Post on 20-Jan-2016
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 1
GLAST Large Area Telescope:GLAST Large Area Telescope:
Presented by P. YoungSLAC
plsyoung@slac.stanford.edu(650) 926-4257
Gamma-ray Large Gamma-ray Large Area Space Area Space TelescopeTelescope
PDU TRRPDU TRR
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 2
ContentsContents
• Introduction– Overview– Significant Changes since CDR– Objectives– Status
• Requirements/Verification• EGSE and Test-Procedures• Verification Test Plan and Flow
– At Assembly Vendor• Test-plan and Flow• Facility• Man-Power• Quality Assurance• Vibration
– At SLAC• Test-plan and Flow• Thermal Vacuum Test• Mass Property• EMI/EMC (at sub-contractor)• Man-Power• Quality Assurance
• Equipment Calibration/Safety• Risk Assessment• Schedule• Status of Procedures• Issues and Concerns
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 3
LAT ElectronicsLAT Electronics
3 Event-Processor Units (EPU) (2 + 1 spare)
– Event processing CPU– LAT Communication Board– SIB
ACD
empty
EPU-3
EPU-2EPU-1
empty empty
Power Dist. Unit*
GASU*
empty
empty
SIU*SIU*
Spacecraft Interface Units (SIU)*
– Storage Interface Board (SIB): Spacecraft interface, control & telemetry
– LAT control CPU– LAT Communication
Board (LCB): LAT command and data interface
16 Tower Electronics Modules & Tower Power Supplies
* Primary & Secondary Units shown in one chassis
Power-Distribution Unit (PDU)*
– Spacecraft interface, power
– LAT power distribution
– LAT health monitoring
Global-Trigger/ACD-EM/Signal-Distribution Unit*
TKR
CAL
TKR Front-End Electronics (MCM)ACD Front-End Electronics (FREE)
CAL Front-End Electronics (AFEE)
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 4
EGSE PDU Mounted on LAT EGSE PDU Mounted on LAT
GASU
PDU
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 5
Flight PDUFlight PDU
Primary and Redundant PDU DAQ Module in same enclosure, separated by metal
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 6
• One enclosure houses primary and redundant Power Distribution DAQ Circuit Card Assembly
– Separated by aluminum wall
• Receives primary and redundant 28V DAQ feed from spacecraft
• Common mode filter
• Selects whether to use primary or redundant feed for a selected DAQ board via control signals from SIU
• Receives LAT command link from primary and redundant SIU into on-board ACTEL FPGA (via LVDS converter IO)
• On/off control of power to each of the loads: 16 TEM/TPS, 3 EPU’s, via configuration registers
• Readback of configuration registers to SIU
• Includes under-voltage, over-current protection and inrush current limiting for each output feed
• Digitization of 28 primary and 28 redundant RTD and 97 primary and 97 redundant thermistor sensor values
– Block redundancy: all primary sensors are connected to primary PDU, all redundant sensors are connected to redundant PDU
– Digitization in response to “digitize” command
– Readback of results after fixed minimum latency
• PDU 3.3V-supply voltage level and thermistor interface to spacecraft
Power Distribution ModulePower Distribution Module
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 7
Changes since LAT CDRChanges since LAT CDR
• Modification of FPGA code – Code was rewritten by Eric Siskind– Code was reviewed by GSFC reviewer (Dr Rod)
• Some resistor/capacitor values have changed to optimize monitoring ranges
• Details of monitoring circuit have changed • Redesigned load-switch circuit
– To incorporate under-voltage protection• Added in case space-craft converters enters current-limiting
mode with subsequent drop in output voltage– To incorporate over-current protection
