Space engineering - Testing guidelines

This handbook provides additional information for the application of the Testing standard EN 16603-10-03.
This handbook will be the guideline for all space projects, related equipment and complete systems, by providing background information that aids the reader to better understand and meet the requirements of the standard.
The document would follow the flow of the Testing standard and in particular w hatever is excluded from the testing standard (see Scope of EN 16603-10-03) should also be excluded.
NOTE: EN 16603-10-03:2014 will be in parallel also updated to take into account the new TR.

Raumfahrttechnik - Prüfrichtlinien

Ingénierie spatiale - Lignes directrices pour les essais

Vesoljska tehnika - Smernice za preskušanje

Ta priročnik vsebuje dodatne informacije za uporabo standarda za preskušanje EN 16603-10-03.
Uporabljal se bo kot smernica za vse vesoljske projekte, povezano opremo in celovite sisteme, saj zagotavlja osnovne informacije, ki bodo bralcu pomagale bolje razumeti in izpolnjevati zahteve standarda.
Ta dokument bi moral slediti strukturi standarda za preskušanje, zlasti pa je iz njega priporočljivo izključiti vse, kar je izključeno tudi iz standarda za preskušanje (glej področje uporabe standarda EN 16603-10-03).
OPOMBA: Standard EN 16603-10-03:2014 se bo tudi sproti posodabljal tako, da bo v njem upoštevano novo tehnično poročilo (TR).

General Information

Status
Published
Public Enquiry End Date
14-Jul-2021
Publication Date
08-Sep-2022
Technical Committee
Current Stage
6060 - National Implementation/Publication (Adopted Project)
Start Date
07-Sep-2022
Due Date
12-Nov-2022
Completion Date
09-Sep-2022

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SLOVENSKI STANDARD
SIST-TP CEN/CLC/TR 17603-10-03:2022
01-oktober-2022
Vesoljska tehnika - Smernice za preskušanje
Space engineering - Testing guidelines
Raumfahrttechnik - Prüfrichtlinien
Ingénierie spatiale - Lignes directrices pour les essais
Ta slovenski standard je istoveten z: CEN/CLC/TR 17603-10-03:2022
ICS:
49.140 Vesoljski sistemi in operacije Space systems and
operations
SIST-TP CEN/CLC/TR 17603-10-03:2022 en,fr,de

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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SIST-TP CEN/CLC/TR 17603-10-03:2022
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SIST-TP CEN/CLC/TR 17603-10-03:2022
CEN/CLC/TR 17603-10-03
TECHNICAL REPORT
RAPPORT TECHNIQUE
TECHNISCHER REPORT August 2022
ICS 49.140
English version
Space engineering - Testing guidelines

Ingénierie spatiale - Lignes directrices pour les essais Raumfahrttechnik - Prüfrichtlinien

This Technical Report was approved by CEN on 16 August 2021. It has been drawn up by the Technical Committee CEN/CLC/JTC

CEN and CENELEC members are the national standards bodies and national electrotechnical committees of Austria, Belgium,

Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy,

Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of North Macedonia, Romania, Serbia,

Slovakia, Slovenia, Spain, Sweden, Switzerland, Türkiye and United Kingdom.
CEN-CENELEC Management Centre:
Rue de la Science 23, B-1040 Brussels

© 2022 CEN/CENELEC All rights of exploitation in any form and by any means Ref. No. CEN/CLC/TR 17603-10-03:2022 E

reserved worldwide for CEN national Members and for
CENELEC Members.
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CEN/CLC/TR 17603-10-03:2022
Table of contents

European Foreword ........................................................................................ 10

Introduction ..................................................................................................... 11

1 Scope ............................................................................................................ 12

2 References ................................................................................................... 13

3 Terms, definitions and abbreviated terms ................................................. 15

3.1 Terms from other documents ......................................................................... 15

3.2 Terms specific to the present document ........................................................ 15

3.2.1 dummy ............................................................................................. 15

3.3 Abbreviated terms.......................................................................................... 16

4 General requirements.................................................................................. 21

4.1 Test programme ............................................................................................ 21

4.1.1 Test programme basics .................................................................... 21

4.1.2 Specific tests .................................................................................... 23

4.1.3 Risks during testing .......................................................................... 23

4.1.4 Overtesting ...................................................................................... 24

4.1.5 Test effectiveness ............................................................................ 25

4.2 Development test prior to qualification ........................................................... 25

4.3 Test management .......................................................................................... 26

4.3.1 General ............................................................................................ 26

4.3.2 Test reviews ..................................................................................... 27

4.3.3 Test documentation .......................................................................... 29

4.3.4 Anomaly or failure during testing ...................................................... 40

4.3.5 Test data .......................................................................................... 40

4.4 Test conditions, input tolerances, and measurement uncertainties ................ 41

4.4.1 Test conditions ................................................................................. 41

4.4.2 Test input tolerances ........................................................................ 42

4.4.3 Measurement uncertainties .............................................................. 42

4.5 Test objectives ............................................................................................... 45

4.5.1 General requirements ...................................................................... 45

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4.5.2 Qualification testing .......................................................................... 45

