Ediz.: Issue: HERSCHEL DPUs/ICU PACS DPU UNIT DECLARED PROCESSES LIST. Firma Signature. Data Date. Ricciu A. (DP/OI) Conte M.

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1 Tipo Doc.: Doc.Type: LIST DRD: DRD : A Doc.: Doc. : Pagin a 1 Di Of 5 Titolo : Title : ome & Funzione ame & Function Firma Signature Data Date LISTA DI DISTRIBUZIOE DISTRIBUTIO LIST A I Preparato da: Prepared by: Approvato da: Approved by: Francini E. (PA/QA) Cinquepalmi C. (PA/CC) Laplena D. (PA) Interna / Internal Laplena D. (PA) Francini E. (PA/QA) Magistrati G. (DP/OI) Ricciu A. (DP/OI) Sciortino A. (DP/OI) Villa M. (DP/OI) X X X X X X Magistrati G. (DP/OI) Applicazione autorizzata da: Application authorized by: Ricciu A. (DP/OI) Esterna / External Conte M. (ASI) 1 X Customer / Higher Level Contractor Accettato da: Accepted by: Approvato da: Approved by: =umero copie A=Applicazione I=Informazione =umber copy A=Application I=Information Gestione documenti: Data Management: Firma / Signature Data / Date File: is..doc Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA: Tutti i ritti sono riservati

2 Doc: HSCHEL DPUs/ICU HSCHEL DPUs/ICU PACS DPU UIT DECLARED PROCESSES LIST EDIZIOE ISSUE DATA DATE REGISTRAZIOE DELLE MODIFICHE / CHAGE RECORD AUTORIZZAZIOE CHAGE AUTHORITY First issue OGGETTO DELLA MODIFICA E SEZIOI AFFETTE REASO FOR CHAGE AD AFFECTED SECTIOS Updated accorng to design mofication, group 7 item 01 (page 14), group 8 item 01 (page 15), group 16 item 03 (page 3). Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

3 Doc: HSCHEL DPUs/ICU HSCHEL DPUs/ICU PACS DPU UIT DECLARED PROCESSES LIST LISTA DELLE PAGIE VALIDE / LIST OF VALID PAGES PAGIA PAGE EDIZIOE ISSUE PAGIA PAGE EDIZIOE ISSUE PAGIA PAGE EDIZIOE ISSUE PAGIA PAGE EDIZIOE ISSUE PAGIA PAGE EDIZIOE ISSUE 1-5 Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

4 Doc: HSCHEL DPUs/ICU HSCHEL DPUs/ICU PACS DPU UIT DECLARED PROCESSES LIST TABLE OF COTET SCOPE...5. APPLICABLE & REFECE DOCUMETS APPLICABLE DOCUMETS...5. REFECE DOCUMETS RESPOSIBILITY METHODOLOGY FOR THE COMPILATIO OF THE DPL DECLARED PROCESSES LIST GROUP 1 ADHESIVE BODIG GROUP COMPOSITE MAUFACTURE GROUP 3 ECAPSULATIO/MOULDIG GROUP 4 PAITIG/COATIG GROUP 5 CLEAIG GROUP 6 WELDIG GROUP 7 CRIMPIG/STRIPPIG/WIRE WRAPPIG GROUP 8 SOLDIG/BRAZIG GROUP 9 SURFACE COVSIO TREATMETS GROUP 10 PLATIG GROUP 11 MACHIIG GROUP 1 FORMIG GROUP 13 HEAT TREATMET GROUP 14 SPECIAL FABRICATIO GROUP 15 MARKIG GROUP 16 MISCELLAEOUS PROCESSES GROUP 17 ISPECTIO PROCEDURES... 5 Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

5 Doc: HSCHEL DPUs/ICU HSCHEL DPUs/ICU PACS DPU UIT DECLARED PROCESSES LIST SCOPE The scope this document is to define all processes to be used in the PACS DPU Unit for HSCHEL DPUs/ICU Program. This document is based on the PACS DPU Unit architecture defined for the Critical Design Review.. APPLICABLE & REFECE DOCUMETS.1 APPLICABLE DOCUMETS AD DOC.. ISSUE TITLE 1 HS-GE-PL-CGS-00 1 HSCHEL DPUs/ICU Product Assurance Plan. REFECE DOCUMETS RD DOC.. ISSUE TITLE 1 ESA PSS The technical reporting and approval procedure for materials, mechanical and processes Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

