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Page 3 of 20 CONTENTS CONTENTS...3 1. INTRODUCTION...5 2. APPLICABLE DOCUMENTS...5 3. OPERATION...6 3.1 General Description...6 3.2 Physical Data...6 3.3 Electrical Bonding...6 3.4 Operating Procedure...7 3.4.1 Tools and Equipment...7 3.4.2 Unpacking the Vibration Adaptor....8 3.4.3 Installation of the Vibration Adaptor onto the ETS FMD....9 3.4.4 Installation of the Vibration Adaptor onto the ETS LEAF Trolley...10 3.4.5 Installation of the Vibration Adaptor onto the IABG FMD...11 4. SAFETY...12 5. PRE-USE INSPECTION...12 6. MAINTENANCE...12 7. TRANSPORTATION...13 8. STORAGE...13 FIGURE 1 VIBRATION ADAPTOR....14 FIGURE 2 LIFTING THE VIBRATION ADAPTOR....15 FIGURE 3 ATTACHMENT BOLT POSITIONS FOR THE ETS LEAF TROLLEY...16 FIGURE 4 ATTACHMENT BOLT POSITIONS FOR THE IABG FMD...17 APPENDIX A - SAFETY SHEET...18 DOCUMENT CHANGE DETAILS...20 DISTRIBUTION LIST...20
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Page 5 of 20 Operations Manual for the Vibration Adaptor. 1. INTRODUCTION 1.1. This document describes the function, use and maintenance of the Vibration Adaptor for the Aeolus and LISA Pathfinder projects. The Vibration Adaptor is used to support the Aeolus Spacecraft in the vertical plane, and interface with the ETS Force Measurement Device (FMD), and the Acoustic Test facility LEAF Trolley. The Vibration Adaptor is used during the Structure Vibration and Acoustic Test Programmes. The Vibration Adaptor is also used to support the LISA Pathfinder LCM Spacecraft in the vertical plane, and interface with the IABG Force Measurement Device (FMD). The supported Spacecraft mass and C of G must be within the envelope of the SWL stated in paragraph 3.2 below. WARNING THIS EQUIPMENT IS DESIGNED FOR THE SPECIFIC PURPOSES DESCRIBED IN THIS DOCUMENT AND MUST NOT BE USED FOR ANY OTHER PURPOSE WITHOUT PRIOR WRITTEN CONSENT FROM THE DESIGN AUTHORITY. HEALTH AND SAFETY STANDARDS AND PRECAUTIONS SHOULD BE EXERCISED DURING HANDLING, MAINTENANCE AND USE. ASTRIUM CANNOT BE HELD RESPONSIBLE FOR ANY CONSEQUENCES ARISING OUT OF USE OF THIS ITEM OTHER THAN THE PURPOSE FOR WHICH IT WAS DESIGNED. CAUTION THERE IS A RISK OF TRAPPING FINGERS DURING THE INSTALLATION OPERATION OF THIS EQUIPMENT. Note: The Vibration Adaptor is supplied with Proof Load Test Certificate, which identifies the Vibration Adaptor by unique serial number marked on the hardware and the certificate. The certificate shall demonstrate that a proof load factor in accordance with Stress Note 967, AD/2(d) has been applied. In other countries, e.g. France, national statute requirements must be followed. 2. APPLICABLE DOCUMENTS In compiling this manual, other documents have been identified as containing information relevant to the subject matter in each section. The documents should be referred to where indicated in this manual, they are referred to as AD/2(x) where x refers to the sub-paragraphs of paragraph 2. (a) DG0035040 Vibration Adaptor Assembly AEOLUS. (b) AE-URS-APC-SY-043 AEOLUS GSE Requirement Specification (c) ACA106 COSHH assessment for the safe use of. IPA (d) HBK/EU2P/00062 Operations Manual for the Heavy Duty Clamp Band. (e) S2.ASU.RS.5040 LISA Pathfinder MGSE Requirement Specification
