WFIRST-ACS-SOW-0022-.pdf

Effective Date: January 23, 2020

National Aeronautics and Space Administration

Goddard Space Flight Center Greenbelt, Maryland

WFIRST-ACS-SOW-0022, Revision

Wide Field InfraRed Survey Telescope (WFIRST), Code 448

WFIRST Coarse Sun Sensor (CSS)

Statement of Work (SOW)

GSFC WFIRST CMO

January 23, 2020

Released

WFIRST CSS Statement of Work WFIRST-ACS-SOW-0022, Revision -ii

Wide Field InfraRed Survey Telescope (WFIRST)

Coarse Sun Sensor Statement of Work (SOW)

Review/Signature/Approval Page

Prepared by:

John Dixon

Approved by:

Jason Hylan

Electronic Approval available on-line In CM tool iii

Preface

This document is a Wide Field Infrared Survey Telescope (WFIRST)

Configuration Management (CM)-controlled document. Changes to this document require prior approval of the applicable Configuration Control Board (CCB) Chairperson or designee.

Proposed changes shall be submitted to the WFIRST CM Office (CMO), along with supportive material justifying the proposed change.

In this document, a requirement is identified by “shall,” a good practice by “should,” permission by “may” or “can,” expectation by “will,” and descriptive material by “is.”

Questions or comments concerning this document should be addressed to:

WFIRST Configuration Management Office

Mail Stop 448

Goddard Space Flight Center

Greenbelt, Maryland 20771 iv

Change History Log

Revision Effective Date Description of Changes

(Reference the CCR & CCB/ERB Approval Date)

Revision - January 23, 2020 Initial release of document per WFIRST-CCR-0135 v

Table of TBDs/TBRs/TBSs [optional]

