LPF Project Template - European Space Agencyemits.sso.esa.int/emits-doc/ASTRIUMLIM/LISA_RF_SCOE/S2.ASU.TN.5065.pdf · LPF Document 1 4.1.1 LTP RTB EGSE Cables The LTP RTB EGSE cables

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EadsAstrium

LISA Pathfinder

S2.ASU.TN.5.065Issue 2

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EADS Astrium Limited owns the copyright of this document which is supplied in confidence and which shall not be used for any purpose other than that for which it is supplied and shall not in whole or in part be reproduced, copied, or communicated to any person without written permission from the owner.

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CONTENTS

1. SCOPE ..........................................................................................................................................................5

2. REFERENCE DOCUMENTS ........................................................................................................................5

3. SOFTWARE VALIDATION FACILITY (SVF) EGSE CONFIGURATION......................................................5 3.1 SVF EGSE Cables .................................................................................................................................6 3.2 SVF Test Harness ..................................................................................................................................6

4. REAL TIME TEST BED (RTB) EGSE CONFIGURATIONS .........................................................................6 4.1 LTP RTB.................................................................................................................................................6

4.1.1 LTP RTB EGSE Cables ...............................................................................................................8 4.1.2 LTP RTB Test Harness ................................................................................................................8

4.2 EM RTB (Phase 1) .................................................................................................................................8 4.2.1 EM RTB (Phase 1) EGSE Cables..............................................................................................10 4.2.2 EM RTB (Phase 1) Test Harness...............................................................................................11 4.2.3 Power Front End Equipment ......................................................................................................11 4.2.4 Test Interface Bracket ................................................................................................................12

4.3 E2E RTB...............................................................................................................................................12 4.3.1 E2E RTB EGSE Cables .............................................................................................................14 4.3.2 E2E RTB Test Harness..............................................................................................................14 4.3.3 EGSE configuration....................................................................................................................14

5. SPACECRAFT EGSE CONFIGURATIONS................................................................................................15 5.1 System Integration and Test EGSE Configurations .............................................................................15

5.1.1 Composite Spacecraft System Integration and Test Configuration ...........................................15 5.1.2 EMC EGSE Configuration..........................................................................................................18 5.1.3 Science Module System Integration and Test Configuration.....................................................20

5.2 Thermal Vacuum EGSE Configuration.................................................................................................22 5.2.1 Thermal Vacuum EGSE Cables.................................................................................................24

5.3 Environmental EGSE Configurations ...................................................................................................24 5.3.1 Vibration Test EGSE Configuration............................................................................................24 5.3.2 Magnetic Test EGSE Configuration ...........................................................................................26 5.3.3 Acoustic Test EGSE Configuration ............................................................................................28

5.4 Launch Site EGSE Configurations .......................................................................................................30 5.4.1 Launch Preparation and Test EGSE Configurations .................................................................30 5.4.2 Launch Pad EGSE Configuration...............................................................................................31

6. CABLE AND HARNESS DESIGN AND MANUFACTURE RESPONSIBILITIES .......................................34

TABLES Table 6-1 Cable / Harness Design and Manufacture Responsibilites.............................................................34

FIGURES Figure 3.1-1 Software Verification Facility (SVF) ..............................................................................................5 Figure 4.1-1 LTP RTB .......................................................................................................................................7 Figure 4.2-1 EM RTB (Phase 1) ........................................................................................................................9 Figure 4.2-2 Test Interface Bracket .................................................................................................................12

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Figure 4.3-1 E2E RTB .....................................................................................................................................13 Figure 5.1-1 Composite Spacecraft System Integration and Test EGSE Configuration.................................16 Figure 5.1-2 EMC EGSE Configuration...........................................................................................................19 Figure 5.1-3 Science Module System Integration and Test EGSE Configuration...........................................21 Figure 5.2-1 Thermal Vacuum EGSE Configuration .......................................................................................23 Figure 5.3-1 Vibration EGSE Configuration ....................................................................................................25 Figure 5.3-2 Magnetic Test EGSE Configuration (Probable) ..........................................................................27 Figure 5.3-3 Acoustic Test EGSE Configuration .............................................................................................29 Figure 5.4-1 Launch Pad EGSE Configuration ...............................................................................................32

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1. SCOPE

This document details the EGSE configurations required to perform both the MDVE test bench and spacecraft system level AIT activities for the LISA-Pathfinder test campaign. It also shows the top level cables and test harnesses that will be required to realise the interfaces between the EGSE and the test bench or Spacecraft.

