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GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 1
GLAST Large Area Telescope:GLAST Large Area Telescope:
Presented by G. HallerSLAC
[email protected](650) 926-4257
Gamma-ray Large Gamma-ray Large Area Space Area Space TelescopeTelescope
GASU TRRGASU TRR
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 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 GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 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*
(GASU)
TKR
CAL
TKR Front-End Electronics (MCM)ACD Front-End Electronics (FREE)
CAL Front-End Electronics (AFEE)
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 4
EGSE GASU Mounted on LAT EGSE GASU Mounted on LAT
GASU
PDU
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 5
Flight GASUFlight GASU
Primary and Redundant GASU DAQ Module in same enclosure, separated by metal
To follow
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 6
Boards in Flight GASUBoards in Flight GASU
• Enclosure contains primary and redundant GASU Power-Supply Boards and DAQ Boards
GASU PS Board
GASU DAQ Board
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 7
• One enclosure houses primary and redundant GASU Power-Supply and GASU DAQ Circuit Card Assemblies
– Separated by aluminum wall
• GASU Power Supply
– Receives 28-V supply voltages for
• Primary and redundant DAQ board, – Generates 3.3V and 2.5v
• ACD FREE cards– Filtering for 28-V– 3.3V regulation
• GASU DAQ Board
– Contains 9 FPGA’s
– Includes Command Response Unit, fan-out and fan-in of commanding to 16 TEMs, PDU, EPU’s, ACD
– Includes Global Trigger Logic
– Includes LAT Event-Builder Logic
– Includes command/control/read-back for ACD sub-system
– Includes power-control for ACD FREE Boards
GASU ModuleGASU Module
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 8
Changes since LAT CDRChanges since LAT CDR
• Code in 9 FPGA’s were modified/finalized and bugs fixed• ACD power-on low-frequency system clock selection added• ACD power circuits replaced with circuit to protect for over-
current and updated ICD interface voltage/current requirements
• Some resistor/capacitor values have changed to optimize monitoring ranges
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 9
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 GASU 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 GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 10
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 GASU functional successfully passed
• Exit– As-run procedures completed– Correct and accurate application of test environment– Test data acquired and archived– No damage to GASU– GASU performance within specification limits– Post-test GASU functional successful
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 11
StatusStatus
• First GASU (to be proto-flight tested)
– Assembled
– Pre-conformal coat GASU with enclosure-internal EGSE harness tested, tests to verify that ACTEL performs over temperature performed (was prerequisite to programming FPGA’s for second GASU box)
– Conformal coated, integrated in enclosure with flight harness
– Final GASUto be delivered to SLAC week of Oct 3, 2005
• Second GASU (to be flight acceptance tested)
– Will be spare or primary flight GASU, 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 GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 12
Tests To-DateTests To-Date
• GASU engineering modules were extensively tested– As EGSE in DAQ/I&T
• Testbed includes GASU for > 1 year• I&T uses EGSE GASU during integration of towers in
LAT for several months• Main difference to flight GASU: ACD power-switch
circuit and monitoring was modified– Two flight boards of each type were assembled with mostly
flight parts and tested in one enclosure– Additional GASU tests
• Informal thermal test -40C to 55C• Informal EMI test on EGSE station sent to Lockheed for
thermal test
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 13
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-07287 Specifications, Level 5 GASU Specification ( to be released)
• LAT-TD-00606 LAT Inter-Module Communications• LAT-TD-0xxxx GASU ICD Specification & Conceptual Design (needs to be
updated)• LAT-TD-00639 AEM, Programming ICD• LAT-TD-01545 GEM, Programming ICD • LAT-TD-01546 EBM, Programming ICD • LAT-TD-01547 CRU, Programming ICD
• LAT-SS-00778 LAT Environmental Specification
• LAT-SS-07287 GASU lists requirements• LAT-TD-04381 contains Verification Matrix which gives approach to verify each
requirement– Lists verification method used
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 14
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 GASU 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 GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 15
Verification StatusVerification Status
• Engineering Module GASU– EM completed full functional test program with exception of
thermal-vacuum, EMI/EMC, mass, and C.G.– Demonstrated compliance with specifications
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 16
EGSE and Test-ProceduresEGSE and Test-Procedures
• EGSE for Functional/Performance Tests– Test-Stand documented in LAT-DS-01717
• Test-Procedures– LAT-TD-04260 Electrical Interface Continuity and Isolation
Test procedure and LAT-TD-06610 Automated Electrical Interface Continuity and Isolation Test procedure
• Power-off impedance tests of I/O– LAT-TD-04382 Stray-Voltage-Test Procedure
• Power-on voltage test of I/O– LAT-TD-01717 Comprehensive Test Procedure
• Functionality and Performance test • (not signed of as of Sept 30, 05)
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 17
Test-ConfigurationTest-Configuration
VME Crate
Slot 0SBC MVME 2304 Card
LCB Mezzanine CardLAT-TD-00860
GASU(Unit Under Test)
JL-45SIU 72104
J5
JP1
P1
P2
JL-40JL-41
DC Power Supply #1 BK 1697Set to 28 V
(-)
(+)
FREEJL-156-179
JS1
JP2
JS2
FREE Board
FREE Board
FREE Boards (Multiple)
Even-numbered GASU connectors to any JP.
