ptim integration into pgba - university of colorado …pgba6+ptim-cdr.pdfptim integration into pgba...

WONDER = PGBA + PTIM Integration Review 1

WONDER = PGBA6 + PTIM Integration Review

Integration / Design ReviewPhase 1 Contract

April – September 2003

PTIM Integration into PGBA

BioServe Space TechnologiesUniversity of Colorado

and

The Bionetics Corporation, Space Life Sciences Lab (SLSL), NASA KSC

09 October 2003

WONDER = PGBA6 + PTIM Document Web Page for Bionetics – BioServe Design Activity

PGBA Overview Payload Description PPT PDF HTM System Diagrams Visio PDF HTM

PGBA Documentation WONDER = PGBA + PTIM CDR Presentation PPT PDF Integration – PGBA4 EXPRESS (ICD) SSP53035.doc

ICD-DOC PDF

Integration – PGBA5 EXPRESS (ICD) SSP53074.doc

ICD-DOC, PVP-DOC PDF

Integration – PGBA-PTIM ICD (draft only) DOC PDF PIRNs Integrated Data Package (IDP) DOC: S/N-01 S/N-02 PDF: S/N-01 S/N-02 Payload Verifications / Payload Verification Plan – Matrix

PDF XLS HTM

Safety Data Package DOC PDF HTM Safety Verifications and Tracking Log (SVTL) XLS PDF HTM Hazardous Material Summary Table / Fluids List HMST V1-Letter V2-Letter Materials Identification and Utilization List – MUA+MIUL

Access PDF HTM

Materials Compatibility DOC PDF HTM

Phase 1 Contract Overview WONDER-Project Schedule MPP PGBA Schedule (PGBA5+PGBA6 Resource) MPP

Pressurized Systems Atmosphere Treatment System (ATS) VISIO PDF HTML Temperature Control System TCS) VISIO PDF HTML Humidity Control System (HCS) VISIO PDF HTML Nutrient Delivery System (NDS) VISIO PDF HTML NDS WONDER Modifications VISIO PDF HTML Pressurized Systems Analysis XLS PDF HTML

Mechanical Design

Electrical Design Circuit Diagram Package (PGBA4) Orcad PDF PGBA-PTIM Interface Connector Orcad PDF Voltage-Current Plots XLS PDF Electrical - Sensor Calibrations / HiLo / ECW Matrix

XLS PDF

PC104 Documentation DOC

Ground Support Equipment CO2 Cabin Air Simulator (“CO2 bucket”) DOC PGBA Stand DOC

Operations – Test – Ground – Flight Procedures Operations - Crew Procedures DOC PDF HTM Crew Training PPT PDF HTM Console Operations DOC PDF HTM

User Manual (EGSE) Displays DOC PDF HTM

Alexander Hoehn, BioServe Space Technologies, Aerospace Engineering Sciences, University of Colorado

College of Engineering - ITLL - DLC - Last Updated 10/13/2003 22:09


Acronyms

Acronyms:• PGBA Plant Generic BioProcessing Apparatus• PTIM Porous Tube Insert Module• WONDER Water Offset Nutrient Delivery Experiment• EMI Electromagnetic Interference• EXPRESS Expedite the Processing of Experiments to the Space Station• ISS International Space Station• JSC Johnson Space Center• KSC Kennedy Space Center• MDL Middeck Locker• NDS Nutrient Delivery System• PI Principal Investigator• PGBA Plant Generic BioProcessing Apparatus• PTNDS Porous Tube Nutrient Delivery System• PTIM Porous Tube Insert Module• STS Space Transportation System• WONDER Water Offset Nutrient Delivery Experiment


References

References:• WONDER-White Paper: Water Offset Nutrient Delivery Experiment (WONDER) Feasibility Study for Flight on the

International Space Station (ISS) • PGBA-WONDER-ICD: Water Offset Nutrient Delivery Experiment (WONDER) PGBA to PTIM Interface Control

Document (draft). • LSSC-WONDER-EIS: Porous Tube Insert Module (PTIM) End Item Specification, 08/04/03• LSSC-WONDER-ERD: Water Offset Nutrient Delivery Experiment (WONDER) Experiment Requirements

Document

• IDD: NSTS-21000-IDD-MDK Rev.B and SSP 52000-IDD-ERP • Safety: NSTS 1700.7B / NSTS 1700.7B ISS Addendum / KHB 1700.7• Electric: MSFC-HDBK-527E