Page 6 of 20 3. OPERATION 3.1 General Description The Vibration Adaptor is an aluminium fabrication, designed to support the Spacecraft, and to transmit the vibration excitation from the Shaker Slip table or Head Expander to the Spacecraft. See figure 1 for an illustration of the Vibration Adaptor. The Vibration Adaptor also supports the Aeolus Spacecraft during Acoustic Testing. The lower flange of the Vibration Adaptor interfaces to the FMD or LEAF Trolley, the upper flange interfaces with the Spacecraft via a heavy-duty clamp band. There is provision to mount eight tri-axial accelerometers on the inner diameter of the upper flange. Three eyebolts are provided to facilitate lifting the Vibration Adaptor onto the FMD. The supported Spacecraft mass and C of G must be within the envelope of the SWL stated below. The vibration excitation must not exceed the levels specified in the GSE equipment specification AD/2(b) and AD/2(e). 3.2 Physical Data 3.2.1 The Vibration Adaptor has the following overall dimensions: Adaptor Size = 1332mm diameter x 300 mm high Adaptor Weight = 212 kg Aeolus SWL = 1500kg at 1250mm above the Separation Plane (Spacecraft Vertical). LISA Pathfinder SWL = 2000kg at 1500mm above the Separation Plane (Spacecraft Vertical) 3.2.2 The Vibration Adaptor Container has the following overall dimensions: Dimensions: 1620 mm x 1620 mm x 520 mm Gross weight of Container: 360 kg 3.3 Electrical Bonding 3.3.1. An M8 earth bonding insert is provided in the edge of the lower flange of the Adaptor. An M8 earth bonding screw and washer are provided. The M8 screw shall be torque loaded to 15Nm. 3.3.2. Provision of earth bonding straps from the adaptor to ground is the responsibility of the user of the equipment
Page 7 of 20 3.4 Operating Procedure Notes: a) Wherever possible, validate these procedures by dry runs with the individuals assigned to their execution, under the supervision of a responsible independent authority assigned to the safe conduct of handling and transportation activities, i.e. Operations Director and Quality Representative. b) Ensure that the equipment log book is completed, and remains with the equipment. c) Ensure that all lifting equipment used has valid insurance certification markings (ref paragraph 5.1(b)) and that personnel are qualified to use the lifting equipment. 3.4.1 Tools and Equipment 3.4.1.1 The following tools are required to operate the Vibration Adaptor. These tools are not provided with the Adaptor and must be provided by the user of the equipment. (a) (b) (c) (d) (e) (f) (g) (h) (i) (j) (k) (l) (m) (n) O/E Wrench 17 mm A/F. 17 mm A/F Socket 10 mm A/F Hex Key 8 mm A/F Hex Key 6 mm A/F Hex Key 5/16" A/F Hex Key 10 mm A/F Hex Key Socket 8 mm A/F Hex Key Socket 6 mm A/F Hex Key Socket 5/16" A/F Hex Key Socket Torque Wrench 0-25 Nm capacity. Torque Wrench 0-120 Nm capacity. Four Strops, minimum 200 Kg SWL x 1000mm long. Four shackles, minimum 200 Kg SWL 3.4.1.1 Unless otherwise stated, bolts used shall be Steel, grade 12.9, and if applicable, grade 12 nuts.
Page 8 of 20 3.4.2 Unpacking the Vibration Adaptor. Activity No Activity CAUTION Ref. or limit Result Refer to AD/2(c) for safety precautions to be used during cleaning operations using IPA, or refer to Test House local procedures. 1 Bring the Vibration Adaptor Container to a suitable place under the facility hoist to enable unpacking. 2 Release the toggle latches securing the lid and lift off the lid. 3 Take out the logbook and inspect the Vibration Adaptor. Update the logbook. Verify that the equipment is in validation and that the proof load certificates are available for inspection and are valid for the current period. 4 The Vibration Adaptor can now be lifted out of the container and taken to the required location. The Vibration Adaptor should only be lifted using 4 sling or strops, attached to the 4 eyebolts using 4 shackles. Bring the slings together at the facility hoist hook as shown in Figure 2. Note: the slings and shackles are not supplied with the Vibration Adaptor. 5 Select and unpack the fasteners required for the particular application to be carried out. 6 Replace the container lid and remove the container from the area. 7 Packing is in general, the reverse of the above procedure. Ensure the logbook is updated and replaced in the container.
