PSC 2000781J MkII MLB Manual

PSC Proprietary 2000781J MkII MLB Operating Procedure Page 1 of 50
2000781J MkII MLB Operating Procedure
Only personnel directly trained and approved by PSC via 3000224 MLB Training Record are authorized to
operate a Lightband for any purpose.
Organization Name
MLB Diameter
MLB Assembly Number &
Revision
MLB Serial Number
Operation Purpose (TVAC,
electrical verification, final
integration, etc.)
Location
This procedure does not involve any high-energy
liquids, solid fuels, or any material with inherently
hazardous physical or chemical properties.

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TABLE OF CONTENTS
1. REVISION HISTORY .................................................................................................................................. 3
2. ACRONYMS AND ABBREVIATIONS........................................................................................................ 4
3. INTRODUCTION......................................................................................................................................... 5
4. WARNINGS...............................................................................................................................................12
5. ANOMALY REPORTING..........................................................................................................................12
6. HANDLING PRECAUTIONS ....................................................................................................................13
7. LIGHTBAND MECHANICAL ATTACHMENT PROCEDURE..................................................................15
8. STOWING THE LIGHTBAND...................................................................................................................18
9. SETTING-FOR-FLIGHT THE LIGHTBAND .............................................................................................28
10. DEPLOYING THE LIGHTBAND ...........................................................................................................33
11. REMOVING THE LIGHTBAND FROM ADJOINING STRUCTURES ..................................................38
12. PREPARING THE LIGHTBAND TO BE COMPRESSED ....................................................................39
13. HORIZONTAL INTEGRATION (OPTIONAL) .......................................................................................40
14. LIGHTBAND ELECTRICAL VERIFICATION .......................................................................................42
15. RECOMMENDED SUPPORT EQUIPMENT.........................................................................................44
16. SETUP PICTURES................................................................................................................................ 45
17. CAUTION - UNINTENDED ELECTRICAL PATHS ..............................................................................46
18. LCT PROCEDURE................................................................................................................................47

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1. Revision History
Rev
Issued
Created
Reviewed
Change Description
-
02Nov06
RW
RW
Initial document
A
to
H
11May07
to
16Jun16
Varies Varies See prior revisions for details.
I
-
-
-
This revision not used as I may be confused for 1 in document number.
J 17Jan19 RH CF
1) General wording and formatting improvements throughout document.
2) Cover page: Updated.
3) Changed all references of STP to NTP.
4) Section 2: Added and updated acronyms.
5) Section 3: Added reference to training record and website check for
latest revision. Reworded Lightband operation descriptions.
6) Figure 3-1, Figure 3-2, Figure 3-5, Figure 3-6: Updated.
7) Section 3.2: Added equipment and organized by section.
8) Section 4: Added #10
9) Section 6: Added Lower Ring # 5.
10) Figure 6-4: Added.
11) Section 7: Removed training verification step. Added Lightband
circularity note.
12) Step 7.1.4: Added cleaning of Lightband surfaces also.
13) Section 8.1: Reordered several steps.
14) Step 8.1.6: Increased allowable lateral stiffness.
15) Step 8.1.7: Removed pre-mate alignment requirements. Changed to
visibly level.
16) Step 8.1.10: Removed LCT reference.
17) Figure 8-5: Updated.
18) Step 8.2.3: Added detailed resistance measurement examples.
19) Figure 8-6, Figure 8-7: Updated power source symbol.
20) Step 8.2.8: Added.
21) Step 8.2.14: Removed picture as allowable data record.
22) Table 8-1: Reduced MLB13 minimum allowable 2nd peak current.
Reduced MLB31 & MLB38 minimum allowable startup current. Added
note to use current for durations.
23) Step 9.1.3: Added detailed resistance measurement examples.
24) Figure 9-1, Figure 9-2: Updated power source symbol.
25) Step 9.1.8: Added.
26) Step 9.1.13: Removed picture as allowable data record.
27) Figure 9-3: Refined notes.
28) Table 9-1: Added note to use current for durations.
29) Step 10.1.3: Added detailed resistance measurement examples.
30) Figure 10-1, Figure 10-2: Updated power source symbol.
31) Step 10.1.8: Added.
32) Step 10.1.5: Removed picture as allowable data record.
33) Table 10-1: Reduced maximum allowable first peak current. Added
note to use current for durations.
34) Section 12: Changed entire section from an electrical operation to a
manual operation.
35) Section 15: Documents now available on website.
36) Table 15-1: Removed #10 shoulder washer and LCTs. Added
alignment screws. Updated figures.
37) Figure 17-1: Updated power source symbol.
38) Section 18: Added. 2002159E LCT Procedure subsumed into this doc
and simplified. Deleted max allowable LCTs. Allowable LCT mounting
torque increased.

