Ref - ESAemits.sso.esa.int/emits-doc/ASTRIUMSAS/ATLID/AO... · The harnesses are the ATLID Harness located inside the instrument and which I/F with EarthCARE S/L between units (ACDM,

ATLID

Ref : EC.RS.ASF.ATL.00070 Issue : 02 Rev. : 00 Date : 07/12/11 Page : ii

FileName EC.RS.ASF.ATL.00070_02-00.doc © Astrium

SUMMARY

The harnesses are the ATLID Harness located inside the instrument and which I/F with EarthCARE S/L between units (ACDM, IDE, TLE, CAS & BSME) and connector brackets (BKT_A&B, SD_HEATERS_OPE_A&B, SD_HEATERS_SAFE & SD_CAS).

Three ATLID harnesses have to be manufactured :

• EM Model : similar to FM model (lengths, AWG, performances, …) but without the routing constraints

• FM Model

• Mechanical Dummy (MD) Model, being representative of FM model mechanical behaviour (mass, diameters and lengths)

The objective of this document is :

• to define all the specification to be taken into account during manufacturing : cable type, EMC covers, Overshielding, ……

Document controlled by : J. Galzin

ATLID

Ref : EC.RS.ASF.ATL.00070 Issue : 02 Rev. : 00 Date : 07/12/11 Page : iii


DOCUMENT CHANGE LOG

Issue/

Revision Date Modification Nb Modified pages Observations

01 20/07/11 All Initial issue

02 7/12/2011 Chapter 2.1 AD13 deleted and replaced by RD7

AD93 modified and AD 94 deleted

Chapter 3 Detailled definition of Harness 2 updated

Harness 4 status updated Chapter 6.1 Modification about

contractual status of Harnesses 3 and 4

All were AD13

exist AD13 replaced by RD7

Chapter 10,

Appendix A

ATL-9095 Ref to Caption deleted and changed by corresponding table

ATL-11352 idem ATL-11357 idem ATL-11400 idem ATL-11318 idem ATL-11546 idem ATL-11556 idem

ATLID

Ref : EC.RS.ASF.ATL.00070 Issue : 02 Rev. : 00 Date : 07/12/11 Page : iv


PAGE ISSUE RECORD Issue of this document comprises the following pages at the issue shown

Page Issue/ Rev.

Page Issue/ Rev.

Page Issue/ Rev.

Page Issue/ Rev.

Page Issue/ Rev.

Page Issue/ Rev.

All 01

All 02

ATLID

Ref : EC.RS.ASF.ATL.00070 Issue : 02 Rev. : 00 Date : 07/12/11 Page : v

TABLE OF CONTENTS

1 SCOPE ............................................................................................................................................. 8

2 DOCUMENTS ................................................................................................................................ 9

2.1 APPLICABLE DOCUMENTS ................................................................................................... 9 2.2 REFERENCE DOCUMENTS................................................................................................... 9

3 HARNESS BREAKDOWN.......................................................................................................... 11

4 HARNESSES DETAILED DESCRIPTION ............................................................................. 13

4.1 HARNESS N°1 .............................................................................................................................. 13 4.2 HARNESS N°2.............................................................................................................................. 13 4.3 HARNESS N°3.............................................................................................................................. 13 4.4 HARNESS N°4.............................................................................................................................. 13 4.5 THERMAL HARNESS N°5 ........................................................................................................... 13

5 ATLID HARNESSES ................................................................................................................... 15

5.1 CONNECTORS LIST .............................................................................................................. 15 5.2 DETAILED EICD .................................................................................................................... 15

6 REQUIREMENTS ....................................................................................................................... 16

6.1 “HARNESS” DEFINITION ....................................................................................................... 16 6.2 DESIGN AND CONSTRUCTION REQUIREMENTS ....................................................... 16 6.2.1 GENERAL REQUIREMENTS ........................................................................................................ 16 6.2.2 SPECIFIC REQUIREMENTS FOR HARNESS ................................................................................... 16 6.2.2.1 Mass........................................................................................................................................ 16 6.2.2.2 Routing ................................................................................................................................... 17 6.2.2.3 Bundle organisation................................................................................................................. 17 6.2.2.4 Bundle marking ....................................................................................................................... 17 6.2.2.5 Isolating resistance .................................................................................................................. 18 6.2.2.6 Wire shielding ......................................................................................................................... 18


ATLID

Ref : EC.RS.ASF.ATL.00070 Issue : 02 Rev. : 00 Date : 07/12/11 Page : vi

6.2.2.7 Miscellaneous .......................................................................................................................... 19 6.2.3 INTERCHANGEABILITY .............................................................................................................. 20 6.2.4 FACILITIES AND FACILITY EQUIPMENT ..................................................................................... 20 6.2.5 PREPARATION FOR DELIVERY ................................................................................................... 20 6.2.6 STORAGE, TRANSPORT AND HANDLING .................................................................................. 20 6.2.7 CLEANLINESS REQUIREMENTS .................................................................................................. 20 6.2.7.1 Facilities .................................................................................................................................. 20 6.2.7.2 Cleaning .................................................................................................................................. 21 6.3 PERFORMANCES REQUIREMENTS.................................................................................. 22 6.3.1 VOLTAGE CAPABILITY ............................................................................................................... 22 6.3.2 SPECIFIC CABLES........................................................................................................................ 22 6.3.3 EMC BACKSHELLS ..................................................................................................................... 22 6.3.4 OVERSHIELDING ....................................................................................................................... 22 6.3.5 SPECIFIC REQUIREMENT FOR BUNDLES ..................................................................................... 22 6.3.6 MATING DEMATING .................................................................................................................. 22 6.4 OPERATIONAL REQUIREMENTS ..................................................................................... 23 6.4.1 IN-ORBIT LIFETIME.................................................................................................................... 23 6.4.2 ON-GROUND LIFETIME ............................................................................................................. 23 6.5 INTERFACES AND PHYSICAL REQUIREMENTS........................................................... 23 6.5.1 ELECTRICAL INTERFACES.......................................................................................................... 23 6.5.2 PHYSICAL INTERFACES .............................................................................................................. 23

7 HARDWARE DELIVERY ........................................................................................................... 24

8 ENVIRONMENT ........................................................................................................................ 25

9 HARDWARE VERIFICATION REQUIREMENTS ............................................................... 26

9.1 GENERAL.................................................................................................................................. 26 9.2 EQUIPMENT INSPECTION AND TESTS .......................................................................... 26 9.2.1 GENERAL REQUIREMENT .......................................................................................................... 26 9.2.2 DETAILED REQUIREMENT ......................................................................................................... 27 9.2.2.1 Test conditions........................................................................................................................ 27 9.2.2.2 Visual examination .................................................................................................................. 27 9.2.2.3 Continuity, insulation resistance and power line resistance tests ............................................... 28 9.2.2.4 Hinge deployment ................................................................................................................... 28 9.3 PERFORMANCES VERIFICATION ..................................................................................... 29

10 APPENDIX A : GDIR ATLID HARNESS MATRIX.............................................................. 30


ATLID

Ref : EC.RS.ASF.ATL.00070 Issue : 02 Rev. : 00 Date : 07/12/11 Page : vii


11 APPENDIX B.............................................................................................................................. 69

ATLID

Ref : EC.RS.ASF.ATL.00070 Issue : 02 Rev. : 00 Date : 07/12/11 Page : 8

1 SCOPE

A) There are several types of harnesses for which the development approach is depicted in RD6 (Harness Definition). The current document identifies all the electrical links inside ATLID instrument. It represents the harnesses between units (ACDM, IDE, TLE, CAS & BSME) and connector brackets (BKT_A&B, SD_HEATERS_OPE_A&B, SD_HEATERS_SAFE & SD_CAS).

B) The current document presents the ATLID harness manufacturing specification in order to allow the subcontractor to manufacture the harness on the Electrical panel.

C) The document is organised into 2 main sections :

Section 5 : The section consists of the detailed definition of the links of ATLID harness.

This section presents refers to RD6 in which one can find :

- the interconnection diagram and the connectors list of the units

- the Electrical Interface data sheets identifying the electrical interconnections between the units connectors and the Connectors brackets.

Section 6 : This sections contains all the technical specification :

a) the specific design requirements which have to be taken into account during harness manufacturing and harness layout definition at system level.

b) the requirements for the performances in terms of insulation, voltage drop.


ATLID


2 DOCUMENTS

2.1 APPLICABLE DOCUMENTS

The following documents have been used as applicable documents (ADx) to define the parameters necessary for this Specification.

AD11 Product assurance Requirements for subcontractors EC.RS.ASD.SY.00002 Issue 4.0 AD12 None

AD91 ACDM EICD EC.IC.SEA.ATL.0004 Issue 1.0 AD92 IDE EICD EC.ICD.CRS.ATL.00001 Issue 1.0 AD93 TXA EICD, (included TLE EICD) EC.IF.GAL.AT.002 Issue 3.0 AD95 CAS EICD To be provided AD95 BSME EICD To be provided AD96 ATLID Harness Interface Requirement Document To be provided at KO AD97 CAD data exchange requirement specification for ASTRIUM satellites SAS - ENS project 2122.NT.CP.07.9822.ASTR Issue 01-00 Nota:

As a summary, Astrium will provide :

• Electrical ICD's and Harness definition for FM models

• Definition List Link including gauges, lengths and cable types

• Definition accommodation (layout 2D + critical area for Mock-up)

• Mechanical ICD's (volume allowed for routing, connector lay-out, .. )

• Data for test (to be provided at MRR)

2.2 REFERENCE DOCUMENTS

[RD1] None

[RD2] None

[RD3] None

[RD4] None

[RD5] None

[RD6] Harness EICD Draft EC.ICD.ASF.ATL.00017 Draft, to be revised at KO

[RD7] : ATLID Requirement specification : EC.RS.ASD.ATL.00001 Issue 5.0; (chapters 4 & 5 are superseded by Appendix A of this specification).


ATLID


As the detailed harness definition is not available for this ITT, this document is replaced for the ITT by the informations provided in appendix B of this Specification.


ATLID



3 HARNESS BREAKDOWN

An overview of the ALTLID Harness is depicted in Figure 3-1

The main features and development approach for each type of harness is provided hereafter :

The ATLID harness represents all the electrical links between the units present in ATLID part (ACDM Nom, ACDM Red, TLE Nom, TLE Red, IDE Nom, IDE Red, CAS, BSME Nom, BSME Red) and the Interfaces Connector Brackets (BKT_A&B, SD_HEATERS_OPE_A&B, SD_HEATERS_SAFE & SD_CAS).

The ATLID harness can be split in several types of harnesses :

The Harness N°1 : links between the Interface Brackets and the ACDM and the EarthCare Platform

The Harness N°2 : links between the ACDM to the IDE & TLE & BSME The Harness N°3 : links between the IDE and the CAS (identified as N°6 in current RD6).

This harness is not part of the present contract, as it will be provided and tested by the CAS subcontractor. Data provided for Harness N°3, in the following chapters are given for information only.

The Harness N°4 : links between the TLE, the PLH and the BSME (identified as N°8 in current RD6). This harness is not part of the present contract, as it will be provided and tested by the TXA subcontractor.