2. REFERENCE DOCUMENTS

The following documents were used as reference documents for this publication [RD-01] LISA Pathfinder AIT Plan S2.ASU.PL.2011 [RD-02] LISA Pathfinder Test Bench Plan S2.ASU.PL.2021

3. SOFTWARE VALIDATION FACILITY (SVF) EGSE CONFIGURATION

The purpose of the SVF testing, both closed and open loop, is to functionally validate the avionics software, validate the Operations Procedures and TM/TC database, and support the development of the Real Time Test Bed (RTB) closed loop tests. Three SVF’s will be used on the Lisa Pathfinder project. SVF 2 will be utilised at Astrium Ltd (ASU) and will be used to validate the data handling, composite AOCS (non-DFACS) and MPACS AOCS functionality. SVF 1 will be used to validate the DFACS functionality at Astrium GmbH (ASD). A third SVF, SVF 3, will be utilised by the Flight Software supplier to allow validation of the OB software before release and to carry out the Independent Software Verification and Validation (ISVV) activities. An overview of the EGSE configuration required for the Software Validation Facility (SVF) is shown in Figure 3.1-1

Figure 3.1-1 Software Verification Facility (SVF)

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3.1 SVF EGSE Cables

All cables associated with the SVF are ‘commercial off the shelf’ (COTS) cables.

3.2 SVF Test Harness

No test harnesses are required for the SVF

4. REAL TIME TEST BED (RTB) EGSE CONFIGURATIONS

Two RTB systems will be employed on the Lisa PathFinder project, the Lisa Test Package (LTP) RTB and the End-to-End (E2E) RTB. The initial configuration of the E2E RTB will be known as the EM RTB (Phase 1).

4.1 LTP RTB

The LTP RTB, shown in Figure 4.1-1, will be utilised at Astrium GmbH (ASD). It will consist of a Development Model (DM) On Board Computer (OBC) together with an Electrical Model (ELM) LTP and a DRS Simulator. The LTP RTB will be used for, but not restricted to, the following:-

• Functional validation of the DFACS software in real time. • Development and validation of DFACS Operations Procedures (OP’s) and Automatic Test

Procedures (ATP’s) for both open and closed loop tests. • The primary validation of the DFACS analysis software and the TM/TC database.

Further details can be found in [RD-02].

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Company Registration No. 2449259 Registered Office: Gunnels Wood Road, Stevenage, Hertfordshire, SG1 2AS, UK

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Figure 4.1-1 LTP RTB

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4.1.1 LTP RTB EGSE Cables

The LTP RTB EGSE cables are shown in Figure 4.1-1 as items (2), (8) and (18). These cables will provide all the signal and power interfaces between the various SCOE’s / FEE’s and the test bench equipments. The cables will be 15m in length to enable connection between the EGSE and the test bench. As there are no flight equipments used on the LTP RTB, both the EGSE and the RTB may be situated together in either an EGSE control room or lab / office environment. Cable items (18) will be defined and procured by Astrium or preferably delivered as part of the SCOE / GMFE equipment. The cables shown as item (2) will be supplied by ASD (LTP), along with the OMU and ISTM SCOE’s. All other EGSE cables associated with the RTB (e.g. VME and LAN) are COTS items.

4.1.2 LTP RTB Test Harness

The LTP RTB Test Harness is shown in Figure 4.1-1 as items (3) and (4). Test harness (3) constitutes the interfaces between the various LTP ELM equipments and as such will be delivered as part of this system by the LTP sub-contractor. The LTP ELM data interface to the OBC DM will utilise a 1553 MilBus, shown in Fig 4.1-1 as item (4). The RTB test harness will consist of two 1553 MilBus highways, with suitable terminators at each end. The LTP ELM and OBC DM will connect to both buses with long stubs, requiring the necessary coupling transformers to be part of the 1553 Bus harness. The recommended maximum length of a long stub, as given by the MilBus1553 specification, is 6m (20 feet). In order for the Simulator FEE to interface to the 1553 bus it will be necessary to extend the test bench MilBus highways to the Simulator FEE, where suitable bus terminators will reside. The Simulator FEE 1553 bus interface can then be made using a short stub connection.

4.2 EM RTB (Phase 1)

The EM RTB (Phase 1), shown in Figure 4.2-1, will be configured at Astrium Ltd (ASU) and will utilise only the EM OBC (EM), with all other avionics hardware being simulated. The EM RTB (Phase 1) will be used for, but not restricted to, the following:-

• Functional validation of the OBC functions including the hardware and software interfaces. • Functional validation of the OBC software in real time. • Development and validation of the OP’s and ATP’s for the open and closed loop testing of the

Composite Attitude Control Subsystem (CACS) and Micro-propulsion Attitude Control System (MPACS)

On completion of the EM (phase 1) testing, additional EM units will be progressively added to the RTB, together with the associated EGSE and cables / harness. There will be several iterations of the RTB build, progressing from the EM RTB (phase 1), shown in Figure 4.2-1, through the EM RTB (phase 2) (all EM units) and culminating in the E2E RTB shown in Figure 4.3-1 (all FM units). The progression of the RTB from phase 1 to phase 2 will be largely governed by the individual spacecraft EM equipment deliveries. Further details can be found in [RD-02].

