ORBITAL SCIENCES CORPORATION

January 2006 Minotaur IV User’s Guide

Release 1.1

Approved for Public Release

Distribution Unlimited

Copyright 2006 by Orbital Sciences Corporation.

All Rights Reserved.
 Minotaur IV User’s Guide Revision Summary

REVISION SUMMARY

VERSION DOCUMENT DATE CHANGE PAGE

1.0 TM-17589 Jan 2005 Initial Release All

1.1 TM-17589A Jan 2006 General nomenclature, history, and administrative updates All
(no technical updates)
• Updated launch history
• Corrected contact information

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Minotaur IV User’s Guide Preface

This User’s Guide is intended to familiarize payload mission planners with the capabilities of the Orbital
Suborbital Program ll (OSP-2) Minotaur IV Space Launch Vehicle (SLV) launch service. The information
provided in this user’s guide is for initial planning purposes only. Information for development/design is
determined through mission specific engineering analyses. The results of these analyses are
documented in a mission-specific Interface Control Document (ICD) for the payloader organization to use
in their development/design process. This document provides an overview of the Minotaur IV system
design and a description of the services provided to our customers.

USAF SMC Det 12/RP

3548 Aberdeen Ave SE
Kirtland AFB, NM 87117-5778

Telephone: (505) 846-8957

Fax: (505) 846-5152

Additional copies of this User's Guide and Technical information may also be requested from Orbital at:

Orbital Suborbital Program - Mission Development

Orbital Sciences Corporation
Launch Systems Group
3380 S. Price Road
Chandler, AZ 85248

Telephone: (480) 814-6566

E-mail: Minotaur@orbital.com

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Minotaur IV User’s Guide Table of Contents

PAGE
1. INTRODUCTION................................................................................................................................. 1
2. MINOTAUR IV LAUNCH SERVICE .................................................................................................... 3
2.1. Minotaur IV Launch System Overview.......................................................................................... 3
2.2. Minotaur IV Launch Service.......................................................................................................... 3
2.3. Minotaur IV Launch Vehicle .......................................................................................................... 4
2.3.1. Stage 1, 2 and 3 Booster Assemblies....................................................................................... 4
2.3.2. Stage 4 Booster/Avionics Assembly ......................................................................................... 5
2.3.2.1. Avionics............................................................................................................................... 5
2.3.2.2. Attitude Control Systems .................................................................................................... 5
2.3.2.3. Telemetry Subsystem ......................................................................................................... 7
2.3.2.4. Payload Fairing ................................................................................................................... 7
2.4. Launch Support Equipment .......................................................................................................... 8
2.4.1. Transportable LSE Shelters ...................................................................................................... 8
3. GENERAL PERFORMANCE ............................................................................................................ 11
3.1. Mission Profiles........................................................................................................................... 11
3.2. Launch Sites ............................................................................................................................... 11
3.2.1. Western Launch Sites ............................................................................................................. 11
3.2.2. Eastern Launch Sites .............................................................................................................. 11
3.2.3. Alternate Launch Sites ............................................................................................................ 11
3.3. Performance Capability............................................................................................................... 11
3.4. Injection Accuracy....................................................................................................................... 23
3.5. Payload Deployment................................................................................................................... 23
3.6. Payload Separation..................................................................................................................... 23
3.7. Collision/Contamination Avoidance Maneuver ........................................................................... 23
4. PAYLOAD ENVIRONMENT.............................................................................................................. 25
4.1. Steady State and Transient Acceleration Loads......................................................................... 25
4.1.1. Transient Loads....................................................................................................................... 26
4.1.2. Steady-State Acceleration....................................................................................................... 26
4.2. Payload Vibration Environment .................................................................................................. 26
4.2.1. Random Vibration ................................................................................................................... 28
4.2.2. Sine Vibration .......................................................................................................................... 28
4.3. Payload Acoustic Environment ................................................................................................... 28
4.4. Payload Shock Environment....................................................................................................... 28
4.5. Payload Structural Integrity and Environments Verification........................................................ 32
4.5.1. Recommended Payload Testing and Analysis ....................................................................... 33
4.6. Thermal and Humidity Environments.......................................................................................... 33

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PAGE
4.6.1. Ground Operations.................................................................................................................. 33
4.6.2. Powered Flight ........................................................................................................................ 34
4.6.3. Nitrogen Purge (Non-Standard Service) ................................................................................. 35
4.7. Payload Contamination Control .................................................................................................. 35
4.8. Payload Electromagnetic Environment....................................................................................... 35
5. PAYLOAD INTERFACES.................................................................................................................. 37
5.1. Payload Fairing ........................................................................................................................... 37
5.1.1. Payload Dynamic Design Envelope ........................................................................................ 37
5.1.2. Payload Access Door.............................................................................................................. 37
5.2. Payload Mechanical Interface and Separation System .............................................................. 37
5.2.1. Standard Non-Separating Mechanical Interface ..................................................................... 38
5.2.2. Orbital Supplied Mechanical Interface Control Drawing ......................................................... 38
5.3. Payload Electrical Interfaces....................................................................................................... 38
5.3.1. Payload Umbilical Interfaces................................................................................................... 38
5.3.2. Payload Interface Circuitry ...................................................................................................... 40
5.3.3. Payload Battery Charging ....................................................................................................... 40
5.3.4. Payload Command and Control .............................................................................................. 40
5.3.5. Pyrotechnic Initiation Signals .................................................................................................. 40
5.3.6. Payload Telemetry .................................................................................................................. 40
5.3.7. Payload Separation Monitor Loopbacks ................................................................................. 41
5.3.8. Telemetry Interfaces ............................................................................................................... 41
5.3.9. Non-Standard Electrical Interfaces ......................................................................................... 41
5.3.10. Electrical Launch Support Equipment................................................................................... 41
5.4. Payload Design Constraints........................................................................................................ 41
5.4.1. Payload Center of Mass Constraints ...................................................................................... 41
5.4.2. Final Mass Properties Accuracy.............................................................................................. 41
5.4.3. Pre-Launch Electrical Constraints........................................................................................... 42
5.4.4. Payload EMI/EMC Constraints................................................................................................ 42
5.4.5. Payload Dynamic Frequencies ............................................................................................... 42
5.4.6. Payload Propellant Slosh ........................................................................................................ 42
5.4.7. Payload-Supplied Separation Systems................................................................................... 42
5.4.8. System Safety Constraints...................................................................................................... 42
6. MISSION INTEGRATION.................................................................................................................. 43
6.1. Mission Management Approach ................................................................................................. 43
6.1.1. RSLP Mission Responsibilities................................................................................................ 43
6.1.2. Orbital Mission Responsibilities .............................................................................................. 43