Item No. Location Summary Individual/

Organization

Actionee

Due Date vi

Table of Contents

1.0 INTRODUCTION

1.1 Purpose

1.2 Scope

1.3 Related Documentation

1.3.1 Applicable Documents [and Forms]

1.3.2 Reference Documents

2.0 MANAGEMENT, REPORTING, REVIEWS, AND DOCUMENTATION

2.1 Program management

2.2 Reporting

2.3 Advanced Notifications

2.4 Reviews And Meetings

2.4.1 Kick-off Meeting

2.4.2 Design Conformance Review (DCR)

2.4.3 Pre-Environmental Review (PER)

2.4.4 Pre-Ship Review (PSR)

2.4.5 Technical Interchange Meetings (TIM)

2.5 Documentation

2.6 NASA/GSFC Furnished Data, Equipment, And Facilities

2.7 Existing Documentation and Analysis

3.0 DESIGN AND ANALYSIS

3.1 Interface Control Documentation

3.2 Drawing Package

3.3 Computer Models

3.3.1 CAD Model and Documentation

3.4 Structural Analysis Report

3.5 Structural Finite Element Model

3.6 Thermal Analysis Report

3.7 Thermal Model and Documentation

3.8 Radiation Hardness Analysis Report

3.9 Error Analysis Report

3.10 Stray Light Analysis Report

3.11 User/Instruction Manual

4.0 HARDWARE PROCUREMENT/MANUFACTURING

4.1 General Requirements

4.2 Coarse Sun Sensor Hardware

4.3 Connector Savers

4.4 Supporting Hardware

4.5 Ground Support Equipment

5.0 PERFORMANCE VERIFICATION AND TEST

5.1 Verification Plan

5.2 Verification Test Procedures

5.3 Verification Test Reports

vii

6.0 SAFETY AND MISSION ASSURANCE

6.1 General Requirements

6.2 Configuration Management

6.3 Training and Certification of Contractor Personnel

6.4 Ground Support Equipment Interfaces

6.5 Design Verification Requirements

6.5.1 Verification Requirements

6.5.2 Analysis, Trending, and Reporting of Test Data

6.5.3 Total and Failure-Free Operation hours

6.6 EEE Parts Requirements

6.6.1 General

6.6.2 Radiation

6.6.3 Parts Age Control

6.6.4 FPGA Programming Stations

6.7 Materials, Processes Requirements

6.7.1 Materials and Processes Control

6.7.2 Commercial-Off-The-Shelf (COTS), Vendor-Designed and Fabricated, and Bilateral

Agreement Furnished Hardware

6.7.3 M&P Usage Documentation

6.7.4 Materials Usage Agreements (MUAs)

6.7.5 Detailed Requirements

6.7.5.1 Flammability, Offgassing, and Compatibility Requirements

6.7.5.1.1 Toxic Offgassing (NASA-STD-6016A Section 4.2.1.2)

6.7.5.1.2 Fluid Compatibility (NASA-STD-6016A Section 4.2.1.3)

6.7.5.1.3 Oxygen Compatibility (NASA-STD-6016A Section 4.2.1.4)

6.7.5.1.4 Electrical Wire Insulation Materials (NASA-STD-6016A Section 4.2.1.5) 17

6.7.5.1.5 Thermal Vacuum Stability (NASA-STD-6016A Section 4.2.3.6)

6.7.5.1.6 Glycols (NASA-STD-6016A Section 4.2.3.9)

6.7.5.2 Processes

6.7.5.2.1 Adhesive Bonding (NASA-STD-6016A Section 4.2.4.5)

6.7.5.2.2 Additive Manufacturing (NASA-STD-6016A Section 4.2.4.11)

6.7.5.3 Material Nondestructive Evaluation (NDE)

6.7.5.3.1 Nondestructive Evaluation Plan (NASA-STD-6016A Section 4.2.5.1)

6.7.5.4 Special Materials Requirements

6.7.5.4.1 Fastener Installation (NASA-STD-6016A Section 4.2.6.6)

6.7.5.4.1.1 Liquid Locking Compounds (NASA-STD-6016A Section 4.2.6.6.1) . 18

6.7.5.4.2 Silver-Plated Fasteners (NASA-STD-6016A Section 4.2.6.6.2)

6.7.5.4.3 Contamination Control (NASA-STD-6016A Section 4.2.6.7)

6.7.5.4.4 Packaging (NASA-STD-6016 Section 4.2.6.8)

6.7.5.4.5 Shelf-Life Items

6.7.5.5 Verification

6.7.5.5.1 Printed Wiring Boards (PWBs)

6.7.5.5.2 Solder Flux

6.7.5.5.3 Fasteners with LL Longitudinal Locking Elements

6.7.6 Materials Procurement Requirements

6.8 Contamination Control Requirements

viii

6.8.1 Contamination Control Plan

6.8.2 Surface Cleanliness

6.8.3 Thermal Vacuum Bakeouts

7.0 HANDLING, STORAGE, PACKAGING, PRESERVATION, AND DELIVERY

APPENDIX A GSFC PCB SUBMITTAL AND MATERIAL SELECTION FORMS

APPENDIX B ABBREVIATIONS AND ACRONYMS

1.0 INTRODUCTION

1.1 Purpose

The Wide Field InfraRed Survey Telescope (WFIRST) is a mission responding to the 2010

National Research Council New Worlds, New Horizons (NWNH) Astronomy and Astrophysics

Decadal Survey top priority recommendation in the large space mission category. The science program includes two dedicated investigations to tackle outstanding questions in dark energy research and exoplanet exploration, and includes a substantial General Observer program to enable targeted investigations of astrophysical phenomena to advance other goals from the

Decadal Survey. A coronagraph instrument is included in the payload for purposes of advancing the present state of the art of coronagraph technology. This document defines the work to be performed by the Contractor in the design, development, fabrication, and delivery of the Wide

Field InfraRed Survey Telescope (WFIRST) Coarse Sun Sensor, from here on referred to as the

CSS.

1.2 Scope

The contractor shall provide the facilities, personnel, services, tools, equipment, and materials necessary to design, analyze, manufacture, test, and deliver the hardware and data in accordance with the requirements of this SOW and the documents referenced herein.

This SOW defines the contractor tasks, deliverables, responsibilities, and schedule, either within this document or by reference. More details for the Deliverable Items List and Schedule (DILS) are contained in WFIRST-ACS-LIST-0033.

The contractor shall generate a matrix listing each section in this statement of work reflecting either compliance or non-compliance. (DIL #1) Areas of non-compliance need to be addressed by the contractor showing how they plan to meet the requirement(s) or why it will remain non-compliant.

1.3 Related Documentation

In the event of a conflict between the SOW and the specification, the SOW shall take precedence.

The latest versions of all documents below shall be used unless otherwise specified in this SOW.

WFIRST documents can be obtained from URL: https://ipdtdms.gsfc.nasa.gov/.

1.3.1 Applicable Documents [and Forms]

The following documents are referenced within this document and are directly applicable or contain policies or other directive matters that are binding for the contents of this document. In the event of conflict between an Applicable Document and the content of this document, the

WFIRST Project Configuration Change Board has the final authority for conflict resolution.

Document Number Title

WFIRST-ACS-SPEC-0074 WFIRST Coarse Sun Sensor Specification

WFIRST-ACS-LIST-0033 WFIRST Coarse Sun Sensor Deliverable Items List and

Schedule (DILS) https://ipdtdms.gsfc.nasa.gov/

WFIRST-SMA-REQ-0032 WFIRST Mission Assurance Requirements

541-PG-8072.1.2C Goddard Space Flight Center Fastener Integrity Requirements

NASA-STD-6016A Standard Materials and Processes Requirements for Spacecraft

EEE-INST-002 Instructions for EEE Parts Selection, Screening, Qualification, and Derating

GSFC-STD-1000G Rules for the Design, Development, Verification, and

Operation of Flight Systems

GSFC-STD-8002 GSFC Standard Quality Assurance Requirements for the Use of

Water Soluble Flux

NASA-STD-6008 NASA Fastener Procurement, Receiving Inspection, and

Storage Practices for Spaceflight Hardware

1.3.2 Reference Documents

The following documents are referenced herein and amplify or clarify the information presented in this document. These documents are not binding on the content of this document.

Document Number Title

WFIRST-SMA-LIST-0027 WFIRST MAR Applicability Matrix

ASTM E-595-15 Standard test method for total mass loss and collected volatile condensable materials from outgassing in a vacuum environment

MSFC-SPEC-445A Adhesive Bonding, Process and Inspection, Requirements for

NASA-STD-5005 NASA Technical Standards System

2.0 MANAGEMENT, REPORTING, REVIEWS, AND

DOCUMENTATION

2.1 Program management

The contractor shall designate a single individual who will be given full responsibility and authority to manage and administer all phases of the work specified by the contract and ensure that all objectives are accomplished within schedule constraints.

The contractor shall designate and identify by name a single individual to serve as a point of contact with the NASA/GSFC Contracting Officer’s Representative (COR) for all technical aspects of the CSS contract.

The contractor shall establish and apply a program control system for managing all resources, controlling schedules, managing all engineering, manufacturing and procurement activities, configuration management, Quality Assurance, and documentation control.

2.2 Reporting

The contractor shall prepare and present to the NASA/GSFC COR monthly technical status reports via telecon and a written report. (DIL #2) The report shall be a summary presentation of the period's progress to include topics such as schedule overview, accomplishments, technical performance measures (e.g. mass and power), status of key milestones, risks, problem areas, challenges/issues, quality assurance issues/status, and activities on-going and planned. The contractor shall generate a list of significant milestones that will enable the NASA/GSFC COR to ascertain program progress. (DIL #3)

2.3 Advanced Notifications

The contractor shall notify the NASA/GSFC COR at least seven (7) calendar days in advance of all mandatory hardware inspections, test activities, TIM’s, and deliveries at either the contractor’s or a subcontractor’s facility to allow timely participation by the NASA/GSFC

Quality Assurance representative. (DIL #4) Event specific notification requirements (such as failures, anomalies, etc.) are included in the appropriate sections.