The Thermal Harness N°5

ATLID


Figure 3-1 : FM Harness breakdown


ATLID


4 HARNESSES DETAILED DESCRIPTION

The harness description is defined in [RD6].

4.1 HARNESS N°1

The following links between the Interfaces (via Brackets A & B), the ACDM and the EarthCare Plateform are :

BKT-B_ACDM-A

BKT-B_ACDM-B

BKT-A_SD_HEATERS_SAFE_Pwr

BKT-A_SURVIVAL_Pwr

4.2 HARNESS N°2

The following links between the ACDM and the IDE & TLE are :

ACDM-A_TLE-A

ACDM-A_TLE-B

ACDM-A_IDE-A

ACDM-A_IDE-B

ACDM-A_BSME-A

ACDM-A_BSME-B

ACDM-B_TLE-A

ACDM-B_TLE-B

ACDM-B_IDE-A

ACDM-B_IDE-B

ACDM-B_BSME-A

ACDM-B_BSME-B

4.3 HARNESS N°3

The following links between the IDE and the CAS (via SD-CAS) are :

IDE-A_SD_CAS

IDE-B_SD_CAS

SD_CAS_CAS

This harness is not part of the present contract, as it will be provided by the CAS subcontractor.

4.4 HARNESS N°4

The following links between the TLE, the PLH, the RLH and the BSME are :

TLE-A_RLH-A

TLE-A_PLH-A

PLH-A_BSME-A

TLE-B_RLH-B

TLE-B_PLH-B

PLH-B_BSME-B

Note: as detailed in section 6.1, this part of the ATLID harness is not part of the current specification

4.5 THERMAL HARNESS N°5


ATLID


ACDM-A_SD-HEATERS_OPE-A

BKT-A_SD_HEATERS-SAFE

ACDM-B_SD-HEATERS_OPE-B


ATLID


5 ATLID HARNESSES

5.1 CONNECTORS LIST

See Appendix B of this Specification

5.2 DETAILED EICD

To be provided at MRR at the latest


ATLID


6 REQUIREMENTS

6.1 “HARNESS” DEFINITION

The term "Harness" includes, for “harness N°1”, “harness N°2” and “harness N°5” as defined in section 4, (“harnesses N°3 and N°4 ” data are provided for information only and are not part of the present contract):

the wires, connectors, shield, EMC covers, cable clamps, tyraps for bundle realisation, crimper sleeves supports, connector fixations ( male for P connectors, female for J connectors ), Overshielding Harness models definition:

• FM harness: fully compliant with the current specification, • EM harness: identical to FM, except that the geometry of the harness can be relaxed versus FM

(but length, cable and connector type, and performances shall remain identical), • MD (Mechanical dummy) harness: representative of FM geometry, mass distribution, length,

bundle diameters and stiffness, but no need for any electrical function.

6.2 DESIGN AND CONSTRUCTION REQUIREMENTS

Verification Method acronyms:

- R: Review/Design

- I: Inspection

- T: Test

6.2.1 General Requirements

The design requirements applicable to the Harness are defined :

* in support specifications : RD7

* in AD11 (Product assurance Requirements for subcontractors)

6.2.2 Specific Requirements for harness

6.2.2.1 Mass

The estimated mass of the ATLID Harness, accounting for the uncertainty margin as defined in GDIR section 10 appendix A, req ATL-9461, shall be lower than:


ATLID


RS-id Requirement text Verif

Method

Upper

Links

HAR2-1 Harness N°1 : 2240 grs including uncertainty T

HAR2-2 Harness N°2 : 8984 grs including uncertainty T

HAR2-3 N/A

HAR2-4 N/A

HAR2-5 Harness N°5 : 12098grs including uncertainty T

6.2.2.2 Routing

See AD96

6.2.2.3 Bundle organisation

See AD96

6.2.2.4 Bundle marking

The identification marking of bundles and connectors to be done as follows :


Method

Upper

Links

HAR2-6 - Marking : the marking shall be done by transfer film nominally on thermo-shrinkable sleeve HT-SCE. For repair onto tags HTCM-SCE

R, I

HAR2-7 - The reading direction is defined by the following sketches :

- Basically every mark shall be legible on connector side, when reading from left to right.

R, I

Connector

021-P14

W1 A22

026-P10

W2 C10

Bundle


ATLID


6.2.2.5 Isolating resistance


Method

Upper

Links

HAR2-8 The isolation resistance is defined between leads which are not connected together. That is to say, between a wire and :

- any other wire ( not connected together )

- any screen ( not connected to the wire )

- any connector shell ( not connected to the wire )

This isolation resistance shall be larger than 100 MΩ under 500 Volts.

R, T

6.2.2.6 Wire shielding

Beside requirements of RD7, specific requirements are identified in this section :


Method

Upper

Links

HAR2-9 The ATLID harness wire shielding shall comply with the ATLID harness IRD [AD96] and “harness definition” [RD6].

R, I

HAR2-10 Termination of shields shall be design controlled to result in a minimum unshielded wire portion.

I

HAR2-11 Shields could be pigtailed serially for connection to a designed terminal ( rather than pin ground point ). Redundancy aspects shall be taken into account to prevent SPF

R


ATLID


HAR2-12 Grounding of shields :

On connectors having EMC backshells, grounding of shields have to be performed on EMC backshells.

On connectors without EMC backshell, grounding of shields have to be performed using a dedicated wire from cable shield termination up to metallic standard backshell (used to maintain cables) or halo-ring.

Whatever the design implementation, the grounding links shall be very short : typically grounding links of shields should not exceed 40 mm.

Shielding continuity through a connector pin connected to chassis is not allowed

R, I

HAR2-13 Grounding of overshields :

At connector level, grounding of overshields have to be performed on EMC backshells.

R, I

HAR2-14 Shields shall not be used intentionally as return path (except shield of coaxial cables)

R

HAR2-15 All external space exposed part of harness shall be overshielded. The overshield shall be ended at the level of spacecraft external skin

R, I

HAR2-16 The overall harness shield shall be grounded at both ends and also at intermediate points approximatively every 25 cms along its length

R, I

HAR2-17 The DC resistance between any shield and the connector shell shall be less than 10 mΩ

R, I, T

6.2.2.7 Miscellaneous


Method

Upper

Links

HAR2-18 Where Flying leads are used, provision for securing these cables (wrt the interface structure, between themselves or to the unit to which they are connected) is to be insured in order to avoid short circuit.

R, I

HAR2-19 The free length from the last bundle tie-base clamp to the connector shall be kept as a minimum but with a minimum loop.

R, I

HAR2-20 Connectors Pins and sockets shall be removable from connectors. No solder contacts are allowed

R, I


ATLID


HAR2-21 Male and Female connectors shall be mechanically locked together, to prevent inadvertent connection

R, I, T

HAR2-22 Cable clamps (or EMC cover or Halo ring or any other accessory that are linked to cables on a connector) shall be thightened sufficiently without damaging cables, in order to prevent wires from being pulled and twisted from their contacts.

R, I

HAR2-23 Unused contacts shall have inserts in all contact holes R, I

HAR2-24 Test connectors shall be fitted with EMC thight metal cover attached to fixation bolt.

R, I

6.2.3 Interchangeability

N/A

6.2.4 Facilities and facility equipment

N/A

6.2.5 Preparation for delivery

N/A

6.2.6 Storage, Transport And Handling

Environmental associated to storage, transport and handling is specified in RD7 and AD11

6.2.7 Cleanliness Requirements

The cleanliness requirements for the Harness are expressed in Product Assurance documents.

6.2.7.1 Facilities


Method

Upper

Links

HAR2-25 The production of the EM harness shall be done in a clean white room class 100000 as it will be connected to flight units prior to FM harness arrival.

I, T

HAR2-26 The production of the FM harness shall be done in clean white room class 100000.

I, T


ATLID


HAR2-27 The production of the MD harness shall be done in clean white room class TBD.

I, T

HAR2-28 Clean rooms must be capable of receiving a manufacturing gig with a diameter of 4.5m deployed and 2.5m height plus 1 m height for table support.

I, T

6.2.7.2 Cleaning


Method

Upper

Links

HAR2-29 The wires and cables shall be cleaned all along bundles manufacturing, then their extremities when completed, before final control inspection key point.

I, T


ATLID


6.3 PERFORMANCES REQUIREMENTS

The performances requirements as specified hereafter shall be considered at end of life under environmental conditions defined in RD7, and shall be met taking into account the interface / physical requirements, as listed in harness IRD (AD96).

6.3.1 Voltage capability

RS-id Requirement text Verif Method

Upper Links

HAR2-30 Each wire shall be capable of transmitting signals with voltages up to 500 V.

R, T

6.3.2 Specific cables


6.3.3 EMC backshells


6.3.4 Overshielding


6.3.5 Specific requirement for bundles


Upper Links

HAR2-31 Each bundle terminated with flying leads shall be provided with a 2m

harness length R, I

HAR2-32 Wires types

All the wires for the ATLID harness will be done with wire ESA/SCC/3901/002 type except for the 120ohms and 100 ohms link which will be done with wire AXON type P819622 and P832241

R, I

6.3.6 Mating demating


ATLID



Upper Links

HAR2-33 Number of connector matings and dematings shall be minimized and registered in the harness logbook

R, I

6.4 OPERATIONAL REQUIREMENTS

6.4.1 In-orbit lifetime


Upper Links

HAR2-34 The ATLID harness shall be designed so that its performances are ensured under the in-orbit environment to meet a minimum in-orbit lifetime defined in chapter 5 of RD7

R, T

6.4.2 On-ground lifetime


Upper Links

HAR2-35 The ATLID harness shall be designed to withstand a storage environment and transport requirements as expressed in chapter 5 of RD7.

R, T

6.5 INTERFACES AND PHYSICAL REQUIREMENTS

6.5.1 Electrical Interfaces


Upper Links

HAR2-36 The instrument harness electrical interfaces (connector types , pin assignment, signal characteristics...) shall comply with Section 4 and section 5 of this document.

R, T

6.5.2 Physical Interfaces


Upper Links

HAR2-37 The instrument harness mechanical interfaces shall comply with IRD (AD96).

R, T


ATLID


7 HARDWARE DELIVERY Refer to SOW for the definition of the deliveries.


ATLID


8 ENVIRONMENT


Upper Links

HAR2-38 The ATLID harness shall be designed to meet all its performances during and after exposure to environmental conditions defined in RD7.

R, T


ATLID


9 HARDWARE VERIFICATION REQUIREMENTS

9.1 GENERAL


Upper Links

HAR2-39 All items of the equipment shall be constructed, inspected and tested in accordance with :

AD11 ("PA requirements" specification) RD7 (GDIR) See Appendix A in Annex

R

HAR2-40 Traceability, documentation and configuration control, and the reporting and controlling of non conformances shall be in accordance with AD11 ( "PA requirements" specification )

R

HAR2-41 Achievement of the performance requirements shall be demonstrated by test and/or analysis and shall be detailed in the Verification Control Document (VCD).

R

9.2 EQUIPMENT INSPECTION AND TESTS

9.2.1 General requirement

This section specifies the inspection and test program to be performed to insure that the harness fulfills all the agreements of the Environment definition (see section 8) and Test sequence (see section 9.2).