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PAGE
6.2. Mission Planning and Development ........................................................................................... 44
6.3. Mission Integration Process........................................................................................................ 44
6.3.1. Integration Meetings................................................................................................................ 44
6.3.2. Mission Design Reviews (MDR).............................................................................................. 45
6.3.3. Readiness Reviews................................................................................................................. 45
6.4. Documentation............................................................................................................................ 46
6.4.1. Customer-Provided Documentation ........................................................................................ 46
6.4.1.1. Payload Questionnaire...................................................................................................... 46
6.4.1.2. Payload Mass Properties .................................................................................................. 46
6.4.1.3. Payload Finite Element Model .......................................................................................... 46
6.4.1.4. Payload Thermal Model for Integrated Thermal Analysis................................................. 46
6.4.1.5. Payload Drawings ............................................................................................................. 46
6.4.1.6. Program Requirements Document (PRD) Mission Specific Annex Inputs ....................... 46
6.4.1.6.1. Launch Operations Requirements (OR) Inputs .......................................................... 47
6.5. Safety .......................................................................................................................................... 47
6.5.1. System Safety Requirements.................................................................................................. 47
6.5.2. System Safety Documentation................................................................................................ 47
7. GROUND AND LAUNCH OPERATIONS ......................................................................................... 49
7.1. Minotaur IV/Payload Integration Overview ................................................................................. 49
7.2. Ground And Launch Operations ................................................................................................. 49
7.2.1. Launch Vehicle Integration...................................................................................................... 49
7.2.1.1. Planning and Documentation............................................................................................ 49
7.2.1.2. GCA/Orion 38 Integration and Test Activities ................................................................... 49
7.2.1.3. PK Motor Integration and Test Activities........................................................................... 49
7.2.1.4. Mission Simulation Tests .................................................................................................. 49
7.2.1.5. Booster Assembly Stacking/Launch Pad Preparation ...................................................... 51
7.2.2. Payload Processing/Integration .............................................................................................. 51
7.2.2.1. Payload Propellant Loading .............................................................................................. 52
7.2.2.2. Final Vehicle Integration and Test .................................................................................... 52
7.3. Launch Operations...................................................................................................................... 53
7.3.1. Launch Control Organization .................................................................................................. 53
8. OPTIONAL ENHANCED CAPABILITIES.......................................................................................... 55
8.1. Mechanical Interface and Separation System Enhancements ................................................... 55
8.1.1. Separation Systems ................................................................................................................ 55
8.1.2. Additional Fairing Access Doors ............................................................................................. 55
8.1.3. Payload Isolation System........................................................................................................ 55

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PAGE
8.2. Performance Enhancements ...................................................................................................... 56
8.2.1. Insertion Accuracy................................................................................................................... 56
8.2.2. Star 48 Stage 4 ....................................................................................................................... 57
8.3. Environmental Control Options ................................................................................................... 58
8.3.1. Conditioned Air........................................................................................................................ 58
8.3.2. Nitrogen Purge ........................................................................................................................ 58
8.3.3. Enhanced Contamination Control ........................................................................................... 58
8.3.3.1. High Cleanliness Integration Environment (Class 10K or 100K) ...................................... 59
8.3.3.2. Fairing Surface Cleanliness Options ................................................................................ 59
8.3.3.3. High Cleanliness Fairing Environment.............................................................................. 59
8.3.4. Launch Pad Environmental Control ........................................................................................ 59
8.3.4.1. Booster Temperature Control ........................................................................................... 59
8.4. Enhanced Telemetry Options ..................................................................................................... 60
8.4.1. Enhanced Telemetry Bandwidth ............................................................................................. 60
8.4.2. Enhanced Telemetry Instrumentation ..................................................................................... 60
8.4.3. Navigation Data....................................................................................................................... 60
8.5. Shared Launch Accommodations ............................................................................................... 60

LIST OF FIGURES
Figure 2-1. OSP-2 Peacekeeper Space Lift Vehicle.................................................................................... 3
Figure 2-2. Minotaur IV Expanded View ...................................................................................................... 4
Figure 2-3. Orion 38 Stage 4 Motor ............................................................................................................. 6
Figure 2-4. Stage 4 Structures..................................................................................................................... 6
Figure 2-5. Existing 92 in. Taurus Fairing, Handling Fixtures, and Processes
will be used for Minotaur IV....................................................................................................... 7
Figure 2-6. Functional Block Diagram of LSE.............................................................................................. 9
Figure 2-7. Portable Launch Support Structure Provide Optional Support From Austere Sites................ 10
Figure 3-1. Minotaur IV Mission Profile...................................................................................................... 12
Figure 3-2. Minotaur IV Launch Site Options............................................................................................. 13
Figure 3-3. Minotaur IV Performance Curves for VAFB Launches (Metric Units) ..................................... 14
Figure 3-4. Minotaur IV Performance Curves for VAFB Launches (English Units) ................................... 15
Figure 3-5. Minotaur IV Performance Curves for CCAFS Launches (Metric Units) .................................. 16
Figure 3-6. Minotaur IV Performance Curves for CCAFS Launches (English Units) ................................ 17
Figure 3-7. Minotaur IV Performance Curves for Kodiak, Alaska Launches (Metric Units)....................... 18
Figure 3-8. Minotaur IV Performance Curves for Kodiak, Alaska Launches (English Units)..................... 19
Figure 3-9. Minotaur IV Performance Curves for Wallops, Virginia Launches (Metric Units).................... 20
Figure 3-10. Minotaur IV Performance Curves for Wallops, Virginia Launches (English Units)................ 21

