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
1
Acronyms
Acronyms:
•
•
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•
•
•
•
•
•
•
•
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•
•
•
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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
WONDER = PGBA + PTIM Integration Review
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References
References:
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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
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Personnel
BioServe Space Technologies:
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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:
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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
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Agenda for CDR
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•
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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
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Background
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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
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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
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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
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
Pin
01:
02:
03:
04:
05:
06:
07:
08:
09:
10:
11:
12:
13:
14:
15:
16:
17:
18:
19:
20:
21:
22:
23:
24:
25:
26:
27:
+12VDC FAN0
+12VDC FAN1
12RET
+24VDC
+ 5VDC
24RET
T chamber
rH chamber
Light sensor (WONDER/PTIM
O2 chamber
(WONDER/PTIM
+5V
5VReturn
CO2 sensor: green
CO2 sensor: yellow
CO2 sensor: gray
CO2 sensor: pink
CO2 sensor: blue
CO2 sensor: white
CO2 sensor: shield
CO2 sensor: brown
chassis ground
+RS485
-RS485
+video Ch.4
-video Ch.4 (same as pin
+video Ch.5
-video Ch.5 (same as pin
WONDER - fans - switch 15
WONDER - pumps - switch 16
WONDER - return for above
(sensor: Humitter-Y and light sensor)
(power 02sensor)
(all sensor grounds/returns)
(from Humitter-Y)
(from Humitter-Y)
not prividing this signal)
not providing this signal)
WONDER CPU power, switch 9
WONDER (same as pin 06, 25, 27)
27)
25)
WONDER/INSERT
WONDER
WONDER
WONDER
WONDER
WONDER
WONDER
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Electrical Interface - Schematic
CO2-GMM220_2
brown
shield
white
blue
pink
gray
yellow
green
OUTSIDE PGC:
Pink
Gray
Gray
Y ellow
Y ellow
Green
Green
13
15
14
13
14
16
18
17
16
15
3
2
3
red
red
black
+12VDC-FAN0-SW15
+12VDC-FAN1-SW16
12RET-FANS
Also used for WONDER 12VDC
Also used for WONDER 12VDC
Also used for WONDER 12VDC
26
Switcher
27
Note:
voltage drop due to line losses as below:
Current DCDC
PTIM
Resistance
0.000
11.95
11.950
[Ohm]
0.648
11.95
11.520
0.664
0.717
11.94
11.474
0.664
0.789
11.94
11.424
0.667
0.870
11.94
11.373
0.663
1.039
11.93
11.252
0.672
1.500
11.92
10.935
0.677
2.000
11.91
10.581
0.685
brown
27
26
26
25
25
23
1
25
24
24
23
1
22 AWG short adapter to 75 Ohm coaxial cable
TP3
TP4
TP5
1
red
Chassis Ground
2
27
11
yellow
WONDER-5V-RET
10
22
11
12
12
3
9
1
10
2
8
21
1
13
gray
WONDER-5VDC-SW09
17
19
9
WONDER 12V POWER ROUTING
14
1
WONDER 5V POWER ROUTING
18
20
20
8
21
solder splice
24AWG to 22 AWG
Switcher
Blue
Pink
15
4
1
24
12
7
white
10
11
TP2
1
19
20
TP1
1
green
5
6
19
7
22
yellow
Analog Ground
16
17
18
6
21
+5VDC
5
23
white-blue
[1-4]=Vin4=O2-Chamber
7
white-blk-green
9
[1-8]=Vin8=Light
White
Blue
4
22
6
white-blk-blue8
[1-2]=Vin3=rH chamber
to line losses is severe.
PTIM
Resistance
4.951
[Ohm]
4.821
0.510
4.798
0.508
4.786
0.506
4.740
0.564
4.697
0.508
4.601
0.501
4.564
0.506
4.462
0.503
4.302
0.510
4.167
0.518
3.899
0.520
5
white-blk-red
[1-0]=Vin0=T chamber
Note:
voltage drop due
Current DCDC
0.000
4.97
0.255
4.97
0.301
4.96
0.326
4.96
0.374
4.96
0.500
4.96
0.698
4.96
0.765
4.96
0.973
4.96
1.273
4.95
1.513
4.95
2.023
4.94
4
white
RETURN
Shield
White
<Value>
black
purple
green
blue
+5VDC
Brown
Shield
J1
ODU-27-Socket: G83F1C-T27LFD0-0000
+24VDC
Brown
TP6
solder splice
Ampro MiniModule SSP
J2 2x5 header, male
WONDER RS485 NETWORK
J2: Opt. RS232/RS485
J2
2x5 header (pin)
DCD/not used
DSR/not used
RXD/+data
RTS/-data
TXD/not used
CTS/not used
DTR/not used
RI/not used
GND/not used
EN(test use)
1
2
3
4
5
6
7
8
9
10
JP2
2x5 socket
1
2
3
4
5
6
7
8
9
10
Teflon Ribbon 28 AWG
J2
not used
not used
TXD/RXD+
TXD/RXDnot used
not used
not used
not used
not used
1
6
2
7
3
8
4
9
5
Connector D9-Female
P2
1
6
2
7
3
8
4
9
5
Twisted Pair, 22AWG
+RS485
-RS485
Connector D9-male
RS485 Serial Port:
Cable length <4,000 feet
data rates
<57.6K bps
PC104 assembly
WONDER VIDEO ROUTING
75 Ohm coax, PTFE
TO VIDEO MUX 'INPUT5'
+VIDEO(1)
-VIDEO(1)
75 Ohm coax, PTFE
TO VIDEO MUX 'INPUT4'
+VIDEO(1)
-VIDEO(1)
Video MUX
Title
WONDER I/F
WONDER = PGBA + PTIM Integration Review
Size
C
Date:
Document Number
Wonder Interface.dsn
Sheet
1
of
Thursday , October 09, 2003
Rev
B
1
9
Electrical Interface - Schematic
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Electrical Interface - Schematic
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Electrical Interface - Schematic
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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 onresistance 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
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Electrical Interface - Other
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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
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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.
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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.
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Mechanical Interface – Hydraulics 2
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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.
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Fluid Interface
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Fluid Interface
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Fluid Interface
Face
Plate Size
(in^2)
Total
Lengt
h (in)
Description
Part Number
Manufacture
Mat.
Mass
(gm)
Beswick SS Female
QDC-101-I-2PM-303
Beswick
303
SS
10.60
0.1104
1.28
Cumbersome for astronaut to
operate, small
Beswick SS Male
QDC-101-E-2PM-303
Beswick
303
SS
7.60
0.1104
1.08
Small
Parker Male Bulkhead
S2-PNV-03-BHB
Parker Fluid
Connectors
PVDF
9.30
0.4534
2.35
Standard Mail QDC
Female Panel Mount
S2-ACV-03-HB
Parker 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
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Fluid Interface
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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.
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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\PressurizedSystems\Sample_Bag_Options.doc
Check Valve Selection:
» \\Phoebe\hardware\PGBA\PGBA6-WONDER\PressurizedSystems\Check_Valve_Selection.doc
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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
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GSE Stand
Not used with Payload Shell
to date.
Additional testing necessary
\\phoebe\hardware\PGBA\GSE\Frame_Op_Manual.doc
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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 ?
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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.
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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.
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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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