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2. Acronyms and Abbreviations
•A (or Amps) – Ampere (SI unit of electric current)
•AR – As required
•Atm – Standard atmospheric pressure (unit of pressure)
•AWG – American wire gauge
•C – Celsius (unit of temperature)
•CG – Center of gravity
•Ch - Channel
•div – Division (scale on oscilloscope)
•Doc – Document (referring to a PSC internal document number)
•DOF – Degrees of freedom
•DMM – Digital multimeter
•ESD – Electrostatic discharge
•FLH – Flathead (type of screw head, conical shape)
•I – Current (measured in Amps)
•IAW – In accordance with
•in – Inch (unit of length)
•lb – Pound force (unit of force)
•LCT – Lightband Compression Tool
•LV – Launch vehicle
•MBA – Motor Bracket Assembly (a subassembly of the MLB)
•Mk II – Mark II, a model designation of the Motorized Lightband
•MLB – Motorized Lightband (used interchangeably with Lightband)
•mtr – Motor
•NTP – Normal temperature and pressure (20°C and 1 Atm)
•OD – Outer diameter
•Ohm (Ω) – SI unit of resistance
•PS – Power supply or power source
•PSC – Planetary Systems Corporation
•QA – Quality assurance
•R – Resistance (measured in Ohms)
•Rev – Revision
•s – Second (SI unit of time)
•SFF – Set-for-flight, a Lightband specific operation
•SHC – Socket head cap (type of screw head)
•SI – International System of Units
•SN – Serial number
•SV – Space vehicle
•TVAC – Thermal vacuum (an environmental test)
•typ. - Typically
•V – Volt (SI unit of electric voltage)
•VDC – Voltage direct current (measured in volts)
•W – Watt (SI unit of power)

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3. Introduction
This document describes the steps required to handle and operate the MKII Motorized Lightband (MLB). Training
and certification by Planetary Systems Corp (PSC) are required to operate any Lightband. This can be verified via
PSC document 3000224 MLB Training Record, provided at training completion. The Training Record also
specifies the certification’s expiration date.
Ensure this is the latest version of the document by visiting PSC’s website, planetarysystemscorp.com. If the
latest version is newer than the version trained on contact PSC to discuss the changes before continuing.
Read this entire document before attempting any procedures.
Contact PSC to clarify any ambiguity or to answer any other questions.
3.1 Lightband Description
The Lightband is composed of two separable halves. The Lower Ring contains the Hinged Leaves, Retaining
Ring, Motor Bracket Assembly (MBA) and Separation Springs. The Upper Ring, smaller and lighter, contains the
accepting groove into which the Leaves engage. The typical orientation is Lower Ring attached to the launch
vehicle and Upper Ring attached to the space vehicle. The electrical interface to operate the Lightband is a DB-9
socket connector on the outside of the MBA. See Figure 3-1 to Figure 3-6. For more information on the Lightband
see PSC document 2000785 MkII MLB User Manual.
The Lightband is not ESD-sensitive.
There are three Lightband operations:
Table 3-1: Lightband operations
Lightband Operation
Description
Stow
Mechanically locks the Upper and Lower Rings together by forcing the Hinged
Leaves to engage the accepting groove in the Upper Ring.
Set-for-Flight
Moves internal components of the Motor Bracket Assembly at low voltage to
minimize separation time. Verifies proper Lightband operation prior to
deploying.
Deploy
Separates the Upper Ring from the Lower Ring.