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PAGE
Figure 3-11. Stage Impact Points for VAFB and CCAFS Launches.......................................................... 22
Figure 3-12. Minotaur IV Injection Accuracy .............................................................................................. 24
Figure 3-13. Typical Pre-Separation Payload Pointing and Spin Rate Accuracies .................................. 24
Figure 4-1. Phasing of Dynamic Loading Events....................................................................................... 25
Figure 4-2. Payload CG Net Transient Lateral Acceleration at Stage 2 Ignition with a Typical
Separation System................................................................................................................... 27
Figure 4-3. Minotaur IV Nominal Maximum Axial Acceleration as a Function of Payload Mass ............... 27
Figure 4-4. Minotaur IV Payload Random Vibration Environment ............................................................. 29
Figure 4-5. Minotaur IV Payload Sine Vibration Environment ................................................................... 29
Figure 4-6. Minotaur IV Payload Acoustic Maximum Predicted Environment (MPE) ................................ 30
Figure 4-7. Minotaur IV Payload Shock Maximum Predicted Environment (MPE) – Launch Vehicle to
Payload .................................................................................................................................... 31
Figure 4-8. Payload Shock Environment – Payload to Launch Vehicle .................................................... 32
Figure 4-9. Factors of Safety Payload Design and Test ........................................................................... 33
Figure 4-10. Recommended Payload Testing Requirements.................................................................... 33
Figure 4-11. Payload Thermal and Humidity Environment ........................................................................ 34
Figure 4-12. Minotaur IV Launch Vehicle RF Emitters and Receivers ...................................................... 36
Figure 5-1. Standard 92 in. Fairing Envelope ............................................................................................ 37
Figure 5-2. Standard, Non-separating Payload Mechanical Interface....................................................... 39
Figure 5-3. Payload Electrical Interface Block Diagram, With No Orbital Supplied Separation System .. 39
Figure 5-4. Payload 1:1 Umbilical Pin Outs ............................................................................................... 39
Figure 5-5. Minotaur IV Payload Electrical Interface Block Diagram ......................................................... 40
Figure 5-6. Payload Mass Properties Measurement Tolerance ................................................................ 42
Figure 6-1. Typical Integrated OSP Organizational Structure ................................................................... 43
Figure 6-2. Typical Mission Integration Schedule...................................................................................... 45
Figure 7-1. Hardware Flow – Factory to Launch Site ................................................................................ 50
Figure 7-2. SLV Processing Flow .............................................................................................................. 51
Figure 7-3. Minotaur IV Processing Flow................................................................................................... 52
Figure 7-4. Minotaur IV Upper Stack Assembly will be Vertically Integrated to Minotaur IV Booster
Assembly in a Similar Manner to Taurus Upper Stack ............................................................ 53
Figure 8-1. 38-in. Separation System Option............................................................................................. 56
Figure 8-2. Soft Ride Payload Isolation System as Integrated on Minotaur LV......................................... 57
Figure 8-3. Hydrazine Auxiliary Propulsion System (HAPS) Used to Provide Insertion Accuracy............ 57
Figure 8-4. Orion 38 Stage 4 Motor can be Replaced with a Star-48 to Provide Increased Performance 58
Figure 8-5. Mobile Scaffolding for Environmental Control Demonstrated on Minotaur Missions .............. 59
Figure 8-6. Modular Minotaur IV Structural Design Easily Accommodates Multiple Payloads ................. 60

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Minotaur IV User’s Guide Table of Contents

LIST OF TABLES
PAGE
TABLE 4-1. PAYLOAD CG PARAMETRIC DESIGN LIMIT LOADS ......................................................... 26

LIST OF APPENDICES
A. PAYLOAD QUESTIONNAIRE..............................................................................................................A-1

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Minotaur IV User’s Guide Glossary

ACS Attitude Control System MACH Modular Avionics Control Hardware

A/D Arm/Disarm MARS Mid-Atlantic Regional Spaceport
AADC Alaska Aerospace Development MDR Mission Design Review
Corporation MIWG Mission Integration Working Groups
AC Air Conditioning MRD Mission Requirements Document
AFRL Air Force Research Laboratory MRR Mission Readiness Review
BER Bit Error Rate NTW Navy Theater Wide
C/CAM Collision/Contamination Avoidance ODM Ordnance Driver Modules
Maneuver OR Operations Requirements
CCAFS Cape Canaveral Air Force Station OSP-2 Orbital Suborbital Program ll
CDR Critical Design Review PAF Payload Attach Fitting
CG center-of-gravity PAM Payload Adapter Module
CLA Coupled Loads Analysis PBCM PK Booster Control Module
CLF Commercial Launch Facility PCF Programmable Clock Filter
CMP Critical Measurements Program PCM Pulse Code Modulation
DPAF Dual Payload Attach Fitting PDR Preliminary Design Review
ECS Environmental Control System PID Proportional-Integral-Derivative
EELV Evolved Expendable Launch Vehicle PK Peacekeeper
EGSE Electrical Ground Support Equipment POC Point of Contact
EMC Electromagnetic Compatibility PPF Payload Processing Facility
EME Electromagnetic Environment PRD Program Requirements Document
EMI Electromagnetic Interference PWB Printed Wiring Board
FLSA Florida Spaceport Authority QES Quick Erect Scaffold
FTS Flight Termination System RF Radio Frequency
GCA Guidance and Control Assembly RSLP Rocket Systems Launch Program
GFE Government Furnished Equipment RTS Range Tracking System
GFP Government Furnished Property RWG Range Working Groups
GPB GPS Position Beacon SEA Statistical Energy Analysis
GPS Global Positioning System SEB Support Equipment Building
GTO Geosynchronous Transfer Orbit SES Saab Ericson Space
HAPS Hydrazine Auxiliary Propulsion SLV Space Launch Vehicle
System SRSS Softride for Small Satellites
HEPA High Efficiency Particulate Air SSI Spaceport Systems International
HVAC Heating, Ventilation and Air START Strategic Arms Reduction Treaty
Conditioning TPS Thermal Protection System
ICD Interface Control Drawing TVAs Thrust Vector Actuators
LCR Launch Control Room TVC Thrust Vector Control
LER Launch Equipment Room USAF United States Air Force
LEV Launch Equipment Van VAFB Vandenberg Air Force Base
LOCC Launch Operations Control Center VPF Vehicle Processing Facility
LRR Launch Readiness Review WFF Wallops Flight Facility
LSE Launch Support Equipment WP Work Package
LSV Launch Support Van
LV Launch Vehicle
MAC Motor Adapter Cone
MAC Modified Adapter Cone