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Figure 4.2-1 EM RTB (Phase 1)

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4.2.1 EM RTB (Phase 1) EGSE Cables

The EM RTB (Phase 1) EGSE cables are shown in Figure 4.2-1 as items (5), (7), (8) and (19). These cables will provide all the signal and power interfaces between the various SCOE’s / FEE’s and the test bench equipments. The cables can be logically separated into two groups, the ‘general EGSE cables’ and the ‘RTB specific EGSE cables’.

4.2.1.1 General EGSE Cables

Cable items (5) and (7) depict the ‘general EGSE cables’. These will be used throughout the project AIT activities and will be utilised at all test levels, from the EM RTB (Phase 1) through the E2E RTB and finally the spacecraft level test activities. The ‘General EGSE cables’ can also be divided into two further groups the ‘SCOE cables’, shown as item (7) in Figure 4.2-1 and the ‘EGSE Interface cables’, shown as item (5) in Figure 4.2-1. The majority of the ‘General EGSE Cables’ will be fitted with Amphenol 162GB (or 62GB solder type) round military style connectors. These will be fitted at both the SCOE interface and the Test I/F Bracket. (item (9)) These connectors are far more robust than the D-type connectors often used for EGSE cables, and are much more capable of surviving a full spacecraft test campaign.

4.2.1.1.1 SCOE Cables

The ‘SCOE cables’ (item (7) in Figure 4.2-1) are used to interface between the SCOE racks and the Test I/F bracket (item (9)). They should be seen as an integral part of the SCOE, and as such, should be delivered by the SCOE sub-contractor. The SCOE cables should interface with a SCOE at a panel situated at the rear of the SCOE rack. The number of cables should be kept to a minimum in order to reduce the effort required, at spacecraft test level, when moving and reconfiguring the EGSE for the various test phases. Fewer cables also reduces the possibility of configuration errors. The ‘SCOE cables’ will be 15 metres in length.

4.2.1.1.2 EGSE Interface cables

These cables (item (5) in Figure 4.2-1) are fitted between the Test I/F Bracket (item (9)) and the spacecraft skin connectors. The length of the ‘EGSE Interface cables’ will be dictated by the position of the skin connectors on the spacecraft structure (not their position on the test bench), but in most instances should be less than 2 metres long.

4.2.1.2 RTB Specific EGSE Cables

The cables shown as item (19) in Figure 4.2-1 are the ‘RTB specific EGSE cables’. These will be used primarily during the EM RTB (Phase 1) test campaign. They will also be utilised, to a varying degree, during the transitional builds of the EM RTB (Phase 2). These cables will only be utilised for the test bench activities and as such will not be subjected to the rigours of a full spacecraft test campaign. It is therefore acceptable to fit these cables with less robust connectors, such as a D-types (as shown in Figure 4.2-1 from the Power Front end to the PCDU interface). In some instances it will be necessary to fit Amphenol 162GB series connectors to an ‘RTB specific EGSE cable’ in order for it to interface to an ‘EGSE Interface cable’ (as shown in Figure 4.2-1 for the TM/TC and Separation link interfaces).

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4.2.2 EM RTB (Phase 1) Test Harness

The EM RTB (Phase 1) Test Harness is shown in Figure 4.2-1 as items (1) and (4). The test harness will be a 2 dimensional (2D) version of the spacecraft flight harness. The 2D harness will be mated to the EM OBC with all other equipment signals, to the OBC, simulated by the GMFE. The simulated signals will be connected to the OBC via the ‘RTB specific EGSE cables’ (item (19)), which will connect to the unit end of the 2D harness, not directly to the OBC connectors, as shown in Figure 4.2-1. As the RTB build progresses, the simulated unit interfaces will be replaced by actual equipment hardware (HITL). There are several advantages to using a 2D version of the flight harness at the early RTB stage:

• Simplified progression from simulation to HITL due to the availability of all unit interfaces. This approach entails connecting the unit simulation data to the OBC via the connectors at a unit interface rather than directly to the OBC connectors. The harness is therefore verified using simulated data thus reducing the risk of damage to HITL when introduced.

• Fewer EGSE cables are required, as it is possible to manufacture cables which can be used at all

test levels from RTB to spacecraft system level. This reduces the necessity of having new EGSE cables at every test phase. The availability of the system level ‘skin connectors’, in the 2D harness, makes this possible.

• As the 2D harness is manufactured to the same design data used for the flight harness; harness

design errors can be highlighted during the RTB test campaigns (initially with the simulated interfaces) and corrected on the flight harness before system level testing.

• Harness design effort is reduced as the 2D harness design is the same as the flight harness. This

considerably reduces the effort needed to design specific harnesses for each stage of the RTB builds.

• Continued use of many of the EGSE cables verifies that the EGSE cable design is correct when

progressing through to system level testing.

4.2.2.1 1553 MilBus Interface

As with the LTP RTB (Figure 4.1-1) the 1553 MilBus highways must be extended for connection to the Simulator FEE. In order to achieve this the 2D (and flight) harness 1553 bus terminators must be removable (fitted with connectors) at one end of the Buses.