4.5.3 Acceptance testing ........................................................................... 45

4.5.4 Protoflight testing ............................................................................. 46

4.6 Retesting ....................................................................................................... 46

4.6.1 Overview .......................................................................................... 46

4.6.2 Implementation of a design modification after completion of

qualification ...................................................................................... 46

4.6.3 Storage after protoflight or acceptance testing ................................. 46

4.6.4 Space segment element or equipment to be re-flown ....................... 46

4.6.5 Flight use of qualification Space segment element or equipment ..... 47

5 Space segment equipment test requirements .......................................... 48

5.1 General requirements .................................................................................... 48

5.2 Qualification tests requirements ..................................................................... 49

5.3 Acceptance test requirements ....................................................................... 49

5.4 Protoflight test requirements .......................................................................... 49

5.5 Space segment equipment test programme implementation requirements .... 50

5.5.1 General tests .................................................................................... 50

5.5.2 Mechanical tests .............................................................................. 53

5.5.3 Structural integrity under pressure tests ........................................... 56

5.5.4 Thermal tests ................................................................................... 57

5.5.5 Electrical/RF tests ............................................................................ 87

5.5.6 Mission specific test ......................................................................... 88

6 Space segment element test requirements ............................................... 89

6.1 General requirements .................................................................................... 89

6.2 Qualification tests requirements ..................................................................... 89

6.3 Acceptance test requirements ....................................................................... 90

6.4 Protoflight test requirements .......................................................................... 90

6.5 Space segment element test programme implementation requirements ........ 90

6.5.1 General tests .................................................................................... 90

6.5.2 Mechanical tests ............................................................................ 113

6.5.3 Structural integrity under pressure tests ......................................... 117

6.5.4 Thermal test ................................................................................... 117

6.5.5 Electromagnetic test ....................................................................... 134

6.5.6 Mission specific tests ..................................................................... 135

6.5.7 Crewed mission specific tests ........................................................ 135

7 Pre-launch testing ..................................................................................... 137

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Annex A Mechanical tests ........................................................................... 138

A.1 Foreword ..................................................................................................... 138

A.2 Physical properties measurements .............................................................. 138

A.3 Static Test ................................................................................................... 143

A.4 Spin test ...................................................................................................... 156

A.5 Centrifuge test ............................................................................................. 159

A.6 Sine burst test .............................................................................................. 161

A.7 Sinusoidal vibration test ............................................................................... 165

A.8 Random vibration testing ............................................................................. 177

A.9 Acoustic testing ........................................................................................... 182

A.10 Shock testing ............................................................................................... 188

A.11 Thermal distortion test ................................................................................. 188

A.12 Gravity release test ...................................................................................... 193

A.13 Micro-vibration environment verification by test ........................................... 194

Annex B Structural integrity under pressure tests .................................... 212

B.1 Foreword ..................................................................................................... 212

B.2 Leak test ...................................................................................................... 214

B.3 Proof pressure test ...................................................................................... 220

B.4 Pressure cycling test .................................................................................... 221

B.5 Design burst pressure test ........................................................................... 223

B.6 Burst test ..................................................................................................... 224

Annex C Audible noise test ......................................................................... 226

C.1 Space segment equipment audible noise emission test ............................... 226

C.2 Space segment element audible noise emission test ................................... 230

Annex D PIM tests ........................................................................................ 234

D.1 PIM – guidelines for equipment testing ........................................................ 234

D.2 PIM – guidelines for payload testing ............................................................ 240

D.3 PIM – Guidelines for Element testing ........................................................... 247

Annex E Alignment measurements ............................................................ 251

E.1 Purpose ....................................................................................................... 251

E.2 General ........................................................................................................ 251

E.3 Test configuration and test aspects ............................................................. 254

E.4 Test preparation .......................................................................................... 259

E.5 Test execution ............................................................................................. 260

E.6 Test evaluation ............................................................................................ 264

E.7 Other alignment methodology ...................................................................... 264

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Annex F List of test bench names .............................................................. 265

Annex G Referenced documents ................................................................ 267

Figures
Figure 4-1: Testing at S/C level and example of typical EGSE setup for JUICE S/C

(courtesy Airbus Defence and Space) ....................................................... 31

Figure 4-2: GOCE spacecraft Container ...................................................................... 33

Figure 4-3: Exomars Schiaparelli Descent Module Container ...................................... 34