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Minotaur IV User’s Guide Section 1.0 - Introduction

1. INTRODUCTION
This User’s Guide is intended to familiarize
payload mission planners with the capabilities of
the Orbital Suborbital Program ll (OSP-2) Minotaur
IV Space Launch Vehicle (SLV) launch service.
The information provided in this user’s guide is for
initial planning purposes only. Information for
development/design is determined through
mission specific engineering analyses. The
results of these analyses are documented in a
mission-specific Interface Control Document (ICD)
for the payloader organization to use in their
development/design process. This document
provides an overview of the Minotaur IV system
design and a description of the services provided
to our customers. Minotaur IV offers a variety of
enhanced options to allow the maximum flexibility
in satisfying the objectives of single or multiple
payloads.
By adopting the austere launch site concepts
developed for Taurus, the Minotaur IV system can
operate from a wide range of launch facilities and
geographic locations. The system is compatible
with, and will typically operate from, commercial
spaceport facilities and existing U.S. Government
ranges at Vandenberg Air Force Base (VAFB),
Cape Canaveral Air Force Station (CCAFS),
Wallops Flight Facility (WFF), and Kodiak Island,
Alaska. This User’s Guide describes Minotaur IV-
unique integration and test approaches (including
the typical operational timeline for payload
integration with the Minotaur IV vehicle) and the
ground support equipment that will be used to
conduct Minotaur IV operations.

The primary mission of the Minotaur IV is to

provide low cost, high reliability launch services to
government-sponsored payloads. Minotaur IV
accomplishes this using flight-proven components
with a significant flight heritage such as surplus
Peacekeeper boosters, the Taurus Fairing and
Attitude Control System, and a mix of Minotaur I,
Pegasus, Taurus, and other orbital standard
avionics, all with a proven, successful track record.
The philosophy of placing mission success as the
highest priority is reflected in the success and
accuracy of all OSP missions to date.

The Minotaur IV launch vehicle system is

composed of a flight vehicle and ground support
equipment. Each element of the Minotaur IV
system has been developed to simplify the
mission design and payload integration process
and to provide safe, reliable space launch
services. This User’s Guide describes the basic
elements of the Minotaur IV system as well as
optional services that are available. In addition,
this document provides general vehicle
performance, defines payload accommodations
and environments, and outlines the Minotaur IV
mission integration process.

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Minotaur IV User’s Guide Section 1.0 - Introduction

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Minotaur IV User’s Guide
2. MINOTAUR IV LAUNCH SERVICE
2.1. Minotaur IV Launch System Overview
The Minotaur IV (Figure 2-1) mission is to
provide a cost effective, reliable and flexible
means of placing satellites into orbit. The launch
vehicle developer and manufacturer is Orbital,
under the Orbital Suborbital Program 2 (OSP-2)
contract for the U.S. Air Force. An overview of the
system and available launch services is provided
within this section, with specific elements covered
in greater detail in the subsequent sections of this
User’s Guide.
Figure 2-1. OSP-2 Peacekeeper Space Lift
Vehicle
Minotaur IV has been designed to meet the
needs of U.S. Government-sponsored customers
at a lower cost than commercially available
alternatives by the use of surplus Peacekeeper
boosters. The requirements of the OSP-2
program stress system reliability, transportability,
and operation from multiple launch sites. Minotaur
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Section 2.0 – Minotaur IV Launch Service
IV draws on the successful heritage of four launch
vehicles: Orbital’s Pegasus, Taurus and Minotaur I
space launch vehicles and the Peacekeeper
system of the USAF. Minotaur IV’s avionics are
derived from the Pegasus and Taurus systems,
providing a combined total of more than 35
successful space launch missions. Orbital’s
efforts have enhanced or updated Pegasus,
Taurus and Minotaur avionics components to meet
the payload-support requirements of the OSP-2
program. Combining these improved subsystems
with the long successful history of the
Peacekeeper boosters has resulted in a simple,
robust, self-contained launch system to support
government-sponsored small satellite launches.
The Minotaur IV system also includes a
complete set of transportable Launch Support
Equipment (LSE) designed to allow Minotaur IV to
be operated as a self-contained satellite delivery
system. To accomplish this goal, the Electrical
Ground Support Equipment (EGSE) has been
developed to be portable and adaptable to varying
levels of infrastructure. While the Minotaur IV
system is capable of self-contained operation
using portable vans to house the EGSE, it is
typically launched from an established range
where the EGSE can be housed in available,
permanent structures or facilities.
The vehicle and LSE are designed to be
capable of launch from any of the four commercial
Spaceports (Alaska, California, Florida, and
Mid-Atlantic), as well as from existing U.S.
Government facilities at VAFB and CCAFS. The
Launch Control Room (LCR) serves as the control
center for conducting a Minotaur IV launch and
includes consoles for Orbital, range safety, and
limited customer personnel. Further description of
the Launch Support Equipment is provided in
Section 2.4.
2.2. Minotaur IV Launch Service
The Minotaur IV Launch Service is provided
through the combined efforts of the USAF and
Orbital, along with associate contractors including
3
Minotaur IV User’s Guide Section 2.0 – Minotaur IV Launch Service

Northrop Grumman and Commercial Spaceports.

