
0185
TBD
All instrument brackets external to the spacecraft shall be blanketed
V5: ref [14], [15], mICD
0188
11/2016
Instruments shall be designed to operate within thermal specifications for the science phase of the mission and not suffer permanent degradation during any other phase of the mission
V5: ref [14], [15]
V1234: TBD
0192
5/2016 
Flight predictions shall demonstrate at least 10°C of margin within the instrument operational or survival test temperatures with the exception that for active heater control, 5°C of temperature margin is acceptable at the lower test limit

7. Instrument: Document(s) Title
Artifact References
Description
Reference #
Instrument: Document(s) Title
iPER slides
[11]
MEP: 007_SPF_MEP_IPER_TVac.pptx
V5: 004_V5_IPER_Thermal_Plan.pptx
V1234: TBD
Test Plan/Procedure
[12]
MEP: SPF_PROC_120_MEP_FM_TV_RevB.pdf
V5: SPF_V5_TVcyclTestProc_RevE-signed.pdf
Complete test procedure & accompanying test report(s)
Note: CPT documents are referenced in the write-up
[13]
MEP: SPF_THM612_MEP_TV_TestReport.pdf & SPF_THM602_MEP_TV_CompletedTestProc.pdf
V5: SPF_THM312_V5_TV_TestReport.pdf & SPF_THM302_V5_TV_CompletedTestProc.pdf
V1234: TBD +ITVT
Thermal design summary
[14]
MEP: SPF_THM601_MEP_Design&Analysis.pptx
V5: SPF_THM201_V5_Design&Analysis.pptx
Thermal model
[15]
MEP: TBD
V5: TBD
Bakeout plan
[16]
FIELDS updated per meetings with the SPP contamination engineer.
SPF_MGMT_024_BakeOut_RevC.xlsx

8. MEP
Thermal Vacuum Cycling Test

9. MEP Action Items, Deviations, Waivers
Closure of action items from IPER
No open thermal actions, deviations, or waivers
Action
Description
Response
Status
MEP PER AI #1
Action: Successfully complete CPT and make test data plus configuration documentation (including versions of Boot and Operational FSW and other configuration items for FIELDS1 and FIELDS2) available before the start of environmental testing
The CPT test was completed. The As-run document was augmented with the versions of Boot and Operational software for both FIELDS1 and FIELDS2.
Complete 2/16/2017
K. Goetz
MEP PER AI #5
Action: Since the LPT is a critical test of instrument performance throughout thermal-vac testing, provide LPT prior to TV. The proc and scripts have been completed and ready to go 2/11/17
For TV testing, all soaks were complete with CPT
Complete 2/11/2017
See response
MEP PER AI #9
No SWEAP I/F testing in CPT performed in TV
Action: Discuss why not including the SWEAP I/F is low risk and why it does not need to be tested during the TV CPT
FIELDS now plans to include testing of the SWEAP interface during MEP TV. This will involve running a SWEAP emulator outside the TV chamber with harnessing into the FIELDS MEP. This allows testing of signals in both directions.
Complete 3/15/2017
MEP PER AI #10
Hi and Lo bus voltage testing during TV.
Action: Perform some system level testing at min and max bus voltage while at hot and cold plateaus during TV
The steps to operate at min and max voltages as requested has been added. Updated MEP TV procedure 
MEP PER AI #11
Cold Turn on in TV
Action: Move the instrument cold turn-on test to the first cold survival soak
The cold turn-on at the survival soak has been added. Please see the updated MEP TV procedure that is attached to this action item.
MEP PER AI #12
Action: Discuss why not testing the Mag heater circuit in TV is acceptable
We have determined a method to allow the heater to be on all the time, and have arranged for the necessary cable adjustment.