Figure 4-4: AEOLUS multipurpose trolley .................................................................... 34

Figure 4-5: Lifting device for Exomars Schiaparelli Descent module............................ 35

Figure 4-6: Test input in-tolerance or out-of-tolerance assessment (decision rule) ...... 43

Figure 4-7: Conformity assessment with the guard bands approach (decision rule) .... 44

Figure 5-1: Relation between FFT, PT and RFT on equipment level ........................... 50

Figure 5-2: Unit TRP and Boundary Temperatures (conductive ITP and T ) ............. 60

Sink

Figure 5-3: Thermal vacuum test profile (example n° 1 for "type a" units) .................... 66

Figure 5-4: Thermal vacuum test profile (example n° 2 for "type a" units) .................... 66

Figure 5-5: Hot plateau TRP temperatures drive (including "type a" units switch-on) ... 70

Figure 5-6: Cold plateau TRP temperatures drive (including "type a" units switch-on) . 71

Figure 5-7: Unit temperature cycling mechanical and thermal configuration ................ 74

Figure 5-8: Some common examples of equipment flight accomodation ..................... 77

Figure 5-9: Temperature controlled support and test set-up representativeness ......... 80

Figure 6-1: Mapping of previous and current test terms in the ECSS-E-ST-10-03

standard .................................................................................................... 92

Figure 6-2: Typical sequence of tests for element level functional verification ............. 96

Figure 6-3: Logical relationship between FFT-D (or FFT-Q), FFT-W(or FFT-A) and RFT

.................................................................................................................. 99

Figure 6-4: Logical relation between model, test bench, test campaign, test item (IUT),

test environment and test infrastructure .................................................. 102

Figure 6-5: Example of an SVF based on the mapping between ECSS-E-ST-10-

02C/03C and ECSS-E-TM-10-21A .......................................................... 103

Figure 6-6: Example of solar generator unloading device for Sentinel 2 .................... 106

Figure 6-7: Exomars TGO antenna offloading device ................................................ 106

Figure 6-8: Top-level AOCS Control Chain Schematic .............................................. 110

Figure 6-9: Fit check of Galileo Spacecraft with the launch dispenser ....................... 113

Figure 6-10: Example of a thermal vacuum test profile for a space segment element 121

Figure 6-11: Unit TRP temperature control bands during space segment element

plateaux .................................................................................................. 123

Figure 6-12: Unit TRP temperatures drive feasibility (example of a P/F equipment bay)

................................................................................................................ 125

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Figure A-1 : CoG measurement along 1st lateral axis ............................................... 139

Figure A-2 : CoG measurement along 2nd lateral axis .............................................. 140

Figure A-3 : CoG measurement along vertical axis .................................................... 140

Figure A-4 : M80 physical properties measurement machine with Bepi-Colombo MCS

at ESTEC ................................................................................................ 141

Figure A-5 : WM50/6 combined CoG and MoI measurement machine with IXV STM 142
Figure A-6 : WM50/6 combined CoG and MoI measurement machine with Goce PFM

................................................................................................................ 142

Figure A-7 : Rack static test configuration-1/4 ........................................................... 146

Figure A-8 : Rack Static tests configuration-2/4 ......................................................... 146

Figure A-9 : Rack Static tests configuration-3/4 ......................................................... 147

Figure A-10 : Rack Static tests configuration-4/4 ....................................................... 147

Figure A-11 : Automated Transfer Vehicle (ATV) primary structure test article .......... 149

Figure A-12 : Setting of ATV primary structure static test .......................................... 150

Figure A-13 : ATV static test fixtures: “Base” to constrain the test article and “Tower” to

support the internal jacks ........................................................................ 151

Figure A-14 : ATV static test: internal loading jacks arrangement .............................. 152

Figure A-15 : ATV static test: internal loading jacks details ........................................ 153

Figure A-16 : ATV static test: external view and external loading jacks ..................... 154

Figure A-17 : ATV static test: layout of the displacement transducers ....................... 155

Figure A-18 : Dynamic balancing facility installed in a vacuum chamber (Large Space

Simulator at ESTEC) ............................................................................... 157

Figure A-19 : Meteosat Flight Model during spin test ................................................. 157

Figure A-20 : GPM spacecraft undertakes centrifuge test at Goddard (courtesy of

NASA) ..................................................................................................... 160

Figure A-21 : Centrifuge test of ExoMars Descent Module (courtesy of Lavoshkin) ... 160

Figure A-22 : Example of Sine Burst with a frequency of 15 Hz and 6 cycles at
maximum load of 12g (figure taken from NESC Technical Bulletin 15-02)

................................................................................................................ 163

Figure A-23 : Example of primary and secondary notching ........................................ 171

Figure A-24 : Typical Sine excitation at spacecraft base ............................................ 176