The primary customer interface will be with the
USAF Space and Missile Systems Center,
Detachment 12, Rocket Systems Launch
Program, designated RSLP. Orbital is the launch
vehicle provider. For brevity, this integrated team
effort will be referred to as “OSP”. Where
interfaces are directed toward a particular member
of the team, they will be referred to directly (i.e.,
Orbital or RSLP).

OSP provides all of the necessary hardware,

software and services to integrate, test and launch
a satellite into its prescribed orbit. In addition, OSP
will complete all the required agreements, licenses
and documentation to successfully conduct
Minotaur IV operations. The Minotaur IV mission
integration process completely identifies,
documents, and verifies all spacecraft and mission
requirements. This provides a solid basis for
initiating and streamlining the integration process
for future Minotaur IV customers.

2.3. Minotaur IV Launch Vehicle

The Minotaur IV vehicle, shown in expanded
view in Figure 2-2, is a four-stage, inertially
guided, all solid propellant ground launched
vehicle. Conservative design margins, state-of-
the-art structural systems, a modular avionics
architecture, and simplified integration and test
capability, yield a robust, highly reliable launch
vehicle design. In addition, Minotaur IV payload
accommodations and interfaces have been
designed to satisfy a wide range of potential
payload requirements.

2.3.1. Stage 1, 2 and 3 Booster Assemblies

The first three stages of the Minotaur IV
consists of the refurbished Government Furnished
Equipment (GFE) Peacekeeper Stages 1, 2 and 3.
These booster assemblies are used as provided
by the Government, requiring no modification or Figure 2-2. Minotaur IV Expanded View
additional components. They have extensive flight
history, including 51 Peacekeeper launches and propellant motors and utilize a movable nozzle
three Stage 1 launches on Taurus with no motor controlled by a Thrust Vector Actuator (TVA)
related failures. All three stages are solid- system for three-axis attitude control. The first

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Minotaur IV User’s Guide
stage consists of a Thiokol motor that provides
500,000 lbf (2224 kN) of thrust. The second stage
motor is an Aerojet motor with a moveable nozzle
contoured with an extendable exit cone. It
provides an average thrust of 275,000 lbf
(1223 kN). The third stage is a Hercules motor
that provides 65,000 lbf (289 kN) of thrust and also
features an extendable exit cone similar to
Stage 2.
2.3.2. Stage 4 Booster/Avionics Assembly
The Minotaur IV Stage 4 motor is the Orion 38
design (Figure 2-3). This motor was originally
developed for Orbital’s Pegasus program and is
used on the Minotaur I launch vehicle, as well as
other Orbital launch vehicles. Common design
features, materials and production techniques are
applied to the motors to maximize reliability and
production efficiency. The Orion 38 motor
provides the velocity needed for orbit insertion for
the SLV, in the same manner as it is used on the
Minotaur. This motor features state-of-the-art
design and materials with a successful flight
heritage. It is currently in production and is
actively flying payloads into space, with 37 fully
successful flights to date and one static test.
Three substructures are utilized to
accommodate the Orion 38 Stage 4 motor and
attach it to the Stage 1-3 PK booster assembly.
These are a Payload Adapter Module (PAM) with
62.01-inch diameter payload interface, a 38-inch
diameter motor adapter cone and a GCA +3/4
interstage. These structures were adapted from
similar Taurus hardware designs and are shown in
Figure 2-4.
2.3.2.1. Avionics
The Minotaur IV avionics system has heritage
to the Minotaur I, OSP TLV, as well as Pegasus
and Taurus designs. The flight computer is a 32-
bit multiprocessor architecture. It provides
communication with vehicle subsystems, the LSE,
and the payload, if required, utilizing standard RS-
422 serial links and discrete I/O. The avionics
system design incorporates Orbital’s innovative,
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Section 2.0 – Minotaur IV Launch Service
flight-proven Modular Avionics Control Hardware
(MACH). Standardized, function-specific modules
are combined in stacks to meet vehicle-specific
requirements. The functional modules from which
the MACH stacks are created include power
transfer, ordnance initiation, booster interface,
communication, and telemetry processing. Orbital
has designed, tested, and flown a variety of MACH
modules, which provide an array of functional
capability and flexibility. MACH has exhibited
100% reliability on all flights including Minotaur
and TLV flights and several of Orbital’s suborbital
launch vehicles including Navy Theater Wide
(NTW), Critical Measurements Program (CMP),
and STORM.
2.3.2.2. Attitude Control Systems
The Minotaur IV Attitude Control System
(ACS) provides attitude control throughout
boosted flight and coast phases. Stages 1, 2 and 3
utilize the PK Thrust Vector Control (TVC)
systems. The PK Booster Control Module (PBCM)
links the flight computer actuator commands to the
individual Stage 1, 2, and 3 Thrust Vector
Actuators (TVAs). Stage 4 utilizes the same TVC
system used by the Pegasus, Taurus and
Minotaur vehicles which combines single-nozzle
electromechanical TVC for pitch and yaw control
with a three-axis, cold-gas attitude control system
resident in the avionics section providing roll
control.
Attitude control is achieved using a three-axis
autopilot that employs Proportional-Integral-
Derivative (PID) control. Stages 1, 2 and 3 fly a
pre-programmed attitude profile based on
trajectory design and optimization. Stage 4 uses a
set of pre-programmed orbital parameters to place
the vehicle on a trajectory toward the intended
insertion apse. The extended coast between
Stages 3 and 4 is used to orient the vehicle to the
appropriate attitude for Stage 4 ignition based
upon a set of pre-programmed orbital parameters
and the measured performance of the first three
stages. Stage 4 utilizes energy management to
place the vehicle into the proper orbit. After the
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Minotaur IV User’s Guide Section 2.0 – Minotaur IV Launch Service

