1. SPP FIELDS V1234 Thermal PSR
Gayle K. Martin
May 26, 2017

2. Contents The Post PER Road… Thermal Compliance
Thermal Environmental Testing
Thermal Vacuum Test Summary
Thermal Balance Test
Thermal Model
Path Forward

3. We passed PER

4. But there was still a long and arduous road…
We all experienced THIS moment
Yet we persevered!

5. Thermal Compliance Action Items, Deviations Waivers Documents
No thermal action items from IPER
No open thermal actions or deviations
Waivers
Analyitical margin (not submitted)
Omission of survival cycle for thermal cycle testing
Documents
iPER slides
Thermal vaccum test procedure
Thermal balance test procedure
Thermal design summary
Thermal model
Bakeout plan
Requirements
SPP EDTRD
SPP CCP
FIELDS Bake-out

6. Thermal Environmental Testing
Thermal cycling
5/13/2017 to 5/20/2017
6 Operational cycles +90°C to -77°C
Hot bake out & hot survival
No cold survival
Thermal Balance
5/21/2017 to 5/25/2017
4 Balance plateaus
2 Heater verification balances
Future Testing
APL-ORNL optical tests of Nb C103 lot 2
APL-ORNL other testing TBD
Previous testing: Reference document presented to APL 5/3/2017
Optical properties (2012)
Choke thermal design (2012)
Outgassing NbC103 (2012)
Material compatibility ( )
Thermal distortion (2013)
Electrical verification (2014)
Shield & stub thermal design (2014)
Hinge deployment ( )
Thermal design (2015)
ETU thermal balance (2015)
Preamp qualification (2016)
ITVT (2017)

7. Thermal Vac Cycling
V1234

8. Thermal Vacuum Test Set-up
The TV test was complete at UCB/SSL in the Bayside chamber
Test dates 5/13/2017 to 5/20/2017
Test set-up
There were three temperature zones for the TV test (main shroud, end shrouds 7 baseplate)
Fully assembled flight units V1234
The flight units were bolted to a mounting plate (shelf) then bolted to the chamber baseplate
The harness rested on top shelf
The heaters were connected for thermostat and heater performance verification
Back shroud
Main shroud
Baseplate
TV set-up in the Bayside chamber

9. Thermal Vacuum Test Set-up
All 4 units mounted on shelf
Harness on shelf top

10. Thermal Vacuum Test Set-up
Selfie time!

11. Thermal Vacuum Test Set-up
Terminator box
V2 flight unit
QA approved!!

12. 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)
TC #
Location  1
Door Shroud  2
Main Shroud  3
Baseplate 4
Back Shroud 5
V2 arm 6
V3 arm 7
V4 arm 8
V1 PinPuller 9
V2 PinPuller 10
V3 PinPuller 11
V4 PinPuller 12
V1 arm 13
V1 Preamp radiator 14
V2 Preamp radiator 15
V3 Preamp radiator 16
V4 Preamp radiator
Arm
Radiator
PinPuller

13. Thermal Vacuum Test Results
6 Operational cycles +90°C to -77°C
Hot bake out & hot survival
Same temperature as operational cases
Left to 90°C overnight to meet 48hr bakeout requirement
Total hours >>48 hours
No cold survival: cold survival at cold operational temperatures
Hot and cold turn-on at first and last hot & cold cycles
CPT at every cycle
Successful cold & hot deployment
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
Thermostat and heater performance was verified after cold soaks 3 and 6

14. 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
Electrical performance (CPT) summarized in Sasha’s slides
Hot deploy
Final Bake & TQCM
Warm-up
Chamber break
Cold deploy

15. Thermal Balance
SN005

16. Thermal Balance Test Set-up

17. Thermal Balance Test Set-up

18. Thermal Balance Test Data
The thermal balance test (4 balance cases & 2 heater verification soaks) completed
Preliminary results:
Most of the critical components are within 3°C of the predicts (as required)
There are some components that are out of predicts
Reasons for the discrepancy
The part of the test set-up (aluminum stand-offs), MLI, & associated radiative view factor were not properly modeled
Minor errors from conversion from the flight model to the test model were not debugged
Optimization of optical properties
Current work
Detailed review of test set-up, specifically the radiative view in question
Model correlation effort

19. Thermal Model
The recommendations provided by Shawn from the last model view (3/2017) were incorporated
Design updated that differed from design and flight unit were included

20. Path Forward Conclusion Model correlation Recommendation
V1234 successfully complete all thermal testing
The thermal model is under review
Captive blankets are under construction for flight unit integration
Model correlation
Finalize the model correlation
Final flight predicts
Final heater power duty cycle predicts (transient)
Recommendation
Despite the differences between the test model and resultant temperatures, the source of the discrepancies have been identified
Confident that the thermal model to date is accurate
It is recommended to proceed as planned

21. It takes a Village… Abiad Jose Brent Keith Chris S1 Paul Chris S2
Peter
David
Sasha
Greg
Steve
Helen
Yvette
John
& al
Jorg