Page 9 of 20 3.4.3 Installation of the Vibration Adaptor onto the ETS FMD. Activity No Activity CAUTION Ref. or limit Result Refer to AD/2(c) for safety precautions to be used during cleaning operations using IPA, or refer to Test House local procedures. 1 Check the FMD mounting face is undamaged then clean using a lint free swab moistened with IPA (Refer to AD/2(c)), or clean in accordance with Test House local procedure. 2 Lift the Vibration Adaptor by sling as described in paragraph 3.4.2. Check the mounting face is undamaged then clean using a lint free swab moistened with IPA (Refer to AD/2(c)), or clean in accordance with Test House local procedure. 3 Lower the Vibration Adaptor onto the FMD and align the bolt holes. Ensure that the Vibration Adaptor axes are in the required orientation on the FMD. WARNING: Keep hands clear of interface whilst fitting the Adaptor. 4 Install 84 off M10 x 90mm long bolts, nuts and washers from the underside of the FMD upper ring. Install 32 off 3/8"UNC x 1.25" long bolts and washers from the top face of the Vibration Adaptor. Progressively tighten each bolt working diagonally around the Vibration Adaptor, and finally torque to 60 Nm, - or to a torque specified by the Test House. 60 Nm 5 Remove the four lifting Eye Bolts from the Vibration Adaptor lower flange. 6 Install and test the eight Tri-axial accelerometer mounting blocks to the inner edge of the Vibration Adaptor in accordance with Test House local procedure. Refer to AD/2(a) for illustration of accelerometer mounting block positions. Note: the accelerometer cables exit between the FMD rings. 7 Check the clamp band interface flange is undamaged then clean using a lint free swab moistened with IPA with (Refer to AD/2(c)) or clean in accordance with Test House local procedure. 8 The Spacecraft can now be fitted to the Vibration Adaptor. The Heavy Duty Clamp Band shall be fitted in accordance with AD/2(d). The required Clamp Band tension is to be specified in the Test Procedure. 9 If required, install Earth bonding cables in accordance with Paragraph 3.3. 10 Removal is in general the reverse of the above procedure. Note: The Accelerometer blocks should be removed prior to lifting.
Page 10 of 20 Activity No 3.4.4 Installation of the Vibration Adaptor onto the ETS LEAF Trolley Activity CAUTION Refer to AD/2(c) for safety precautions to be used during cleaning operations using IPA, or refer to Test House local procedures. Ref. or limit Result 1 Check the Leaf Trolley mounting face is undamaged then clean using a lint free swab moistened with IPA (Refer to AD/2(c)), or clean in accordance with Test House local procedure. 2 Lift the Vibration Adaptor by sling as described in paragraph 3.4.2. Check the mounting face is undamaged then clean using a lint free swab moistened with IPA (Refer to AD/2(c)), or clean in accordance with Test House local procedure. 3 Lower the Vibration Adaptor onto the Leaf Trolley and align the bolt holes. Ensure that the Vibration Adaptor axes are in the required orientation on the Leaf Trolley. Refer to Figure 3 for the required bolt positions. WARNING: Keep hands clear of interface whilst fitting the Adaptor. 4 Install 44 off M10 x 55mm long socket head bolts and washers. Progressively tighten each bolt working diagonally around the Vibration Adaptor, and finally tighten to 60 Nm, - or to a torque specified by the Test House. 60 Nm 5 Remove the four lifting Eye Bolts from the Vibration Adaptor lower flange. 6 Check the clamp band interface flange is undamaged then clean using a lint free swab moistened with IPA with (Refer to AD/2(c)) or clean in accordance with Test House local procedure. 7 The Spacecraft can now be fitted to the Vibration Adaptor. The Heavy Duty Clamp Band shall be fitted in accordance with AD/2(d). The required Clamp Band tension is to be specified in the Test Procedure. 8 If required, install Earth bonding cables in accordance with Paragraph 3.3. 9 Removal is in general the reverse of the above procedure.