Figure 2-3. Orion 38 Stage 4 Motor

Figure 2-4. Stage 4 Structures

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Minotaur IV User’s Guide
final boost phase, the three-axis cold-gas attitude
control system is used to orient the vehicle for
spacecraft separation, contamination and collision
avoidance and downrange downlink maneuvers.
The autopilot design is modular, so additional
payload requirements such as rate control or
celestial pointing can be accommodated with
minimal additional development.
2.3.2.3. Telemetry Subsystem
The Minotaur IV telemetry subsystem provides
real-time health and status data of the vehicle
avionics system, as well as key information
regarding the position, performance and
environment of the Minotaur IV vehicle. This data
may be used by Orbital and the range safety
personnel to evaluate system performance. The
Minotaur IV baseline telemetry subsystem
provides a number of dedicated payload discrete
(bi-level) and analog telemetry monitors through
dedicated channels in the SLV encoder. The
Minotaur IV telemetry system provides a baseline
1 Mbps data rate (both payload and Minotaur IV
telemetry). However, the output data rate is
selectable from 2.441 kbps to 10 Mbps to allow
flexibility in supporting evolving mission
requirements, as limited by link margin and Bit
Error Rate (BER) requirements. The telemetry
subsystem nominally utilizes Pulse Code
Modulation (PCM) with a RNRZ-L format.
However other types of data formats, including
NRZ-L, S, M, and Bi-phase may be implemented if
required, in order to accommodate launch range
limitations.
Minotaur IV telemetry is subject to the
provisions of the Strategic Arms Reduction Treaty
(START). START treaty provisions require that
certain Minotaur IV telemetry be unencrypted and
provided to the START treaty office for
dissemination to the signatories of the treaty.
2.3.2.4. Payload Fairing
Orbital’s flight-proven Taurus 92-inch diameter
payload fairing (Figure 2-5) is used to encapsulate
the payload, provide protection and contamination
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Section 2.0 – Minotaur IV Launch Service
control during ground handling, integration
operations and flight. The fairing is a bi-conic
design made of graphite/epoxy face sheets with
an aluminum honeycomb core. The fairing
provides for low payload contamination through
prudent design and selection of low contamination
materials and processes. Acoustic blankets and
internal air conditioning ducts are available to
provide more benign payload environments. Air
conditioning will keep the payload environment to
a specified temperature between 60 to 120 °F
dependent upon requirements.
The two halves of the fairing are structurally
joined along their longitudinal interface using
Orbital’s low contamination frangible joint system.
An additional circumferential frangible joint at the
base of the fairing supports the fairing loads. At
separation, a gas pressurization system is
activated to pressurize the fairing deployment
thrusters. The fairing halves then rotate about
external hinges that control the fairing deployment
to ensure that payload and launch vehicle
clearances are maintained. All elements of the
deployment system have been demonstrated
through test to comply with stringent
contamination requirements.
Options for payload access doors and
enhanced cleanliness are available. Further
Figure 2-5. Existing 92 in. Taurus Fairing,
Handling Fixtures, and Processes
will be used for Minotaur IV
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Minotaur IV User’s Guide
details on the baseline fairing are included in
Section 5.1. With the addition of a structural
adapter, the fairing can accommodate multiple
payloads. This feature, described in more detail in
Section 8.5 of this User’s Guide, permits two or
more smaller payloads to share the cost of a
Minotaur launch, resulting in a lower launch cost
for each as compared to other launch options.
OSP has access to several Multiple Payload
Adaptor (MPA) designs that allow for a cost
sharing benefit to programs with excess payload
and/or mass capability.
2.4. Launch Support Equipment
The Minotaur IV LSE is designed to be readily
adaptable to varying launch site configurations
with minimal unique infrastructure required. The
EGSE consists of readily transportable consoles
that can be housed in various facility
configurations depending on the launch site
infrastructure. The EGSE is composed of three
primary functional elements: Launch Control,
Vehicle Interface, and Telemetry Data Reduction.
The Launch Control consoles are located in a
Launch Control Room (LCR), or mobile launch
equipment van depending on available launch site
accommodations. The Vehicle Interface EGSE is
located in a permanent structure, typically called a
Support Equipment Building (SEB) or Launch
Equipment Room (LER). Fiber optic connections
from the Launch Control to the Vehicle Interface
consoles are used for efficient, high bandwidth
communications and eliminates the need for
copper wire. The Vehicle Interface racks provide
the junction from fiber optic cables to the copper
cabling interfacing with the vehicle. Figure 2-6
depicts the functional block diagram of the LSE.
The LCR serves as the control center during
the launch countdown. The number of personnel
that can be accommodated are dependent on the
launch site facilities. At a minimum, the LCR will
accommodate Orbital personnel controlling the
vehicle, two Range Safety representatives (ground
and flight safety), and the Air Force Mission
Manager. Mission-unique, customer-supplied
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Section 2.0 – Minotaur IV Launch Service
payload consoles and equipment can be
supported in the LCR and SEB, within the
constraints of the launch site facilities or temporary
structure facilities. Interface to the payload
through the Minotaur IV payload umbilicals and
landlines provides the capability for direct
monitoring of payload functions. Payload
personnel accommodations will be handled on a
mission-specific basis.
2.4.1. Transportable LSE Shelters
In order to perform mission operations from
alternative, austere launch sites, Orbital can
provide self contained, transportable shelters for
the Launch Support Van (LSV) and Launch
Equipment Van (LEV) as an unpriced option.
These shelters are the same approach and design
used on all six of Orbital’s Taurus launches
(Figure 2-7). The OSP-2 Ground Support
Consoles have been intentionally made modular
and portable to allow their use in these
accommodations.
The LSV consists of a shelter which is located
at a Range Safety-approved man-safe distance
from the launch site. The LSV contains the vehicle
control and telemetry monitor consoles described
in Section 2.4. Sufficient space is available for
additional equipment racks depending on
Government and/or Payload requirements. The
LEV consists of an 8 foot x 20 foot shelter which is
located near the launch stool and is unmanned
during launch. This shelter contains the vehicle
interface racks described in Section 2.4. The LEV
has sufficient room available for payload power
supplies and interface electronics. Both shelters
are designed for shipping and transportation with
exterior tiedown and anchor locations used to
facilitate the loading and unloading operations.
The shelters can be delivered to any level location
and be set up within hours. The transportable
support console design also allows for the LSE to
be moved into a fixed blockhouse and LER if
required.
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Figure 2-6. Functional Block Diagram of LSE

