Harness Tests

Test Summary

Item Test Item Test Result Details

T1 Continuity Test PASS

T2 Wire Tension EM not done

Test conclusions: i.e. The EPS board passes all NR-SRD-*** qualifications.

Physical Characteristics Summary

Item Test Item Test Result Details

P1 Visual inspection PASS

P2 Measurement of the length and mass of the wiring PASS

1.Visual Inspection 

• Item: P1

• Test Item: Visual Inspection

• Test Specification: Visually inspect connector connections and wiring going from each connector. 

• Judge Criteria: No disconnect in wires to the connector. 

• Test Period: EM

  • • Start Date: Nov 8,2024

    • End Date: Nov 15, 2024

• Test Equipment: EPS boards (3 PWAs)

• Major Problem: 

• Warning: Use the ESD safe mat for all these inspections. 

• Recommendation: 

• Raw Data: 

  • • Connector : Pass/Fail: Initial:

    • ADCS to CDH Pass EVS

    • ADCS to Power Pass EVS

Pictures from test: 

ADCS to CDH:

ADCS to Power: 

2. Measurement of length and mass of the wiring

• Item: P2

• Test Item: Measurement of length and mass of the wiring.

• Test Specification: Measure the length of each wire in the harness as well as the mass of each connector. 

• Judge Criteria: All wires are the correct lengths and mass needed to make proper connections. 

• Test Period: 

  • • Start Date: Nov 8, 2024

    • End Date: Nov 15, 2024 

• Test Equipment: EPS boards (3 PWAs)

• Major Problem: 

• Warning: Use the ESD safe mat for all these inspections. 

• Recommendation: 

• Raw Data: 

  • • • Connector: Weight: Length: Initial:

      • ADCS to CDH 14.67 g 14 cm EVS

      • ADCS to Power: 23.95 g 29 cm EVS

Photos of connectors being weighed:

3. Continuity Test 

• Item: T1

• Test Item: Continuity

• Test Specification: Continuity check the connections to verify that the signal and power wires connect to the correct points on the connectors.

• Judge Criteria: All power and data wires shall show a small resistance (<0.1 ohms). The pinouts shall match the harness diagrams listed in ICD. 

• Sample(s): EM, FM, FLATSAT

• Test Period: 

  • • Start Date: Nov 15, 2024

    • End Date: Nov 15, 2024

• Test Equipment: EPS mat [ only required when electronic boards are connected], digital multimeter, harness connectors, test PCB.

• Major Problem: 

• Warning: 

• Recommendation: 

• Raw Data: 

  • • Connector #: Comments Initials: 

    • ADCS to CDH PASS EVS

    • ADCS to Power PASS EVS

Photos from connectivity test: 

Detailed Instructions: 

The following is a picture of the Connectivity Test PCB made: 

1. Connect the male connectors to the built pcb jig.

2. Connect the fully assembled female connectors on each side of wires.

3. To test connectivity, apply the multimeter to one of the plates of connector 1 and a connecting plate of connector 2 to confirm a connection is there.

4. Wire Tension 

• Item: T2

• Test Item: Wire Tension

• Test Specification: Test pull strength/ tension of the wire to verify that the assembled wires can withstand the satellite vibrations, launch conditions, assembly tensions. 

• Judge Criteria:

  • • All power wires shall withstand a pull force of [TBD] 

    • All data wires shall withstand a pull force of [TBD] 

    • Must comply with Table 12.1 of NASA STANDARD 8739.4A

• Sample(s): EM, FM, FLATSAT

• Test Period: 

  • • Start Date: 

    • End Date: 

• Test Equipment: ESD mat [only required when electronic boards are connected], harness connectors, weight, wire pull test jig/ equipment.

• Major Problem: 

• Warning: 

• Recommendation: 

• Raw Data: 

  • • Connector #: Pinout AWG Tensile Strength

    • 
      
    • 
      
    • 
      

Detailed Instructions: 

There are two types of ways to do this test: 

1. The Built Test Jig: 

This can be done with the M80-4C11205F1-02-325-00-000 (Female Connector) that is either fully assembled or partially assembled. Partially assembled being testing one wire pinout at a time. If the test equipment is:

1. Attach connector and wire to the test jig. The mass is determined by using the table in the appendix. This table is based on the gauge of the wire being tested and the minimum force needed to withstand before breakage of the crimp of the wire. 