Upper Links

HAR2-42 The subcontractor is responsible for performing all inspections and tests required in section 9.2

It does not relieve the subcontractor of performing additional inspection and tests as deemed necessary to demonstrate the fulfilment of all applicable requirements.

R, I, T

HAR2-43 Qualification and acceptance testing at harness and subsystem level shall be confined to functional test at room temperature. Qualification and acceptance testing for environmental conditions shall be performed on the integrated EarthCARE S/L

R, T

HAR2-44 If additionnal boxes are envisaged in the harness design and contain electrical parts (excluding connector and wires), these boxes shall be subjected to environmental tests as separate units.

R, T

HAR2-45 The test will be carried out on completion of manufacture and prior to removal of the harness from the wiring jig.

R, T


ATLID


HAR2-46 The testing will consist of continuity tests, insulation resistance test,power line resistance measurements and hinge deployment, but preceded by a visual examination

T

9.2.2 Detailed requirement

9.2.2.1 Test conditions


Upper Links

HAR2-47 Refer to RD7 R, T

9.2.2.2 Visual examination


Upper Links

HAR2-48 A visual examination of the harness will be carried out for evidence of the following defects :

- Incorrect termination of screens - Damage insulation, particulary nicks, burning, abrasion or cold flow - Broken stands of wire at joints to pins - Tension in any branch, or single wire in any branch - Excessive unsupported loops - pins not fully inserted - Bent pins

- .......

R, T

HAR2-49 Plugs and sockets will be fitted with protective caps at all times, except when connected or being visually examined.


ATLID


9.2.2.3 Continuity, insulation resistance and power line resistance tests


Upper Links

HAR2-50 These tests will be carried out using the dedicated test facility. R, T

HAR2-51 Connections between the harness and the device test will be via test cables and the test will be carried out in the following order :

(a) Continuity Criteria of success to be adjusted to 5 Ω (including Test set-up)

(b) Insulation resistance > 100 MΩ at 500 V

> 10 GΩ at 10 kV (for High Voltage lines when specified)

(c) Resistance measurements Performed individually to meet resistance requirements.

An accurate measurement will be performed on each type of line (power, analog signals, ...) with identification of the Test Cable resistance.

(d) Capacitance measurements None

9.2.2.4 Hinge deployment


Upper Links

HAR2-52 The hinge deployment capability (see design requirement and performance ) shall be demonstrated by test:

• On a dedicated mock-up prior S/C CDR

• On FM harness

T


ATLID



9.3 PERFORMANCES VERIFICATION


Upper Links

HAR2-53 The test sequence shall include at minimum the list of test defined in Tableau 9.3-1

R, T

TEST ITEM MODEL EM FM MD

Dimensional and visual inspection X X X

Weight measurement at +/- 50 g X X

Pin to pin verification (section 9.2.2.3)

Continuity check in order to verify all the specified links are correctly implemented in the H/W

X X

Measurement of wire resistance (section 9.2.2.3)

Resistance to verify all resistance drop

X X

Measurement of isolation (section 9.2.2.3)

Insulation check on each contact of each connector of the Harness in order to check that :

a) There is no other link than the one specified wrt other contact of any connector in the harness

b) There is no connection to ground ( all backshelss connected together )

X X

Hinge deployment capability demonstration (see section 9.2.2.4) X

Dismountability X X

Accessibility X X

Vaccuum / bake out X X

Tableau 9.3-1 : Test matrix

ATLID


10 A


PPENDIX A : GDIR ATLID HARNESS MATRIX

The following table provides the applicability of GDIR (RD7) to be considered for ATLID harness.

ID APP HR ATLID

ATL-26 4 Requirements

ATL-89 4.2 Functional, Operational and Performance Requirements

ATL-9082

4.2.4 Design Requirements

ATL-105

4.2.4.1 General Design Requirements

ATL-9085

Use of organic or non-metallic materials shall be minimised as far as possible in the design of the ATLID instrument and, in particular, in those areas containing critical (as defined in ECSS-P001B, ND-56) and contamination sensitive units. All organic materials in the vicinity of critical components shall be demonstrated by test to be compliant with the operational requirements of the instrument.

Y

ATL-9088

The outgassing properties of all materials in vicinity of optical surfaces and detectors shall be evaluated and demonstrated compliant with the Cleanliness and Contamination Control Plan required to meet the instrument performance requirements. Y

ATL-9089

Measures such as component bake-out or use of molecular absorber shall be considered in the design phase to reduce contamination sources for any identified critical element. Y

ATL-9093

The ATLID design shall allow for decontamination of the instrument in orbit by outgassing, and shall enable the temperature of critical elements to be such as to prevent condensation of outgassing contaminants from non- critical areas of the instrument and the rest of the satellite.

Y

ATL-9094

There shall be no direct view from any critical unit (with respect to the contamination) to the spacecraft. Y


ATLID


ATL-9095

The following minimum cleanliness levels shall be maintained for ATLID :

in vicinity of critical units Away from critical units

in laser beam vicinity

out of laser beam vicinity

other optical components

non optical components

Molecular cleanliness level 2x10-7gcm-2 5x10-7gcm-2 5x10-7gcm-2 5x10-7gcm-2

Particulate cleanliness level 100 mm2/m2 300 mm2/m2 300 mm2/m2 300mm2/m2

Y

ATL-113

4.3 Data Product Requirements

ATL-9141

4.3.1 ATLID Specific Data Product Requirements

ATL-9142

The generic and ATLID specific Data Product Requirements are specified in Requirements for the ESSS and ECGP [AD-2]. Y

ATL-115

4.4 AIV Requirements

ATL-116

4.4.1 General Requirements

ATL-12298

4.4.2 Functional Requirements

ATL-9292

5 General Design and Interface Requirements

ATL-9387

5.2 General Requirements

ATL-9388

5.2.1 General Design Requirements

ATLID



ATL-9389

This section contains requirements relating to: Outgasing Parts, materials and processes Handling, packing and transportation Identification and marking Workmanship Reliability, Availability, Maintainability, Safety (RAMS) Engineering standards Note, Product Assurance (PA) requirements are specified within [AD-1] which are applicable to Subcontractors through the Statement of Work (SOW). However, descriptive PA issues may be found within this document.

Y

ATL-9390

5.2.1.1 Lifetime

ATL-9391

The on-ground lifetime of flight hardware is defined as the duration between unit delivery and satellite launch. Y

ATL-9392

The unit shall meet the requirements of this specification after a minimum on-ground lifetime of 7 years including up to 2 years in storage. Y

ATL-9393

The in-orbit lifetime of the satellite is defined as the duration from launch until the end of the mission, including the time required for execution of LEOP and Commisioning. Y

ATL-9394

The instruments, sub-systems, units shall be designed with positive margins of safety to meet the requirements of this specification for a minimum in-orbit lifetime of 36,3 months. Y

ATL-12128

EarthCARE will be designed for a duration in-orbit of: LEOP: 5 days commissioning phase: 6 months, and operational phase at least 30 months. With allocation of consumables to allow the above plus an extension of 1 year in-orbit operations

Y

ATL-9395

Maintenance during storage shall be limited as far as possible and shall be identified by the supplier for approval by the customer. Y

ATL-9396

5.2.1.2 Design Safety

ATL-9397

The unit shall be designed and fabricated with compatible materials in such a manner that all hazards associated with the unit are eliminated, minimised and controlled. Y

ATLID



ATL-12153

All elements of the system shall be designed to avoid (minimize) hazards to personnel and property. Y

ATL-12154

Any potential hazard will have to be duly identified and agreed with the prime contractor and the Agency. Y

ATL-9399

5.2.1.3 Venting

ATL-9400

Adequate venting shall be provided to preserve the structural integrity of the S/C, insturments and units during launch depressurisation. Y

ATL-9405

5.2.1.4 Interchangeability

ATL-9406

All spacecraft units of the same part or configuration number shall be interchangeable in terms of form, fit and functions. The units must be of the same qualification status and reliability in order to meet the interchangeability requirement. Y

ATL-9407

5.2.1.5 Identification & Marking

ATL-9408

The unit hardware shall be identified with a nameplate in order to achieve configuration traceability. The identification shall contain the following information: Name of Manufacturer Project Name CI Number Serial Number Date of Manufacture Each Individual unit shall be marked with a serial number. For standard parts and where the physical size of an item precludes identification of the hardware itself, a 'bag and label’ technique shall be used (up to final integration) e.g. flying leads.

Y

ATL-9409

The unit identification nameplate shall be mounted on the connector face, visible when installed on the satellite. Its location shall be noted on the ICD. The identification shall be legible with unaided eye from 0.5m distance. The identification label shall meet all the requirements relevant to the unit.

Y

ATL-12044

If it is necessary for pratical reasons to fit the nameplate on an other face than the connector face of a unit this should be agreed by ASD. Y

ATLID



ATL-9410

For the particular case of connector identification, the following requirements shall apply: Each unit or bracket is required to bear visible connector labels closely adjacent to the appropriate connector in order to allow a correct mating of the corresponding harness connector. For each unit or bracket, the connector identification shall be three alphanumeric characters: a. The first character is “J” for fixed (hard-mounted) connectors and “P” for mobile connectors. b. The two last characters consist of a 2 digits sequential number starting from 01. The location and content of the above described connector identification labels shall be included in the ICD of the relevant unit, instrument.

Y

ATL-9416

5.2.1.7.1 Transport

ATL-9417

The units shall be transported using a container specifically designed to protect the flight hardware during ground or air transportation. Y

ATL-9418

The unit containers, covers (for optics and exposed connectors) and packaging shall be environmentally controlled / monitored (vibration, shock, temperature, pressure, humidity, electrical static discharge and contamination) and instrumented to ensure that the environments encountered during shipping and storage do not exceed expected flight (acceptance) levels.

Y

ATL-9419

The transport container shall ensure that the environment during transportation shall be maintained within the envelope of the defined launch mechanical environment (flight acceptance levels), i.e. transportation shall not drive the design. Y

ATL-9420

The storage container shall be designed to protect the unit without causing deterioration for the specified storage period. During storage the unit shall be stored under the following conditions: Pressure: 970 mbar to 1050 mbar Temperature: 20°C ± 10°C Humidity: 45% ± 15% Cleanliness: Class 100,000 or better

Y

ATL-9421

5.2.1.7.2 Unit Packing

ATL-9422

Where applicable blanking caps shall be fitted to any ports. Blanking caps shall be labelled and instructions included in the Handling and Transportation Procedures, to 'Remove Before Flight or Test' as applicable. Y

ATLID



ATL-9423

All units shall be packaged to ensure that it is sealed in a dry inert atmosphere using non-contaminating materials. The packing of the units shall be such that: The pre-cleaned unit shall first be placed in a bag and sealed within, The protected unit shall then be placed in a second bag with a dehydrating agent and a label stating "OPEN IN A CONTAMINATION CONTROLLED ENVIRONMENT", The second bag shall also be sealed, The sealing of both bags shall be performed in cleanroom conditions (class 100,000 at least for the first bag) and a dry atmosphere. The double packaged units shall then be placed in a container that shall protect against all risk of degradation during transport and storage.