2.4 Reviews And Meetings

2.4.1 Kick-off Meeting

The Contractor shall organize and hold a Kick-off Meeting at the Contractor’s facility prior to any activity identified in this SOW. (DIL #5)

The Contractor shall provide to the NASA/GSFC COR a Kick-off Presentation Package and all other required deliverables. (DIL #6) The Kick-off Meeting shall address program management and quality assurance activities outlined in this SOW, as well as the performance and environmental requirements outlined in the CSS specification in sufficient detail to demonstrate understanding of contract requirements. At a minimum, the presentation package should cover the following areas:

Program Management

Quality Assurance

CSS Design Description

Preliminary Interface Control Documents

Flight Heritage

Facilities

Qualification Verification Plan and Procedure

Mechanical Analysis with Boundary Conditions

2.4.2 Design Conformance Review (DCR)

The contractor shall organize and present a Design Conformance Review to a GSFC Review

Team at the contractor’s facility prior to the manufacturing program. (DIL #7) The contractor shall provide to the NASA/GSFC COR a Design Conformance Review Presentation Package and all other required deliverable data prior to the review. (DIL #8) The Design Conformance

Review shall address all program management, design, drawings, analysis, manufacturing, test, and quality assurance activities outlined in this SOW and the WFIRST CSS Specification

WFIRST-ACS-SPEC-0074 in sufficient detail to ensure that the proposed design conforms to all requirements and is ready for fabrication to begin. At a minimum, the design package should cover the following areas:

Program Management

Quality Assurance

Electrical, Mechanical, and Environmental specifications

Parts, including stress analysis and radiation hardness assessment

Detailed architectural block diagrams for the different deliverable units

Fabrication, Assembly, and Inspection Flow plan

Facilities

Verification Test Plan (Including Performance Test Description)

Materials and Processes

Contamination Control (for items sensitive to contamination or with explicit surface cleanliness or outgassing requirements)

Mechanical/Structural analyses

Electrical Worst-Case analyses

Failure Modes Effects Criticality Analysis

Flight Heritage

Verification Matrix (per Section 6.5.1)

Review minutes shall be prepared and, as a minimum, include attendance, action items, action item accomplishment responsibility and agreements. All items shall be in sufficient detail to be self-explanatory. A Design Conformance Review Report shall be prepared following the review and, as a minimum, contain meeting notice, agenda, review meeting minutes described above and responses to all recommendations and action items. (DIL #9)

2.4.3 Pre-Environmental Review (PER)

The contractor shall organize and conduct a Pre-Environmental Review (PER) at the contractor’s facility before the environmental test program begins. (DIL #10) This presentation shall demonstrate overall conformance of the requirements specified in the WFIRST CSS

Specification WFIRST-ACS-SPEC-0074 and this Statement of Work for this phase of the procurement. This presentation shall cover programmatic, technical, test and verification, and quality assurance topics, and address any changes made to the Verification Matrix since DCR.

(DIL #11) This review shall also provide an opportunity to review test plans and procedures and all analyses required to approve the testing of the hardware.

2.4.4 Pre-Ship Review (PSR)

The contractor shall hold a Pre-Ship Review at the contractor's facility at the completion of verification tests and prior to the shipment of each hardware item to NASA/GSFC. (DIL #12)

This presentation shall demonstrate completion of all activities required for delivery of any hardware deliverable item to NASA/GSFC, and note any activities that are incomplete. In particular, the contractor shall present the completed verification matrix that shows verification of all requirements and presents actual data (results of tests or analyses) where applicable. (DIL

#13) Any requirements that are not met shall be identified in the Deviations/Waivers etc. list and discussed with NASA/GSFC during the review.

An End Item Data Package (EIDP) shall be made available for review during pre-ship reviews for each of the different hardware deliverables. (DIL #14) This package shall also be delivered with each end item with the level of detail required of that item. The package should be comprised of, but not limited to, the following data:

The deliverable CSS, serial number, part number, and classification status (e.g., flight, non-flight, ground support).

Appropriate approval signatures (e.g., contractor’s quality representative, product design lead, government Representative)

Work orders for the final assembly and associated tests

As-Built vs. As Designed Parts List, (EEE parts, includes serialization/revisions)

As-Built Final Drawing Package (including rework instructions, if any)

Problem/anomaly reporting (complete copies of report)

Deviations/Waivers/shortages/open items/non-conformances and their dispositions, with supporting rationale

Status of all action items from previous reviews

Class I MRBs (complete copies of reports)

List of As-Built Materials and Processes used

Achieved surface cleanliness and outgassing rate data (when applicable)

Log of total operating time and failure-free operation, separated by primary/redundant sides, if any

List and status of all identified Life-Limited Items

Trended Critical Parameters Data (when applicable)

Verification matrix (including environmental), test data and reports

Photograph Documentation (Pre and Post conformal coating, Pre-Closure and Closed)

Certificate of Conformance, with management signature

End Item Inspection Report

As-Built Configuration List

Mate/Demate log

Printed circuit board coupon results

Storage and Transportation Plans and Requirements

2.4.5 Technical Interchange Meetings (TIM)

The contractor shall plan for and facilitate up to three (3) informal, face-to-face technical interchange meetings to be held at the contractor facilities. (DIL #15) These TIMs shall support review and coordination of technical issues including, but not limited to, parts, test plans, test procedures, software changes, design modifications, and design analyses.

2.5 Documentation

The contractor shall ensure the generation and delivery of all documentation as called for in the contract (Section B Table) and listed in the DILS document, WFIRST-ACS-LIST-0033.