10. MEP Thermal Vacuum Test Set-up
Back shroud
Main shroud
Baseplate
The TV test was complete at UCB/SSL in the Bayside chamber
Test dates March 16 to March 28, 2017
Test set-up
There were three temperature zones for the TV test (baseplate and shrouds)
Fully assembled flight MEP
The MEP was bolted to a mounting plate then bolted to the chamber baseplate
The harness and instruments rested on baseplate
The following instruments were inside the chamber during the test: FM V5, EM SCM, 4 EM V1234 preamps
The following instruments were outside the chamber during the test: FM Mag-o and FM Mag-I, both in the stimulus cans.
The magnetometer heaters were jumpered out for heater testing
MEP TV set-up in the Bayside chamber

11. MEP Thermal Vacuum Test Set-up
Our fearless leader standing next to the stim rack during MEP TVac.
Thermal control rack
Stim rack
Clean room
Bayside Chamber

12. MEP Thermal Vacuum Test Set-up
FIELDS I&T lead and electrical lead sweating through the MEP electrical wiring.

13. MEP Thermal Vacuum Test Set-up
Mounting plate
V1234 EM preamps (under harness)
SCM (EM)
V5 (FM)

14. MEP Thermal Vacuum Test Set-up
Electrical configuration
Instruments internal to the chamber were connected directly to the MEP
The harness was connected via DB25 and BNC feedthroughs in the Bayside chamber
V1234 & V5 stimulus was connected to the Stim Rack via BNC
Electrical isolation
V5 was electrically isolated with ChoTherm in the same configuration as the V5 TV configuration
The V1234 EM preamps were grounded to the baseplate with grounding wires
Thermal control
The flight MEP was controlled and monitored via thermocouples and AnaWin2 controller

15. MEP Thermal Vacuum Test Set-up
Thermocouples were mounted along the flight unit and instruments internal to the chamber to verify temperatures during thermal cycling
The thermocouples were electrically isolated with Kapton tape and thermally coupled with aluminum tape
The internal thermistor recorded that the temperatures stabilized during instrument operation (not available during survival) 4 5 6
Back Shroud
Main Shroud 8 9 15 14
MEP “back” with control TC bolted to mounting plate.
TC #
Location  1
Door Shroud  2
Main Shroud  3
Baseplate 4
MEP top 5
MEP front (broken) 6
MEP side near mag-i 7
MEP side near mag-o (Bayside wall) 8
MEP back 9
MEP base (control TC) 10
EM V1 preamp 11
EM V2 preamp 12
EM V3 preamp (broken) 13
EM V4 preamp 14
FM V5 preamp 15
EM SCM

16. MEP Thermal Vacuum Test Results
Instrument functionals were complete
Pre-test functional
Hot and cold operation CPTs (all op cycles)
Post-test functional
Test parameters as indicated in PER were met
The transition rate of the instrument did not to exceed 3°C per minute
Soak was achieved at a minimum of four hour at case temperatures with a change in temperature of ±1°C
Temperature set-points for each case
Survival = -30°C to 65°C
Operational = -25°C to 60°C
Additional operational case at nominal spacecraft interface temperature of 46°C
TQCM measurement was made at the end of the test after the 48 hour bakeout

17. MEP Thermal Vacuum Test Results
The table summarizes the test trends to illustrating compliance with specifications
Hot and cold turn-on at every cycle
CPT at every cycle
Magnetometer heaters were turned on for cycles 3-6
Additional hot operational case at 46°C
No CPT
Nominal spacecraft temperature interface temperature
Verified current draw during nominal operations (31 V)
Cycle
Hot T (°C)
Voltage
CPT
Cold T (°C)
Survival 65
 n/a
n/a
 -30
Operational 1
 62
 31
Complete
-30/-25
Operational 2
 Complete
-25
Operational 3
Operational 4
 61
Operational 5
 26
Nominal interface 46 31
Operational 6
 35

18. MEP Thermal Vacuum Test Results
Hot and cold operational cycle illustrated (comparable for all soaks)
Baseplate (yellow) temperatures used for thermal control

19. MEP Thermal Vacuum Test Results
Acceptance temperature margins
Flight allowable limits were tested at all soaks
No non-conformances or differences from PER during test
Measured test margins vs. design estimates: MEP tested to 10°C beyond predicts
No rework/replacement, or changes to test plan since IPER

20. MEP Thermal Model and Documents
Updated thermal model to be delivered April 2017
Documents: refer to slide 7
Photo location:

21. MEP Thermal Vacuum Electrical and Performance Summary
CPT was performed during every hot and cold soaks
Soak Properties
CPT Results
Date
Temperature
Cycle #
Voltage
MAG Htr
Automated Results
MAGo/i
DFB
FIELDS2
19-Mar-17
Cold 1
31V
Nominal
Pass
20-Mar-17
Hot 2
21-Mar-17 3
22-Mar-17 4
High
TDS Issues Cold
23-Mar-17 5
26V
24-Mar-17 6
35V
NCR-020

22. MEP Problems, Failures, Anomalies
A few anomalies occurred during TVac testing and an FRB was held on 6 Apr 2017 to address them

23. V5
Thermal Vacuum Cycling Test

24. V5 Action Items, Deviations, Waivers
Closure of action items from IPER
No open thermal actions, deviations, or waivers
Action
Description
Response
Status
V5 PER AI #3
Confirm that the connector can survive the tested cold temperatures without damage.
The connector in question is a 311P409-2P-B pin male (pins) connector, rated from -55 C to +125 C.
At the project level, heritage use aboard SDO and other GSFC Magnetometer missions of this connector type is being used to met the component qual requirements at cold temperatures [R. Kinder, Feb 2017; attached Memo]. On SDO this connector type was qualified to a minimum test temperature of -83 to C over many tens of cycles, and readily passed. At the Fields level, the connector in question was cycled in FM V5 TVAC over 6 Ops cycles from -59 C to + 71 C and one survival cycle from -68 C to +77 C, not as cold as the predicts, but still colder than the nominal cold limit of -55 C. No degradation of the electrical properties of the connector were observed during the test (isolation or continuity), and there were no obvious physical issues with the connector in visual inspection upon completion of the TVAC testing. The V5 cold cycle limits on the connector were warmer than expected in flight as the connector was not strongly coupled to the V5 preamp and sensor, nor was it blanketed as it would be in flight.
Complete 3/27/2017
V5 PER AI #5
Measure the continuity from the box to antenna element during TVAC to see if there is a problem
In FM V5 TVAC testing, the electrical continuity through the elements in question was verified at Cold Operational ( -85 C) and hot ( +75 C) conditions throughout all 6 Operational TVAC cycles, as well as after the Cold and Hot Survival cycles (-141 C and +110 C respectively). No issues with the DC or AC electrical conductivity of the elements in question were found during the test, which verified fulfillment of the required functionality over the required range of thermal environments.
V5 PER AI #6
Action - A test report for the thermal balance test and an update to the thermal analysis (reflected in the test procedure) is requested. Rationale - Since the response to I-CDR RFA 10 (updated thermal analysis), the V5 surface has been changed to black nickel and there has been a V5 EM thermal balance test.
Document with summary submitted
SPF_THM201_V5_Analysis&Test.pptx
V5 PER AI #7
Action - Check the usage of the Micro Phase K thermal interface material over the temperature range needed and that the magnetic properties are acceptable.
Using ChoTherm instead per preference of APL team
Complete 3/20/2017
V5 PER AI #8
Action - Perform a thermal balance test to validate flight thermal design over the expected interface temperature range. Rationale - Test matrix shows a thermal balance test is required. Plan doesn't call out a thermal balance test.
The V5 flight unit thermal balance was incorporated into the thermal cycle test. The V5 flight unit was thermally cycled beyond required flight allowable temperatures. Each thermal cycle reached balance conditions, thus a separate balance test was not deemed necessary. The results from the TV test will be correlated for the final flight thermal model. Due to the test heating/cooling zones within the chamber, gradients were experienced on the V5 unit to properly correlate the data. An additional soak case was included after the final cold cycle to define the preamp warm-up protocol. As noted in the rational, a thermal balance test is required per the EDTRD test matrix. The requirement for V5 is at the subsystem level (that is with the boom). A balance test at cold conditions was performed at APL in Another balance test was planned for 2017 and has been incorporated into the SPP Observatory test.
Complete 3/24/2017