Y

ATL-9424

5.2.1.7.3 Container Identification

ATL-9425

Each container shall be labelled, tagged or marked to show at least the following: Name Of Manufacturer Project Name Unit Name / Model CI Number Serial Number Date Of Manufacture Astrium Purchase Order Number (where applicable) Contact Number (where applicable) Quantity or weight (kg)

Y

ATL-9426

In addition to the above, the container shall also be labelled with: The statement "ONLY TO BE OPENED IN CLEANROOM CONDITIONS" Any recommendations necessary for the protection of the unit.

Y

ATL-9427

5.2.1.7.4 Handling

ATL-9428

Units weighing more than 10 kg shall be equipped with handling points (e.g. threaded bushes) that will enable the connection of special handles provided by the unit supplier for use during the (de) integration of the unit. As any other piece of hardware used only during ground operations, such handles shall be clearly identified as non-flight item (red anodised and a red flag carrying the notation "NOT FOR FLIGHT" attached to them). Such items shall be clearly identified on the relevant Interface Control Drawing.

Y

ATL-9434

5.2.1.7.7 Seals

ATLID



ATL-9435

Any seals used shall comply with all the applicable requirements of this specification, particularly regarding propellant and simulant compatibility and out-gassing. Y

ATL-9436

Any seals requiring periodic replacement during ground activities, and especially prior to launch, shall be identified to the Customer. The Unit supplier shall provide any procedures and special tooling required for replacement of seals. Y

ATL-9437

5.2.1.7.8 Lubricants

ATL-9438

No lubricants shall be used without the prior written agreement of the Customer. Y

ATL-9439

5.2.1.7.9 Screw Locking

ATL-9440

All fasteners used on the unit shall be locked by adequate measures. This includes fixations of units onto the structure. Y

ATL-9441

5.2.1.8 Workmanship

ATL-9442

All designs, munufacturing activities and equipments shall be comply with the Product Assurance Requirements for Subcontractors and the relevant space industry standards. Y

ATL-9443

5.2.2 Mechanical Design and Interface Requirements

ATL-9451

5.2.2.1 Structural Design

ATL-9452

5.2.2.1.1 General Requirements

ATLID



ATL-9453

The following failure modes, for units at all levels of integration, shall be prevented: Permanent deformation, Yield, Rupture, Instability, Buckling, Gapping of bolted joints, Degradation of bonded joints, Vibration induced mounting interface slip, Loss of alignment of units that are subjected to alignment stability requirements, distortion violating any specified envelope, Distortion causing functional failure or short circuit.Y

Y

ATL-9454

The unit shall be designed to withstand the environments it will encounter during its lifetime without degradation of its performance and without detrimental influence on the spacecraft or any other unit. The following shall be taken into account: 1) Ground loads due to: i) handling, transportation (incl. launch specific transportation) and storage loads ii) manufacturing, assembly and integration loads iii) test loads 2) Launch loads as defined by the Launcher Authority and including: i) quasi-static loads, ii) sinusoidal loads iii) random and acoustic loads, iv) shock loads, v) depressurization. 3) In-orbit loads: i) operational pressures, ii) static and dynamic loads induced by thrusters, iii) shocks due to pyrotechnical operation and deployment of appendages, iv) thermo-elastic loads induced by temperature variations, 4) hygroscopic-induced load due to variations in moisture content.

Y

ATL-9460

5.2.2.1.2 Mass properties

ATLID



ATL-9461

All mass estimations shall be accompanied by the definition of the design maturity of the concerned item (categories as per module or equipment SOW). The margin to be added to each item estimated mass for budget consolidation shall follow the rules expressed in Table below. The mass budget shall be reported to the customer through the datasheet as defined in GDIR section of [RD7].

Y

ATL-9463

The mass of an item shall be measured with the following accuracy: Item mass up to 10Kg: +/- 0.005 Kg Item mass from 10 to 20 Kg: +/- 0,010 Kg Item mass from 20 to 50 Kg: +/- 0,020 Kg Item mass from 50 to 100 Kg: +/- 0,050 Kg Item mass from 100 to 350 Kg: +/- 0,100 Kg

Y

ATL-9522

5.2.2.2 Design Requirements

ATL-9567

5.2.2.3 Mechanical Interface Control Documents

ATL-9568

The mechanical configuration and its interface requirements and dimensions, shall be fully detailed in one (or more) Interface Control Drawing(s) that shall be fully referenced by the unit subcontractor. This drawing shall detail all co-ordinate systems utilised and their relationship to each other, together with the principal unit interfaces. The content of the mechanical ICD shall conform to appendices A.

Y

ATL-9569

Interfaces shall be subjected to a formal inspection, using interface data sheets in respect to mechanical properties (see appendix A). These data sheets shall be completed by the unit subcontractor and then included in the unit Mechanical ICD. Y

ATL-9571

One of the attachment holes on a unit shall be specified as the reference hole and must be clearly indicated on the mechanical interface drawings. The reference hole shall support the Unit Reference Frame.

Y

ATL-9572

The dimensioning of the attachment hole pattern shall be specified with respect to the Unit Reference Frame. Y

ATL-9573

Interface Control Drawings shall be provided to the customer, with the following media and file formats: Operating system: HP-UNIX and Windows Compatible Media type: project FTP-Server and CD-ROM (other media to be agreed on a case-by-case basis) File format (by order of preference): a. CATIA V5.14 b. STEP AP214 c. 2D DXF

Y

ATLID



ATL-9952

5.2.5.5 Connectors and Harness General Design Requirements

ATL-9953

ESA approved materials shall be used or materials shall be approved for use accordingly. Y

ATL-9954

5.2.5.5.1 Connector Types

ATL-9956

For the spacecraft cable harness the following connector types shall be used: Rectangular connectors D-Sub or High Density in accordance with MIL-DTL-24308 [ND-250], or with ESA SCC 3401 [ND-240]. Circular connectors in accordance with MIL-DTL-38999 Series 1 [ND-252] (bayonet + scoop proof), or with ESA SCC 3401-052 [ND-242]. Connectors, which interface with release initiators (such as electro-explosive and non-explosive devices) in accordance with MIL-DTL-26482 [ND-251], or with ESA SCC 3401-008 [ND-241]. Non-magnetic coaxial connectors of the SMA type (ESA SCC 3402/001[ND-244] and 3402/002 [ND-245]), or TNC (ESA SCC 3402/008 [ND-246] and 3402/009 [ND-247]) for RF cables. Non-magnetic coaxial connectors of the crimp and solder type per MIL-PRF-39012 [ND-253]. Non-magnetic SMA coaxial connectors per MIL-DTL-83517 [ND-254]. Special connectors, or connectors at of-the-shelf equipment may deviate from the requirement, but the connector counterpart shall be delivered by the manufacturer of the respective unit. Connectors shall accomodate crimp removable contacts.

Y

ATL-9957

All connectors shall incorporate light weight EMC tight removable backshells. Shrink shells shall not be used. Backshells with cable clamp shall be used for circular connectors. Y

ATL-9958

Connectors including filters shall not be used. Y

ATL-9959

The number of mate - demate cycles of flight connectors shall not exceed 15, up to unit delivery and shall be designed to cope with , without damage, at least for further 35 mating / demating applications. Y

ATLID



ATL-9960

Different connector classes shall be implemented in order to separate the different type of links: Power, Signal, and Pyros. Classifications: Power and signal lines shall be gathered into the following EMC classes: Class 1 : power Class 2 : digital signals , high level analogue signals (except RF) Class 3 : pyrotechnics Class 4 : low level analogue signals Class 5 : RF signals (via coaxial lines , waveguides , microwave transmission lines) Signals falling into different EMC classifications shall be assembled to separate connectors and cable bundles. Sensitive, "High Quality" secondary power shall not be routed together with primary power in the same bundle.

Y

ATL-9961

5.2.5.5.2 Connector Characteristics

ATL-9962

Connectors at interfaces shall be clearly identified in particular in the ICD and General Assembly drawing. This applies to equipment connectors as well as to interface brackets connectors. Y

ATL-9963

For new equipment development, when the connection is not aligned to a defined standard, 10% spare contacts at unit PDR and at least 5% at CDR shall be achieved with, in any case, a minimum of two spare contacts at CDR. Y

ATL-9964

Equipment or structure-mounted connectors supplying or distributing power or coaxial cable connectors, shall be female (socket). Y

ATL-9965

For units or unit assemblies located close to one another, the risk of an operator making a wrong connection shall be minimised. This shall be achieved e.g. by attaching the cables to the structure or by carefully choosing the position and orientation of each connector, and by using easily readable labels.

Y

ATL-9966

Male and female connectors shall be mechanically locked together to prevent inadvertent disconnection (single coax and SMA connectors are excluded). Y

ATL-9967

Active lines together with their return shall be on adjacent contacts to facilitate cable twisting and shielding. Y

ATL-9968

Connectors shall be made of non-magnetic material. Y

ATL-9969

Nominal and redundant lines shall have separate connectors. Y

ATL-9970

The gender (female or male) of power and of signal connectors carrying none short circuit protected signals shall be determined such, that there are no live lines on pin contacts ( male connectors ). In case of serial interfaces such as RS422 UART or MIL BUS the unit shall implemennt socket contacts.

Y

ATLID



ATL-9971

Where a shield connection through a connector is necessary (at units or at connector brackets), separate pins shall be used. Y

ATL-9972

5.2.5.5.3 Connector Mounting

ATL-9973

All electrical connectors shall be located at a minimum distance of 25mm from the unit-mounting plane in order to avoid problems with cable routing and cable harness support fixation. When connectors are located above 80mm from the unit mounting plane, the unit supplier shall define and provide means to support the harness fixation on the unit. These fixations and the associated harness routings shall be iterated with and approved by the customer and shall be clearly identified in the unit ICD.

Y

ATL-9974

Connectors shall be arranged in such a way that the harness connectors can be mated and demated easily without special tools and without touching any neighbouring connectors. The minimum free space around each connector shall be at least 20mm to allow for installation of spacers and covers.

Y

ATL-9975

Mechanical methods in conjunction with identification markings shall be employed to prevent incorrect mating of connectors. Y

ATL-9976

Connector savers shall be utilized on all flight standard connectors to minimize the number of times a flight connector is mated/demated during the unit and subsystem integration activities. The unit manufacturer shall provide these savers. Y

ATL-9977

The use of connector savers for ground testing shall not alter the performance of the affected unit. Y

ATL-9978

The connection shield ground pin to case shall be as short as possible in order to minimize its effectiveness to act as an antenna, receiving and/or transmitting shield currents. The maximum allowable length is 6 cm. Y

ATL-9979

5.2.5.5.4 Test Connectors

ATL-9980

Test connectors shall have sufficient protection to prevent from any potential hazards to the unit during testing via the unit test set. The protection shall be in the form of current limiting resistors, diodes or protection via the test set when other forms of protection are not practical. The unit supplier is responsible for the protection provided.