Figure A-25 : Example of test sequence for random vibration.................................... 181

Figure A-26 : Typical full level random specification .................................................. 181

Figure A-27 : Rosetta in the ESTEC Large Acoustic Facility ...................................... 184

Figure A-28 -Antenna reflector acoustic test in ESTEC acoustic facility ..................... 184

Figure A-29 : ATV STM-B Solar array wing in IABG reverberant chamber (Courtesy

Dutch Space) .......................................................................................... 186

Figure A-30 : Typical acoustic noise specification ...................................................... 187

Figure A-31 : LISA Pathfinder Science Module structure on kinematic support for

thermal distortion test .............................................................................. 188

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Figure A-32 : Typical temperature profile for thermal distortion test ........................... 189

Figure A-33 : Illustration of different courses of laser beams for LISA Pathfinder

Science Module thermal distortion test .................................................... 190

Figure A-34 : Videogrammetry measurements during LISA Pathfinder Science Module

thermal distortion test .............................................................................. 191

Figure A-35 : Overview of camera positions used during LISA Pathfinder Science
Module thermal distortion test to generate the images of the test article . 191

Figure A-36 : Displacement of targets mounted on LPF SCM external structure for a

temperature variation from +9,5°C (reference temperature) to +40,5°C .. 192
Figure A-37 : NIRSpec engineering test unit (ETU) during gravity-release test

(courtesy: EADS Astrium) ....................................................................... 194

Figure A-38 Principle of measurement of the micro-vibration generated by an

equipment ............................................................................................... 195

Figure A-39 : ESA reaction wheel characterisation facility in room conditions and in with

vacuum bell (mN range frequency band up to 1 kHz ) ............................. 196

Figure A-40 : Micro-vibration measurement test, indirect force characterisation ........ 198

Figure A-41 : Example of test instrumentation for micro-vibration test at equipment level

using indirect method measurement ........................................................ 199

Figure A-42 : View of test instrumentation during Water Pump Assembly (WPA) micro-

vibration test at equipment level using indirect method measurement ..... 199

Figure A-43 : Test setup for a test of equipment susceptibility to microvibrations ...... 202

Figure A-44 : Micro-vibration measurement system of ESA ESTEC allows 6 Dof

excitation and 6 Dof measurement .......................................................... 202

Figure A-45 : Example of configuration used for the microvibration test on MTG, by

using small shakers (grey) to introduce well defined excitations on a mass

dummy of a reaction wheel...................................................................... 204

Figure A-46 : Example of configurations used for the microvibration test on MTG, by

using small shakers (grey) to introduce well defined excitations on a mass
dummy of a reaction wheel. Force (left), and moments (centre and right)

................................................................................................................ 205

Figure A-47 : SPOT4 satellite micro-vibration test ..................................................... 207

Figure A-48 : Typical background noise acceleration PSD ........................................ 208

Figure A-49 : VVIS acceptance test time history red top surface blue – bottom input 210

Figure A-50 : ESA micro-vibration universal reference excitation unit (0,05 Hz to 10Hz,

10 μN to 5 N, 10 µNm to 1,5 Nm) ............................................................ 210

Figure A-51 : Typical table for microvibration emission measurement (mN range limited

frequency bandwidth) .............................................................................. 211

Figure B-1 : Sketch of the Vacuum chamber method ................................................ 215

Figure B-2 : Accumulation Leak Test set up .............................................................. 216

Figure B-3 : Enclosure Calibration ............................................................................. 216

Figure B-4 : Cupola Accumulation leak test overview ................................................ 216

Figure B-5 : Cupola Accumulation Leak Test He capillary leak source ...................... 217

Figure B-6 : Node 2 accumulation leak test on a joint _typical set-up ........................ 217

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Figure C-1 : View of Water Pump Assembly (WPA) test article during audible noise test

at equipment level ................................................................................... 227

Figure C-2 : Example of test instrumentation plan for audible noise test at equipment

level ........................................................................................................ 227

Figure C-3 : View of test instrumentation during Water Pump Assembly (WPA) audible

noise test at equipment level ................................................................... 228

Figure C-4 : View of COLUMBUS test article (external view: seen from deck-aft

perspective) during audible noise test at element level ............................ 230

Figure C-5 : Illustration of different microphone position inside COLUMBUS during

audible noise test at element level........................................................... 231

Figure C-6 : Picture of COLUMBUS internal microphones during audible noise test at

element level ........................................................................................... 232

Figure D-1 : Sketch from a typical Conducted PIM test bed ....................................... 235

Figure D-2 : Radiated PIM test bed: each carrier is transmitted via a dedicated antenna

................................................................................................................ 235

Figure D-3 : Radiated PIM test bed: both carriers are transmitted by the same antenna