In addition to that documentation specifically called for in the contract, upon request by the

NASA/GSFC COR, the contractor shall make available a copy of any document or data generated during this contract performance for review by GSFC at either the contractor's facility or via the internet. This includes, but is not limited to, technical reports and memorandums, drawings, schematics, studies, analyses, parts and materials data, test data, alerts, etc.

2.6 NASA/GSFC Furnished Data, Equipment, And Facilities

Reserved

2.7 Existing Documentation and Analysis

If analysis or documentation exists already for the flight unit that satisfies the requirements within the CSS Specification, WFIRST-ACS-SPEC-0074, and the descriptions in Section 3.0, then the analysis or documentation may not need to be redone, and the requirement can be satisfied by similarity and with the delivery of the previous analysis/documentation to the

NASA/GSFC COR.

3.0 DESIGN AND ANALYSIS

The contractor shall perform analyses of the technical and environmental requirements specified in the WFIRST CSS Specification (WFIRST-ACS-SPEC-0074) to ensure compliance of the hardware fabrication and to assemble the documentation necessary to ensure its usability by

NASA/GSFC users. Previous analyses may be submitted for the items below per Section 2.7.

3.1 Interface Control Documentation

The Contractor shall provide the following documents (DIL #16):

Mechanical Interface Control Document (MICD), including physical characteristics, mounting interface, outline drawing, thermal coatings on surfaces

Electrical Interface Control Document (EICD), including connector identification, connector pinouts, detailed description of each signal, interface circuits, command description, command sequencing/timing, and data (telemetry) description (Data

Interface Control Document could be a part of this EICD or a standalone document)

3.2 Drawing Package.

The contractor shall provide a drawing package that includes, but is not limited to: (DIL #17)

ELECTRICAL: assembly and interface drawings (board level schematics available on request)

MECHANICAL: assembly and interface drawings

3.3 Computer Models

The contractor shall deliver the following computer models (DIL #18)

a) A Computer-Aided Design (CAD) file for the CSS

b) A Mechanical Model in STEP file format

3.3.1 CAD Model and Documentation

A computer aided design (CAD) model shall be delivered for the CSS components in Creo

(*.asm, *.prt) or STEP (*.stp,*.step) and ACIS (*.sat) formats to the following specifications:

- Models should include the component outer frame, connectors and backshells, and payload mounting holes at a minimum.

The preferred format is Creo utilizing a version of wildfire equal to or later than version 3. Full assembly models are desired.

3.4 Structural Analysis Report

The purpose of the structural analyses is to demonstrate compliance with the mechanical/structural design and test requirements. Structural analyses verify the structural integrity of the flight hardware by assessing the size and location of applied loads, load paths, and critical failure modes. A Structural Analysis shall be provided for the Flight Unit structure to ensure the capability to withstand and survive launch and ascent loads. (DIL #19) The analysis shall also address loads on any lift points as well. The effects of any thermal inputs shall be reflected in the analyses as appropriate. This analysis shall include a Venting analyses for applicable flight components (such as thermal blankets and contamination enclosures) susceptible to pressure loadings to verify that positive strength margins exist at loads equal to the maximum pressure differential during launch. Electronics boxes which meet the design requirements of Electronic Box Minimum Vent Area need not perform additional venting analysis. The results of these analyses shall be summarized in a contractor format Structural

Analyses Report that will be provided to the NASA/GSFC COR for review.

3.5 Structural Finite Element Model

Contractors shall submit finite element models and model documentation that describes the following: (DIL #20)

1. The version of the model, including date of creation

2. A list of element, node, property, and material identification (ID) numbers

3. A description of the nonstructural mass represented on each property card

4. A description of units

5. A description of the local reference coordinate system

6. The results of satisfying the following model validity checks

Equilibrium/grounding: Rigid body equilibrium/grounding checks using the

NASTRAN GROUNDCHECK case control statement to assess the presence of mechanisms, over-constraints, etc. for all six model degrees-of-freedom for the various constraint sets.

Free-free dynamics (showing rigid body modes): In the unconstrained condition, the deployed on-orbit model should have six rigid body modes with frequencies below 0.005 Hz, with a goal of 0.0005 Hz, and the ratio of the lowest elastic mode frequency and the highest rigid body mode frequency should be greater than 100, with a goal of 1000. In their unconstrained condition, the stowed dynamics and thermal distortion models should have six rigid body modes with frequencies below 0.001 Hz, with a goal of 0.0001 Hz.

Unit gravity loading (each axis): With the model constrained at appropriate interfaces, and 1G inertial loadings applied separately in three orthogonal directions, the sum of constrained forces in the loading direction should be within

0.01% of the model weight. The magnitude of the sums orthogonal to the loading direction should be less than 1.0 N.

Enforced displacement/rotation (all 6 degrees-of-freedom): Grounding forces will be determined by applying unit rigid body displacements and rotations to a stiffness matrix of the unsupported model, and determining the resultant grid point forces. Full capability of NASTRAN GROUNDCHECK case control can be used to determine grounding forces and moments. Grounding forces should be less than 1.0 N, and moments less than 0.5 N-m.

Matrix Conditioning Checks: The maximum ratio of any diagonal term to its corresponding term of the triangular factor matrix should be less than 5.0E7. The evaluation should be performed in a static decomposition with restraints applied to remove rigid body modes. A negative value of NASTRAN Param, Bailout, and forcing program execution with near singularities will not be used.

In NASTRAN static analysis (for instance unit gravity and thermal load checks), epsilon is a measure of the error in the load predicted from the product of stiffness matrix and solution set displacement compared to the actual input load vector

Epsilon should be less than 1.0E-8.