2. Start timer and allow mass to hang. 

3. Record the time that it takes for the wire to break connection and fall.

2. ALPHATRON MPT-200A (Test Equipment) 

The second this is done with the wires individually.

Testing LISSA's Payload Interface with New Intermodular Connectors 

We conducted additional testing using the 3D-printed FM board and the new data and power intermodular connectors to evaluate how LISSA interfaces with the payload. As shown in the layout below (Figure 4) , the intermodular data connector on the payload board connects directly to the corresponding data connector on the power board. However, since the payload requires regulated power from the regulator board, the intermodular power connector on the payload board must connect to the corresponding power connector on the regulator board, which requires a longer cable. To assess this, we carried out testing using mock boards. 

Figure 5, 6: The data connection comes from the power board, and the regulated power is supplied through a dedicated power connector on the regulator board. 

Figure 7, 8: The power and regulator boards are housed inside the FM shells. The setup demonstrates the extra wire lengths needed to ensure sufficient slack and stress relief. Any excess wiring will be neatly stacked in the second payload module.

Based on our evaluation and wire measurements, the optimal lengths—accounting for sufficient slack and stress relief—are 12 cm for the data wire and 24 cm for the power wire. This was part of an initial test, and while these lengths may be slightly longer than necessary, it’s safer to have extra length rather than too little, as we can always trim them later if needed. Additionally, according to input from the payload team (Bornea), there is enough space in the second payload module to accommodate and neatly stack any excess wiring.

Also, based on our recent communication with Bornea, they are currently using the same intermodular data and power connectors as those used in the LISSA bus. The links to these connectors can be found below. 

Data intermodular connectors (Female part):

https://www.mouser.ca/ProductDetail/Harwin/M80-4613405?qs=7jyBjEprRBh0V6ACNktP4g%3D%3D 

Power intermodular connectors (Female part): 

https://www.mouser.ca/ProductDetail/Harwin/M80-4000000F1-02-325-00-000?qs=N%2F3wi2MvZWA%252BU4nhYmPXlg%3D%3D 

Phase D Tests

Interface Board Connectors Tests:

Start Date:

End Date:

Part Name: UMS-0893 (male) - UMS-0894 (female)

Application: The interface connectors provide the electrical and mechanical connection between the Regulator Board and external subsystems including the GNSS antenna, Star Tracker, and COMS radio. 

Quantity: 2 Harness bundles - 4 connectors in total

Type of tests needed to be done:

1) Visual Inspection Test: 

• Test Specification: Visually inspect each connector, connections, and wiring going from each connector. 

• Judge Criteria: No disconnect in wires to the connector. 

• Test Period: FM

  • • Start Date: 

    • End Date: 

• Test Equipment: Male and female interface connectors and data wires

• Major Problem: 

• Warning: Use the ESD safe mat for all these inspections. 

• Recommendation: 

• Raw Data: 

  • • Connector :                                                               Pass/Fail:           Initial:

    • GNSS Interface Board to Regulator Board                                   MZ

    • Transceiver Interface Board to Regulator Board                                            MZ

2) Length and Mass Test: 

To be defined during the dry assembly. 

• Test Specification: Measure the length of each wire in the harness as well as the mass of each connector. 

• Judge Criteria: All wires are the correct lengths and mass needed to make proper connections. 

• Test Period: FM

  • • Start Date: 

    • End Date: 

• Test Equipment: Male and female interface boards, connectors, data wires 

• Major Problem: 

• Warning: Use the ESD safe mat for all these inspections. 

• Recommendation: 

• Raw Data: 

  • • • Connector:                                           Weight: Length: Initial:

      • GNSS Interface Board to Reg Board                 g cm MZ

      • Transceiver Interface Board to Reg Board         g cm MZ

3) Continuity and Pin Verification Test:

• Test Specification: Continuity check the connections to verify that data wires connect to the correct points on the connectors.

• Judge Criteria: All power shall show a small resistance (<0.1 ohms). 