4.2.3 Power Front End Equipment

It should be noted that Figure 4.2-1 shows the power interface required for the EM RTB (phase 1) only i.e. power to the EM OBC. Additional interfaces will need to be provided, within the PFE, as equipments are integrated to the RTB and progression to the EM RTB (phase 2) takes place. The number of PFE interfaces required (LCL’s / FCL’s) will depend largely on the availability of the PCDU with respect to other spacecraft equipments. Once the PCDU is available the power configuration shown in Figure 4.3-1 can be utilised.

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4.2.4 Test Interface Bracket

An example of the test interface bracket (item (9) in Figure 4.2-1) is shown in Figure 4.2-2. This bracket is utilised mainly at spacecraft system level, where it is attached to the spacecraft handling trolley. The bracket acts as a ‘single point’ for the EGSE cable to spacecraft connections. This scheme allows the ‘EGSE Interface Cables’ to remain in place during most spacecraft movements and reconfigurations, which allows for a fast and reliable spacecraft to EGSE connect / disconnect system.

Figure 4.2-2 Test Interface Bracket

4.3 E2E RTB

Progression from the EM RTB (Phase 1) will commence when EM spacecraft hardware becomes available. On completion of the EM RTB (Phase 1) test campaign, the available EM hardware will be integrated to the RTB, from which point it will be known as the EM RTB (Phase 2). For final testing the EM units will be replaced by FM units, whereby the RTB will be known as the E2E RTB. The E2E RTB, in Figure 4.3-1, shows the final configuration, with all equipments and EGSE, although there is likely to be several intermediate build configurations of the RTB, dependent on equipment availabilities. The E2E RTB will be used for, but not restricted to, the following:-

• Functional validation of the OBC software functions and interfaces in real time. • Further development and validation of the AOCS OP’s and ATP’s for the open and close loop tests. • Validation of the analysis models, with hardware in the loop (which will initially be EM hardware and

will progressively incorporate Flight Model (FM) hardware when available). • Validation of the TM/TC database. • Interface checks with the Disturbance Reduction System (DRS). • DRS and LTP functional tests (if required). • PSS functional and (some) performance tests. • TT&C functional tests. • Data handling functional and (some) performance tests.

Further details can be found in [RD-02].

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Figure 4.3-1 E2E RTB

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4.3.1 E2E RTB EGSE Cables

The E2E RTB EGSE cables are shown in Figure 4.3-1 as items (2), (5), (6), (7), (8), (10) and (11). These cables will provide all the signal and power interfaces between the various SCOE’s / FEE’s and the test bench equipments. As for the LTP RTB (Para 4.1.1) the ELM LTP interface cables (shown as item (2) in Figure 4.3-1) will be supplied by the LTP sub-contractor. The cables shown as item (6) in Figure 4.3-1 will be supplied by the DRS sub-contractor, but will need to conform to interface details provided by Astrium (in the EID-A), to ensure that the DRS cable interfaces allow for all possible spacecraft system operations. A number of cables (items (5) and (7)), which were used on the EM RTB (Phase 1 & 2), will also be utilised for the E2E RTB. Additional cables (also items (5) and (7) in Figure 4.3-1) will be required to interface with the increased spacecraft hardware fitted to the E2E RTB. The additional cables will also be used at system level spacecraft testing, so can be designated ‘General EGSE cables’ as described in Para 4.2.1.1 The use of these cables during the E2E RTB test campaign will allow early verification of the cable design and build. The EGSE control interface cables, shown as item (8) in Figure 4.3-1, will be, wherever possible, COTS items, but it may be necessary to design and build specific cables in order to provide the necessary interfaces. All other EGSE cables associated with the RTB (e.g. VME and LAN) will be COTS items.

4.3.1.1 X-Band RF Interface

The X-Band sub-system RF interface is shown as items (10) and (11) in Figure 4.3-1. The X-Band SCOE RF cables will interface to the RTB via the interface bracket (item (9)). This will allow a transition from the heavy ruggedised 15 metre RF cable (item (10)) to smaller and lighter (non-ruggedised) RF cables (item (11)). This allows a more convenient interface to the X-Band sub-system RF cables and removes the necessity of interfacing and securing heavy ruggedised cables to the flight hardware.

4.3.2 E2E RTB Test Harness

The E2E RTB test harness is the same 2D harness as installed on the EM RTB (Phase 1 & 2). As all equipment interfaces are available in the 2D harness the only additional harness required is that for the ELM LTP (item (3) in Figure 4.3-1). As this is specific to the ELM LTP it will be provided by the LTP sub-contractor.

4.3.3 EGSE configuration

The EGSE and cable configuration for the E2E RTB is very similar to that which will be used at system level spacecraft testing.