Unit increase temperature (if required): When thermal stress assessment are performed, model checks are needed to ensure proper results. Remove all rigid elements (if not assigning thermal expansion values), equate all material coefficients of thermal expansion and reference temperatures, assign a uniform temperature field and allow for expansion/contraction of the model in all 6 degree-of-freedom. Results should show minimal element force generation and uniform expansion/contraction.

7. Mass Properties (CG location, Inertias, and total model mass)

Contractors shall submit finite element models that adhere to the following:

1. Model submitted as a MacNeal Schwendler Corporation (MSC)/ NASA Structural

Analysis (NASTRAN) data deck, version 2016 compatible

2. All model property and material cards have descriptive names

3. Models submission is "full" model with no symmetry assumptions made to reduce model size

4. Model includes no "Super Elements"

5. Model submission includes an explicit Single Point Constraint set

6. Until actual hardware mass properties are verified and final, the finite element model is adjusted to the allowable mass for each subsystem and component

Frequency and mode shapes shall be correlated with the modal survey test results as described:

1. the frequency predictions agree with the modal survey results to within 5 percent for the first mode and 10 percent for all other significant modes up to 50 Hz.

2. the mode shape correlations between test and the analytical model should include a cross-orthogonality check ([T

(FEM)][MFEM][T

(test)] resulting in 0.9 or greater on diagonal and

0.1 or less on off-diagonals.

Note: Significant modes are identified by having equal to or more than 5% modal mass participation in a fixed base modal analysis of the instrument/subsystem. a mode shape geometric similarity check, and a static deflection check.

3.6 Thermal Analysis Report

The contractor shall provide a worst case thermal analysis that illustrates that the device and/or the electronic parts junction temperatures are within the Electrical, Electronic, and

Electromechanical (EEE) EEE-INST-002 (DIL #21) de-rated operational temperature limits when subjected to the boundary conditions specified in the CSS Specification (WFIRST-ACS-

SPEC-0074). This analysis shall be performed with the components operating at their maximum expected power dissipations. All analysis results shall be summarized in a thermal analyses report, to be provided for review as per the contract schedule. This report shall contain a comprehensive list of each component’s maximum expected power dissipation, maximum case temperature, theta JC, maximum junction temperature, and de-rated operational temperature limit. Additionally, this report shall contain a thorough description of the computer models (or reference to the documentation required from section 3.7 (Thermal Model and Documentation) of this document) and the assumptions that were used to perform the analysis including boundary conditions, surface finish thermo-optical properties, interface conductances.

3.7 Thermal Model and Documentation

The contractor shall provide reduced Thermal Math Models (TMMs) for the CSS with less than

50 nodes per box, in Thermal Desktop/SINDA format or another format pre-approved by the

WFIRST Thermal group (DIL #22).

The Thermal model documentation shall include:

Labeled figures (drawings, cross-sections, etc) in sufficient detail to show all critical components and their relative locations within the CSS

List of all critical components, their material composition and relevant properties

(density, specific heat, conductivity, etc).

Listing of other relevant modeling assumptions (boundary conditions, interface conductances, thermo-optical properties, etc)

Listing of component thermal dissipations for all operational and survival modes over which the hardware is intended to operate

If the contractor does not have the project-compatible software to create TMMs, then the contractor shall provide sufficient detailed information such that GSFC can create the

TMMs. Documentation shall be provided including detailed descriptions of all aspects of the model necessary for GSFC to run and/or recreate the TMMs.

3.8 Radiation Hardness Analysis Report

The contractor shall perform a Radiation Hardness Analysis on the CSS design to determine the effects of Total Ionizing Dose (TID), Displacement Damage Dose (DDD) and Single Event

Effects (SEE) on performance. (DIL #23) The analysis shall address all the requirements contained in WFIRST-ACS-SPEC-0074. The results of these analyses shall be summarized in a

Contractor format Radiation Hardness Analyses Report that will be provided to the NASA/GSFC

COR for review.

3.9 Error Analysis Report

An Error Analysis shall be performed on the Flight Unit CSS Design that identifies all the factors that introduce error into the accuracy of the CSS, and shows that the system can meet its performance requirements in spite of the errors. Errors may include, but not be limited to:

Alignment error, radiation effects, electronic noise, degradation of parts, optical distortions, thermal distortions, quaternion algorithm calculations, etc. An Error Tree shall be generated documenting ALL the sources of error, along with an Error Analyses Report and provided to

NASA/GSFC COR for review. (DIL #24)

3.10 Stray Light Analysis Report

Reserved

3.11 User/Instruction Manual

The contractor shall deliver a user’s guide/instruction manual for the CSS. (DIL #26).

This manual shall include setup instructions for the stimulator driver box, installation of the stimulator to the CSS, and operation of the stimulators from the stimulator driver box.

4.0 HARDWARE PROCUREMENT/MANUFACTURING

4.1 General Requirements

The contractor shall either procure or manufacture all components required to assemble, integrate, and test the CSS to support the delivery dates as called for in the contract (Section B

Table) and listed in the DILS document, WFIRST-ACS-LIST-0033.

The contractor shall assemble the quantities of CSS hardware described below. The contractor shall provide a Fabrication, Assembly, and Inspection Flow plan at the DCR that includes a step-by-step procedure that describes the method of fabrication, assembly, and inspection from piece parts to the completely assembled CSS.

4.2 Coarse Sun Sensor Hardware

The contractor shall provide the following hardware to meet the requirements of the WFIRST

CSS Specification (WFIRST-ACS-SPEC-0074).

Twenty Six (26) CSS Flight Units, including Twenty Four (24) associated Flight Baffles

(DIL #45)

Optional loaner CSS Engineering Test Unit (ETU) for two 2 week periods.

The contractor shall include in the proposal the cost to purchase all hardware including all supporting hardware.

