WONDER = PGBA + PTIM Integration Review 1 WONDER = PGBA6 + PTIM Integration Review Integration /...

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 Technologies

University of Coloradoand

The Bionetics Corporation,

Space Life Sciences Lab (SLSL), NASA KSC

09 October 2003


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/Management

PI:

• 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

RX D/+data

red

[1-4]=V in4=O2-Chamber

not used

Also used for WONDER 12VDC

E N(test use)

white

TX D/RX D-

TP 21

blackAlso used for WONDER 12VDC

Video MUX

Teflon Ribbon 28 AWG

white

Wonder Interface.dsn B

WONDER I/F

C1 1Thursday, October 09, 2003

Title

S ize Document Number Rev

Date: S heet of

Green

yellow

WONDER-5V-RET

WONDER RS485 NETWORK

CTS /not used

+V IDE O(1)

+12V DC-FA N0-S W 15

J22x5 header (pin)

123456789

10

brown

Switcher

DS R/not used

WONDER VIDEO ROUTING

-V IDE O(1)

J2: Opt. RS232/RS485

not used

gray

purple+24V DC

WONDER 12V POWER ROUTING

B lue

GND/not used

OUTSIDE PGC:

[1-0]=V in0=T chamber

JP 22x5 socket

12345678910

black

Switcher

green

green

Chassis Ground

A nalog 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

-RS 485

+5V DC

TP 11

Twisted Pair, 22AWG

yellow

not used

CO2-GMM220_2

<Value>

B rown

S hield

W hite

B lue

P ink

Gray

Yellow

Green

TX D/not used

TP 6

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

S hield

white-blk-red

12RE T-FA NS

+RS 485

TP 5

1

RI/not used

J2

Connector D9-Female

594837261

TO VIDEO MUX 'INPUT4'

blue

B rown

+12V DC-FA N1-S W 16

not used

white-blk-blue

P 2

Connector D9-male

594837261

+5V DC

22 AWG short adapter to 75 Ohm coaxial cable

solder splice

[1-8]=V in8=Lightwhite-blk-green

RTS /-data

75 Ohm coax, PTFE

solder splice24AWG to 22 AWG

white

white-blue

P ink

75 Ohm coax, PTFE

shield

not used

-V IDE O(1)

yellow

Ampro MiniModule SSP

J2 2x5 header, male

TX D/RX D+

Gray

TO VIDEO MUX 'INPUT5'

DTR/not used

brown

PC104 assembly

[1-2]=V in3=rH chamber

TP 3

1

12

5

1

23

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

+V IDE O(1)

W hite

red

TP 4

1

RE TURN







• 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


Fluid Interface

Description Part Number Manufacture Mat.Mass (gm)

Face Plate Size

(in^2)

Total Length (in) Comment

Beswick SS Female QDC-101-I-2PM-303 Beswick303 SS 10.60 0.1104 1.28

Cumbersome for astronaut to operate, small

Beswick SS Male QDC-101-E-2PM-303 Beswick303 SS 7.60 0.1104 1.08 Small

Parker Male Bulkhead S2-PNV-03-BHBParker Fluid Connectors PVDF 9.30 0.4534 2.35 Standard Mail QDC

Female Panel Mount S2-ACV-03-HBParker Fluid Connectors PVDF 16.00 0.9499 2.34

Connect / Disconnect with Push / Pull

Parker Female Bulkhead S2-ACV-03-BHB

Parker Fluid Connectors PVDF 16.00 0.5024 2.89 Standard Female QDC

Colder Panel mount SS Female MCD1802SST Colder

136 SS ? ? 1.4 1/8 NPT Fitting

Colder Panel Mount PP Female PMCD170212 Colder PP 5.50 0.4899 1.65 Standard Female QDC


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_Sel

ection.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 Interface

BioServe: 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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