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5. SPACECRAFT EGSE CONFIGURATIONS

There will be four nominal AIT EGSE configurations, although there could possibly be intermediate configurations, dependant on the required test activities, the following EGSE configurations will allow all foreseen AIT activities to be carried out as detailed in [RD-01]. The four EGSE configurations will be System integration and test, Thermal vacuum, Environmental test and Launch. The System integration and test configuration will be utilised for the AIT activities on the two spacecraft configurations, the Composite spacecraft and the Science module. It will also be utilised for the EMC test activities. The environmental test configuration will be used for the Magnetic, Vibration and Acoustic test activities.

5.1 System Integration and Test EGSE Configurations

The System Integration and Test configuration will be used for most AIT test activities, from initial integration through to system tests, such as IST’s and SPT’s. It can be viewed as being the nominal EGSE configuration that will be used to support test activities for both spacecraft configurations, the Composite spacecraft (propulsion module integrated) and the Science module.

5.1.1 Composite Spacecraft System Integration and Test Configuration

The System Integration and Test configuration to be used with the Composite spacecraft is shown in Figure 5.1-1.

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Figure 5.1-1 Composite Spacecraft System Integration and Test EGSE Configuration

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5.1.1.1 Composite Spacecraft EGSE Cables

The Composite Spacecraft EGSE cables are shown in Figure 5.1-1 as items (5), (6), (7), (8), (10), (11) and (12). These cables will provide all the signal and power interfaces between the various SCOE’s / FEE’s and the spacecraft. As for the E2E RTB (Para. 4.3.1 ) the cables shown as item (6) in Figure 5.1-1 will be supplied by the DRS sub-contractor. All cables (items (5), (6), (7), (8), (10) and (11)), previously used on the E2E RTB, will also be utilised in the Composite Spacecraft configuration.

5.1.1.2 X-Band RF Interface

The RF cable interface to the Composite Spacecraft is identical to that used for the E2E RTB. An additional interface via anechoic caps will be required at system level, in order to verify the end-to-end functionality of the X-Band sub-system. The RF interface cables, shown as item (11) in Figure 5.1-1 will also be used to interface to the anechoic caps.

5.1.1.3 Thermal Override Unit

The Thermal Override Unit is part of the Power / Pyro SCOE and is used to manually override the spacecraft heater thermostats to allow heaters and their associated circuits to be verified at ambient temperatures. It is also used during the Thermal Vacuum testing to override thermostats, if required, to assist in achieving a required satellite thermal environment suitable for testing.

5.1.1.4 NDIU

The TM/TC link between the satellite and ESOC will be realised by the use of an NDIU Lite and a LAN router / switch. The NDIU Lite will be located at ESOC with the LAN router / switch located at the test facility. The NDIU Lite will interface to the Satellite via an ISDN line, the LAN router / switch and finally the TM/TC FEE. The ESOC interface will be utilised for conducting SVT’s and ‘listening in’ to satellite test activities. Figure 5.1-1 shows the connection of the LAN router / switch, where the interface to the TM/TC FEE will be a TCP/IP LAN Interface, via a (COTS) LAN cable, shown as item (12) in Figure 5.1-1.

5.1.1.5 1553 MilBus Interface

As with the E2E RTB (Figure 4.3-1) the 1553 MilBus highways (item (4) in Figure 5.1-1) must be extended for connection to the Simulator FEE. In order to achieve this the flight harness 1553 bus terminators must be removable (fitted with connectors) at one end of the Buses.

5.1.1.6 Battery Simulator

The Battery Simulator is part of the Power / Pyro SCOE and as such will be controlled via the SCOE controller. The Battery Simulator will be situated in close proximity to the Satellite in order to keep the EGSE cable length to a minimum. These cables will be 3 metres in length. The Battery Simulator EGSE cables will interface directly to the flight battery harness. Where possible connector savers will be used for the interface between the flight harness connectors and the Battery Simulator EGSE cable connectors. Due to the type of connector used for the Battery power, it is probable that a connector saver will not be available. In this case, flight standard connectors will be fitted to the Battery Simulator EGSE cables, allowing direct connection to the flight harness. Suitable handling precautions will need to be observed when developing, testing and validating the Battery Simulator in order to maintain the integrity of these connectors.

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5.1.1.7 Battery Isolation Box (BIB)

The BIB will be a simple test aid, fixed as close to the satellite Battery Offline interface skin connector as possible. It will be fitted early in the AIT program, before the battery is installed on the satellite. If this is not practical, then the BIB will be fitted with the battery at a low state of charge. The BIB will allow the battery charge / discharge lines to be isolated from the EGSE, enabling hazard free EGSE cable connection and disconnection. The BIB will be removed from the satellite skin connector before the Environmental test campaign and depending on the AIT battery management and/or test requirements, may or may not need to be refitted to the satellite post environmental testing. It is recognised that the disconnection (and possible reconnection) of the BIB before (after) the environmental campaign will be performed with a charged battery. This will be treated as a hazardous operation and tightly controlled by procedure.