4.3 Connector Savers

Flight Units shall be tested with connector savers to minimize mates and de-mates. Flight-like connector savers shall be delivered with each Flight Unit. (DIL # 46)

4.4 Supporting Hardware

The Contractor shall provide the following supporting hardware (DIL # 47):

One set of the mating half of the external connectors for each delivered flight unit, plus two additional sets per contract delivery schedule

Electrostatic Discharge (ESD) flight protective caps, as applicable

Closeout caps for test connectors

Non-flight CSS protective covers

4.5 Ground Support Equipment

The Contractor shall provide Ground Support Equipment to support Integration and Test activities at the Observatory level. Ground Support Equipment includes:

Twenty Four (24) CSS Stimulators (DIL #48)

One (1) or multiple CSS Stimulator Controllers capable of controlling 24 Stimulators simultaneously (DIL #48)

Shipping Container (DIL #48)

5.0 PERFORMANCE VERIFICATION AND TEST

5.1 Verification Plan

A Verification Plan shall be generated by the contractor to describe the details of how the analyses, inspections, and verification tests identified in the WFIRST CSS Specification

WFIRST-ACS-SPEC-0074 will be performed. (DIL #28) Verification tests shall demonstrate the item meets all of the specified performance requirements over the specified range of environments, measure performance parameters and reveal inadequacies in manufacturing and assembly such as workmanship or material problems. Any requirement that exceeds previous qualification test data shall be presented to the NASA/GSFC COR as part of the planning process for evaluation and a possible delta qualification test.

The plan shall state the purpose of each test, state acceptance criteria, describe in detail the test method, set up, instrumentation, data analysis methods (if applicable), and give the sequence of the tests. The plan shall include a verification matrix summarizing how all requirements are verified (analysis, inspection, test, per the definitions in the Spec.), and listing all tests that will be performed on the CSS.

This plan shall be a contractor controlled document and indicate all changes made after the initial approval by the NASA/GSFC COR. After Verification Plan approval, no changes shall be made without written NASA/GSFC COR approval.

If any individual test plans are created in addition to the master Verification Plan, such as for

Thermal Vacuum testing, those plans shall also be provided. (DIL #29)

5.2 Verification Test Procedures

The contractor shall generate Verification Test Procedures and provide them to the NASA/GSFC

COR. (DIL #30) The verification procedures shall be step-by-step instructions for performing tests outlined by the Verification Test Plan. The procedures shall define the environmental conditions for the tests, required equipment and facilities, test constraints, use of diagnostic or performance test software, operating conditions, tolerance on all input stimuli, data to be recorded and pass/fail limits.

Verification Test Procedures shall be contractor controlled documents and indicate all changes made after the initial release for review to NASA. The Thermal Vacuum Test Procedure shall include the contents listed in Section 6.8.3 for the Chamber Configuration.

5.3 Verification Test Reports

The contractor shall generate Verification Test Reports. (DIL #31) These reports shall document the results of each test that was performed, what test levels were achieved, what performance requirements were verified, what anomalies were seen, and how they were resolved. The

Thermal Vacuum Test Report may include the Bakeout results (see Section 6.8.3) if it can be delivered by the delivery date for Bakeout Test Results.

6.0 SAFETY AND MISSION ASSURANCE

6.1 General Requirements

The Contractor shall comply with the applicable safety and mission assurance requirements documented in the WFIRST Mission Assurance Requirements (MAR) (WFIRST-SMA-REQ-

0032). All corresponding deliverables shall be delivered as described in MAR Data Item

Descriptions (DIDs). Sections 1 through 4 and Sections 7 through 15 apply in their entirety.

There are some reductions in scope for Section 5, System Safety, and Section 6, Reliability, that only require support to the WFIRST Project Safety and Mission Assurance (SMA) group for component level requirements/deliverables.

The Contractor’s plan for compliance with the MAR shall be documented in the WFIRST-specific Mission Assurance Implementation Plan (MAIP) or Quality Assurance Plan. (DIL #32)

The work activities and operations of the contractor, subcontractors, and suppliers are subject to evaluation, review, survey, audit, and inspection by NASA/GSFC representative.

6.2 Configuration Management

The contractor’s Configuration Management (CM) system (available for review on request) shall control the design and hardware/software by means of drawings, specifications, and other documents and ensure all applicable changes are reviewed in a systematic manner to determine the validity and impact on performance, schedule and cost. The contractor’s Configuration

Management system shall have a change classification and impact assessment process that ensures Class I changes are forwarded to the CO for approval prior to release/incorporation.

(DIL #33) Class I changes are defined as changes that affect form, fit, function, external interfaces, or requirements as stated within this document and the CSS specification.

All other changes are considered to be Class II changes and shall be controlled and dispositioned by the contractor. All Class II changes shall be provided monthly to the NASA/GSFC COR for review purposes. (DIL #34) NASA/GSFC reserves the right to review all Class II changes for technical content to ensure the proper classification has been assigned. Any flight item that is found to be non-compliant with the quality, workmanship and performance requirements of the contract shall be dispositioned via a waiver or Materials Review Board (MRB), unless the affected item is reworked to restore compliance or is replaced with a fully compliant item. The contractor shall submit Waivers and MRBs to the NASA/GSFC COR for final approval.

A contractor QA representative shall be a member of the Configuration Control Board. The QA activities shall be defined in the Configuration Management Plan and described in detail in the

QA Plan. Related portions of the plans shall be cross-referenced.

6.3 Training and Certification of Contractor Personnel

All personnel performing work on flight hardware requiring a prerequisite set of skills and competency shall be certified as having completed the required training, appropriate to their involvement.

6.4 Ground Support Equipment Interfaces

Mechanical and electrical ground support equipment (GSE) and associated software that directly interface with flight deliverable items shall be assembled and maintained to mitigate potential risk to flight hardware. Parts and materials selection and reporting requirements are exempted as long as deliverable flight item contamination requirements are not compromised. However, all

GSE interfaces to flight hardware shall be flight quality (connectors, baseplates, etc.).