Y

ATL-9981

The gender of a test connector shall be female. Y

ATL-9982

Skin and Test connectors shall be protected by conductive EMC tight metal covers attached to fixation bolts. Y

ATL-9983

Connectors including bridges which are mated to Skin and Test connectors shall be EMC tight. Y

ATLID



ATL-9984

5.2.5.5.5 Harness

ATL-9985

The harness design shall take into account the characteristics of the relevant electrical power and signal sources and loads of all equipment to be interconnected by the harness Y

ATL-9986

The harness shall guarantee reliable electrical interconnection, all harness matings shall be mechanically reliable during launch and in-orbit mission under all environmental conditions. No piece of harness shall be used as a mechanical support "

Y

ATL-9987

The harness shall provide adequate distribution and separation of all power supply, analogue and digital lines, command and actuation pulse and stimuli lines between all units, the test/skin connectors, the safe/arm brackets and connectors and the umbilical connectors.

Y

ATL-12214

The harness shall be designed in accordance with ECSS-E-20A [ND-128]. Y

ATL-9989

The harness design shall ensure an easy access to the connectors for mating, dismounting and test adapter interconnection on satellite level. Y

ATL-9991

Electrical interconnections between spacecraft modules shall be realized by mating connectors. Y

ATL-9992

Electrical interconnections between the interior of the spacecraft modules and any components attached to the spacecraft's outside, i. e. Antennas , Sun Sensors, Earth Sensors, Star Sensors, Magnetometers, Solar Array and associated units shall be realized by mating connectors.

Y

ATL-9993

In general, the platform harness wiring for the primary power shall be implemented using twisted pair wires not smaller than AWG 22, although selection of the wire gauge depends on current density through the wires. Y

ATL-9994

Although the gauge and the number of shielded cables shall be minimised as far as the electrical considerations will allow, the wiring for signal lines shall generally be implemented using twisted shielded pair, or multiple-core shielded wires not smaller than AWG 26.

Y

ATL-9996

Physical separation along common lines of the categories listed below (power, signals and lines for the mechanisms, if applicable) shall be retained between these categories up to and inclusive of the module interface connectors. Exceptions can be only the routing of harnesses down to connectors in the satellite separation plane. Class 1 : power (primary / secondary) Class 2 : digital signals , high level analogue signals (except RF) Class 3 : pyrotechnics Class 4 : low level analogue signals Class 5 : RF signals (via coaxial lines , waveguides , microwave transmission lines)

Y

ATLID



ATL-9997

Wiring of redundant systems, subsystems or units of subsystems shall be routed through separate wire bundles. Y

ATL-9998

Cable bundles of the different EMC classes shall be separated by the use of overall shields or metallic barriers between adjacent bundles. If the above mentioned solution cannot be provided the cable bundles shall be routed separately from each other by at least 10 cm.

Y

ATL-9999

Cross strapping of redundant paths and circuits shall not be carried out in the harness. Y

ATL-10000

Harness design and connector labels shall ensure that no possibility of incorrect mating exists. Y

ATL-10001

Harness connectors shall be easily accessible, attachable and removable from the corresponding unit connectors. Removal of cable harness shall not be necessary. Y

ATL-10002

All cable bundles shall be routed as close as possible to the structure ground plane/ground rail respectively, in order to reduce the common mode noise. Y

ATL-10003

Harness shall be tested up to connector brackets under 500V DC between conductors, conductors and structure, conductors and shielding. The isolation shall be at least 10MΩ at both polarities. Y

ATL-10004

All individual wire-to-pin interfaces shall be covered with transparent heat shrink sleeves. Y

ATL-10005

The harness shall be fixed onto the structure in order to avoid any damage during the launch phase. As a general rule it will be fixed: At equipment level: the harness connectors shall be fitted onto the equipment connectors by appropriate locking systems At the structure level At interface level: the connectors shall be fixed on metallic rackets themselves fixed onto the structure.

Y

ATL-10006

The harness restraining system on the structure shall not bring any stress at connector level. Y

ATL-10007

The wire and bend radius shall be at least 5 times the bundle diameter. Y

ATL-10008

The wire and cables shall be routed without contact to sharp edges. Y

ATL-10009

5.2.5.5.6 Cable and Harness Shields

ATL-10010

Wires shall be acc. to ESA-SCC standards. Y

ATLID



ATL-10011

The structure termination of shields shall be made via connector housing. When multiple shielding is used, each shield shall be grounded separately. Y

ATL-10012

The maximum unshielded length of any shielded wire shall not exceed 2.5cm. Cable shields shall be grounded at both ends. Y

ATL-10013

Daisy chaining of shield terminations shall be avoided. If this is not feasible due to connector limitations, a maximum of three shields of similar electrical interfaces are allowed for daisy chaining. Y

ATL-10014

Shields shall not be used as an intentional current carrying conductor and not as return lines for power and signal with the exception of the RF coaxial lines. Y

ATL-10015

All harness bundles shall have a continuous overall shield. The harness overall shield shall consist of bare aluminium foil (thickness = 30...50 µm). The shield shall be wrapped with 50% overlap in two directions. All lacing cords shall be removed during the wrapping that no lacing cord remains underneath. The top layer shall end at the connector end to support possible harness branch repair. The overall harness shields shall be connected to the connector housing or the connector backshells. Overall harness shields shall be connected with structure respective connector brackets by the connector backshell and at intermediate points gapped 0,2 meters via the ty-bases.

Y

ATL-10028

5.2.5.7 Electrical Interface Control Document

ATL-10029

Interfaces shall be formally controlled within the Electrical Interface Control Documents. The Electrical Interface Control Document will present all the electrical properties and additional useful details for each unit through the electrical datasheets of APPENDIX C: EICD.

Y

ATL-10030

5.2.5.8 EMC Requirements

ATL-10031

5.2.5.8.1 Bonding

ATL-10032

Bonding is the method by which adjacent conductive elements are electrically connected in order to minimise any potential differences and flow of electrical currents. If dissimilar materials are bonded, the relative areas of the anode and the cathodes are important and finishing should be applied on both materials.

Y

ATL-10033

The bond shall be resistant against corrosion and shall have an adequate cross section to carry fault currents of 1.5 times the unit/circular protection device for an indefinite time. Y

ATL-10034

Metallic parts of structure or of each electrical equipment chassis (case) shall be mutually bonded together by direct metal contact (preferred method) or bonding strap. Bonding interfaces shall be designed to achieve a contact resistance of 2.5 mΩ or less per bonding junction (including strap, if used).

Y

ATLID



ATL-10035

Joint faces shall be flat and clean before assembly; the only permitted surface finishes for joint faces are (preference order) :alodine 1200 for aluminium alloys, clean metal except for Aluminium alloys.

Y

ATL-10036

For the purpose of electrostatic protection , all equipment without any electrical function shall be bonded to the structure with less than 1 kΩ for a 1 m² space exposed surface 100 kΩ for ≤ 10 cm² space exposed surface for LEO auroral worst case.

Y

ATL-10037

Each electrical equipment chassis (case) shall be bonded to structure or GRR by means of a bond strap or direct metal contact. The bonding interfaces shall be designed not to exceed an overall chassis to structure bonding resistance (i.e. end-to-end) of 2.5mΩ for direct metal contact 5mΩ for bondstrap contact. The bondstrap shall have a length to width ratio of 5:1 max.

Y

ATL-10038

Every conductive element shall be grounded to structure according to the rules given below. In case there are conductive elements which cannot be grounded easily (e.g. small parts or components), the supplier shall demonstrate that the floating of such elements will not impose any risk of electrostatic charging/discharging. For parts or components of similar size, material and function, and located at the same location in the satellite/equipment, demonstration of no electrostatic charging/discharging risk need only be provided for one example of the part/component.

Y

ATL-10039

Metallic receptacles of connectors shall be electrically bonded to the equipment case with a DC resistance of 10mΩ or less. Y

ATL-10040

The DC resistance between the single cable shield and the shield ground point (at the connector, unit case, PCB or intermediate points) shall be ≤ 10 mΩ. Y

ATL-10053

5.2.5.8.1.3 Mechanical Parts

ATL-10054

Mechanical Parts without electrical nor shielding function shall show a bonding resistance of less than 100 kOhm between any adjacent parts and the local GRR. Y

ATL-10055

Mechanical Parts used for electromagnetic shielding shall show a bonding resistance of less than 2.5 mOhm between any adjacent parts and the local GRR (or connector bracket) Y

ATL-10071

5.2.5.8.2.4 Thermal parts

ATLID



ATL-10077

HEATERS & THERMISTORS: Heaters, thermistors and other discrete thermal components shall be galvanically isolated from structure with: Resistance > 10 MΩ DC

Y

ATL-10078

5.2.5.8.3 Primary and Secondary Power Lines

ATL-10079

5.2.5.8.3.1 Primary Power Lines

ATL-10080

Grounding: Power buses supplied by the platform EPS (Electrical Power Subsystem) are considered as primary power. This power will be referenced to structure at one point only within the EPS. This grounding shall be within the power control unit of the EPS.

Y

ATL-10081

No electrical current shall be flown through the structure The structure shall not be used as an intended current return path of primary or secondary power. Y

ATL-11312

5.3 Environment Design Requirements

ATL-11313

5.3.1 Atmospheric Conditions

ATL-11314

5.3.1.1 Humidity

ATL-11315

The unit shall be designed to withstand a relative humidity of 60% maximum during testing and transport. Transport containers shall be designed to to withstand a relative humidity between 10 and 100% during transport. Y

ATL-11321

5.3.1.2 Pressure Environment

ATL-11322

Decreasing atmospheric pressure from launch pad level conditions down to vacuum will occur at a rate dependent on the flight profiles and venting schedule. Y

ATL-11323

Units mounted on the S/C shall be designed to withstand without degradation, a de-pressurization rate of 70mbar/s maximum and a Delta-P of 150mbar over ambient. Y

ATL-11343

5.3.2 Mechanical Environment

ATL-11344

5.3.2.1 Ground Operations Loads

ATL-11345

This section defines the mechanical environments, which the units and their GSE will be subjected to during ground operations. Y

ATLID



ATL-11346

The ground operation phase begins with the units manufacturing and ends before launch. It includes all the manufacturing, assembly, integration and verification (AIV) and storage activities. Y

ATL-11347

The units, the transportation container and other MGSE are exposed to dynamic loads during the required transportation modes (road, air, ship, train…) and handling operations. Y

ATL-11348

All MGSE, containers, transportation and handling methods shall be such that Flight Hardware for which it is intended, never experience any environmental condition outside the defined envelope. Y

ATL-11349

For containers, the shock requirement is a drop of 100 mm onto concrete of one corner of the container, with another corner of the container lying on the concrete floor. The transportation containers shall be designed to ensure that the flight unit contained within is protected from and shall be undamaged by shocks.