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Figure 3-1: MLB15.000-24, stowed

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Figure 3-2: MLB15.000-24, deployed (also referred to as separated)

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Figure 3-3: Motor Bracket Assembly, internal view
Figure 3-4: Motor Bracket Assembly, external view

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Figure 3-5: Motor Bracket Assembly, stowed
Figure 3-6: Motor Bracket Assembly operations

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3.2 Required Equipment
The items listed in the tables below may be replaced with a customer’s preferred substitute. For instance, some
customers create a custom data acquisition system, thereby negating the need for an oscilloscope. Any
substitutions shall be thoroughly vetted prior to use with the Lightband.
Table 3-2: Mechanical attachment (section 7)
Qty
Item
Make & Model Typically Used by PSC
1
Adjoining structure for Upper Ring
PSC 2000741 Transition Ring
1
Adjoining structure for Lower Ring
PSC 2000741 Transition Ring
AR
0.25 inch SHC fastener (to attach Lower and Upper Rings
to adjoining structure)
NAS1351N4-XX or PSC 4000845 Reduced
Head SHC Screw
AR
<0.50 inch OD washer (to attach Lower and Upper Rings to
adjoining structure)
NAS620C416
AR
0.25 inch nut (if applicable, to attach Lower and Upper
Rings to adjoining structure)
NASM21043-4
1
3/16 inch hex key (minimum 1.5 inch shank length) with
interface for torque wrench
-
1
Torque wrench, 150 in∙lb capability
Sturtevant Richmont CCM-150I
1
Small tweezers to aide in fastener handling
-
AR
Isopropanol (to clean interface surfaces)
-
AR
Lint Free Wipes (to clean interface surfaces)
-
1
Ability to verify flatness of adjoining structures
-
Table 3-3: Preparing to stow (section 8.1)
Qty
Item
Make & Model Typically Used by PSC
AR
Ability to compress Lightband (payload1, weights,
compression fixture, LCTs).
-
1
Ability to verify Lightband flange separation distance. Either
a) Caliper to measure Lightband flange separation
(1.3 to 2.1 inch range), or
b) Go-No go gauge
Mitutoyo 500-175-30
or
PSC 2002486 MLB Go No Go Stow Gauge
1) An in-line load cell is highly recommended if using a crane to raise and lower a payload. This allows real-time
monitoring of the Lightband’s net Separation Spring force.
Table 3-4: Operating (sections 8.2, 9, 10)
Qty
Item
Make & Model Typically Used by PSC
1
Power source, adjustable, 32 VDC and 6.5 A capability
BK Precision 1687B
12
Patch cord (to connect Lightband to power source,
minimum 3.5 A per line)
Pomona, Banana-to-Banana, 18 AWG
1
Oscilloscope, 4 channels (isolated channels preferred)
Tektronix TPS2014B
2
Current probe for oscilloscope, 0.05 to 4.0 A range
Tektronix A622
1
Adjustable timer relay with trigger, 0.5 to 1.5 s with 0.1 s or
finer increments
Macromatic TD-78122
1
Trigger switch (minimum 7 A & 32 V)
-
2
10 Ω power resistor, ≥100 W, used to simulate Lightband
motor
Dale HL-100-06Z-10R00-J-J
1
Digital Multimeter (DMM) with leads
Fluke 77IV
1
DB-9 pin breakout cable to connect to Lightband
-
1
DB-9 socket breakout cable for Test Circuits
-