• Avoids damage to MOSFET switches– Changed resistor values to optimize in-rush current level
• Worst Case Analysis updated to incorporate changes• Thermal Analysis from CDR/Delta-CDR remained since changes don’t
impact thermal performance
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 8
ObjectivesObjectives
• Demonstrate that hardware, software, procedures, and support equipment are prepared to support system environmental test
• Demonstrate that planned and completed testing meets performance and interface requirements
• Identify and understand all the risks and limitations• TRR is not intended to
– Review PDU design– Review flight readiness– Buy-off hardware or software
• RFA’s should only be of sufficient concern to stop test– Prior to start of an given test, any applicable TRR RFAs
must be closed
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 9
Test Entrance / Exit CriteriaTest Entrance / Exit Criteria
• Entrance– All required paperwork released and in place
• Procedures, drawings, etc– Test configuration verified and approved– Essential personnel in place– Pre-test PDU functional successfully passed
• Exit– As-run procedures completed– Correct and accurate application of test environment– Test data acquired and archived– No damage to PDU– PDU performance within specification limits– Post-test PDU functional successful
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 10
StatusStatus
• First PDU (to be proto-flight tested)
– Assembled
– Pre-conformal coat PDU with enclosure-internal EGSE harness tested, tests to verify that ACTEL performs over temperature performed (was prerequisite to programming FPGA’s for second PDU box)
– Conformal coated, integrated in enclosure with flight harness
– Final PDU to be delivered to SLAC week of July 18, 2005
• Second PDU (to be flight acceptance tested)
– Will be spare or primary flight PDU, depending on schedule
– Board went thru reflow surface-mount assembly step
– ACTEL FPGA’s were programmed and are being assembled on boards
– Remaining are staking, integration of boards into enclosure, integration of EGSE harness, testing at SLAC, conformal coating, integration of flight harness, testing
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 11
Tests To-DateTests To-Date
• PDU engineering modules were extensively tested– As EGSE in DAQ/I&T
• Testbed includes PDU for > 1 year• I&T uses EGSE PDU during integration of towers in LAT
for several months• Main difference to flight PDU: under-voltage/over-
current circuit was not implemented on EGSE PDU’s supplied to I&T and testbed
– One flight board was assembled with mostly flight parts and tested
– Additional PDU tests• Informal thermal test -40C to 55C• Informal EMI test on EGSE station sent to Lockheed for
thermal test
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 12
RequirementsRequirements
• LAT-SS-00285 Specifications, Level 4 LAT Dataflow System
• LAT-SS-00019 Specifications, Level 3 T&DF Subsystem Specification
• LAT-SS-00136 Specifications, Level 3 Power Supply System
• LAT-SS-00183 Specifications, Level 4 Power Supply System
• LAT-SS-06988 Specifications, Level 5 PDU Specification
• LAT-TD-00606 LAT Inter-Module Communications
• LAT-TD-01743 PDU ICD Specification & Conceptual Design
• LAT-TD-01543 PDU, Programming ICD
• LAT-SS-00778 LAT Environmental Specification
• LAT-SS-06988 PDU lists requirements
• LAT-TD-06989 contains Verification Matrix which gives approach to verify each requirement
– Lists verification method used
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 13
System PerformanceSystem Performance