Links:• BioServe Automation and Operations Server: http://bioserve-boulder.colorado.edu


Personnel

BioServe Space Technologies:• Jon Genova, Mechanical design.• Kevin Gifford, Automation lead.• Alex Hoehn, Systems.• Seb Kuzminski, Automation.• Jim Russel, Project management.• Shea Williams, Automation / Test / Verification.• Peter Journey-Kahler, atmosphere control.• Chris Madsen, fluids.Bionetics:• April Boody, WONDER Project Engineer• Kevin Burtness, WONDER Hardware/Software Engineer• Trevor Murdoch, WONDER Electrical• Bill Wells, Flight Experiment Development/ManagementPI:• Howard Levine, Dynamac, NASA KSC LSLS


Agenda for CDR

• 11:30/13:30 Alex Hoehn (Chris Madsen, Jim Russel, Peter Journey-Kahler)

» Introduction, tasks of SOW, schedule » hydraulic design» electric design» remote site GSE enhancements (mech., CO2) (Alex Hoehn) » documentation exchange

• 12:30/14:30 Kevin Gifford / Shea Williams» automation, incl. user new interfaces (Kevin Gifford, Shea Williams)» remote site GSE enhancements (automation) (Shea Williams)

• 13:30/15:30 All:» Questions / open items / tasks / test schedule» Phase 2 target accomplishments (PGBA deploy, remote site ops.)

• 14:30/16:30 Adjourn


Background

• After Columbia accident, no flights assigned.• Previously working in parallel on:

» PGBA-5: PGBA + Pine trees, STS-118 / ISS.13A.1» PGBA-6: PGBA + PTIM, STS-120 Sortie Science Only

• Potential use conflicts for PGBAs unknown» Currently use both PGBAs for testing, development, software upgrades» 1. one PGBA to be deployed to KSC for WONDER testing.» 2. one PGBA to be deployed to Ames for PINE testing.» Maintain, whenever possible / especially initially, at CU for trouble shooting.» Currently no plans to develop 3rd PGBA.

• Other / General PGBA Work in preparation:» Updated heat exchangers (corrosion, backpressure)» Updated dehumidifier (seal life time, serviceability)» Updated chamber lid (seal life time, seal verifications)» Software / Automation – lessons learned ISS.9A / usability enhancements» Operations – web plots incl. online performance analysis, PDH payload data historian


Phase 1 Tasks

Design, test, and (as necessary for testing) implementation of:• PGBA Integration documentation delivery:

» Safety, verification, electrical, mechanical, operations documentation.

• Electrical interfaces for PTIM:» Power (5V, 12V) – switched and fused.» Data (RS485).» Video (2 channels analog color video).

• Mechanical interfaces for PTIM:» PTIM alignment structure.» PTIM water/fluid replenishment and PGBA interface.

• PGBA GSE support:» PGBA CO2 GSE, Stand, video interface box, power supply

• Automation interfaces for PTIM:» Updated S/W architecture for PTIM.» Updated touch-screens.» Updated remote user interfaces (webplots, EGSE documentation/interfaces)


Electrical Interface

• Single Interface Connector to PGBA Chamber» 27 pins, share power, analog data, digital signal, digital communication

ODU-27-Socket: G83F1C-T27LFD0-0000:

Pin 01: +12VDC FAN0 WONDER - fans - switch 15Pin 02: +12VDC FAN1 WONDER - pumps - switch 16Pin 03: 12RET WONDER - return for abovePin 04: +24VDC (sensor: Humitter-Y and light sensor)Pin 05: + 5VDC (power 02sensor)Pin 06: 24RET (all sensor grounds/returns)Pin 07: T chamber (from Humitter-Y)Pin 08: rH chamber (from Humitter-Y)Pin 09: Light sensor (WONDER/PTIM not prividing this signal)Pin 10: O2 chamber (WONDER/PTIM not providing this signal)Pin 11: +5V WONDER CPU power, switch 9Pin 12: 5VReturn WONDER (same as pin 06, 25, 27) Pin 13: CO2 sensor: greenPin 14: CO2 sensor: yellowPin 15: CO2 sensor: grayPin 16: CO2 sensor: pinkPin 17: CO2 sensor: bluePin 18: CO2 sensor: whitePin 19: CO2 sensor: shieldPin 20: CO2 sensor: brownPin 21: chassis ground WONDER/INSERTPin 22: +RS485 WONDERPin 23: -RS485 WONDERPin 24: +video Ch.4 WONDERPin 25: -video Ch.4 (same as pin 27) WONDERPin 26: +video Ch.5 WONDERPin 27: -video Ch.5 (same as pin 25) WONDER