5.1.1.8 Test Interface Bracket

The test interface bracket, shown as item (9) in Figure 5.1-1 and detailed in Figure 4.2-2, is the same as that used on the E2E RTB. For Spacecraft system activities the bracket will be secured to the spacecraft handling trolley, ensuring that the ‘EGSE Interface Cables’ (items (5), (6) and (11)) can remain in place for many of the spacecraft movements and reconfigurations.

5.1.2 EMC EGSE Configuration

The EMC Configuration is shown in Figure 5.1-2 and is essentially the same as the configuration for the composite spacecraft shown in Figure 5.1-1.

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Figure 5.1-2 EMC EGSE Configuration

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5.1.2.1 EMC EGSE Cables

The EGSE cables, shown as items (5), (6), (7), (10), (11) and (12) in Figure 5.1-2, are those used in previous EGSE configurations. No specific EMC cables are required. All EGSE used for the EMC test activities will be located in an anechoic EGSE control room adjacent to the EMC chamber, therefore no EGSE will be present inside the EMC chamber during EMC testing. The ‘SCOE cables’ (items (6), (7) and (10)) will pass through the EMC chamber feed through holes which are available between the EMC EGSE control room and the EMC chamber. The cables will connect to the Test I/F bracket (item (9)), which will be fitted in close proximity to the spacecraft. The ‘EGSE Interface cables’ (items (5), (6) and (11) in Figure 5.1-2) are also those used in previous EGSE configurations.

5.1.3 Science Module System Integration and Test Configuration

The Science Module EGSE configuration is shown in Figure 5.1-3 and is the same as that used for the Composite Spacecraft configuration.

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Figure 5.1-3 Science Module System Integration and Test EGSE Configuration

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5.1.3.1 Science Module EGSE Cables

The EGSE cable configuration for the Science Module is the same as that for the Composite Spacecraft (Figure 5.1-1) with the exception of the Umbilical interface. The spacecraft connectors, which carry the umbilical functions, fitted between the Science Module and the Propulsion Module will be different to those fitted between the Propulsion Module and the Launch Vehicle Adaptor (LVA). Therefore different EGSE Umbilical interface cables (item (5) in Figure 5.1-3) will be used for this Spacecraft configuration to those used in the Composite Spacecraft configuration (Figure 5.1-1).

5.2 Thermal Vacuum EGSE Configuration

The thermal vacuum EGSE configuration, shown in Figure 5.2-1, will be used for all AIT test activities, on both the Composite spacecraft and Science module, while in the thermal vacuum test facility.

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Figure 5.2-1 Thermal Vacuum EGSE Configuration

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5.2.1 Thermal Vacuum EGSE Cables

The Thermal vacuum EGSE cables, shown in Figure 5.2-1 as items (6), (7), (8), (10), and (12), are the same as those used in previous spacecraft and test bench configurations. There are two additional ‘sets’ of EGSE cables required for the Thermal Vacuum AIT activities, the chamber adapter cables and the thermal vacuum interface cables.

5.2.1.1 Chamber Adapter Cables

The Chamber Adapter cables are shown as item (13) in Figure 5.2-1. These cables are used to interface the general EGSE cables to the hermetically sealed chamber connectors fitted into the chamber feed-through panels. The cables are essentially used as a ‘connection adapter’ between the special connectors of the vacuum chamber and the ‘SCOE cables’ and as such will be less than 0.5 metres in length.

5.2.1.2 X-band Interface

No adapter cables are required between the X-band RF SCOE cables (item (10) in Figure 5.2-1) and the Thermal Vacuum chamber feed-though panels. The provision of SMA or N-type RF hermetically sealed connectors on the panels will allow direct connection of the SCOE RF cables to the chamber interface.

5.2.1.3 Thermal Test Equipment (TTE)

The TTE is used to power and control substitution and guard heaters during the thermal vacuum tests. This equipment maybe available from the facility provider.

5.2.1.4 Thermal Vacuum Interface Cables

The Thermal Vacuum interface cables are shown as item (14) in Figure 5.2-1. These cables effectively replace the ‘EGSE interface cables’ (item (5) in previous setup’s) and interface between the Thermal vacuum chamber feed-through connectors and the spacecraft connectors. The cables must be manufactured from materials which are compatible with the environment present inside the thermal vacuum chamber. The length of the thermal vacuum interface cables will largely depend on the test facility chamber used and the location of the spacecraft within the chamber, but normally a length of between 10 and 15 metres is sufficient.

5.3 Environmental EGSE Configurations

The environmental EGSE configurations will be used to support the vibration, magnetic and acoustic test activities.

5.3.1 Vibration Test EGSE Configuration

The EGSE configuration shown in Figure 5.3-1 will be used to support the vibration test activities.