25. V5 Thermal Vacuum Test Set-up
The TV test was complete at UCB/SSL in the SNOUT1 chamber
Test dates January 30 to February 13, 2017
Test set-up
There were four temperature zones for the TV test (baseplate, main shroud, heater plate and cold finger)
Fully assembled flight V5 unit
The V5 was isolated from the heater mounting plate with ChoTherm (flightlike) and bolted with flight hardware
The heater plate was mounted to the cold finger bolted to the chamber baseplate
GSE heater plate (dubbed "the burrito") will have the V5 mounted to it with ChoTherm interface. The burrito will then be mounted on the Cold Finger (LN2 reservoir).
V5 Heater plate
Cold finger

26. V5 Thermal Vacuum Test Set-up
Shroud
Cold plate mounting
Cold plate
Heater plate
Connector rested on mounting block
Electrically isolated (ChoTherm under V5)

27. V5 Thermal Vacuum Test Set-up
Electrical configuration
V5 was connected to external GSE to operate CPTs via GSE computer
The V5 flight unit was stimulated through BNC
Electrical isolation
V5 was electrically isolated with ChoTherm
Thermal control
The flight V5 was controlled and monitored via thermocouples and AnaWin2 controller

28. V5 Thermal Vacuum Test Set-up
Thermocouples were mounted along the flight unit to verify temperatures during thermal cycling
The thermocouples were electrically isolated with Kapton tape and thermally coupled with aluminum tape
The internal thermistor recorded that the temperatures stabilized during instrument operation (not available during survival) 7 3 5 6
TC #
Location  1
Baseplate  2
Shroud  3
V5 top 4
V5 side 5
Heater plate 6
V5 antenna 7
Connector

29. V5 Thermal Vacuum Test Results
Instrument functionals were complete
Pre-test functional
Hot and cold operation CPTs (all op cycles)
Post-test functional
Test parameters as indicated in PER were met
The transition rate of the instrument did not to exceed 3°C per minute
Soak was achieved at a minimum of four hour at case temperatures
Temperature set-points for each case
Survival: 110 to -140°C
Operational: 75 to -85°C
TQCM measurement was made at the end of the test

30. V5 Thermal Vacuum Test Results
The table summarizes the test trends to illustrating compliance with specifications
As defined in the procedure (section 12), the pass criteria were all met.
Adequate temperature data collected at steady state from all test cases
Pass all CPTs (every operational soak)
No workmanship failures
Completed 6 operational and 1 survival cycle
Hot and cold turn-on
Cold turn-on at -140°C during op cycle 1.
Cycle
Date
Hot T (°C)
DT (°C/hr)
CPT
Cold T (°C)
Survival
2/1/17
110 ±1
n/a
-142 2
Operational 1
2/2/17 75
Complete
-85
+1, -22*
Operational 2
2/3/17
 Complete
+1, -32*
Operational 3
2/6/17
Operational 4
2/7/17
+1, -5
Operational 5
2/8/17
+1, -3
Operational 6
2/9/17
Warm-up Heater
2/10/17
-109
+3, -2**
*The V5 remained below the -85°C flight allowable/test temperature limit for the duration of the soak. The V5 temperature dropped as low as -107°C due to hysteresis between the cold finger and V5 control TC.
**Review write-up for details on the heater warm-up authority cases evaluated.

31. V5 Thermal Vacuum Test Results
Hot and cold survival and 6 operational cycles are illustrated
V5 top (blue) temperatures was used for thermal control

32. V5 Thermal Vacuum Test Results
Acceptance temperature margins
Flight allowable limits were tested (or exceeded) at all soaks
No non-conformances or differences from PER during test
No rework/replacement, or changes to test plan since IPER

33. V5 Thermal Model and Documents
Updated thermal model to be delivered April 2017
Documents: refer to slide 7
Photo location in folder “V5 TV Pictures”

34. V5 Thermal Vacuum Test Summary
All CPTs were completed successfully
Recorded in folder “Functional Check Log”
Hot Soak 6 CPT report:

35. V5 Problems, Failures, Anomalies
No workmanship failures or performance anomalies identified
The instrument performed as expected during each operational cycle and during the post-test check-out
The instrument also performed as expected for the 6 operational cycles during the MEP TV test
No identified residual risk