• Sample(s):  FM

• Test Period: 

  • • Start Date: 

    • End Date: 

• Test Equipment: EPS mat [only required when electronic boards are connected], digital multimeter, harness connectors

• Major Problem: 

• Warning: 

• Recommendation: 

• Raw Data: 

  • • Connector #:                                                               Comments Initials: 

    • GNSS Interface Board to Reg Board                               MZ

    • Transceiver Interface Board to Reg Board           MZ

4) Functional / Data Transmission Test:

• Test Specification: Verify that all interface connectors correctly deliver regulated power and signals between the required modules. These connectors supply regulated power from the regulator board to each necessary component, such as the transceiver and the GNSS. Each connector will be checked for proper continuity, correct polarity, and stable voltage under nominal load conditions. 

• Judge Criteria: 

Voltage at receiving modules within specified tolerance range.

No excessive voltage drop across connectors.

All pins show correct continuity and polarity.

No loose, overheated, or damaged terminals after testing.

• Sample(s):  FM

• Test Period: 

  • • Start Date: 

    • End Date: 

• Test Equipment: EPS mat, digital multimeter, FM interface harness connectors, FM regulator board, GNSS receiver and transceiver

• Major Problem: 

• Warning: 

• Recommendation: 

• Raw Data: 

  • • Connector #:                                                                   Comments Initials: 

    • GNSS Interface Board to Reg Board                                                       MZ

    • Transceiver Interface Board to Reg Board                             MZ

Umbilical Connectors Tests:

Start Date:

End Date:

Part Name: UMS-0891 (female) - UMS-0892 (male)

Application: In LISSA, the umbilical connectors serve as external ground-support interfaces that connect the satellite to test equipment or the launch vehicle prior to deployment. Their primary function is to provide temporary electrical access to internal systems for power, data, and debugging while the satellite is still on the ground. 

Below are the pinouts of the umbilical connectors used in LISSA:

Quantity: 3

1) Visual Inspection Test: 

• Test Specification: Visually inspect each connector, connections, and wiring going from each connector. 

• Judge Criteria: No disconnect in wires to the connector. 

• Test Period: FM

  • • Start Date: 

    • End Date: 

• Test Equipment: Male and female umbilical connectors and data wires

• Major Problem: 

• Warning: Use the ESD safe mat for all these inspections. 

• Recommendation: 

• Raw Data: 

  • • Connector :                                                     Pass/Fail: Initial:

    • REG/PWR umbilical connector                                           MZ

    • ADCS/CDH umbilical connector                                                 MZ

    • Thruster umbilical connector                                                 MZ

2) Length and Mass Test: 

To be defined during the dry assembly. 

• Test Specification: Measure the length of each wire in the harness as well as the mass of each connector. 

• Judge Criteria: All wires are the correct lengths and mass needed to make proper connections. 

• Test Period: FM

  • • Start Date: 

    • End Date: 

• Test Equipment: Male and female umbilical connectors, data wires 

• Major Problem: 

• Warning: Use the ESD safe mat for all these inspections. 

• Recommendation: 

• Raw Data: 

  • • • Connector: Weight: Length: Initial:

      • REG/PWR umbilical connector                 g        cm MZ

      • ADCS/CDH umbilical connector         g       cm MZ

      • Thruster umbilical connector                                   g        cm MZ

3) Continuity and Pin Verification Test:

• Test Specification: Continuity check the connections to verify that the programming and CCLSM wires connect to the correct points on the connectors.

• Judge Criteria: All data wires shall show a small resistance (<0.1 ohms). The pinouts shall match the harness diagrams listed in ICD. 

• Sample(s):  FM

• Test Period: 

  • • Start Date: 

    • End Date: 

• Test Equipment: EPS mat [only required when electronic boards are connected], digital multimeter, FM umbilical harness connectors, test PCB.

• Major Problem: 

• Warning: 

• Recommendation: 

• Raw Data: 

  • • Connector #:                               Comments                   Initials: 

    • REG/PWR umbilical connector                                   MZ

    • ADCS/CDH umbilical connector                           MZ

    • Thruster umbilical connector                                                                                          MZ

Detailed Instructions: 

The following is a picture of the test jig for the umbilical connector: 

Sun sensor Connectors Tests:

Start Date:

End Date:

Part Name: UMS-0207 (male) - UMS-0276 (female)

Application: Sun sensor connectors are used to interface the sun sensor units (boards) with the ADCS board. 