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Figure 5.3-1 Vibration EGSE Configuration

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5.3.1.1 Vibration Test EGSE Cables

The vibration test EGSE cables, shown as items (5), (7) and (12) in Figure 5.3-1, are those used in previous test configurations. No specific vibration test EGSE cables are required. During the vibration test activities the spacecraft is configured into launch mode, and as such, the only connection required is via the umbilical interface, no other cables will be connected. Possible spacecraft health checks, performed between axis re-configurations, will be performed using the spacecraft telemetry.

5.3.1.2 Core EGSE

It can be seen from the vibration EGSE configuration (Figure 5.3-1) that a reduced number of core EGSE terminals will be required to support the vibration test activities.

5.3.2 Magnetic Test EGSE Configuration

The EGSE configuration required for the Magnetic test is presently TBD, but is likely to be one of the following two options:- Option 1:- as shown in Figure 5.3-2 using a full suite of EGSE. It is essentially the same as that for the science module Integration and Test configuration (Figure 5.1-3). This, or a slight variation, is the most likely configuration. Option 2 (least likely):- using a reduced suite of EGSE, as for the Vibration test configuration shown in Figure 5.3-1.

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Figure 5.3-2 Magnetic Test EGSE Configuration (Probable)

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5.3.2.1 Magnetic Test EGSE Cables

The magnetic test ‘EGSE cables, shown as items (7), (10) and (12) in Figure 5.3-2, are those used in previous test configurations. All EGSE used for the magnetic test activities will be located in an EGSE control room adjacent to the magnetic test area, therefore no EGSE will be present within the magnetic field measurement area. The ‘SCOE cables’ (items (7) and (10) in Figure 5.3-2) will pass from the EGSE control room into the Magnetic test area. The cables will connect to the Test I/F bracket (item (9)), which will be situated as far from the magnetic field measurement area as possible.

5.3.2.2 Magnetic Test EGSE Interface Cables

The X-Band RF Interface cables (item (11) in Figure 5.3-2) are those used in previous test configurations. It maybe necessary to increase the length of these cables depending on the location of the Test I/F bracket. The Magnetic Interface cables, shown as item (20) in Figure 5.3-2, will replace the standard ‘EGSE Interface cables’ used in previous configurations. These cables will be 5m in length and designed and built to stringent magnetic requirements.

5.3.3 Acoustic Test EGSE Configuration

The EGSE configuration required for the Acoustic test activities is shown in Figure 5.3-3.

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Figure 5.3-3 Acoustic Test EGSE Configuration

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5.3.3.1 Acoustic Test EGSE Cables

The acoustic test EGSE cables, shown as items (7) and (12) in Figure 5.3-3, are those used in previous test configurations. In addition to these cables, a set of LVA adapter cables are required, shown as item (15) in Figure 5.3-3. The LVA adapter cables will interface between the LVA Umbilical connectors and the Test I/F bracket (item (9)) The ‘SCOE cables’ (items (7) in Figure 5.3-3) will pass through the acoustic chamber feed through holes, which are available between the EGSE control room and the chamber. The cables will connect to the Test I/F bracket (item (9)), which will be fitted in close proximity to the spacecraft. The acoustic test activities will be carried out on the composite spacecraft, configured into launch mode, and mounted on the LVA adapter, on loan from the launch authority. All EGSE used for the acoustic test activities will be located in an EGSE control room adjacent to the acoustic chamber, therefore no EGSE will be present inside the chamber during testing.

5.3.3.2 Core EGSE

It can be seen from the acoustic EGSE configuration (Figure 5.3-3) that a reduced number of core EGSE terminals will be required to support the acoustic test activities.

5.4 Launch Site EGSE Configurations

There will be three EGSE configurations required to support the launch site activities. Two of the configurations will be used to support the Launch Preparation and Test activities and one to support the Launch pad activities, with the spacecraft mounted on the launch vehicle.

5.4.1 Launch Preparation and Test EGSE Configurations

The two EGSE configurations required to support the pre-launch test and preparation activities will be the final test and launch preparation configuration and the spacecraft encapsulation configuration.

5.4.1.1 Final Test and Launch Preparation Configuration

This configuration will be used for the final test and launch preparation activities, which will be performed at the Launch preparation facility (at the launch site). The configuration will be the same as that used to support the composite spacecraft system integration and test activities shown in Figure 5.1-1.

5.4.1.2 Spacecraft Encapsulation EGSE Configuration

This configuration is used to carry out the integration of the spacecraft to the Launch Vehicle Adapter (LVA), prior to encapsulation. The integration activities will include the LVA electrical interface checks and spacecraft power up health tests. The EGSE configuration used to support the spacecraft encapsulation tests will be the same as that used for the acoustic test Figure 5.3-3, with the exception of the NDIU router / switch, which will not be connected during these test activities.

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5.4.2 Launch Pad EGSE Configuration

The Launch pad EGSE Configuration shown in Figure 5.4-1 will be used to power and monitor the spacecraft once it has been mounted on top of the launch vehicle. Battery charging activities will also be performed with this configuration.