Y

ATL-11351

The hoisting and handling environments which shall be considered for the MGSE are listed in the table below regarding Transport Handling Lifting / Hoisting

Y


ATLID


ATL-11352

Ground Operation Load Environment (1/2) :

Quasi-Static Load factors (QSL)

Vertical Note 1)

Horizontal Note 1)

Reference/Remark

Hoisting/Handling Devices S/C Lifting Device

-1.0 g ± 0. 35 g ± 0.3 g DIN 15018-1 slow crane velocity

Lifting Devices incl. STC

-1.0 g ± 0.6 g ± 0.4 g DIN 15018-1 moderate crane velocity

Handling Adapter

-1.0 g ± 1.5 g ± 2.5 g

Incl. S/C handling adapter / ground handling adapter

Test Adapter -1.0 g ± 1.0 g ± 1.5 g Incl. S/C mass property adapter / thermal test adapter

Support Stands -1.0 g ± 1.0 g ± 1.5 g MGSE used for S/C Mechanical Testing Vibration Test Adapter incl. clampband

Worst case loads as defined in note 2)

Worst case loads as defined in note 2)

S/C VTA / ATA dedicated requirements to be considered e.g. stiffness

S/C Transport Container (STC) Quasi-Static:

-1.0 ± 2.0 g

Axis I) Axis II) ± 2.5 g ± 1.5 g

Axis I): main transport directionAxis I I): transverse to I)

Y


ATLID


ATL-11352

Ground Operation Load Environment (2/2) :

Dynamic Environment

Level [g]

Remark

Container Road Transport (incl. S/C Transport Container STC, see note 4 ) Sine excitation

2 Hz - 10 Hz 10 - 200 Hz

DA = 6 mm 1.2g peak

Sweep rate 1oct/min 3 axis independently See note 3)

Random

2 Hz- 100 Hz 0.004 g²/Hz,

0.63gRMS 3 axis independently See note 3)

Shock 3 axis T = 10 ms 10.0 g Nominal saw tooth shock Container Air Transport (incl. S/C Transport Container STC, see note 4 ) Sine excitation

2 Hz - 20 Hz 20 Hz - 50 Hz 50 Hz - 200 Hz

200 Hz - 1000 Hz 1000 Hz - 2000 Hz

DA = 1.1 mm 0.85 g 2.0 g 2.4 g 0.3 g

3 axis independently See note 3)

Shock 3 axis T = 20 ms 5.0 g Nominal half sine shock 3 axis independently

Shock 3 axis T = 20 ms 6.0 g Worst case half sine shock. 3 axis independently

Y


ATLID


ATL-11353

Note: 1) Vertical is the direction parallel to gravity; Down (-) / Up (+) ; Vertical and lateral Quasi Static Loads (QSL) are acting simultaneously. 2) Worst case from S/C QSL with KQ=1.5 ( GDIR-228 ) and S/C handling loads ( GDIR-230 ) 3) The worst case envelope (peek values) for short time sine dwell, sine sweep sequences random loads are to be considered in the analysis (design, stress); no permanent excitation w.r.t. fatigue ( not as long-term stress). 4) The container design has to protect the spacecraft against the specified sine, random and nominal shock environment by means of a low-frequent suspension device with high damping such that the resulting loads acting on the S/C C.o.G. shall not exceed the levels specified in requirement GDIR-2447.

Y

ATL-11356

The instrument / unit transport container shall protect the Flight Hardware (e.g. by shock absorption) such that the Ground Operational Load Environments as given in the Table above do not induce loads on the INSTRUMENT / UNITS C.o.G. greater than defined in the Table below:

Y

ATL-11357

Limit Accelerations for Ground Operations for Units inside Unit Container]

GROUND EVENT VERTICAL (*)

Down (+) / Up (-)

HORIZONTAL

Ground Handling

(nominal handling loads

1 g (gravity) ± 3.0 g ± 2.0g

(*) Vertical is the direction parallel to the gravity

Y

ATL-11394

5.3.3 Thermal and Climatic Environment

ATL-11395

For the definition of the unit’s thermal environment, 2 phases of the mission are considered: On-ground phase covering all on-ground AIT activities at all level of assembly including pre-launch and launch phases In-orbit phase

Y

ATL-11396

5.3.3.1 On-ground phase

ATL-11397

5.3.3.1.1 AIV Environment Conditions

ATLID



ATL-11398

The climatic conditions in the integration, test and launch campaign facilities are: Temperature 21°C ± 3°C Humidity 50 ± 10% RH Air Presure ambient Cleanliness 100000 Moisture senitive parts, e.g. mechanism shall be protected if critical from exposure to high relative humidity (>50%) outside cleanrooms by sealing in plastic wrap and using desiccant.

Y

ATL-11399

5.3.3.1.2 Transportation Environment Conditions

ATL-11400

The transport environmental definitions shall apply for MGSE and for all transportation activities which come up in the S/C program. The satellite -, solar array - and instrument Transport Containers shall meet the following transport environmental conditions: Transport Environment Conditions]

Y


ATLID


ATL-11400

O u t s i d e C o n t a i n e r o n G r o u n d O u t s i d e C o n t a i n e r i n C a r g o C o m p a r t m e n t - A i r t r a n s p o r t

I n s i d e C o n t a i n e r T h e a t m o s p h e r e i n s i d e a c o n t a i n e r i n t e n d e d t o c a r r y F / H s h a l l b e c o n t r o l l a b l e t o w i t h i n t h e f o l lo w i n g v a l u e s :

T e m p e r a t u r e s : T h e e x t e r n a l e x t r e m e c o n d i t i o n s t o b e c o n s i d e r e d a r e t h e f o l l o w i n g : - 4 0 ° C t o + 6 5 ° C d u r i n g 1 2 h o u r s

T h e t e m p e r a t u r e s c a n b e a d j u s t e d w i t h i n t h e r a n g e o f 0 ° C u p t o 2 0 ° C d u r i n g f l i g h t . T h e I A T A r e g u l a t i o n s s h a l l a p p l y .

+ 0 ° C t o + 3 0 ° C

E x t r e m e a i r t e m p e r a t u r e c h a n g e ( t h e r m a l s h o c k ) D u r i n g a 1 - h o u r p e r i o d : I n c r e a s e o r d e c r e a s e o f a i r t e m p e r a t u r e o f 1 0 K

T h e r m a l r a d i a t i o n : P o s s i b l e d i r e c t 1 2 h S u n i l l u m i n a t i o n w i t h f l u x o f 1 0 0 0 W / m 2

s i m u l t a n e o u s l y w i t h a m a x i m u m e x t e r n a l t e m p e r a t u r e n o t e x c e e d in g 4 0 ° C

H u m i d i t y : 0 % t o 1 0 0 % w i t h p o s s i b l e r a i n f a l l o f 6 4 m m in 2 h o u r s

T h e r e l a t i v e h u m i d i t y i s n o t c o n t r o l l e d a n d d e p e n d s o n f l i g h t a l t i t u d e a n d a t m o s p h e r ic c o n d i t i o n s . A t c r u i s e a l t i t u d e o f 3 0 , 0 0 0 f t t h e r e l a t i v e h u m i d i t y d r o p s d o w n t o a p p r o x i m a t e l y 1 0 % R H . O n t h e g r o u n d t h e h u m i d i t y i n s i d e t h e a i r c r a f t c o m p a r t m e n t c o i n c i d e s w i th t h e e x t e r n a l e n v i r o n m e n t a l h u m i d i t y .

L e s s t h a n 6 0 % T h e d e w p o i n t s h a l l n e v e r b e r e a c h e d i n s i d e t h e c o n t a i n e r

P r e s s u r e : F o r t r a n s p o r t a t i o n o n r o a d a n d s e a , a n d f o r i n t e g r a t i o n o p e r a t i o n s , t h e a t m o s p h e r i c p r e s s u r e e x t r e m e s f o r t r a n s p o r t a t i o n b e t w e e n m a j o r l o c a t i o n s o f t h e p r o g r a m a r e : m a x . p r e s s u r e = 1 0 6 0 h P a ( b a r o m e t r i c p r e s s u r e ) m i n . p r e s s u r e = 9 2 0 h P a F o r M G S E s t o r a g e p u r p o s e s , a m b i e n t p r e s s u r e a p p l i e s , u n l e s s a n i t e m s p e c i f i c a t i o n c a l l s f o r s p e c i a l c o n d i t i o n s .

M a x i m u m r a t e s o f c h a n g e o f p r e s s u r e d u r i n g a i r t r a n s p o r t a t i o n ( a i r f r e i g h t i n g c o n d i t i o n s ) : 6 7 0 N / m 2 / s ( 6 , 7 m b a r / s ) . F o r e m e r g e n c y c a s e , t h e d e c o m p r e s s i o n s a f e t y d e v i c e ( b u r s t d i s k , b u r s t f l a p ) o f t h e c o n t a i n e r s h a l l b e i n a c c o r d a n c e t o t h e i n t e r n a t i o n a l I A T A f l i g h t r e g u l a t i o n s

C l e a n l i n e s s : U n c o n t r o l l e d . T h e a i r m i g h t b e s a l i n e .

U n c o n t r o l l e d B e t t e r t h a n 1 0 0 . 0 0 0

ATLID



ATL-11405

5.3.3.1.3 Storage Environment Conditions

ATL-11406

The MGSE conatiners, satellite -, instrument - and solar array transport containers shall be compatible with the following storage environmental conditions: Temperature -40°C - + 60°C Humidity ∠ 100% RH Air Pressure ambient Pressure 5 - 10 mbar above external pressure (container pressure inside) The dew point shall never be reached.

Y

ATL-11407

The satellite -, instrument - and solar array transport containers shall be designed to limit the outer environment as defined in the Table above to the following conditions inside the container when loaded: Temperature: +10°C - + 30°C Humidity: 45% ± 15% RH Air Pressure: 970 - 1050 (ambient)* Cleanliness: 100000 or better Moisture senitive parts, e.g. mechanism shall be protected if critical from exposure to high relative humidity (>50%) outside cleanrooms by sealing in plastic wrap and using desiccant. * For air transport the pressure of the container outer environment is the pressure in the cargo bay at cruise altitude. The container pressure regulation system must be "breathing". The pressure inside the container shall be controlled to the cargo bay pressure +20 mbar maximum.

Y

ATL-11423

5.3.4 Space Radiation Environment and Design Requirements

ATL-11424

The ECSS-E-10-04A [ND-126] shall be applicable for the space radiation environment. Y

ATL-11316

5.3.7.1 Cleanliness

ATL-12147

The cleanliness design requirements on the unit H/W shall be as defined in the PA requirements [AD-1] Y

ATL-11318

Asa minimum the following cleanliness control, monitoring and implementation requirements up to launch shall be considered to respect the cleanliness requirements. [Cleanliness Control Measures]

Y


ATLID


Cleanliness Control Measure Level of Implementation Instruments BP Satellite Comment Selection of materials with very low outgassing

y y y

Bake-out of materials: harness, MLI, structures, GSE (in vicinity of contamination critical equipment), …

y y

Bagging of contamination critical equipment, y protection of contamination critical equipment by covers

y

Purging of contamination critical equipment y Decontamination of contamination critical with dedicated heaters

y

Implementation of a cold trap (cold plate) y y Optimised design and positioning of venting apertures

y y y

Cleaning of critical equipments after delivery to satellite AIT

y

Instrument specific measures y Cleanliness Monitoring Measures Monitoring with PFOs, molecular witness plates,

y y y

Molecular witness monitoring in access protected zones of contamination critical equipment with adequate measures (e.g. QCMs)

y

ATL-11319

The contamination analysis shall put special attention to the following main sources of molecular contamination (outgasing): Epoxy adhesives from optical and mechanical parts CFRP resin from structural parts Varnish from electronic boards Cable insulating material Black paint from MLI inner side (if applicable) and electronic boxes MLI foils and residual contaminations.