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Table 3-5: Preparing to compress (section 12)
Qty
Item
Make & Model Typically Used by PSC
1
Dial torque wrench cable of indicating 1 in∙lb
Seekonk SL-6
1
7/64 inch ball hex key to fit on torque wrench (regular hex
end and universal joint may be substituted for ball driver)
-
Table 3-6: Using LCTs (section 18)
Qty
Item
Make & Model Typically Used by PSC
1
Caliper to measure Lightband flange separation (1.3 to 2.1
inch range)
Mitutoyo 500-175-30
1
Optional: Telescoping gage to measure Lightband flange
separation (1.3 to 2.1 inch range)
Starrett 229C
AR
(2 per
Spring
typ.)
4000637 Lightband Compression Tool -
1 per
LCT
pair
Nylon cable tie, minimum 50 lb breaking strength, 7 inch
long
MS3367-1-0 (The ‘0’ specifies the color.
Any final number is acceptable.)
1
Cable tie tool with adjustable force
Ty-Rap ERG 50
1
1/4 inch open end wrench
-
1
Dial torque wrench (not break-over), 12 in∙lb capability
Precision Instruments DS1F15CHNM
1
3/32 inch hex key attachment for torque wrench
-
1
Wire cutter (to cut cable tie)
-
1
Optional: break-over torque wrench with 3/32 inch hex key,
12 in∙lb capability (useful if access to LCTs is limited)

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4. Warnings
Violating any of the below shall void PSC Document 1001015 MLB Warranty.
1. All technicians completing this procedure shall be trained directly by PSC and given authority to operate their
specific Lightband(s) via PSC Document 3000224 MLB Training Record.
2. The Lightband shall only be operated using this procedure. This procedure shall be filled out for every
operation of the Lightband. Steps shall not be skipped or modified.
3. If a Lightband ever fails to operate correctly, PSC shall be contacted for recommendations and
troubleshooting techniques. Subsequent operations shall not be attempted without first understanding the
cause of the failure. See section 5 Anomaly Reporting for instructions.
4. All fasteners shall be used when attaching the Lightband to adjoining structures. Fasteners shall not be
omitted from any mounting hole in the Lightband.
5. Never power the Lightband in the stow direction without the Upper Ring mated per Section 8. This would
cause damage by repeatedly slamming the MBA drivetrain against a hard stop at high speed and force.
6. Objects which may inhibit proper stowing shall not be placed between the Lightband flanges. The tolerance
on the pre-stowed Lightband height is not the same as the stowed tolerance. Common potential objects
include wiring harnesses and height gages.
7. The Upper Ring shall be physically separated from the Lower Ring after every deployment. A stow operation
shall not be attempted without first inspecting the Lightband.
8. Both motors shall always be powered when operating the Lightband.
9. The Lightband shall only be stowed within the temperature range of 10 to 32 °C (50 to 90 °F).
10. PSC sends power to both motors simultaneously (via a single relay) in all operations. The customer may
power each motor via separate circuits provided the timing is synchronized within 0.005 s. This applies to
power on and power off.
5. Anomaly Reporting
If an anomaly occurs, contact PSC immediately. PSC will attempt to respond in a timely manner.
To facilitate the review of data, avoid confusion, and expedite response, PSC requests the following:
1. Stop immediately and maintain the existing configuration (if safe).
2. Thoroughly document the state of the Lightband with pictures and notes. Verify the quality and focus of every
picture prior to sending.
3. Provide the three prior operation’s electrical profiles (if applicable to anomaly) as an Excel file. Ensure all data
is properly formatted, titled, graphed and labeled. Sending only the raw oscilloscope .CSV files will increase
PSC’s response time. Ensure all date labels correspond to the actual event date.
4. Provide a copy of the as-run procedure.
5. Provide any relevant operation details including, but not limited to:
a) Adjoining structures. To what is the Lightband bolted?
b) How many Lightband operations have been performed?
c) Reason for operation. Was it an environmental test, avionics verification, integration, etc.? This informs
potential failure modes.
d) Are all components accessible? Are there any access restrictions? Is the Lightband in a clean room?