................................................................................................................ 236

Figure D-4 : Radiated PIM test bed: both carriers are transmitted via the same antenna

................................................................................................................ 236

Figure D-5 : Typical RF power profile for PIM tests: transmission carriers. ................ 238

Figure D-6 : Typical element (payload) inside an anechoic chamber for validation tests

under nominal scenario. .......................................................................... 240

Figure D-7 : Test bed placed to radiate the anechoic chamber walls according to

payload disposition. ................................................................................. 242

Figure D-8 : Radiated PIM test bed: each carrier is transmitted via a dedicated antenna

................................................................................................................ 242

Figure D-9 : Radiated PIM test bed: both carriers are transmitted by the same antenna

................................................................................................................ 243

Figure D-10 : Radiated PIM test bed: both carriers are transmitted via the same

antenna ................................................................................................... 243

Figure D-11 : Typical RF power profile for PIM tests: transmission carriers. .............. 245

Figure E-1 Coordinate Systems relationship .............................................................. 252

Figure E-2 : General sketch of a laser tracker ........................................................... 255

Figure E-3 : Typical setup for alignment using laser tracker ...................................... 256

Figure E-4 : Laser tracker axis and laser beam ......................................................... 256

Figure E-5 : Theodolites main components ............................................................... 258

Figure E-6 : Typical Theodolites ................................................................................ 258

Figure E-7 : Measurement setup with theodolites ...................................................... 260

Figure E-8 : Laser Tracker environment creation ....................................................... 262

Figure E-9 : Laser tracker (Aligned to MBS) measuring theodolite line of sight .......... 263

Figure E-10 : Corner Cube Reflector ......................................................................... 263

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Tables

Table 4-1: Typical EGSE/SCOE list ............................................................................. 32

Table 5-1: Nomenclature for temperature cycling implementation on "type a" units ..... 65

Table 5-2: Thermal vacuum step by step procedure (example n° 1 for "type a" units) . 67

Table 5-3: Thermal vacuum step by step procedure (example n° 2 for "type a" units) . 68

Table 6-1: List of typical Space segment element models on which functional tests are

executed (Verification Level: Space segment el
...

SLOVENSKI STANDARD
kSIST-TP FprCEN/CLC/TR 17603-10-03:2021
01-julij-2021
Vesoljska tehnika - Smernice za preskušanje
Space engineering - Testing guidelines
Raumfahrttechnik - Prüfrichtlinien
Ingénierie spatiale - Lignes directrices pour les essais
Ta slovenski standard je istoveten z: FprCEN/CLC/TR 17603-10-03
ICS:
49.140 Vesoljski sistemi in operacije Space systems and
operations
kSIST-TP FprCEN/CLC/TR 17603-10- en,fr,de
03:2021

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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kSIST-TP FprCEN/CLC/TR 17603-10-03:2021
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kSIST-TP FprCEN/CLC/TR 17603-10-03:2021
TECHNICAL REPORT
FINAL DRAFT
FprCEN/CLC/TR 17603-
RAPPORT TECHNIQUE
10-03
TECHNISCHER BERICHT
April 2021
ICS 49.140
English version
Space engineering - Testing guidelines

Ingénierie spatiale - Lignes directrices pour les essais Raumfahrttechnik - Prüfrichtlinien

This draft Technical Report is submitted to CEN members for Vote. It has been drawn up by the Technical Committee

CEN/CLC/JTC 5.

CEN and CENELEC members are the national standards bodies and national electrotechnical committees of Austria, Belgium,

Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy,

Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Republic of North Macedonia, Romania, Serbia,

Slovakia, Slovenia, Spain, Sweden, Switzerland, Turkey and United Kingdom.

Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are

aware and to provide supporting documentation.

Warning : This document is not a Technical Report. It is distributed for review and comments. It is subject to change without

notice and shall not be referred to as a Technical Report.
CEN-CENELEC Management Centre:
Rue de la Science 23, B-1040 Brussels

© 2021 CEN/CENELEC All rights of exploitation in any form and by any means Ref. No. FprCEN/CLC/TR 17603-10-03:2021 E

reserved worldwide for CEN national Members and for
CENELEC Members.
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kSIST-TP FprCEN/CLC/TR 17603-10-03:2021
FprCEN/CLC/TR 17603-10-03:2021 (E)
Table of contents

European Foreword ........................................................................................ 15

Introduction ..................................................................................................... 16