Page 11 of 20 3.4.5 Installation of the Vibration Adaptor onto the IABG FMD. Activity No Activity CAUTION Ref. or limit Result Refer to AD/2(c) for safety precautions to be used during cleaning operations using IPA, or refer to Test House local procedures. 1 Check the FMD mounting face is undamaged then clean using a lint free swab moistened with IPA (Refer to AD/2(c)), or clean in accordance with Test House local procedure. 2 Lift the Vibration Adaptor by sling as described in paragraph 3.4.2. Check the mounting face is undamaged then clean using a lint free swab moistened with IPA (Refer to AD/2(c)), or clean in accordance with Test House local procedure. 3 Lower the Vibration Adaptor onto the FMD and align the bolt holes. Ensure that the Vibration Adaptor axes are in the required orientation on the FMD. WARNING: Keep hands clear of interface whilst fitting the Adaptor. 4 Refer to figure 4 and AD/2(a) for bolt positions; Install 80 off M10 x 60mm long bolts and washers into the FMD upper ring. Install 8 off M10 x 65mm long bolts and special washers G0093912 into the FMD upper ring. Install 8 off M10 x 55mm long bolts and washers into the FMD upper ring. 60 Nm Progressively tighten each bolt working diagonally around the Vibration Adaptor, and finally torque to 60 Nm - or to a torque specified by the Test House. 5 Remove the four lifting Eye Bolts from the Vibration Adaptor lower flange. 6 If required, install and test the eight Tri-axial accelerometer mounting blocks to the inner edge of the Vibration Adaptor in accordance with Test House local procedure. Refer to AD/2(a) for illustration of accelerometer mounting block positions. Note: the accelerometer cables exit between the FMD rings. 7 Check the clamp band interface flange is undamaged then clean using a lint free swab moistened with IPA with (Refer to AD/2(c)) or clean in accordance with Test House local procedure. 8 The Spacecraft can now be fitted to the Vibration Adaptor. The Heavy Duty Clamp Band shall be fitted in accordance with AD/2(d). The required Clamp Band tension is to be specified in the Test Procedure. 9 If required, install Earth bonding cables in accordance with Paragraph 3.3. 10 Removal is in general the reverse of the above procedure. Note: The Accelerometer blocks, if fitted, should be removed prior to lifting.
Page 12 of 20 4. SAFETY 4.1. The supported Spacecraft mass and C of G must be within the envelope of the SWL stated in paragraph 3.2. 4.2. The vibration excitation must not exceed the levels specified in the GSE equipment specification AD/2(b) 5. PRE-USE INSPECTION 5.1 The equipment must pass the following inspection procedure before use. If any item is found to be faulty, the equipment shall be placed in quarantine until the appropriate rectification action has been carried out. Check the logbook. If the equipment has already been subject to a pre-use inspection on the current calendar day, there is no need to repeat the inspection below. a) Check that all items are present against the assembly drawings AD/2(a). b) Check that the equipment has valid insurance approval, in the UK represented by a visual inspection tag attached to the lifting point or an appropriate coloured disk adhered to the item. Check the equipment has current proof load test certification and is available for inspection. c) Ensure all items are securely fitted and fully functional. Examine all items for degradation, deformation or damage, which is likely to impair efficiency or safety. If in doubt, compare items with their drawings. Replace any worn or damaged bolts. d) Visually inspect all welds for cracking or damage. If in doubt, further inspection and tests may be called for. e) Visually check lifting points for damage (e.g. weld cracking), wear and corrosion. f) Examine the equipment for cleanliness. The equipment shall be free of oil, grease, dirt, etc. Clean items, if necessary, using the cleaning procedures in Section 6. g) Check that all labels are present and that they are secure and legible and located as specified on the equipment drawing. h) Check that all lettering, identification marking, stated masses, etc, are present and legible and located as specified on the equipment drawing. 6. MAINTENANCE 6.1. Under normal daily use no general maintenance of the equipment is required other than to inspect the equipment for cleanliness, damage to the structure, tightness of fasteners and finish. This should be done before and after use. 6.2. Items sustaining major damage should be returned to Astrium, Stevenage for repair / salvage and retest. ANY item of equipment subject to repair for major damage should be re-proof load tested prior to reuse.