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Figure 5.4-1 Launch Pad EGSE Configuration

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5.4.2.1 Launch Pad EGSE Cables

The launch pad EGSE cables are shown as items (7), (12) and (16) in Figure 5.4-1. Cable items (7) and (12) are the same as those used in previous configurations. The Launch Umbilical Adapter cables (item (16) in Figure 5.4-1) will be required to interface between the ‘SCOE cables’ (item (7)) and the Umbilical Interface cabinet.

5.4.2.1.1 Umbilical Interface Cabinet

The umbilical interface Cabinet is used to connect the ‘SCOE cables’ (item (7)) to the spacecraft umbilical interface via the launch tower umbilical cables (item (17)). The interface method used within the cabinet will be dependant on the launch service provider, but will normally be either ‘screw terminal strips’ (as shown in Figure 5.4-1) or discrete connectors. Whichever method is provided, the Launch Umbilical Adapter cables (item (16)) will be used to interface between the SCOE cables (item (7)) and the launch tower cables (item (17) and therefore need only be <0.5 metres in length. The launch tower umbilical cables are approximately 180 metres in length (launcher dependant)

5.4.2.2 EGSE Location

The core EGSE will be situated in the Launch Preparation Facility EGSE control room, while the spacecraft support EGSE, Power SCOE and TM/TC FEE, will be situated close to the launch vehicle (in the under table room). A LAN connection is required between the support EGSE and the core EGSE to allow spacecraft data exchange and SCOE control and monitor functions to take place. The Launch Preparation Facility and the under table room are several kilometres apart, so the launch provider must supply either a LAN connection in both locations or a fibre optic link, with suitable media conversion units.

5.4.2.3 NDIU Interface

The NDIU router / switch will be situated in the under table room, with a connection to an ISDN line. The voice link, available from ESOC, will be located in the Launch Preparation Facility, where the spacecraft control and monitoring personnel will be situated, with the core EGSE.

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6. CABLE AND HARNESS DESIGN AND MANUFACTURE RESPONSIBILITIES

Table 6-1 below, lists the parties responsible for the design and manufacture of the various cables and harnesses depicted throughout this document. Cable No.

Cable / Harness Name Party Responsible Design Manufacture

1 2D harness (flight representative) ASD (MDVE) ASD (MDVE) Sub-contractor 2 LTP ELM Interface Cables ASD (LTP) ASD (LTP) Sub-contractor 3 LTP ELM Unit Harness ASD (LTP) ASD (LTP) Sub-contractor 4 1553 MilBus Harness ASD (MDVE) ASD (MDVE) Sub-contractor 5 EGSE Interface cables ASU ASU ASU 6 DRS Interface cables JPL JPL JPL 7 SCOE cables ASD (MDVE) / ASU EGSE Supplier EGSE Supplier 8 EGSE Control Interface cables ASD (MDVE) ASD (MDVE) / COTS Sub-con / COTS 9 Interface Panel ASU ASU Sub-Contractor

10 RF SCOE cables EGSE supplier EGSE supplier COTS 11 RF Interface cables ASU ASU COTS 12 NDIU router / switch cables ESOC ESOC COTS 13 TV Chamber Adapter cables ASU ASU ASU 14 Thermal Vacuum Interface cables ASU ASU ASU 15 LVA Adapter cables ASU ASU ASU 16 Launch Umbilical Adapter cables ASU ASU ASU 17 Launch Tower Umbilical cables Launch Authority Launch Authority Launch Authority 18 LTP RTB EGSE cables ASD (MDVE) EGSE Supplier EGSE Supplier 19 EM RTB (Phase 1) EGSE cables ASD (MDVE) EGSE Supplier EGSE Supplier 20 Magnetic Interface cables ASU ASU ASU

Table 6-1 Cable / Harness Design and Manufacture Responsibilites

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INTENTIONALLY BLANK

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DOCUMENT CHANGE DETAILS

ISSUE CHANGE AUTHORITY CLASS RELEVANT INFORMATION/INSTRUCTIONS

B - - Initial Issue

1 - - Comments incorporated, diagrams updated to show latest known test bench and EGSE configurations.

1A - - Updated diagrams to reflect latest known EGSE configurations. Added description of the BIB in paragraph 5.1.1.7 .

1B - - Added Battery simulator. Removed all references to Cold gas and OBC DM1 & DM2.

2 S2CA134 - Updated AST and Gyro interfaces to reflect selected equipments. Formal document issue for EMITS release.

DISTRIBUTION LIST

INTERNAL

EXTERNAL

S. Amos E. Balaguer (ESA)

D. Head

H. Sondermann (ASD)

R. Gray

N. Ravilious

Configuration Management ESA Configuration Management

Documents

LPF Project Template - European Space Agencyemits.sso.esa.int/emits-doc/ASTRIUMLIM/LISA_RF_SCOE/S2.ASU.TN.5065.pdf · LPF Document 1 4.1.1 LTP RTB EGSE Cables The LTP RTB EGSE cables