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Figure 2-7. Portable Launch Support Structure Provide Optional Support From Austere Sites

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Minotaur IV User’s Guide
3. GENERAL PERFORMANCE
3.1. Mission Profiles
Minotaur IV can attain a range of posigrade
and retrograde inclinations through the choice of
launch sites made available by the readily
adaptable nature of the Minotaur IV launch
system. A typical mission profile to a sun-
synchronous orbit is shown in Figure 3-1. All
performance parameters presented herein are
typical for most expected payloads. However,
performance may vary depending on unique
payload or mission characteristics. Specific
requirements for a particular mission should be
coordinated with OSP. Once a mission is formally
initiated, the requirements will be documented in
the Mission Requirements Document (MRD).
Further detail will be captured in the Payload-to-
Launch Vehicle Interface Control Drawing (ICD).
3.2. Launch Sites
Depending on the specific mission and range
safety requirements, Minotaur IV can operate from
several East and West Coast launch sites,
illustrated in Figure 3-2. Specific performance
parameters are presented in Section 3.3.
Facilities used for OSP Minotaur and Taurus
launches are generally compatible with Minotaur
IV operations.
3.2.1. Western Launch Sites
For missions requiring high inclination orbits
(greater than 60°), launches can be conducted
from facilities at VAFB or Kodiak Island, AK. Both
facilities can accommodate inclinations from 60° to
120°, although inclinations below 72° from VAFB
require an out-of-plane dogleg, thereby reducing
payload capability. As with the initial Minotaur
missions, Minotaur IV can be launched from the
California Spaceport facility, Space Launch
Complex 8 (SLC-8) operated by Spaceport
Systems International (SSI), on South VAFB. The
launch facility at Kodiak Island, operated by the
Alaska Aerospace Development Corporation
(AADC) has been used for both orbital and
suborbital launches.
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Section 3.0 – General Performance
3.2.2. Eastern Launch Sites
For Easterly launch azimuths to achieve
orbital inclinations between 28.5° and 60°,
Minotaur IV can be launched from facilities at
Cape Canaveral, FL or Wallops Island, VA.
Launches from Florida will nominally use the
Florida Spaceport Authority (FLSA) launch
facilities at LC-46 on CCAFS. These will be
typically for inclinations from 28.5° to 40°, although
inclinations above 35° may have reduced
performance due to the need for a trajectory
dogleg. Inclinations below 28.5° are feasible,
albeit with doglegs and altitude constraints due to
range safety considerations. The Mid-Atlantic
Regional Spaceport (MARS) facilities at the WFF
may be used for inclinations from 30° to 60°.
Some inclinations may have reduced performance
due to range safety considerations and will need
to be evaluated on a case-by-case mission-
specific basis.
3.2.3. Alternate Launch Sites
Other launch facilities can be readily used
given the flexibility designed into the Minotaur IV
vehicle, ground support equipment, and the
various interfaces. Orbital has experience
launching vehicles from a variety of sites around
the world. To meet the requirements of
performing mission operations from alternative,
austere launch sites, Orbital can provide self
contained, transportable shelters as described in
section 2.4.1.
3.3. Performance Capability
Minotaur IV performance curves for circular
and elliptical orbits of various altitudes and
inclinations are detailed in Figure 3-3 through
Figure 3-10 for launches from all four Spaceports
in both metric and English units. These
performance curves provide the total mass above
the standard, non-separating interface. The mass
of any Payload Attach Fitting (PAF) or separation
system is to be accounted for in the payload mass
allocation. Figure 3-11 illustrates the stage
vacuum impact points for launch trajectories from
VAFB and CCAFS.
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Minotaur IV User’s Guide Section 3.0 – General Performance

Figure 3-1. Minotaur IV Mission Profile

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Figure 3-2. Minotaur IV Launch Site Options

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Figure 3-3. Minotaur IV Performance Curves for VAFB Launches (Metric Units)

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Figure 3-4. Minotaur IV Performance Curves for VAFB Launches (English Units)

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Figure 3-5. Minotaur IV Performance Curves for CCAFS Launches (Metric Units)

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Figure 3-6. Minotaur IV Performance Curves for CCAFS Launches (English Units)

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Figure 3-7. Minotaur IV Performance Curves for Kodiak, Alaska Launches (Metric Units)

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Figure 3-8. Minotaur IV Performance Curves for Kodiak, Alaska Launches (English Units)

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Figure 3-9. Minotaur IV Performance Curves for Wallops, Virginia Launches (Metric Units)

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Figure 3-10. Minotaur IV Performance Curves for Wallops, Virginia Launches (English Units)

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Figure 3-11. Stage Impact Points for VAFB and CCAFS Launches