1 Scope ............................................................................................................ 17

2 References ................................................................................................... 18

3 Terms, definitions and abbreviated terms ................................................. 20

3.1 Terms from other documents ......................................................................... 20

3.2 Terms specific to the present document ........................................................ 20

3.3 Abbreviated terms.......................................................................................... 20

4 General requirements.................................................................................. 26

4.1 Test programme ............................................................................................ 26

4.1.1 Test programme basics .................................................................... 26

4.1.2 Specific tests .................................................................................... 28

4.1.3 Risks during testing .......................................................................... 28

4.1.4 Overtesting ...................................................................................... 29

4.1.5 Test effectiveness ............................................................................ 30

4.2 Development test prior to qualification ........................................................... 30

4.3 Test management .......................................................................................... 31

4.3.1 General ............................................................................................ 31

4.3.2 Test reviews ..................................................................................... 32

4.3.2.1 Test programme ............................................................................ 32

4.3.2.2 Test readiness review (TRR) ........................................................ 32

4.3.2.3 Post test review (PTR) .................................................................. 32

4.3.2.4 Test review board (TRB) ............................................................... 33

4.3.3 Test documentation .......................................................................... 33

4.3.3.1 General .......................................................................................... 33

4.3.3.2 Assembly, integration and test plan .............................................. 33

4.3.3.3 Test specification (TSPE) .............................................................. 40

4.3.3.4 Test procedure (TPRO) ................................................................. 42

4.3.3.5 Test report (TRPT) ........................................................................ 42

4.3.4 Anomaly or failure during testing ...................................................... 43

4.3.5 Test data .......................................................................................... 43

4.4 Test conditions, input tolerances, and measurement uncertainties ................ 43

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4.4.1 Test conditions ................................................................................. 43

4.4.2 Test input tolerances ........................................................................ 45

4.4.3 Measurements uncertainties ............................................................ 45

4.5 Test objectives ............................................................................................... 47

4.5.1 General requirements ...................................................................... 47

4.5.2 Qualification testing .......................................................................... 48

4.5.3 Acceptance testing ........................................................................... 48

4.5.4 Protoflight testing ............................................................................. 48

4.5.4.1 Overview........................................................................................ 48

4.5.4.2 Requirements ................................................................................ 48

4.6 Retesting ....................................................................................................... 49

4.6.1 Overview .......................................................................................... 49

4.6.2 Implementation of a design modification after completion of

qualification ...................................................................................... 49

4.6.3 Storage after protoflight or acceptance testing ................................. 49

4.6.4 Space segment element or equipment to be re-flown ....................... 49

4.6.5 Flight use of qualification Space segment element or equipment ..... 49

5 Space segment equipment test requirements .......................................... 50

5.1 General requirements .................................................................................... 50

5.2 Qualification tests requirements ..................................................................... 51

5.3 Acceptance test requirements ....................................................................... 51

5.4 Protoflight test requirements .......................................................................... 51

5.5 Space segment equipment test programme implementation requirements .... 51

5.5.1 General tests .................................................................................... 51

5.5.1.1 Functional and performance tests ................................................. 51

5.5.1.2 Humidity test .................................................................................. 53

5.5.1.3 Life test .......................................................................................... 53

5.5.1.4 Burn-in test .................................................................................... 54

5.5.2 Mechanical tests .............................................................................. 54

5.5.2.1 Physical properties measurements ............................................... 54

5.5.2.2 Acceleration test (static, spin or sine burst) .................................. 55

5.5.2.3 Random vibration test ................................................................... 56

5.5.2.4 Acoustic test .................................................................................. 56

5.5.2.5 Sinusoidal vibration test ................................................................ 56

5.5.2.6 Shock test ...................................................................................... 57

5.5.2.7 Micro-vibration generated environment test .................................. 57

5.5.2.8 Micro-vibration susceptibility test .................................................. 57

5.5.3 Structural integrity tests .................................................................... 57

5.5.3.1 Leak test ........................................................................................ 57

5.5.3.2 Proof pressure test ........................................................................ 57

5.5.3.3 Pressure cycling test ..................................................................... 58

5.5.3.4 Design burst pressure test ............................................................ 58

5.5.3.5 Burst test ....................................................................................... 58

5.5.4 Thermal tests ................................................................................... 58

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5.5.4.1 Guidelines to thermal vacuum test and to thermal ambient test at

mission pressure ........................................................................... 60