6 Doc: HSCHEL DPUs/ICU HSCHEL DPUs/ICU PACS DPU UIT DECLARED PROCESSES LIST RESPOSIBILITY CGS shall be responsible that all listed processes are in accordance with the applicable documents. 4. METHODOLOGY FOR THE COMPILATIO OF THE DPL The processes list consist 11 columns which shall be completed as incated below in accorng to [RD 1] document. Furthermore, the processes shall be classified as specified in table: GROUP PROCESSES 1 Adhesive bonng Composite manufacture 3 Encapsulation/moulng 4 Painting/coating 5 Cleaning 6 Welng 7 Crimping/stripping/wire wrapping 8 Soldering/brazing 9 Surface conversion treatments 10 Plating 11 Machining 1 Forming 13 Heat treatment 14 Special fabrication: processes developed specifically for the programme 15 Marking 16 Miscellaneous processes 17 Inspection procedures Column 1:Item number Sequential item number in each group. One only per process type. Column :Process identification Process name, title, standard identification. Column 3:Specification Issue/Rev Specification number with issue/revision status relevant the process. Column 4:Process description Brief description the process. Column 5:Use and location Define location and use process in the spacecraft/equipment. Column 6:Manufacturer s name This identifies the abbreviated name the manufacturer and name the supplier if fferent (the one who applies the process). Column 7:Associated items in materials list Corresponng materials list or mechanical list item number. Column 8:Criticality the process Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

7 Doc: HSCHEL DPUs/ICU HSCHEL DPUs/ICU PACS DPU UIT DECLARED PROCESSES LIST Incate here whether process is critical or noncritical. In the case a critical process, add reason for criticality (see the definition in [RD 1] document annex A) Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

8 Doc: HSCHEL DPUs/ICU HSCHEL DPUs/ICU PACS DPU UIT DECLARED PROCESSES LIST Column 9:Justification for validation approval The purpose this column is to enter any adtional information that may be necessary in order to achieve customer s approval. This information comprises reference and issue the RFA/Approval, processes justification file, evaluation reports and waivers. Column 10:Contractor s approval (Prime val.) The Prime contractor shall complete this subcolumn and by doing so confirms that: the line incations are correct and complete the process has passed all applicability tests (inclung quality control testing) A=Approved. The validation is approved by the Contractor. W=Approved with a waiver. The use such processes shall be reduced to a minimum. The waiver number shall be entered in column 9. P=Penng a decision. Processes for which a validation report or a waiver is awaiting the Contractor s decision. O=Open. ew process or process for which investigations and qualification are in progress. D=Deleted. This classification is used for a process which is no longer use. Column 11:Customer approval (Customer val.) This column will be completed by Customer in accordance with the standard comments listed in [RD 1] document annex G. 5. DECLARED PROCESSES LIST In the following pages are listed the processes envisaged during the manufacturing phase. Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

9 Doc: GROUP 1 ADHESIVE BODIG PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO 01 Adhesion non-structural 0 Adhesion identification label and nonstructural PA07 Is.1 3M Technical bulletin manufacturer Adhesion nonstructural with epoxide adhesive Eccobond 85 cat.11. Mixing rations (by weight): 4,5% cat.11, cured 8h-8 C 50%R.H. Adhesion identification label and nonstructural with Scotchweld EC- 16B/A. Mixing rations (by weight): 7pbw A: 5pbw B. cured h-70 C 50%R.H. Adhesion non-structural Adhesion identification label and nonstructural CGS DML:10/01 ot Critical ASA/MSFC MAPTIS: CGS DML:10/03 ot Critical ESA PSS : S- 7, ASA/MSFC MAPTIS: Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

10 Doc: GROUP COMPOSITE MAUFACTURE PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO OE Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

11 Doc: GROUP 3 ECAPSULATIO/MOULDIG PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO OE Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

12 Doc: GROUP 4 PAITIG/COATIG PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO 01 Conformal coating CIBA, HUTSMA Technical Data Sheets Conformal coating on assembled PCBs with ARATHAE (Uralane) 5750 A/B (LV) clear. Mixing rations(by weight):18 A and 100 B (LV). Cured 7 days 5 C or 9 h 65 C 50% R.H. Conformal coating PCBs CGS DML:10/0 ot Critical ASA/MSFC MAPTIS: 009 Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

13 Doc: GROUP 5 CLEAIG PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO 01 Cleaning PA071 Is.1 Cleaning PCBs PCBs the electronic box CGS DML:0/01 and 0/0 ot Critical PA071 is.1 Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

14 Doc: GROUP 6 WELDIG PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO OE Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

15 Doc: GROUP 7 CRIMPIG/STRIPPIG/WIRE WRAPPIG PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO 01 Crimping ECSS-Q-70-6A Crimping high reliability electrical connections Wires crimping on connector contacts CGS DML:19/01, 19/07, 19/08, 19/09, 19/10, 19/11 Critical for reliability PA08 Is.1, ECSS-Q-70-6A Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