6.5 Design Verification Requirements

6.5.1 Verification Requirements

The contractor shall implement a program to verify all requirements specified in the WFIRST

CSS Specification (WFIRST-ACS-SPEC-0074).

The contractor shall provide a verification matrix defining the method of verification for each specific requirement of the CSS Specification (WFIRST-ACS-SPEC-0074) per Section 5.1 of this SOW. (DIL #28)

In-process production evaluation tests and environmental stress screening tests shall also be considered to be verification tests.

6.5.2 Analysis, Trending, and Reporting of Test Data

The contractor shall properly record, maintain and analyze test information during the normal test program to assess performance and flight worthiness and to aid in the identification and analysis of flight hardware failures and problems.

6.5.3 Total and Failure-Free Operation hours

The number of total and failure-free operating hours prior to delivery to NASA/GSFC shall be documented and delivered in the EIDP. (DIL #14/MAR DID 15-1) The requirements for the number of hours are specified in the WFIRST CSS Specification (WFIRST-ACS-SPEC-0074).

6.6 EEE Parts Requirements

6.6.1 General

The contractor shall meet the EEE Parts requirements per section 10 of the WFIRST MAR, WFIRST-SMA-REQ-0032.

6.6.2 Radiation

The predicted WFIRST mission radiation environment to be used in the radiation assessment of

EEE parts is defined in the WFIRST CSS Specification WFIRST-ACS-SPEC-0074. Test plans and reports for parts that require radiation testing shall be submitted to the NASA/GSFC COR for review. (DIL #35 & DL #36)

6.6.3 Parts Age Control

Parts more than 5 years old, comparing the part Lot Date Code (LDC) to the Project DCR date, require NASA/GSFC COR approval for use. (DIL #37) Parts drawn from inventory having lot date codes older than 5 years, shall be reviewed by the Government to determine the need for re-screen. Parts stored in conditions where moisture or ESD are not controlled shall not be used.

Contractors shall present justification with inspection and test requirements.

6.6.4 FPGA Programming Stations

Reserved

6.7 Materials, Processes Requirements

6.7.1 Materials and Processes Control

Materials, processes, and lubrication approval by the WFIRST Materials and Processes Engineer

(MPE) is required for each usage or application in spaceflight hardware with criteria, including

Data Deliverables, as follows. The contractor shall ensure the relevant requirements are flowed to vendors.

All Materials and Processes (M&P) shall be defined by standards and specifications, and be selected from government, industry, and subcontractor specifications and standards. There is a preference for the use of active government or industry specifications.

The MPE shall be a voting member of subcontractor M&P Control Boards, if established.

6.7.2 Commercial-Off-The-Shelf (COTS), Vendor-Designed and Fabricated, and Bilateral

Agreement Furnished Hardware

The use of any hardware, including those listed above, for which a detailed M&P list (as defined herein) is not available and/or an M&P List is not available for review and approval will be treated as non-compliant. A Materials Usage Agreement (MUA) shall be prepared and submitted to define what measures are taken to ensure that all M&P in the hardware are acceptable for use. Supporting rationale may include documentation supporting qualification of heritage flight hardware per GSFC-STD-1000G (Rule 1.11), documentation supporting Safety and Mission Assurance (SMA) acceptance of hardware, hermetic sealing, vacuum bake-out, material changes for known non-compliant materials, etc. The disposition of the MUA will be coordinated through the MPE.

6.7.3 M&P Usage Documentation

The Materials and Processes List shall be provided per the WFIRST MAR, WFIRST-SMA-

REQ-0032. The list of Processes will include those processes that ensure a repeatable/controlled process that produces a consistent and reliable product. An As-Built Materials List (ABML) shall be included as part of the end item data package. (DIL #14) Sample forms are available upon request.

The lists shall include the following information in an electronically searchable format:

Non-Metallics Usage List – Material Identification (including full specification, manufacturer, and part number), Mix Formula, Cure, Amount, Expected Environment, Special Reason for Selection, Outgassing Values (including reference source and test reference), Usage, MUA Number (if applicable).

Metallics Usage List – Materials Identification (including full specification), Condition, Surface Finish and/or Coating, Application, Expected Environment, Stress Corrosion

Cracking Rating, Corrosion Rating, Usage, MUA Number (if applicable), complete fastener part number (identifying material, condition, finish, locking element).

Lubrication Usage List – Component Type, Size and Material; Component Manufacturer and Manufacturer Identification; Proposed Lubrication System and Amount of Lubricant;

Type and Number of Wear Cycles; Speed, Temperature and Atmosphere of Operation;

Type of Loads and Amount; Other Details.

Material Processes Utilization List – Process Type; Contractor Specification Number;

Military, ASTM (American Society for Testing and Materials), Federal or Other

Specification; Description of Material Processed; Application.

The Materials and Processes List shall include references to Materials Usage Agreements

(MUAs) at entries for non-compliant materials and processes (see 6.7.4).

Wire, cable, and connectors shall meet the requirements of this document and be reported on the

M&P List, as well as, the PIL and ABPL. All other standard and nonstandard Electrical, Electronic, and Electromechanical (EEE) parts shall be exempt from these requirements and reporting on the Materials and Processes List. In general, items that are listed in GSFC-EEE-

INST-002 are considered standard EEE Parts.

6.7.4 Materials Usage Agreements (MUAs)

MUAs shall be submitted for all M&P that are technically acceptable but do not meet M&P requirements. (DIL #38) The MUA shall include sufficient information to demonstrate that the application is technically acceptable.

6.7.5 Detailed Requirements

Detailed Requirements in Section 4.2 of NASA-STD-6016A are applicable to all WFIRST flight hardware, except as specified below. The contractor shall ensure the relevant requirements are flowed to vendors.