Y

ATLID



ATL-11324

5.3.7.2 Contamination

ATL-11325

The satellite and its equipments shall be designed to operate in the space environment as specified in ECSS-E10-04A [ND-126], and to survive the environment and handling during assembly, integration and testing, transport and the launch. Y

ATL-11326

The satellite and its instruments / equipments shall be designed to meet their full performance under consideration of the cleanliness environment of the entire lifecycle up to EOL as specified in table ATL-11327. Y

ATL-11820

The cleanliness environment for instruments / equipments of the entire life cycle consist of: the instrument / equipment development -, integration - and test phase at the supplier side satellite AIT program and test phase launch preparation and launch in orbit commisioning and nominal operation

Y

ATL-11329

The instruments, the Base Platform and equipments shall provide a Cleanliness and Contamination Control Plan in accordance with ECSS-Q-70-01A [ND-185] and ATL-11326 considering the entire lifecycle up to EOL. Y

ATL-11334

Ground covers shall be provided to protect the ingress of contamination into apertures except when such apertures are specifically required to be open. The environments in which the satellite resides shall minimize contamination during AIT campaign, to a level that guarantees operational requirements for the instruments.

Y

ATL-11337

The out-gassing of materials shall not compromise the instrument performance. For potential sources of contamination (e.g. solar arrays, thermal control paints, MLI, harness, CFRP-structure), the out-gassing shall be defined and minimized by conditioning (e.g. vacuum bake-out).

Y

ATL-11484

5.3.8.2 Conducted Susceptibility on Primary Power Lines

ATL-11494

5.3.8.2.4 Units linked by Secondary power lines

ATL-11501

5.3.8.2.4.2 Requirement at subsystem or system level

ATL-11502

In addition, a margin of at least +6dB shall be demonstrated in frequency domain between the supplier highest emission levels and the supplied unit susceptibility level.

ATL-11528

5.4 Satellite, Instrument & Unit Level Environment Test Requirements

ATL-11529

5.4.1 General

ATLID



ATL-11530

5.4.1.1 Test Definition

ATL-11533

5.4.1.1.2 Acceptance Tests

ATL-11534

Environmental acceptance testing shall be performed on all deliverable flight and flight spare hardware. The objectives of acceptance testing are: Demonstrate freedom from manufacturing and workmanship errors. Demonstrate that hardware and software performance comply with design specifications. During environmental acceptance testing, conditions or effects, similar to the mission environment shall be simulated. Acceptance testing shall be conducted at the relevant level according to the requirements defined in this section.

Y

ATL-11537

5.4.1.1.4 Functional Tests

ATL-11538

The objective of the test item functional test is to verify the function of the item/unit during the test program. Satisfactory and un-degraded function before, during and after the specified environmental loads are required prior to approval for qualification or acceptance. An initial and a final functional test shall be conducted at the beginning and at termination of each environmental test. Units which are in-operational/function condition during launch, shall be also "in-operation" during all unit level environmental tests. Intermediate functional tests, which may be simplified, may take place in order to show successful test results concerning the previous test step. The tests shall be performed in compliance with approved test procedures, which reflect the verification criteria of the unit specification. Beside electrical function, all mechanical functions operated electrically shall be commanded and shall function.Failure detection, isolation and recovery functions shall be tested to the maximum extent possible without destroying the test article. Functional test shall be performed by operating all required operational modes. Unit interface functions shall be simulated. Unit function shall be checked considering at least: All required modes Begin/end of life power Maximum/minimum load Redundancies Emergency/safety modes Power protection Variation of input parameters Software if applicable

Y

ATLID



ATL-11539

5.4.1.1.5 Performance Tests

ATL-11540

The objective of the test item performance test is to verify that the item/unit under test meets the specified performance requirements within its specified performance range under adequate environmental conditions. The test results shall further allow to confirm performance margins. The tests shall be performed in compliance with approved test procedures, which reflect the performance verification criteria of the unit specification. Performance tests shall be performed by operating all required operational modes and redundancies and considering variation of input parameters on which the equipment performance depends on.Unit interface functions shall be simulated.

Y

ATL-11541

5.4.1.2 Test Facilities Requirements

ATL-11542

Any test facility to be used within the instrument assembly or unit test programme shall be capable to perform the required test within the specified limits and shall not impact the test objective or degrade the test article performance. Y

ATL-11543

5.4.1.2.1 Accuracy of Test Instrumentation

ATL-11544

The accuracy of instrument and test equipment used to control or measure the test parameters shall be in general, one order of magnitude better than the tolerance for the variable to be measured Exceptions shall be specified in the relevant specifications and shall be agreed by the customer. All instrumentation to be used for qualification and acceptance tests shall be subjected to approved calibration procedures and shall be within the normal calibration periods at the time of test. Instrumentation which will run out of calibration during the planned test time shall be not used.

Y

ATL-12006

All instrumentation to be used for qualification and acceptance tests shall be subjected to approved calibration procedures and shall be within the normal calibration periods at the time of test. Y

ATL-11545

5.4.1.2.2 Tolerances of Test Parameters

ATL-11546

The allowed test condition tolerances shall be applied to the specified nominal test values. Unless otherwise specified, the maximum allowable tolerances on test conditions or measurements shall be as per Table given below. The tolerance on test parameters specifies the maximum allowable range within which the specified test level (input level) or measurement (output) may vary and excludes instrument accuracy.

Y

ATL-11546

Tolerances of Test Parameters]

Y


ATLID


T O L E R AN C E S

(a ) T em p erature R a n g e M inim u m T em p erature M ax im um T em p erature

-200°C to - 50°C - 4 °C / 0 °C 0°C / + 4 °C - 50°C to + 1 00°C - 3 °C / 0 °C 0°C / + 3 °C + 100°C to + 37 0°C - 4 °C / 0 °C 0°C / + 4 °C

(b ) P ress ure

A bov e 1 .3 x 10 2 P a (1 T orr) ±15% 1 .3 x 10 -1 to 1 .3 x 10 2 P a ±30% Les s than 1 .3 x 1 0 -1 P a ±80%

(c ) R e la tive H um id ity ±5% (d ) A c ce lera tio n 0 / + 10 %

(e ) V ib ra tio n F req ue n cy R and o m ±5% or 1 H z (w h ic hev er the g re a te r)

S in e ±2% from 1 0 to 20 00 H z (f) V ib ra tio n le ve l S in e V ib ra t io n A m p litud e: ±10 % g p eak

S w ee p R ate ±5 %

R and o m V ib ra tio n A c ce lera tio n:

P o w er S p ectra l D e nsity Q ualifica tio n A c cep ta n ce

20 to 50 0 H z (25 H z o r na rrow er) + 3 .0 dB / -1 .0 dB + 1 .5 dB / -3 .0 dB

500 to 2 000 H z (5 0 H z o r na rrow er) + 3 .0 dB / -1 .0 dB + 1 .5 dB / -3 .0 dB

R andom O v era ll g rm s ±10% ±10%

(g ) A co u stic N o ise S ound P ress ure L ev e l

1 /3 o cta ve b a n d (ce n tre freq u e ncy ) + 3 .0 dB / -1 .0 dB

o vera ll ±1 .5 dB

(h ) T est D ura tio n T im e 0 / + 10 %

ATL-

11546 Tolerances of Test Parameters (continued)] Y


ATLID


T O L E R A N C E S

( i ) S h o c k

R e s p o n s e s p e c t r u m a m p l i t u d e ( 1 /6 o c t a v e c e n t r e f r e q u e n c y )

± 6 . 0 d B ( w i t h 3 0 % o f t h e r e s p o n s e s p e c t r u m c e n t r e f r e q u e n c y a m p l i t u d e s g r e a t e r t h a n n o m i n a l t e s t s p e c i f i c a t i o n )

S h o c k d u r a t i o n

= 2 0 m s

> 2 0 m s

0 / + 2 0 %

0 / + 1 0 %

S h o c k le v e l 0 / + 2 0 %

( j ) S o la r S i m u l a t i o n So l a r i n t e n s i t y d i s t r i b u t i o n i n r e f . P l a n e

± 4 %

So l a r i n t e n s i t y

d i s t r i b u t i o n i n r e f . V o l u m e

± 6 %

So l a r i n t e n s i t y s t a b i l i t y ± 1 %

So l a r i n t e n s i t y s t a b i l i t y (a b s o l u t e ) ± 3 %

T y p e W a v e le n g t h ( A n g s t r o m ) P e r c e n t O f T o t a l E n e r g y

F a r U l t r a v i o l e t 1 - 2 . 0 0 0 0 . 0 0 8

N e a r U l t r a v i o l e t 2 . 0 0 0 - 3 . 8 0 0 6 . 9 9 5

V i s i b l e 3 . 8 0 0 - 7 . 0 0 0 3 9 . 8 8 ± 5 %

N e a r In f r a r e d 7 . 0 0 0 - 1 0 .0 0 0 2 2 . 5 9

In f r a r e d 1 0 . 0 0 0 - 2 0 . 0 0 0 2 4 . 0 2

F a r In f r a r e d 2 0 . 0 0 0 - 1 0 0 . 0 0 0 6 .4 5

( k ) F o r c e ( s t a t i c ) + 3 / - 0 %

( l ) C . o .G . s e e Se c t i o n x . 2 . 2 . 1 . 3

( m ) M o f I . s e e Se c t i o n x . 2 . 2 . 1 . 3

( n ) F o r c e s a n d M o m e n t s ( d y n . ) + 3 / - 0 %

( o ) P r e s s u r e ± 5 % o f m a x . s p e c i f i e d v a l u e

( p ) F lo w R a t e ± 5 %

( q ) L e a k a g e ± 1 0 -4 s c c / s H e a t 1 0 1 3 h P a p r e s s u r e d i f f e r e n t i a l , i f n o t o t h e r w i s e s p e c i f i e d

( r ) M a s s s e e Se c t i o n x . 2 . 2 . 1 . 2

( s ) D im e n s i o n s L e n g t h < 0 .1 2 5 m m

( t ) B a l a n c i n g St a t i c < 0 . 2 5 m m

D y n a m i c < ± 0 . 1 °

( u ) A n g u l a r M e a s u r e m e n t s 0 . 5 a r c m i n w i t h r e s p e c t t o e a c h a x i s o f

t h e r e f e r e n c e s y s t e m o f t h e f a c i l i t y i f n o t o t h e r w i s e s p e c i f i e d

ATLID



Note: "x" in the table refers to the GDIR-chapter "General Design and Interface Requirements

ATL-11549

5.4.1.2.3 Facility Ambient Condition

ATL-11550

Unless otherwise specified herein, all measurements and tests shall be made at room ambient atmospheric pressure, temperature and relative humidity conditions, whereby 22 ± 3°C and 50 % ± 10 % RH shall not be exceeded. Whenever these conditions must be closely controlled in order to obtain reproducible results a reference temperature of 21°C, a relative humidity of 50 % and an atmospheric pressure of 1013 hPa shall be used together with whatever tolerances are required to obtain the desired precision of measurement. Actual ambient test conditions shall be recorded periodically during the test period. The cleanliness requirements for the test items during assembly, integration, transport and test shall be in accordance with PA cleanliness requirements.