16 Doc: GROUP 8 SOLDIG/BRAZIG PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO 01 Soldering GD-PL-CGS- 016, ECSS-Q-70-08A 0 SMT Soldering GD-PL-CGS- 016, ESA PSS is.1 Soldering high reliability electrical connections High-reliability soldering for surface-mount and mixedtechnology printed-circuit boards Electrical components on PCBs the electronic box Electrical components on PCBs the electronic box CGS DML: 19/01, 19/04, 19/07, 19/08, 19/09, 19/10, 19711, 0/01 and 0/0 Critical for reliability CGS DML:0/01 and 0/0 Critical for reliability GD-PL-CGS-016, ECSS-Q-70-08A GD-PL-CGS-016, ESA PSS is.1 SMT ESA approval ref.: QM/0-440/BD Tables 1 and Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

17 Doc: GROUP 9 SURFACE COVSIO TREATMETS PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO 01 Chemical conversion coating on aluminum alloy with Alone Anoc coating on aluminum alloy 03 Passivation treatment for corrosionresistant steel MIL-C-5541C class 3 MIL-A-865 class type III QQ-P-35C Surface treatment aluminum alloy to prevent corrosion Surface treatment aluminum alloy to prevent corrosion Surface Passivation treatment for corrosionresistant steel Mechanical Mechanical Mechanical DUE GI DML:01/01 to 01/06 Critical MIL-C-5541C class 3 DUE GI DML:01/01 to 01/06 Critical MIL-A-865 class type III DUE GI DML:06/01 and 06/0 Critical QQ-P-35C Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

18 Doc: GROUP 10 PLATIG PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO 01 ickel plating (electro deposited) QQ--90 A Surface plating copper alloy to prevent corrosion Thermal ssipators on PCBs and/or conductor bridge on PCBs DUE GI DML:0/01and 0/0 ot critical QQ--90 A Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

19 Doc: GROUP 11 MACHIIG PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO 01 Mechanical machining 0 PCBs manufacturing ECSS-Q-70-10A, ECSS-Q A Construction mechanical Manufacturing double side and multilayer PCBs All mechanical PCBs electronic box DUE GI DML:01/01 to 01/06, 0/01 and 0/0, 06/01 and 06/0 PRITCA Denmark, ZICOCELE DIVISIO CSI Italy ot critical DML:0/01 and 0/0 ot critical ECSS-Q-70-10A, ECSS-Q-70-11A Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

20 Doc: GROUP 1 FORMIG PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO OE Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

21 Doc: GROUP 13 HEAT TREATMET PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO OE Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

22 Doc: GROUP 14 SPECIAL FABRICATIO PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO OE Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

23 Doc: GROUP 15 MARKIG PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO OE Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

24 Doc: GROUP 16 MISCELLAEOUS PROCESSES PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO 01 Repair and mofication PCB and solder joints 0 Flight electronic equipment production and inspection control plan PA063 Is.1, ECSS-Q-70-8A GD-PL-CGS- 016 Is.1 03 Cabling ECSS-Q-70-6A, Technical cabling doc. See column Flight electronic equipment production and inspection control plan Electrical Isolation connection by mean shrinkable tubes THMOFIT RT876 PCBs Electronic box Equipment production and inspection control plan Cabling inside the box CGS DML:0/01 and 0/0 Critical for reliability PA063 Is.1, ECSS-Q-70-8A CGS All items ot critical GD-PL-CGS-016 Is.1 CGS DML:19/01, 19/07, 19/08, 19/09, 19/10, 19/11 ot critical ECSS-Q-70-6A Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

25 Doc: GROUP 17 ISPECTIO PROCEDURES PROCESS SPECIFICATIO PROCESS USE AD MAUFACTURE ASSOCIATED S I CRITICALITY OF JUSTIFICATIO FOR PRIME IDETIFICATIO ISSUE/REV. DESCRIPTIO LOCATIO R AME MATIAL LIST THE PROCESS VALIDATIO 01 Incoming inspection procedure 0 MIP and KIP inspection plan 03 Inspection on assembled PCBs 04 Ultrasonic inspection on mechanical 05 DI inspection on mechanical GD-PR-CGS- 070 Is.1 GD-PL-CGS- 003 Is.1 Incoming inspection HI-REL MIP and KIP inspection PA005 Is.1 See column PCBs Electronic box MIL-STD-154 See column Semimanufactu red mechanical materials ASTM-E-1417 See column Mechanical critical Electronic box CGS All items ot Critical GD-PR-CGS-070 Is.1 Electronic box CGS All items ot Critical GD-PL-CGS-003 Is.1 CGS DML:0/01 and 0/0 ot Critical PA005 Is.1 CGS DML:01/01 to 01/06 ot Critical MIL-STD-154 CGS DML:01/01 to 01/06 ot Critical ASTM-E-1417 Questo documento contiene informazioni proprietà CARLO GAVAZZI SPACE SpA. Tutti i ritti sono riservati.

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