Electrical Interface - Schematic

red

RXD/+data

red

[1-4]=Vin4=O2-Chamber

not used

Also used for WONDER 12VDC

EN(test use)

white

TXD/RXD-

TP21

blackAlso used for WONDER 12VDC

Video MUX

Teflon Ribbon 28 AWG

white

Wonder Interface.dsn BWONDER I/F

C1 1Thursday, October 09, 2003

Title

Size Document Number Rev

Date: Sheet of

Green

yellow

WONDER-5V-RET

WONDER RS485 NETWORK

CTS/not used

+VIDEO(1)

+12VDC-FAN0-SW15

J22x5 header (pin)

123456789

10

brown

Switcher

DSR/not used

WONDER VIDEO ROUTING

-VIDEO(1)

J2: Opt. RS232/RS485

not used

gray

purple+24VDC

WONDER 12V POWER ROUTING

Blue

GND/not used

OUTSIDE PGC:

[1-0]=Vin0=T chamber

JP22x5 socket

12345678910

black

Switcher

green

green

Chassis Ground

Analog Ground

DCD/not used

Note:voltage drop due to line losses is severe.Current DCDC PTIM Resistance0.000 4.97 4.951 [Ohm]0.255 4.97 4.821 0.5100.301 4.96 4.798 0.5080.326 4.96 4.786 0.5060.374 4.96 4.740 0.5640.500 4.96 4.697 0.5080.698 4.96 4.601 0.5010.765 4.96 4.564 0.5060.973 4.96 4.462 0.5031.273 4.95 4.302 0.5101.513 4.95 4.167 0.5182.023 4.94 3.899 0.520

-RS485

+5VDC

TP11

Twisted Pair, 22AWG

yellow

not used

CO2-GMM220_2

<Value>

Brown

Shield

White

Blue

Pink

Gray

Yellow

Green

TXD/not used

TP6

1

not used

RS485 Serial Port:Cable length <4,000 feetdata rates <57.6K bps

grayYellow

blue

WONDER 5V POWER ROUTINGWONDER-5VDC-SW09

Also used for WONDER 12VDC

pink

Note:voltage drop due to line losses as below:Current DCDC PTIM Resistance0.000 11.95 11.950 [Ohm]0.648 11.95 11.520 0.6640.717 11.94 11.474 0.6640.789 11.94 11.424 0.6670.870 11.94 11.373 0.6631.039 11.93 11.252 0.6721.500 11.92 10.935 0.6772.000 11.91 10.581 0.685

not used

Shield

white-blk-red

12RET-FANS

+RS485

TP5

1

RI/not used

J2

Connector D9-Female

594837261

TO VIDEO MUX 'INPUT4'

blue

Brown

+12VDC-FAN1-SW16

not used

white-blk-blue

P2

Connector D9-male

594837261

+5VDC

22 AWG short adapter to 75 Ohm coaxial cable

solder splice

[1-8]=Vin8=Lightwhite-blk-green

RTS/-data

75 Ohm coax, PTFE

solder splice24AWG to 22 AWG

white

white-blue

Pink

75 Ohm coax, PTFE

shield

not used

-VIDEO(1)

yellow

Ampro MiniModule SSP

J2 2x5 header, male

TXD/RXD+

Gray

TO VIDEO MUX 'INPUT5'

DTR/not used

brown

PC104 assembly

[1-2]=Vin3=rH chamber

TP3

1

12

5

12

3

46

7

8

9 1011

16

20

13

14

1517

18

19

21

2223 24

25

26

27

J1ODU-27-Socket: G83F1C-T27LFD0-0000

4

1

2

3

5

6

7

8

9

10

11

12

131415161718192021 22 23 24 25 26 27

4

1

2

3

5

6

7

8

9

10

11

12

131415161718192021 22 23 24 25 26 27

green

+VIDEO(1)

White

red

TP4

1

RETURN



• Issues:» Voltage drop doesn’t allow PGBA voltages to be used for ratiometric sensors.» Line length, wire size, fusing and switches result in 0.5-0.6 Ohm line resistance, and

subsequent voltage drop at PTIM location.» PTIM load varies, and subsequent ratiometric sensor signals change. » 5V supply may drop below usable level.