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6. Handling Precautions
Lower Ring
1. Do not touch the portion of the Hinged Leaves that engage the Upper Ring. Do not wipe off the grease
during cleaning. See Figure 6-1.
2. Do not touch the ball screw. Be especially careful when installing fasteners immediately next to the Motor
Bracket Assembly. See Figure 6-2.
3. Do not grab the motors or use them to rotate the Lightband.
4. Do not allow the motors to contact anything. This is especially crucial when rotating the Lower Ring. See
Figure 6-3.
5. Do not touch the gear cover on the Motor Bracket Assembly. See Figure 6-4.
Upper Ring
1. Do not touch the Leaf groove. Do not remove grease from the groove when cleaning. See Figure 6-1.
2. Do not touch the spring plungers. Do not allow the spring plungers to contact anything. See Figure 6-5.
3. Do not place the Upper Ring “face down” on a surface if there are Separation Connectors or Separation
Switches installed. Doing so could damage or contaminate Connector pins, Switch plungers or the Upper
Ring flange. See Figure 6-6
.
Figure 6-1: Do not touch Leaf lip or corresponding groove in Upper Ring.
Figure 6-2: Installing fasteners immediately adjacent the MBA

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Figure 6-3: Do not allow motors to contact the table or any other objects
Figure 6-4: Do not touch the gear cover
Figure 6-5: Do not touch spring plungers or allow them to contact anything
Figure 6-6: Do not allow Upper Ring accessories to contact anything

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7. Lightband Mechanical Attachment Procedure
Step
Procedure
Date & Initials
Tech.
QA
7.1.1
Ensure the SN on the Upper Ring corresponds to the SN on the Lower
Ring.
Record all Lightband info on the cover page.
(This can be found on both the Upper and Lower Rings, typically adjacent
to the Motor Bracket Assembly.)
7.1.2
The Lightband is designed to accommodate 0.25 inch socket head cap
(SHC) screws and small pattern washers (< 0.50 inch OD). Have ready
the required tools and hardware necessary to attach the Lightband to
both upper and lower adjoining structures. See Section 15 for helpful
equipment.
-----N/A-----
7.1.3
Verify the mating surfaces of both adjoining structures are flat per PSC
Document 2000785 MkII MLB User Manual.
7.1.4
Clean the mating surfaces of both adjoining structures and the Lightband
interface surfaces with isopropanol and lint free wipes.
7.1.5
Lower Ring attachment to adjoining structure for all Lightbands except
the MLB 15.000-24.
Place the Lower Ring on the adjoining structure. Insert fasteners and
washers through mounting holes. It is often easier to place the washer on
the Lower Ring prior to inserting the screw. Tighten fasteners until hand
tight. See Figure 7-2 & Figure 7-4. Then skip to step 7.1.7.
For MLB31 & MLB38 see Note 1 at the end of this section.
7.1.6
Lower Ring attachment to adjoining structure for the MLB 15.000-24 only.
(If using reduced head fasteners per Section 15 follow step 7.1.5 instead.)
The spacing between Leaves is tight and requires a unique attachment
procedure.
1) Elevate the Lower Ring off the table to allow all screws to hang out
the bottom.
2) Place the washer on the Lower Ring prior to inserting the screw.
3) If the screw head rubs, push on each adjacent Leaf Pin to move it out
of the way slightly.
4) If the adjoining structure has through holes place the Lower Ring on
the structure allowing all screws to drop in the holes.
5) If the adjoining structure has threaded holes, the screws must be
inserted gradually. Work around the Lightband, turning each screw a
few turns at a time until hand tight. Take care to prevent the screw
heads from jamming up into the Leaf Pins.
See Figure 7-1 to Figure 7-4.

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Figure 7-1: Pushing Leaf Pin to side to make room for SHC screw (15.000-24 only).
Figure 7-2: Inserting a SHC screw between Leaves on Lower Ring.
Figure 7-3: SHC screw and washer inserted between Leaves on elevated Lower Ring.