Quantity: 1

1) Visual Inspection Test: 

• Test Specification: Visually inspect each connector, connections, and wiring going from each connector. 

• Judge Criteria: No disconnect in wires to the connector. 

• Test Period: FM

  • • Start Date: 

    • End Date: 

• Test Equipment: Male and female sun sensor connector and data wires

• Major Problem: 

• Warning: Use the ESD safe mat for all these inspections. 

• Recommendation: 

• Raw Data: 

  • • Connector :                                                     Pass/Fail: Initial:

    • FM sun sensor connector                                                           MZ

2) Length and Mass Test: 

To be defined during the dry assembly. 

• Test Specification: Measure the length of each wire in the harness as well as the mass of each connector. 

• Judge Criteria: All wires are the correct lengths and mass needed to make proper connections. 

• Test Period: FM

  • • Start Date: 

    • End Date: 

• Test Equipment: Male and female sun sensor connectors, data wires 

• Major Problem: 

• Warning: Use the ESD safe mat for all these inspections. 

• Recommendation: 

• Raw Data: 

  • • • Connector:                                   Weight: Length: Initial:

      • FM sun sensor connector                 g       cm MZ

3) Continuity Test:

• Test Specification: Continuity check the connections to verify that the sun sensor boards connect to the ADCS board.

• Judge Criteria: All data wires shall show a small resistance (<0.1 ohms). The pinouts shall match the harness diagrams listed in ICD. 

• Sample(s):  FM

• Test Period: 

  • • Start Date: 

    • End Date: 

• Test Equipment: EPS mat [only required when electronic boards are connected], digital multimeter, FM sun sensor connector, test PCB.

• Major Problem: 

• Warning: 

• Recommendation: 

• Raw Data: 

  • • Connector #:                               Comments                   Initials: 

    • FM sun sensor connector                                                MZ

COMS Connectors Tests:

Start Date:

End Date:

Part Name:

Application:

Quantity:

Z-torque rod Connector Tests:

Start Date:

End Date:

Part Name: First option: UMS-0896 (male) - UMS-0897 (female) -- Second option: UMS-0898 (male) - UMS-0899 (female)

Application: The Z-torque rod connector provides the electrical interface between the thin torque rod wires and the ADCS board.

Quantity: 1

1) Visual Inspection Test: 

• Test Specification: Visually inspect each connector, connections, and wiring going from each connector. 

• Judge Criteria: No disconnect in wires to the connector. 

• Test Period: FM

  • • Start Date: 

    • End Date: 

• Test Equipment: Male and female z-torque rod connector and data wires

• Major Problem: 

• Warning: Use the ESD safe mat for all these inspections. 

• Recommendation: 

• Raw Data: 

  • • Connector :                                                     Pass/Fail: Initial:

    • z-torque rod connector                                                                           MZ

2) Length and Mass Test: 

To be defined during the dry assembly. 

• Test Specification: Measure the length of each wire in the harness as well as the mass of each connector. 

• Judge Criteria: All wires are the correct lengths and mass needed to make proper connections. 

• Test Period: FM

  • • Start Date: 

    • End Date: 

• Test Equipment: Male and female z-torque rod connector, data wires 

• Major Problem: 

• Warning: Use the ESD safe mat for all these inspections. 

• Recommendation: 

• Raw Data: 

  • • • Connector:                                   Weight: Length: Initial:

      • FM z-torque rod connector                 g       cm MZ

3) Continuity Test:

• Test Specification: Continuity check the connections to verify that the z-torque rod connects to the ADCS board.

• Judge Criteria: All data wires shall show a small resistance (<0.1 ohms). The pinouts shall match the harness diagrams listed in ICD. 

• Sample(s):  FM

• Test Period: 

  • • Start Date: 

    • End Date: 

• Test Equipment: EPS mat [only required when electronic boards are connected], digital multimeter, FM z-torque rod connector, test PCB.

• Major Problem: 

• Warning: 

• Recommendation: 

• Raw Data: 

  • • Connector #:                               Comments                   Initials: 

    • z-torque rod connector                                                MZ