6.7.5.1 Flammability, Offgassing, and Compatibility Requirements

6.7.5.1.1 Toxic Offgassing (NASA-STD-6016A Section 4.2.1.2)

This section is not applicable for this component.

6.7.5.1.2 Fluid Compatibility (NASA-STD-6016A Section 4.2.1.3)

Heritage usage may be solely considered when assessing compatibility.

6.7.5.1.3 Oxygen Compatibility (NASA-STD-6016A Section 4.2.1.4)

This section is not applicable for this component.

6.7.5.1.4 Electrical Wire Insulation Materials (NASA-STD-6016A Section 4.2.1.5)

In addition to being included in M&P Lists, wire insulation will be the reviewed by the Parts

Control Board as defined in Safety and Mission Assurance’s requirements and plans.

6.7.5.1.5 Thermal Vacuum Stability (NASA-STD-6016A Section 4.2.3.6)

Nonmetallic materials shall meet outgassing requirements defined in the WFIRST MAR, Paragraph 12.2 and DID 11-3. A Contamination Control Plan shall define the approach to mitigate outgassing, as required in the WFIRST MAR, Paragraph 12.1 and DID 12-1.

6.7.5.1.6 Glycols (NASA-STD-6016A Section 4.2.3.9)

This requirement is not applicable for this component, as glycols will not be utilized.

6.7.5.2 Processes

6.7.5.2.1 Adhesive Bonding (NASA-STD-6016A Section 4.2.4.5)

While GSFC does not specifically work to MSFC-SPEC-445A, all bonding processes should meet the intent of MSFC-SPEC-445A.

All materials are reviewed against the appropriate requirements.

Processes are qualified and documented.

The shelf life of adhesives and primers are managed. Only materials with remaining shelf life are used.

Personnel are trained and certified to perform all bonding processes.

Adhesives are handled and stored per manufacturer recommendations.

Appropriate contamination-free facilities are used for surface preparation and bonding operations.

Non-destructive techniques and destructive coupon testing is performed to verify bonding operations.

Adhesive mix records should be kept by the vendor for the duration of the mission life.

These should show date, planned mix ratio, measured mix ratio, cure parameters, and hardness coupon hardness.

6.7.5.2.2 Additive Manufacturing (NASA-STD-6016A Section 4.2.4.11)

When structural hardware is manufactured by additive manufacturing techniques, an Additive

Manufacturing and Qualification Plan shall be submitted 30 days prior to hardware fabrication.

The plan shall be approved by the Government before manufacturing begins. (DIL #39)

6.7.5.3 Material Nondestructive Evaluation (NDE)

6.7.5.3.1 Nondestructive Evaluation Plan (NASA-STD-6016A Section 4.2.5.1)

The requirements in this section of NASA-STD-6016A are applicable as written.

If it is determined that a fracture control plan is not applicable to WFIRST hardware, then an

NDE Plan is not necessary, but this determination will be documented.

6.7.5.4 Special Materials Requirements

6.7.5.4.1 Fastener Installation (NASA-STD-6016A Section 4.2.6.6)

The contractor may use NASA-STD-6008, 541-PG-8072.1.2C or a demonstrated successful contractor practice for procuring, receiving, inspecting, and storing fasteners used for spaceflight hardware with counterfeit protections. Regardless of the approach, the contractor shall provide a

Fastener Integrity Control Plan at least 30 calendar days before the DCR. (DIL #40)

The contractor shall determine if there are critical fasteners as defined by 541-PG-8072.1.2C in hardware, and provide the part number at least 30 calendar days before the DCR. (DIL #41) If there are no critical fasteners, this shall be indicated.

6.7.5.4.1.1 Liquid Locking Compounds (NASA-STD-6016A Section 4.2.6.6.1)

Conformance to the requirements on this Section of NASA-STD-6016A is recommended.

6.7.5.4.2 Silver-Plated Fasteners (NASA-STD-6016A Section 4.2.6.6.2)

The requirements in this section of NASA-STD-6016A are not a concern to WFIRST.

6.7.5.4.3 Contamination Control (NASA-STD-6016A Section 4.2.6.7)

Contamination Control is required, see Section 6.8. In addition to the materials prohibited by

NASA-STD-6016A, M&P Lists shall be screened for any materials designated as prohibited by

Contamination Control.

6.7.5.4.4 Packaging (NASA-STD-6016 Section 4.2.6.8)

The Contamination Control Plan shall define the packaging requirements for the component during shipping and storage, per Section 6.8.1.

6.7.5.4.5 Shelf-Life Items

Polymeric materials, such as adhesive films and resins, tapes, composites, o-rings, etc., have a limited shelf life. Prior to purchase, the vendor shall ensure that an appropriate storage environment (freezer, cryogenic, inert, etc.) is available for these materials. Purchased materials shall have a Certificate of Compliance, which includes, but is not limited to, the following information: identification of the material(s) or resin(s), lot and/or batch number, date of manufacture, date of expiration, and date of shipment, if applicable. Use of a procured material

(in-house or by a vendor) that has exceeded its original shelf life shall require approval from the

COR.

It is recommended that a receiving inspection be considered for items having a limited shelf life, not only to address material integrity, but also to characterize salient properties in the event a recertification (though discouraged) might be needed.

While it may be possible to recertify some materials, consideration shall be given to procuring new material as a quicker and more cost effective means to obtain flight materials.

6.7.5.5 Verification

Verification of compliance with NASA-STD-6016A consists of NASA approval of the contractor Materials and Processes Selection, Control, and Implementation Plan and other applicable materials data requirements documents, such as the Contamination Control Plan and

NDE Plan, NASA approval of MUAs, and NASA approval of MIULs.

6.7.5.5.1 Printed Wiring Boards (PWBs)

The M&P List shall contain the vendor and part number for all PWB laminate materials.

All flight…