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Figure 7-4: Separated Lightband halves attached to adjoining structures.
Step
Procedure
Date & Initials
Tech.
QA
7.1.7
Torque all fasteners on the Lower Ring. Minimum allowable torque is 70
in∙lb. PSC typically torques 100 to 115 in∙lb. Higher torque is allowable for
high line-loading.
7.1.8
Attach Upper Ring to adjoining structure by inserting fasteners and
washers through the counterbores. Tighten fasteners until hand tight. Do
not contact the Lightband with the wrench. See Figure 7-4 and note 1
below.
7.1.9
Torque all fasteners on the Upper Ring. Minimum allowable torque is 70
in∙lb. PSC typically torques 100 to 115 in∙lb. Higher torque is allowable for
high line-loading.
(1) 31.600 and 38.810 inch diameter MLBs are very flexible due to their large size. When attaching each Ring
ensure the bolt circle remains circular and is not unintentionally deformed into an ellipse. This is especially
important if attaching a Ring with the X-axis orthogonal to gravity. PSC temporarily inserts three evenly
spaced custom FLH screws or gauge pins through the mounting holes and into the adjoining structure to
ensure Ring circularity. See Section 15.

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8. Stowing the Lightband
8.1 Preparing the Lightband to be Stowed
Step
Procedure
Date & Initials
Tech.
QA
8.1.1
Verify that the Upper and Lower Rings are attached to adjoining structures
per Section 7.
8.1.2
Inspect the Lightband to verify:
1. It is visually free from damage.
2. All Hinged Leaves are properly latched over the Retaining Ring.
3. The Leaf Retaining Cord is seated in the groove of every Hinged Leaf.
See Figure 8-1 for proper orientation.
a) Incorrect Leaf position. b) Correct Leaf position.
Figure 8-1: Verifying Leaf positions.
Step
Procedure
Date & Initials
Tech.
QA
8.1.3
Verify the Sliding Tube can move fully radially inward such that it contacts the
Motor Bracket deploy hard stops. This is required for the Lightband to be
compressed. See Figure 8-2. If it cannot, go to Section 12.
a) Incorrect position (stowed) b) Correct position (deployed)
Figure 8-2: Verifying pre-stow Sliding Tube position.

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Step
Procedure
Date & Initials
Tech.
QA
8.1.4
Consider how the Lightband will be compressed. The Separation Springs may
be distributed asymmetrically around the Lightband to induce tip-off or
compensate for an offset CG. In this case using a central single compression
point may not be adequate. Lightband Compression Tools (LCTs) are
effective. See section 18 for details.
-----N/A-----
8.1.5
Verify the system being used to compress the Lightband has a total axial (X
LB
)
stiffness less than 2,000 lb/in (the entire loop from the Upper Ring around to
the Lower Ring). This applies to a crane system offloading a mass, a
compression clamp fixture, etc. An isolation system (if attached to the
Lightband) can be included in this stiffness calculation. See Figure 8-3.
This compliance ensures the Lightband is able to expand or contract slightly
when being stowed. If the system is overly stiff, the Lightband motors may not
be able to impart the necessary power required to stretch/compress the
system.
Figure 8-3: Verifying compliance in Lightband compression system. Two common methods shown.
Step
Procedure
Date & Initials
Tech.
QA
8.1.6
Verify the lateral (Y
LB
& Z
LB
) stiffness between the Upper and Lower Rings is
less than 100 lb/in.
This compliance ensures the Lightband can self-align while stowing. If the
system is overly stiff, the Lightband motors will not be able to impart the
necessary power required to rapidly align the system.
8.1.7
Ensure the Lower Ring is on a stable and visually level surface.

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Step
Procedure
Date & Initials
Tech.
QA
8.1.8
Bring the Upper Ring close to the Lower Ring for alignment checks. Verify
alignment before any force is applied to compress the Lightband.
Per Figure 8-4 ensure:
1. Cutout in Upper Ring aligns over Motor Bracket Assembly on Lower Ring.
2. All Separation Connector/Switch cutouts align.
3. All Separation Spring tips protrude through appropriate holes in the
Upper
Ring.
Note if using a crane to lower a payload, perform all crane adjustments with
the Upper Ring above the Separation Springs to prevent damage due to
excess crane movement.
For horizontal integration, see Section 13.
Figure 8-4: Aligning the Lower and Upper Rings.