• Options:» PTIM to generate own fixed (regulated voltages) where needed from 12V lines ?» PTIM to use ratiometric sensors and ratiometric A/D ? » PTIM use fixed reference sensors with referenced A/D ?» PGBA can trim up slightly (increase margin: 5.00 5.25V, 12.0 12.5 V), but on-

resistance will remain at 0.5-0.6 Ohm.

• Recommended Solution:» PTIM uses high-efficiency 5V DCDC converter within PTIM as necessary, using both

12V supply lines.» 5V line from PGBA remains available for users not sensitive to load-dependent voltage

drop.

http://www.colorado.edu/ASEN/asen5519/WONDER/Electrical/Power-draw-voltage.xls


Electrical Interface - Other

• Replace PGBA ‘Switcher’ for flight:» Current switcher PCB (fused – Polyswitch - PhotoMOS switches) has been ‘modified’

for evaluation and testing, and requires replacement with ‘clean’ PCB for flight. Usable for ground usage.

• PGBA DCDC Converters:» Voltages tightly controlled at PGBA computer only. Testing if trim-up will provide

enhanced performance for distributed users at extreme ends of distribution (inside chamber,…).

• Video Transmission Quality:» To date not tested. ODU connector requires twisted pair feed-through with other users.

Quality impact unknown. Testing necessary.» New video lines installed for testing, but never tested.

http://www.colorado.edu/ASEN/asen5519/WONDER/Electrical/Power-draw-voltage.xls


Mechanical Interface - Structure

PTIM – PGBA Structural Interface:• PTIM Insert retention:

» Chamber lid used to retain PGBA insert. » PGBA chamber depth varies between units – requires adjustable height ‘bumper’.» Alternative – use PGAB chamber lip (also requires height adjust from unit to unit).» Electric connector provides some retention during zero-g harvest.

• PTIM Insert alignment:» Inserts aligned horizontally within PGAB chamber base.» Alignment issues and thermal performance questionable during STS-112.» Old design currently removed from PGBA.» May not be necessary, or re-install modified version for flight.

– Potential impact on thermal performance.

• Other:» Improved chamber lid seal (more reliable seal for on-orbit re-seal).» Improved thumb screw (longer, easier to engage).» Automated leak test procedure via computer under considerations.


Mechanical Interface - Hydraulics

Hydraulic Design – NDS Refill:• Science requires crew-assisted nutrient solution concentrate

refill:» Water content expected almost constant (excluding plant fresh matter and some

atmospheric moisture loss) during mission, but nutrients depleted.» Based on concentration (salinity) and pH (<4, >10), may be hazard level 2 fluid

(Bionetics to clarify). Assume hazard level 1.

• Requirements:» Connect at faceplate (syringe / QD).» Route injected nutrient solution to PTIM.» Contain fluids with adequate factors of safety (1 level). » Protects PGBA humidity condensate control and return system (over-pressurization,

salt-solution vs. distilled water).» Seamless interface to PGBA condensate return system.» Crew-applied loads.» Tethered (req.) and sealed (desire) cap when not used.


Mechanical Interface – Hydraulics 2

• Risk – Over-pressurization:» Solenoid pumps (Lee 50 ul/stroke piston pump) max. pressure = 2 psi.» Crew injection (20 lbm force, 20ml/sec, brute force) = 15 psi MDP.

– Note: PTIM tank may not be able to withstand that pressure – limit at astronaut end.

• Constraint:» Provide water make-up during crew harvest to porous plate – requires additional PGBA

water tank / cannot use PTIM water due to salinity. add new bladder tank.» Minimize / avoid changes to PGBA.


Fluid Interface


Fluid Interface

Standard Female QDC1.650.48995.50PPColderPMCD170212Colder Panel Mount PP Female

1/8 NPT Fitting1.4??136 SSColderMCD1802SST

Colder Panel mount SS Female

Standard Female QDC2.890.502416.00PVDFParker Fluid ConnectorsS2-ACV-03-BHB

Parker Female Bulkhead

Connect / Disconnect with Push / Pull2.340.949916.00PVDF

Parker Fluid ConnectorsS2-ACV-03-HBFemale Panel Mount

Standard Mail QDC2.350.45349.30PVDFParker Fluid ConnectorsS2-PNV-03-BHBParker Male Bulkhead

Small1.080.11047.60303 SSBeswickQDC-101-E-2PM-303Beswick SS Male

Cumbersome for astronaut to operate, small1.280.110410.60

303 SSBeswickQDC-101-I-2PM-303Beswick SS Female

Comment

Total Length (in)

Face Plate Size

(in^2)Mass (gm)Mat.ManufacturePart NumberDescription


Fluid Interface


Fluid Interface Location

• Location: on Faceplate or Internal ?» Bionetics requests faceplate, not internal» Mufflers cover most faceplate area – WONDER is sortie / no muffler / or on-orbit

muffler ?» Internal requires opening of PGBA (crew-time / power-down / approval to open

powered ?), but shorter lines / less bending / less backpressure.» Option: Left side (chamber I/F) above connectors, 1” spacing, tethered cap.