Odd-numbered GASU connectors to any JS.
2092
Connector Savers
Connector Saver
3611P3
• LAT-TD-01717 shows several test-configurations, below the AEM functionality test configuration is shown
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 18
Verification Level – Module DetailVerification Level – Module Detail
• Breakout of verification at GASU 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 GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 19
VerificationVerification
• Test-Stand– Supplied by SLAC– Operated by SLAC engineers
• Vibration facility at Wyle– LAT-TD-03634 Vibration test-procedure – SLAC engineers present for vibration tests
• Thermal Cycle in thermal chamber in SLAC clean-room
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 20
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 GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 21
Mass PropertyMass Property
• Mass properties checked at SLAC – Procedure LAT-TD-07037-01 (performed at SLAC
Metrology)– Expected: (ref LAT-TD-00564)
• Total 13.9 kg• Allocation 12% above = 16.7 kg
– C.G. to be measured for the proto-flight unit only
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 22
Thermal Vacuum TestThermal Vacuum Test
• Thermal Vacuum facility in Building 33 at SLAC– Thermal Vacuum Chamber Operating Procedure LAT-TD-
02541 – GASU Thermal Vacuum Test-Procedure LAT-TD-03635 (not
released as of 9-30-05)– First GASU tested to proto-flight specifications (same
Temperatures as qualification, but 4 TV cycles versus 12 cycles)
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 23
Proto-Flight and Flight Acceptance Thermal Proto-Flight and Flight Acceptance Thermal Vacuum TestVacuum Test
• See GASU Thermal Vacuum Test-Procedure LAT-TD-03635
+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 GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 24
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 (to be provided)
– 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-03633
• Only CE102, CS102
– SLAC supplies test-report
– LAT QA at SLAC present for tests
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 25
Manpower & Quality AssuranceManpower & Quality Assurance
• Test man-power – GASU: L. Sapozhnikov/ J. Thayer– 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 GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 26
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 GASU assembly
• Configuration Management– Via standard LATDOC system
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 27
Planned TestsPlanned Tests
• Function/Performance Tests (LAT-TD-01717)– Verifies all requirements in LAT-SS-07287 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-01717 are omitted at that stage as will be documented in work-order
– Frequency margin tested pre-conformal coat as well as on final GASU– Temperature testing performed during TV testing
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 28
Equipment CalibrationEquipment Calibration
• 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 GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 29
Sub-System SafetySub-System Safety
• EGSE– Safe-to-mate– Configuration control– Calibration verification– Functionality verification with “golden” EGSE GASU 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 GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 30
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
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 31
Test-ScheduleTest-Schedule
• Estimated as follows, order subject to EMI/TV availability• First GASU
– 10/5: functional test – 10/13: TC– 10/14: functional test – 10/17: vibration test – 10/18: functional test– 10/24: TV start– 10/31: TV end– 11/1: mass, c.g. property – 11/2: EMI start – 11/16: EMI end
• 2nd GASU– Lags first GASU by about 8 weeks
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 32
Status of Main Test ProceduresStatus of Main Test Procedures
• All procedures must be released before respective test• Procedures to be released
– EMI vendor procedure to be released– CPT and TV modified, revisions are in review
GLAST LAT Project GASU TRR, July, 2005
4.1.7 DAQ & FSW V1 33
Issue & ConcernsIssue & Concerns
• Schedule– Tight
• Vibration test– Concern that harness/connectors pass vibration tests
• (should be ok, but is concern)