glast lat projectgasu trr, july, 2005 4.1.7 daq & fswv1 1 glast large area telescope: presented...
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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
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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
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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)
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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)
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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
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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
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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
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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
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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
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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)
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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Issue & ConcernsIssue & Concerns
• Schedule– Tight
• Vibration test– Concern that harness/connectors pass vibration tests
• (should be ok, but is concern)