• QD location to be finalized.


Fluid Interface

Remaining Tasks:• QD Selection:

» Beswick (smallest, SS), Colter CPC (larger, PP).» \\Phoebe\hardware\PGBA\PGBA6-WONDER\Pressurized-

Systems\QDC_Comparison.xls

• Tubing Selection:» Tbd – materials compatibility / permeability» \\Phoebe\hardware\PGBA\Pressurized-Systems\Tubing-Selection.doc» \\Phoebe\transfer\tom\tubing_writeup.doc

• Water Tank Installation:» Metallized bladder tank, 15-25 psi ultimate, low water loss / diffusion. (APPLIED

RESEARCH PRODUCTS LTD).» \\Phoebe\hardware\PGBA\PGBA6-WONDER\Pressurized-

Systems\Sample_Bag_Options.doc

• Check Valve Selection:» \\Phoebe\hardware\PGBA\PGBA6-WONDER\Pressurized-

Systems\Check_Valve_Selection.doc


GSE Updates for Remote Operations

Operation of PGBA at Bionetics w/o BioServe presence required updates and enhancements of PGBA mechanical, automation and operations GSE equipment, as well as improved procedures / training material:

• Updated stand (mechanical interface, power supply).• Updated CO2 supply (ISS/NSTS atmosphere simulation / enriched

CO2 supply, humidity control).• Updated operations, setup and checkout procedures.• Additional training and user manuals in preparation.• EGSE documentation and updates in progress (remote operation,

commanding via KSC firewall, BioServe/Bionetics dual login,….• Webplots at: http://bioserve-boulder.colorado.edu


GSE Stand

Not used with Payload Shellto date.Additional testing necessary

\\phoebe\hardware\PGBA\GSE\Frame_Op_Manual.doc


Documentation Support

• Existing electronic documentation provided to Bionetics:» Includes PGBA4:

– Safety and Interface documentation and verifications.– Operational documents (crew and ground procedures, test procedures).

» Not all files are available electronically.» Mechanical drawing package not provided.

• Need to Update (with PGBA delivery):» Updated electrical documentation.» Updated plumbing documentation.» Updated hazard reports (?)

– Plumbing / crew interface: Bionetics or BioServe ?


WONDER-Independent Upgrades Under Considerations

• Install updated heat exchangers (enhanced corrosion protection).• Install updated porous plate frame (enhanced thermal and seal

performance).• Investigate science data analysis enhancements

» Rate of photosynthesis/respiration via draw-down and PWM flow rate.

• Investigate payload automation robustness enhancements:» Actuator failure detection (porous plate / NDS flow / pressure)» Fire detection updates via parameter monitoring as necessary.

• Update Atmosphere Treatment Performance Tests:» New GC testing.» Re-verified CO2 scrubbing selection.» Re-verifying activated carbon selection.» Re-verifying ethylene scrubbing via UV-TiO2 vs. KMnO4 / Purafil.


Open Action Items – Phase 1

Bionetics Docs: Updates/Modifications to LSSC-WONDER-EIS:• Update new 5V/12V wiring (PTIM internal 5V) (2.2.5, 2.2.6)• Update average and peak current draw numbers (3.2.1)• Update Connector P1 Wire List (3.2.2)BioServe Docs: Update PGBA-PTIM ICD:• Structures I/F (mass, C.G)• Mechanical I/F• Electrical Interface• Thermal Interface• S/W InterfaceBioServe: Update Payload Schedule:• Project timeline.• Phase 2 Contract.


Phase 2 Action Items

• NDS Hydraulics Implementation.• Electric Verification and checkout incl. video transmission.

» Flight preparation: new switcher.

• Thermal testing with simulated PTIM load. • Automation implementation incl. remote ops. support.• HW handover preparation

» Replace limited life items as necessary for successful testing.» Complete procedures and Bionetics training (test, setup, operate).

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