• Level 3 and level 4 DAQ and TRG and power-system requirements are met with a combination of DAQ modules (TEM/TPS, GASU, SIU, PDU, etc), since the DAQ and trigger and power system is comprised of several sub-system module types– Level 5 PDU requirements which are verified are derived
from Level 3 and Level 4 DAQ and Trigger and Power system specifications (as noted in the L5 requirements doc)
– Level 5 requirement doc includes derived requirement addressing
• Functionality/performance• Power• Mass/C.G.• EMI/EMC• Environmental incl temperature and vibration
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 14
Verification StatusVerification Status
• Engineering Module PDU– EM completed full functional test program with exception of
thermal-vacuum, EMI/EMC, mass, and C.G.– Demonstrated compliance with specifications
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 15
EGSE and Test-ProceduresEGSE and Test-Procedures
• EGSE for Functional/Performance Tests– Test-Stand documented in LAT-DS-06627
• Test-Procedures– LAT-TD-04332 Electrical Interface Continuity and Isolation
Test procedure • Power-off impedance tests of I/O
– LAT-TD-04384 Stray-Voltage-Test Procedure• Power-on voltage test of I/O
– LAT-TD-01744 Comprehensive Test Procedure• Functionality and Performance test
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 16
EGSE Test-ConfigurationEGSE Test-Configuration
• LAT-TD-01744-03
LAT-DS-03402-01
PDU BOXLAT-DS-01696
VMECRATE
MVME2304-0123 SBCv 0143 r VXWORKS 5.5
PDUPRIM
PDURDNT
Variable 28VDC PS 35A
Passive loads emulatingTEMs EPUs GASU ACD
3 BOARDS
LAT-DS-03405-03VERSION T, M, B
Local PC withLATTE, VxWorks,PDU test scripts
LCB v 03 r Xilinx V3.9 ActelV2.4
LAT-DS-03253
Networktaps(2)
Resistors emulating temp sensors
2 BOARDS
LAT-DS-03409-02VERSIONS T, B
Switches toemulate SIU
PowerResistors oncopper plate
LAT-DS-03886-01
COOLINGFANS
ACAdapter
JL13-28
JL8
JL7
JL6
JL31-34
JL29,30,248
JL4
JL3
LAT-DS-04307
LAT-DS-04305 (3)
LAT-DS-04306 (4)
LAT-DS-04308 (16)
RS232-CABLE
PDU TEST BOX 19" Rack Mount ChassisLAT-DS-3400-02schematic = LAT-DS-3401-02
GASU BOXLAT-DS-01611
JL40
JL41
JL44 LAT-DS-02104
LAT-DS-05550
LAT-DS-05550
Systran VMESC5
5 DAC128V IPModules
LAT-DS-04309-03
(3)
JL9-11LAT-DS-04308 (3)
LAT-DS-05940 (5)
Mates with PDU JL9-11,13-28 for VMon Cal Test.
J1-3
J1-3 (Ver. T)
J2 (Ver. B, Ver. M, Ver.T)
Resistors emulating tempsensors (7 BOARDS)
LAT-DS-03409-02VERSIONS 7590, 19800, 30100,60400, 205000, 361000, 806000
JL-29, 30, 248
JL-31-34
JL-31-34
JL-29, 30, 248
Lug typeconnector
J66
P2
P2
SIU
JL5
P5
P1-4
P1
JL7 J20
J78S
J78S
GASU
J20JL8
J78P
J78P
P1
P2
P2JL-9-11
JL-13-28
P1
P1
CAT5 Ethernet Cable
Debug
10/100Base
N/C
CAT5 Ethernet Cable
JL5
JL6LAT-DS-04307
serial port
GASU TEST BOXLAT-DS-04969
BK Precision1786A Power
Supply
LAT-DS-05218
JL153
Agilent 33250AFunction
Generator
gasu test
test box
gasu
LAT-DS-03246P3
P2
P1+_
B1B2
B1
B2
P1-3
BK Precision1786A Power
Supply
+_
coax cable
ext clk in
28v
kings-lemo 1075-1
BNC
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 17
Verification Level – Module DetailVerification Level – Module Detail
• Breakout of verification at PDU Module Level• Tests to be conducted after successful TRR (order may change
depending on availability of resourced (TV/EMI)• EICIT & SVT• Functional test• Vibration (Wyle)• Functional test• Thermal cycle• Functional test• Mass properties including CG• Thermal vacuum (in-situ testing)• EMI/EMC (at CKC-lab for proto-flight, at SLAC for flight
acceptance)• Functional test • Review• Deliver to I&T
– DAQ (out-going) / I&T (incoming) test combined
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 18
VerificationVerification
