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WONDER = PGBA6 + PTIM Integration Review

WONDER = PGBA6 + PTIM Integration Review. Integration / Design Review Phase 1 Contract April – September 2003 PTIM Integration into PGBA BioServe Space Technologies University of Colorado and The Bionetics Corporation, Space Life Sciences Lab (SLSL), NASA KSC 09 October 2003.

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WONDER = PGBA6 + PTIM Integration Review

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  1. WONDER = PGBA6 + PTIM Integration Review Integration / Design Review Phase 1 Contract April – September 2003 PTIM Integration into PGBA BioServe Space Technologies University of Colorado and The Bionetics Corporation, Space Life Sciences Lab (SLSL), NASA KSC 09 October 2003 WONDER = PGBA + PTIM Integration Review

  2. 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 Acronyms WONDER = PGBA + PTIM Integration Review

  3. 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 References WONDER = PGBA + PTIM Integration Review

  4. 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 WONDER = PGBA + PTIM Integration Review

  5. 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 WONDER = PGBA + PTIM Integration Review

  6. 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 WONDER = PGBA + PTIM Integration Review

  7. 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) WONDER = PGBA + PTIM Integration Review

  8. Electrical Interface • Single Interface Connector to PGBA Chamber • 27 pins, share power, analog data, digital signal, digital communication WONDER = PGBA + PTIM Integration Review

  9. Electrical Interface - Schematic WONDER = PGBA + PTIM Integration Review

  10. Electrical Interface - Schematic WONDER = PGBA + PTIM Integration Review

  11. Electrical Interface - Schematic WONDER = PGBA + PTIM Integration Review

  12. Electrical Interface - Schematic • 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 WONDER = PGBA + PTIM Integration Review

  13. 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 WONDER = PGBA + PTIM Integration Review

  14. 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. WONDER = PGBA + PTIM Integration Review

  15. 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. WONDER = PGBA + PTIM Integration Review

  16. 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. WONDER = PGBA + PTIM Integration Review

  17. Fluid Interface WONDER = PGBA + PTIM Integration Review

  18. Fluid Interface WONDER = PGBA + PTIM Integration Review

  19. Fluid Interface WONDER = PGBA + PTIM Integration Review

  20. Fluid Interface WONDER = PGBA + PTIM Integration Review

  21. 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. WONDER = PGBA + PTIM Integration Review

  22. 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 WONDER = PGBA + PTIM Integration Review

  23. 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 WONDER = PGBA + PTIM Integration Review

  24. GSE Stand Not used with Payload Shell to date. Additional testing necessary \\phoebe\hardware\PGBA\GSE\Frame_Op_Manual.doc WONDER = PGBA + PTIM Integration Review

  25. 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 = PGBA + PTIM Integration Review

  26. 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. WONDER = PGBA + PTIM Integration Review

  27. 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. WONDER = PGBA + PTIM Integration Review

  28. 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). WONDER = PGBA + PTIM Integration Review

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