Y

ATL-11551

5.4.1.3 Test Execution

ATL-11552

Before commencing any formal qualification or acceptance test, a Test Readiness Review meeting shall be convened. At this meeting, the status of the test item and all documentation shall be discussed and any discrepancies shall be assessed as to their effect on the representation of the test. All discrepancies and all decisions shall be minuted and accepted by all participants before permission to commence the test is granted. Test execution shall be started only if all starting prerequisites have been positively accepted, i.e., if all HW under test and the associated support equipment, SW and documentation is found to be complete and ready for test start. Prior to and after every environmental test activity a limited functional test and a through visual inspection are required on the basis of the related approved procedure. After completion of all formal qualifications or acceptance tests a post-test review shall be convened. All test results shall be presented for review. In the case of any parameter being outside its specified range or any other evidence of failure the review shall take the form of a test failure review board. In any case the meeting shall consider all the evidence, decide on the degree of success of the test and decide what further action if any is necessary.

Y

ATL-11553

5.4.1.4 Success Criteria


ATLID


ATL-11554

The test is successfully performed if all measurement results are in accordance with the design requirements as stated in the particular unit design and performance specification and transformed into test criteria listed in the test plan or specification. Modifications, repair, replacement or refurbishment of an item, which failed an initial test, shall be subject to a retest. When it can be shown that the test interruption was caused by a GSE or software problem the retest shall be started from that point of GSE or software failure after appropriate repair has taken place and positive confirmation can be given for the nominal performance of the GSE item. Any repetition of qualification or acceptance test needs the prior decision of the MRB responsible.

Y

ATL-11555

5.4.2 Unit Tests

ATL-11556

The preferred unit level test sequence is: : Preferred unit level test sequence]

Sequence Test 1 Pre-test inspection 2 Initial Functional Test 1) 3 Mechanical tests 4 Depressurisation / Corona discharge (if applicable) 5 Thermal Vacuum 6 EMC / RF 7 Final Functional Test 2) 8 Mass Properties Measurement 9 Post-test inspection

1) incl. electrical and performance tests 2) incl. performance tests Note: Variations to this proposed test sequence shall be agreed with the prime contratcor prior to the start of any unit level test programme.

Y

ATL-11558

5.4.2.1 Mechanical Environment Tests

ATL-11619

5.4.2.3 Radiation Test

ATL-11620

With regard to unit radiation testing the manufacturer shall comply with the PA Requirements for Sub-Contractors (section 7.4.3.4). Y

ATLID



ATL-11621

5.4.2.4 Electromagnetic Compatibility Tests

ATL-11622

5.4.2.4.1 General EMC Test Requirements

ATL-11623

5.4.2.4.1.1 EMC Development Test

ATL-11624

Development tests may be performed to evaluate the design approach, indicate critical areas where design improvement is required, assure compliance with the design requirements, confirm and support analytical methods or generate essential design data at an early stage.

Y

ATL-11625

5.4.2.4.1.2 EMC Qualification Test

ATL-11626

Qualification tests for PFM shall be performed as specified in the Unit Test Matrix Y

ATL-11633

5.4.2.4.1.6 Pre and Post Test Inspection

ATL-11634

The pre- and post-test inspection is specified in the Product Assurance Requirements [AD-1] Y

ATL-10942

5.5.3.4 MGSE INTERFACE REQUIREMENTS

ATL-10943

5.5.3.4.1 General

ATL-10953

5.5.3.4.3 Pneumatical / Purging I/F

ATL-10969

5.5.3.4.5 Facility Interfaces

ATLID



ATL-10970

The MGSE shall be compatible with the facility interfaces in effect, i.e. shall be compatible with interfaces like: Crane (capacity, usable height, hook dimensions) Fork Lift Truck Facility Environment Ground (Floor) Loading Access Door Dimensions Room Height Test Facilities I/F (dimensions, load capacity) Air Pressure Fluid I/F (purgeing) Electrical I/F (Voltage, Current, Fuse) Safety Aspects

Y

ATL-12291

MGSE shall be compliant with following cranehook design: Cmini = 50mm Dmini = 60mm Gmaxi = 100mm Emaxi = 55mm A height of 9.50 m maxi under crane hook shall be considered

Y

ATL-12292

All MGSE shall be compliant with Clean room access door dimensions: height = 7 m, width = 6 m ; except MPT which shall enable the satellite with X-axis between vertical and horizontal to be rolled into the EMC chamber (height 6 m, width 4 m). Y

ATL-12293

The maximum weight of MGSE assemblies and units shall be limited by an average floor load of 1000kg/m², or a point floor load of 200kg/cm². These are generalised requirements - specific exceptions must be agreed. Y

ATL-10971

5.5.3.4.6 Transportation Interfaces

ATL-10972

All AIV Tools shall be designed for road, air and ship transportation by normal commercial facilities readily available in Europe. Y

ATL-10973

The MGSE shall be compatible with the corresponding national transport regulations covering all countries coming up in the program. Y

ATL-10995

5.5.3.6 MGSE PREPARATION FOR DELIVERY

ATLID



ATL-10998

5.5.3.6.1 Packing

ATL-10999

Packaging shall ensure transport without damages to the items being transported. Y

ATL-11000

To maintain specified environmental conditions, the packaging shall be sealed with wrapping material and drying agents shall be included Y

ATL-11001

The packaging design shall feature provisions for forklift handling. Y

ATL-11002

All operations shall be performed in accordance with the contractor provided packaging, handling and transportation procedure. Y

ATL-11003

Packing materials selected for cleaned items shall ensure compatibility with the required cleanliness levels. Y

ATL-11004

5.5.3.6.2 Labeling and Marking

ATL-11005

Adequate handling, opening, closing and storage instructions shall be provided on each packing. Labelling and marking of all MGSE shall be in accordance with the transportation/shipping and storage practice and any national and international regulations.

Y

ATLID



ATL-11006

The marking shall indicate the following informations: 1) Gross weight in kg 2) Tare weight in kg 3) Net weight in kg 4) Overall volume in m³ 5) Lifting I/F point identification (fork lift, crane lift, complete container, only lid lifting) 6) Tow down fixation points 7) Overal dimensions in m (length, width, height) 8) Centre of Gravity (C.o.G.) loaded or unloaded 9) Grounding point 10) Consignee and address of receiving destination 11) Shipper's address and origin of transportation 12) Identification of content 13) Special markings and tags 14) Project Name 15) Container markings "REUSABLE CONTAINER DO NOT DESTROY" 16) Container marking "FLIGHT HARDWARE TO BE OPENED BY AUTHORISED PERSONNEL ONLY" 17) Full/Empty indication 18) Environment Requirements 19) Packing transportation orientation arrows 20) Package date 21) Location of data package (Documentation Box) 22) Orientation markings of removal lid or cover 23) Stackable or non stackable container

Y

ATL-11008

The specifications for symbols, their positions, colours and sizes shall be in accordance with appropriate national/international regulations and guidelines. Y

ATL-11015

5.5.5 EGSE Support Requirements

ATL-11212

5.5.5.3 Verification Requirements

ATLID



ATL-11213

The verification process is that part of the subcontractor's task, which demonstrates conformance to applicable requirements. A satisfactory completion of the verification process is the basis for a contractual acceptance of the product by the customer.Requirements in this specification indicated by the identification and numbering scheme explained in section 1 shall be subjected to formal verification close out. As far as the equipment or S/W is a rebuilt from lower level test equipment (e.g. unit tester), the formal verification of the corresponding functions may be achieved by demonstration of successful use in lower level integration and testing.

Y

ATL-11214

Adequate test equipment and simulators shall be made available to support the equipment verification process. This test equipment is not deliverable and may therefore be recruited from the suppliers laboratory inventory. Of particular importance are the simulation of the communication interface with the CCS (Core EGSE) and the simulation of the interfaces with the on-board systems. These shall be fully representative on all protocol layers including the physical interface. Software test stubs used for such tests are deliverable in source code to the customer.

Y

ATL-11215

The subcontractor shall establish a verification program that assures that: The product (H/W and S/W) is in compliance with the specified requirements. The design is qualified. The product (H/W and S/W) is in agreement with the qualified design, free from workmanship defects and acceptable for use.

Y

ATL-11216

Qualification is defined as the proof that a design fulfils the requirements with adequate margin. For re-used software modules / components acceptance test reports / qualification test reports may be used to demonstrate compliance with the requirements stated. The sub-contractor shall not be required to re-run acceptance / qualification tests for existing, re-used software. In case reference is made to already performed and existing acceptance / qualification in the frame of other space programs, requirements tracing of the relevant requirements to the existing test procedures and test result has to be provided as well as the existing test procedures and test reports themselves.

Y

ATL-11217

The verification process activities shall be incrementally performed at different levels and in different stages applying a coherent bottom-up concept and utilizing a suitable combination of different verification methods. The verification process flow shall be basically subdivided into the following steps: Identification and classification of all the requirements to be verified Selection of verification criteria (methods/levels/stages) against identified requirements Establishing the planning for the associated verification activities Obtain customer concurrence Performance of verification tasks and verification control Completion of verification control and evidence for verification close-out Customer review and final approval. All above tasks shall be executed in accordance to \\SD4\\.

Y

ATLID



ATL-11218

All specific support test equipment must be compliant with the intended purpose, within its useful life and calibration. The test tolerances quoted in the specifications shall be applied to the nominal test values specified. The tolerance of test parameters specifies the maximum allowable range within which the specified test level (input level) may vary and does not take into account instrument accuracy. All instruments and measurement equipment used in conducting the tests shall have an accuracy of better than one third of the tolerance for the variable to be measured unless otherwise specified. Note: This is to be recorded in as-run-test procedure/test report

Y

ATL-11219

For tests performed using automated test equipment running scripts, batch files or generally S/W the test procedures and -reports shall provide the relevant test-step information in the S/W source code or in the print-out/protocol of each test S/W item. Test Report shall include configuration control information (compilation date, check-sum, version/revision-number, etc.) for each test S/W item used for the reported test.

Y

ATL-11220

The specified item shall undergo a incremental test program, starting at module level up to system level. Objectives of these tests shall be at least: Function Performance Interface Failure Tolerance

Y

ATL-11221

Details of the tests, test planning, test requirements and test procedures shall be defined/specified by the subcontractor in accordance with the verification method given in this specification and shall be approved by the customer in advance. Y

ATL-11222

Module level testing shall include testing of tolerance against erroneous input data and signals. This shall include as a minimum: User input error Corrupted input data from external sources

Y

ATL-11223

The product functional performance test shall include at least: all interfaces all system functions all system command functions all telecommand and telemetry functions all I/F board functions all operational modes and all transitions applicable. under the specified performance loads.

Y

ATL-11224

The objective of the functional performance test shall not only be the verification of the user requirements but also the verification of the correct and consistent system behavior. Y

ATLID



ATL-11225

The functional performance test shall include testing of the quantifiable functions and parameters of the product (performance, accuracy, etc.) in all operational modes specified Y

ATLID


11 APPENDIX B

Extract of [RD6] (harness EICD)


ATLID



ATLID




ATLID



ATLID


ATLID



ATLID



ATLID




ATLID