• Test-Stand– Supplied by SLAC– Operated by SLAC engineers
• Vibration facility at Wyle– LAT-TD-06101 Vibration test-procedure – SLAC engineers present for vibration tests
• Thermal Cycle in thermal chamber in SLAC clean-room
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 19
TC and Vibration RequirementsTC and Vibration Requirements
Parameter Required Characteristic Thermal Cycling (4 cycles) -40 to +55 °C (Qualification and
Proto-flight) Thermal Cycling (4 cycles) -35 to +50 °C (Acceptance) Random Vibration See Figure 1. Sinusoidal Vibration 0.5g rms, 20 to 2000Hz
Figure 1. Vibration Levels, Duration, and Spectra
Electronics Module (Special Boxes)Random Vibration Spectra
ASD Level (G2/Hz)Freq (Hz) Accept Qual20 0.010 0.01075 0.037 0.03880 0.040 0.055115 0.180 0.360160 0.180 0.360325 0.040 0.060350 0.040 0.050500 0.040 0.0502000 0.025 0.050Overall 8.91 Grms 11.51 GrmsDuration 60s/axis AT, PT
120s/axis QT
0.001
0.010
0.100
1.000
10 100 1000 10000Freq. (Hz)
AS
D L
evel
(G
^2/H
z)
Accept
Qual
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 20
Mass PropertyMass Property
• Mass properties checked at SLAC – Procedure to be written (performed at SLAC Metrology)– Expected: (ref LAT-TD-00564)
• Total 9.8 kg• Allocation 12% above = 11 kg
– C.G. to be measured for the proto-flight unit only
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 21
Thermal Vacuum TestThermal Vacuum Test
• Thermal Vacuum facility in Building 33 at SLAC– Thermal Vacuum Chamber Operating Procedure LAT-TD-
02541– PDU Thermal Vacuum Test-Procedure LAT-TD-03639– First PDU tested to proto-flight specifications (same
Temperatures as qualification, but 4 TV cycles versus 12 cycles)
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 22
Proto-Flight and Flight Acceptance Thermal Proto-Flight and Flight Acceptance Thermal Vacuum TestVacuum Test
• See PDU Thermal Vacuum Test-Procedure LAT-TD-03639
+55C +2/-2C
PROTO-FLIGHT THERMAL VACUUM CYCLE TIMELINE
Hot Qualification Limit
4 Cycles Total
Open Chamber
CloseChamber
Start Pump Down
Chamber
Vent ChamberSetup Flight Unit
CPT
Start of Cycle 1
End of Cycle 12
Hot Survival Limit+60C +2/-2C
-40C +2/-2C Cold Survival/Cold Qualification Limit
EGSE Unit
Start Bake Out/Outgas
CPT
Open Chamber
Turn OFF+30C +2/-2C
CPTFlight Unit
Turn OFF
Verify End Bake Out O
N-O
FF
-ON
4Hrs
4Hrs
OF
FC
PT
LP
T
ON
-OF
F-O
N
CP
T
LP
T
4Hrs 4Hrs
4Hrs
4Hrs
OF
F-O
N
OF
F-O
N
OF
F-O
N
OF
F-O
N
ContinuePeriodic
LPT
CP
T
Continue Periodic
LPT
4Hrs
Cycles 2-3
CP
T
ContinuePeriodic
LPT
OF
F
CP
TO
FF
OF
F-O
N
Start Periodic
LPT
ContinuePeriodic
LPTOF
F-O
N
At < 10-5 Torr
X 4
+50C +2/-2C
ACCEPTANCE THERMAL VACUUM CYCLE TIMELINE
Hot Acceptance Limit
4 Cycles Total
Open Chamber
CloseChamber
Start Pump Down
Chamber
Vent ChamberSetup Flight Unit
CPT
Start of Cycle 1
End of Cycle 4
Hot Survival Limit+60C +2/-2C
-35C +2/-2CCold Acceptance Limit
EGSE Unit
Start Bake Out/Outgas
CPT
Open Chamber
Turn OFF+30C +2/-2C
CPTFlight Unit
Turn OFF
Verify End Bake Out O
N-O
FF-
ON
4Hrs
4Hrs
OF
FC
PT
LPT
ON-OFF-ON
CPT
LPT
4Hrs 4Hrs
4Hrs
4Hrs
OF
F-O
N
OF
F-O
N
OF
F-O
N
OF
F-O
N
ContinuePeriodic
LPTC
PT
Continue Periodic
LPT
4Hrs
Cycles 2-3
CPT
ContinuePeriodic
LPT
OF
F
CPT OF
F
OF
F-O
N
Start Periodic
LPT
ContinuePeriodic
LPT
-40C +2/-2CCold Survival Limit4Hrs
OF
F-O
N
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 23
EMI/EMC TestEMI/EMC Test
• Proto-Flight = Qualification Test (Conductive & Radiative)– Sub-contracted to CK Labs– Statement of Work: LAT-PS- 04568
• CE102, CECN, CS102, CSCM, CS06, RE101, RE102, RS101, RS103
– Detailed EMI/EMC procedure provided by CKC lab (TP05-83489-0.doc, to be released?)