5.5.4.2 Guidelines to thermal vacuum test ................................................ 84

5.5.4.3 Guidelines to thermal ambient test at mission pressure ............... 85

5.5.4.4 Alternative thermal approaches .................................................... 85

5.5.5 Electrical/RF tests ............................................................................ 88

5.5.5.1 EMC Test....................................................................................... 88

5.5.5.2 Magnetic test ................................................................................. 88

5.5.5.3 ESD Test ....................................................................................... 88

5.5.5.4 Passive intermodulation test ......................................................... 89

5.5.5.5 Multipactor test .............................................................................. 89

5.5.5.6 Corona and arc discharge test ...................................................... 89

5.5.6 Mission specific test ......................................................................... 89

5.5.6.1 Audible noise test .......................................................................... 89

6 Space segment element test requirements ............................................... 90

6.1 General requirements .................................................................................... 90

6.2 Qualification tests requirements ..................................................................... 90

6.3 Acceptance test requirements ....................................................................... 91

6.4 Protoflight test requirements .......................................................................... 91

6.5 Space segment element test programme implementation requirements ........ 91

6.5.1 General tests .................................................................................... 91

6.5.1.1 Optical alignment measurement ................................................... 91

6.5.1.2 Functional tests ............................................................................. 91

6.5.1.3 Performance test ......................................................................... 108

6.5.1.4 Mission test ................................................................................. 109

6.5.1.5 Polarity test .................................................................................. 110

6.5.1.6 Launcher interface test ................................................................ 112

6.5.2 Mechanical tests ............................................................................ 113

6.5.2.1 Physical properties measurements ............................................. 113

6.5.2.2 Modal survey test ........................................................................ 114

6.5.2.3 Static load test ............................................................................. 114

6.5.2.4 Spin Test ..................................................................................... 114

6.5.2.5 Transient test ............................................................................... 114

6.5.2.6 Acoustic test ................................................................................ 115

6.5.2.7 Random vibration test ................................................................. 115

6.5.2.8 Sinusoidal vibration test .............................................................. 116

6.5.2.9 Shock test .................................................................................... 116

6.5.2.10 Micro-vibration susceptibility test ................................................ 117

6.5.3 Structural integrity tests .................................................................. 117

6.5.3.1 Proof pressure test ...................................................................... 117

6.5.3.2 Pressure cycling test ................................................................... 117

6.5.3.3 Design burst pressure test .......................................................... 117

6.5.3.4 Leak test ...................................................................................... 117

6.5.4 Thermal test ................................................................................... 118

6.5.4.1 Guidelines to thermal vacuum test and to thermal ambient test at

mission pressure ......................................................................... 120

6.5.4.2 Guidelines to thermal vacuum test .............................................. 133

6.5.4.3 Guidelines to thermal ambient test at mission pressure ............. 134

6.5.4.4 Thermal balance test ................................................................... 135

6.5.5 Electromagnetic test ....................................................................... 135

6.5.5.1 General ........................................................................................ 135

6.5.5.2 Electromagnetic compatibility test ............................................... 135

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6.5.5.3 Electromagnetic auto-compatibility test ....................................... 136

6.5.5.4 Passive intermodulation test ....................................................... 136

6.5.5.5 Magnetic field measurements ..................................................... 136

6.5.6 Mission specific tests ..................................................................... 136

6.5.6.1 Aero-thermodynamic test ............................................................ 136

6.5.7 Crewed mission specific tests ........................................................ 136

6.5.7.1 Micro-vibration emission test ....................................................... 136

6.5.7.2 Human factor engineering (HFE) test ......................................... 136

6.5.7.3 Toxic off gassing test ................................................................... 136

6.5.7.4 Audible noise test ........................................................................ 136

7 Pre-launch testing ..................................................................................... 138

Annex A Mechanical tests ........................................................................... 139

A.1 Foreword ..................................................................................................... 139

A.2 Physical properties measurements .............................................................. 139

A.2.1 Purpose ......................................................................................... 139

A.2.2 General .......................................................................................... 139

A.3 Static Test ................................................................................................... 144

A.3.1 Purpose ......................................................................................... 144

A.3.2 General .......................................................................................... 144

A.3.3 Definition of static test configuration and load cases ...................... 144

A.3.4 Static test evaluation ...................................................................... 149

A.4 Spin test ...................................................................................................... 157

A.4.1 Purpose ......................................................................................... 157

A.4.2 General .......................................................................................... 157

A.4.3 Test configuration and test aspects ................................................ 157

A.4.4 Test Instrumentation ...................................................................... 158

A.4.5 Test control parameters ................................................................. 159

A.4.6 Test Preparation ............................................................................ 159

A.4.7 Test execution ................................................................................ 159

A.4.8 Test Evaluation .............................................................................. 159

A.5 Centrifuge test ............................................................................................. 160

A.5.1 Purpose ......................................................................................... 160

A.5.2 General .......................................................................................... 160

A.5.3 Test configuration and test aspects ................................................ 160

A.5.4 Test instrumentation ....................................................................... 161

A.5.5 Test control parameters ................................................................. 162

A.5.6 Test preparation ............................................................................. 162

A.5.7 Test execution ................................................................................ 162

A.5.8 Test evaluation ............................................................................... 162

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A.6 Sine burst test .............................................................................................. 162

A.6.1 Purpose ......................................................................................... 162

A.6.2 General .......................................................................................... 162

A.6.3 Test configuration and test aspects ................................................ 163