Page 13 of 20 6.3. Minor damage or scratches to the components are to be dressed out. Aluminium Alloy components are to be protected by applying a brush Alocrom 1200 finish to PS2068. WARNING Alocrom 1200 is a hazardous substance classified under the Control of Substances Hazardous to Health (COSHH) Regulations 1988 (UK). See Appendix A. Similar EC Regulations exist for the control of Alocrom 1200. All persons using this substance must be aware of the safety precautions prescribed for its use. 6.3. The preferred cleaning agent for general cleaning of the Vibration Adaptor is a weak detergent solution, which should be applied using a lint free cloth. Any detergents used should contain no fragrance, wax or silicones. 6.4. Should a solvent be required for local cleaning of exceptionally severe contamination then advice should be sought from the Health Safety and Environment Group (or local Health and Safety Authority) before using any approved solvent to remove stubborn marks. See Appendix A. 6.5. The cleaning of loose debris only should be accomplished using a dry lint free cloth and where practical by vacuum cleaning. Note that the use of portable electrically operated vacuum cleaners must be fully compliant with the facilities safety requirements for electrical portable tools and the National Electrical Regulations of the country concerned. 7. TRANSPORTATION 7.1. Transport of the Vibration Adaptor shall be undertaken in a closed vehicle, within the transport container. 7.2. Any documentation (logbook etc.) relevant to the equipment must travel with it. 8. STORAGE 8.1 When not in use, the Vibration Adaptor shall be stored in its Transport Container, away from adverse atmospheric conditions, i.e. in a dry clean environment. 8.2 It is not recommended that the Vibration Adaptor is left outside exposed to the weather.
Page 14 of 20 Tri-axial Accelerometer Block (8 posn s) Eye bolt (4 posn s) Spacecraft Interface Flange Earth Point FMD Top Ring 3/8" UNC Attachment Bolts ETS FMD only M10 Attachment Bolts On 80 x 80 mm grid Note: ETS FMD bolt configuration shown FIGURE 1 VIBRATION ADAPTOR.
Page 15 of 20 Hoist Sling (4 off) 1000 mm FIGURE 2 LIFTING THE VIBRATION ADAPTOR.
Page 16 of 20 OUTER BOLTS (24 POSITIONS) INNER BOLTS (20 POSITIONS) FIGURE 3 ATTACHMENT BOLT POSITIONS FOR THE ETS LEAF TROLLEY.
Page 17 of 20 8 off Position C = M10 X 55 mm long with standard washer 8 off Position D = M10 X 65 mm long with Special Washer DG0115204 80 off = M10 X 60 mm long with standard washer. FIGURE 4 ATTACHMENT BOLT POSITIONS FOR THE IABG FMD.
Page 18 of 20 APPENDIX A - SAFETY SHEET SAFETY PRECAUTIONS AND COSHH (CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH REGULATIONS 2002) 1. Personnel working in accordance with this document shall be familiar with the requirements of current legislation and to Astrium Ltd. documentation that is provided on the Health and Safety intranet site. Approved COSHH Assessments for most commonly used substances at Astrium Ltd. are also available on the Health and Safety intranet site. 2. The Departmental Heads, responsible for both the work area and the personnel performing work in accordance with this document, share a joint responsibility for ensuring that: - 2.1. The statutory requirements to carry out an assessment of the risks to health of all substances used in this document have been made before work commences and that an assessment report has been completed. 2.2. The assessment is reviewed if there are any changes proposed to the working practices prior to those changes occurring. 2.3. Personnel work in accordance with the instructions as laid down in the assessment. 2.4. Personnel are provided with such information, instructions and training, as far as is reasonably practicable, to ensure that they know the risk to health and the precautions which must be taken to ensure that the process is carried out in a safe manner. 3. Safety information relating to substances and processes invoked by this document can be obtained either from the local COSHH handbook or from the Health Safety and Environment Group.
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Page 20 of 20 DOCUMENT CHANGE DETAILS ISSUE CHANGE AUTHORITY CLASS RELEVANT INFORMATION/INSTRUCTIONS 1 AECA0082 - Initial Issue 2 AE.ECO.ASU.PL.00506 - Update to incorporate use on LISA Pathfinder. DISTRIBUTION LIST INTERNAL EXTERNAL A. Pilbeam. M. Sherring. J. Holt. A. Hutchins. D. Head M. Hummerstone J. McCall Configuration Management