– SLAC engineers present at vendor for tests– Vendor supplies test-report– LAT QA at SLAC present for tests
• Flight Acceptance Test (Conductive)– Performed at SLAC– LAT-TD-03637
• Only CE102, CS102– SLAC supplies test-report– LAT QA at SLAC present for tests
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 24
Manpower & Quality AssuranceManpower & Quality Assurance
• Test man-power – PDU: Patrick Young– Test Support: J. Ludvik– Thermal Cycle and TV support: R. Williams, P. Hart– TV shift support: 2 contractors– EMI support: D. Nelson – Vibration support: D. Tarkington
• Quality assurance: Joe Cullinan– QA representative (Y.C. Liew) present during tests, review
of test-procedure and results– Required changes to documentation are red-lined and
included in new revisions– NCR are created for non-conformance (e.g. exceeding of
min/max test limits) and submitted for disposition
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 25
Problem Failure Report/ Configuration Problem Failure Report/ Configuration ManagementManagement
• Problem Failure Reporting– Via standard SLAC LAT Non-Conformance Reporting (NCR)
System• NCR is entered• Reviewed/accepted/resolved
– LAT engineering
– LAT QC
• Already exercised during pre-conformal coat PDU assembly
• Configuration Management– Via standard LATDOC system
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 26
Planned TestsPlanned Tests
• Function/Performance Tests (LAT-TD-01744)– Verifies all requirements in LAT-SS-06988 except below
• Thermal Vacuum Tests– Verifies performance/function over temperature
• Mass/C.G.– Verifies/measures mass and C.G.
• Vibrations test– Verifies vibration performance requirements
• EMI/EMC– Verifies EMI/EMC performance
• Note to margin testing– External Voltage margin testing is performed at all stages (28V +/-1V)– Internal Voltage margin testing (3.3V/2.5V) is only performed at pre-
conformal coat stage while using internal EGSE harness– No internal voltage margin testing once flight harness is used. Respective
tests in TD-01744 are omitted at that stage as will be documented in work-order
– Frequency margin tested pre-conformal coat as well as on final PDU– Temperature testing performed during TV testing
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 27
Equipment CalibrationEquipment Calibration
• Electrical Functional Test Equipment– EGSE Test-Stand documented at
• http://www-glast.slac.stanford.edu/Elec_DAQ/EGSE/I&TPDU/TESTSTAND_1164/teststand1164docs.htm
• EMI/EMC Test Equipment– Quantitative measurement equipment (sensors, antennas, etc)
calibrated to NIST standards– Calibration performed annually
• All item are (will be) within calibration at time of testing• Vibration Test Equipment
– Accelerometers calibrated against a standard accelerometer traceable to NIST
– Signal conditioners calibrated annually• TVAC Equipment
– Thermocouples calibrated against standard temperature; calibrated prior to test
– Thermocouple reader calibrated very 2 years
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 28
Sub-System SafetySub-System Safety
• EGSE– Safe-to-mate– Configuration control– Calibration verification– Functionality verification with “golden” EGSE PDU prior to
test with flight hardware• MGSE
– No custom MGSE• Environment
– Temperature controlled in all test-facilities– Cleanliness actively controlled in clean-room; hardware
bagged and purged when required• Training
– ESD training completed– Clean room training completed
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 29
Risk AssessmentRisk Assessment
• Schedule– Pressure to deliver flight hardware could force less than
complete characterization and analysis of modules, could result in replicating a problem in the second module
• Performance– None known
• Software to support TV test is still in development
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 30
Test-ScheduleTest-Schedule
• Estimated as follows, order subject to EMI/TV availability• First PDU
– 7/25: functional test – 7/28: vibration test– 7/29: functional test – 8/1: TC – 8/2: functional test– 8/3: EMI start– 8/17: EMI end– 8/18: mass, c.g. property – 8/9: TV start – 8/29: TV end
• 2nd PDU– Lags first PDU by about 8 weeks
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4.1.7 DAQ & FSW V4 31
Status of Main Test ProceduresStatus of Main Test Procedures
• All procedures must be released before respective test• Procedures to be released
– Mass/CG procedure to be written/released– EMI vendor procedure to be released– CPT and TV modified, revisions are in review– Vibration procedure released?
GLAST LAT Project PDU TRR, July, 2005
4.1.7 DAQ & FSW V4 32
Issue & ConcernsIssue & Concerns
• Schedule– Tight
• Vibration test– Concern that harness/connectors pass vibration tests
• (should be ok, but is concern)