A.6.4 Test instrumentation ....................................................................... 163

A.6.5 Test control parameters ................................................................. 163

A.6.6 Test Preparation ............................................................................ 164

A.6.7 Test execution ................................................................................ 164

A.6.8 Test Evaluation .............................................................................. 165

A.7 Sinusoidal vibration test ............................................................................... 165

A.7.1 Purpose ......................................................................................... 165

A.7.2 General .......................................................................................... 166

A.7.3 Test configuration and test aspects ................................................ 166

A.7.4 Test preparation ............................................................................. 172

A.7.5 Test execution ................................................................................ 175

A.7.6 Test run evaluation......................................................................... 176

A.8 Random vibration testing ............................................................................. 176

A.8.1 Purpose ......................................................................................... 176

A.8.2 General .......................................................................................... 176

A.8.3 Test configuration and test aspects ................................................ 177

A.8.4 Test Preparation ............................................................................ 179

A.8.5 Test Execution ............................................................................... 179

A.8.6 Test run Evaluation ........................................................................ 180

A.9 Acoustic testing ........................................................................................... 181

A.9.1 Purpose ......................................................................................... 181

A.9.2 General .......................................................................................... 181

A.9.3 Test Configuration and test aspects ............................................... 181

A.9.4 Test preparation ............................................................................. 183

A.9.5 Test execution ................................................................................ 184

A.9.6 Test evaluation ............................................................................... 184

A.10 Shock testing ............................................................................................... 184

A.11 Thermal distortion test ................................................................................. 185

A.11.1 Purpose ......................................................................................... 185

A.11.2 General .......................................................................................... 185

A.11.3 Test configuration and test aspects ................................................ 185

A.11.4 Test instrumentation ....................................................................... 186

A.11.5 Temperature measurement ............................................................ 189

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A.11.6 Test evaluation ............................................................................... 190

A.12 Gravity release test ...................................................................................... 190

A.12.1 Purpose ......................................................................................... 190

A.12.2 General .......................................................................................... 190

A.12.3 Test configuration and test aspects ................................................ 190

A.13 Micro-vibration environment verification by test ........................................... 191

A.13.1 Characterisation of the disturbance generated by an equipment –

direct force measurement ............................................................... 191

A.13.2 Characterisation of the disturbance generated by an equipment –

indirect force measurement ............................................................ 194

A.13.3 Characterisation of the susceptibility of an equipment/instrument to

microvibrations ............................................................................... 199

A.13.4 Characterisation at element level of a transfer function between a
source of disturbance and an equipment/instrument ...................... 201
A.13.5 Micro-vibration susceptibility test at element level (End to End

test) ................................................................................................ 203

A.13.6 Background noise characterisation and reduction .......................... 206

Annex B Structural integrity tests ............................................................... 210

B.1 Foreword ..................................................................................................... 210

B.2 Leak test ...................................................................................................... 211

B.2.1 Purpose ......................................................................................... 211

B.2.2 General .......................................................................................... 212

B.2.3 Test Configuration and Test Aspects ............................................. 212

B.2.4 Test Instrumentation ...................................................................... 216

B.2.5 Test control Parameters ................................................................. 217

B.2.6 Test Preparation ............................................................................ 217

B.2.7 Test Execution ............................................................................... 217

B.2.8 Test Evaluation .............................................................................. 217

B.3 Proof pressure test ...................................................................................... 218

B.3.1 Purpose ......................................................................................... 218

B.3.2 General .......................................................................................... 218

B.3.3 Test configuration and Test Aspects .............................................. 218

B.3.4 Test Instrumentation ...................................................................... 218

B.3.5 Test Control Parameters ................................................................ 219

B.3.6 Test Preparation ............................................................................ 219

B.3.7 Test Execution ............................................................................... 219

B.3.8 Test Evaluation .............................................................................. 219

B.4 Pressure cycling test .................................................................................... 219

B.4.1 Purpose ......................................................................................... 219

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B.4.2 General .......................................................................................... 219

B.4.3 Test configuration and Test Aspects .............................................. 220

B.4.4 Test Instrumentation ...................................................................... 220

B.4.5 Test Control Parameters ................................................................ 220

B.4.6 Test Preparation ............................................................................ 220

B.4.7 Test Execution ............................................................................... 220

B.4.8 Test Evaluation .............................................................................. 220

B.5 Design burst pressure test ........................................................................... 221

B.5.1 Purpose ......................................................................................... 221

B.5.2 General .......................................................................................... 221

B.5.3 Test configuration and Test Aspects .............................................. 221

B.5.4 Test Instrumentation ...................................................................... 221

B.5.5 Test Control Parameters ................................................................ 221

B.5.6 Test Preparation ............................................................................ 221

B.5.7 Test Execution .................................................
...

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