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Minotaur IV User’s Guide
3.4. Injection Accuracy
Minotaur IV injection accuracy is summarized
in Figure 3-12. Better accuracy can be provided
dependent on specific mission characteristics. For
example, heavier payloads will typically have
better insertion accuracy, as will higher orbits. An
enhanced option for increased insertion accuracy
is also available (Section 8.2.1). It utilizes the
flight-proven Hydrazine Auxiliary Propulsion
System (HAPS) developed on the Pegasus
program.
3.5. Payload Deployment
Following orbit insertion, the Minotaur IV
Stage 4 avionics subsystem can execute a series
of ACS maneuvers to provide the desired initial
payload attitude prior to separation. This
capability may also be used to incrementally
reorient Stage 4 for the deployment of multiple
spacecraft with independent attitude requirements.
Either an inertially-fixed or spin-stabilized attitude
may be specified by the customer. The maximum
spin rate for a specific mission depends upon the
spin axis moment of inertia of the payload and the
amount of ACS propellant needed for other
attitude maneuvers. Figure 3-13 provides the
typical payload pointing and spin rate accuracies.
3.6. Payload Separation
Payload separation dynamics are highly
dependent on the mass properties of the payload
and the particular separation system utilized. The
primary parameters to be considered are payload
tip-off and the overall separation velocity.
Payload tip-off refers to the angular velocity
imparted to the payload upon separation due to
payload center-of-gravity (CG) offsets and an
uneven distribution of torques and forces. If an
optional Orbital-supplied Marmon Clamp-band
separation system is used, payload tip-off rates
are generally under 5°/sec per axis. Separation
system options are discussed further in Section
8.1.1. Orbital performs a mission-specific tip-off
analysis for each payload.
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Section 3.0 – General Performance
Separation velocities are driven by the need to
prevent recontact between the payload and the
Minotaur IV upper stage after separation. The
value will typically be 2 to 3 ft/sec (0.6 to 0.9
m/sec).
3.7. Collision/Contamination Avoidance
Maneuver
Following orbit insertion and payload
separation, the Minotaur IV Stage 4 will perform a
Collision/Contamination Avoidance Maneuver
(C/CAM). The C/CAM minimizes both payload
contamination and the potential for recontact
between Minotaur IV hardware and the separated
payload. OSP will perform a recontact analysis for
post-separation events.
A typical C/CAM begins soon after payload
separation. The launch vehicle performs a 90°
yaw maneuver designed to direct any remaining
Stage 4 motor impulse in a direction which will
increase the separation distance between the two
bodies. After a delay to allow the distance
between the spacecraft and Stage 4 to increase to
a safe level, the launch vehicle begins a “crab-
walk” maneuver to impart a small amount of delta
velocity, increasing the separation between the
payload and the fourth stage of the Minotaur IV.
Following the completion of the C/CAM
maneuver as described above and any remaining
maneuvers, such as downlinking of delayed
telemetry data (per START treaty provisions), the
ACS valves are opened and the remaining ACS
nitrogen propellant is expelled.
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Minotaur IV User’s Guide Section 3.0 – General Performance

Tolerance
Error Type Error Source
(Worst Case)
Altitude Stage 4 motor performance uncertainty and guidance
±10 nmi (18.5 km)
(Insertion Apse) algorithm uncertainty
Altitude Stage 4 motor performance and guidance algorithm
±50 nmi (92.6 km)
(Non-Insertion Apse) uncertainty and navigation (INS) error
Altitude Stage 4 motor performance and guidance algorithm
±30 nmi (55.6 km)
(Mean) uncertainty and navigation (INS) error
Guidance algorithm uncertainty and navigation
Inclination ±0.2°
(INS) error
Figure 3-12. Minotaur IV Injection Accuracy

Figure 3-13. Typical Pre-Separation Payload

Pointing and Spin Rate Accuracies

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4. PAYLOAD ENVIRONMENT
CAUTION
The predicted environments provided
in this user's guide are for initial
planning purposes only.
Environments presented here bound
typical mission parameters, but should
not be used in lieu of mission-specific
analyses. Mission-specific levels are
provided as a standard service and
documented or referenced in the
mission ICD.
This section provides details of the predicted
environmental conditions that the payload will
experience during Minotaur IV ground operations,
powered flight, and launch system on-orbit
operations. The predicted environments provided
in this user’s guide are for initial planning purposes
only.
Minotaur IV ground operations include payload
integration and encapsulation within the fairing,
subsequent transportation to the launch site and
final vehicle integration activities. Powered flight
begins at Stage 1 ignition and ends at Stage 4
burnout. Minotaur IV on-orbit operations begin
after Stage 4 burnout and end following payload
separation. To more accurately define
simultaneous loading and environmental
conditions, the powered flight portion of the
mission is further subdivided into smaller time
segments bounded by critical, transient flight
Figure 4-1. Phasing of Dynamic Loading Events
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Section 4.0 – Payload Environment
events such as motor ignition, stage separation,
and transonic crossover.
The environmental design and test criteria
presented have been derived using measured
data obtained from previous Taurus, Minotaur I,
and Peacekeeper missions, motor static fire tests,
other system development tests and analyses.
The predicted levels presented are intended to be
representative of a standard mission. Satellite
mass, geometry and structural components vary
greatly and will result in significant differences
from mission to mission.
Dynamic loading events that occur throughout
various portions of the flight include steady-state
acceleration, transient low frequency acceleration,
acoustic impingement, random vibration, and
pyrotechnic shock events. Figure 4-1 identifies
the time phasing of these dynamic loading events
and environments and their significance.
Pyroshock events are not indicated in this figure,
as they do not occur simultaneous with any other
significant dynamic loading events. In addition,
dynamic loading associated with S4 ignition is
insignificant.
4.1. Steady State and Transient Acceleration
Loads
Design limit load factors due to the combined
effects of steady state and low frequency transient
accelerations are largely governed by payload
characteristics. A mission-specific Coupled Loads
Analysis (CLA) will be performed, with customer
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Minotaur IV User’s Guide Section 4.0 – Payload Environment

provided finite element models of the payload, in
order to provide precise load predictions. Results
will be referenced in the mission specific ICD. For
preliminary design purposes, Orbital can provide
initial Center-of-Gravity (CG) netloads given a
payload’s mass properties, CG location and
bending frequencies. Design limit loads due to
both transient and steady-state accelerations are
presented in Table 4-1 for select payload masses.
vehicle model. A Monte-Carlo analysis is
performed to determine variations in vehicle
acceleration due to changes in winds, motor
performance and aerodynamics. The steady-state
accelerations must be added to transient
accelerations from the CLA as indicated in
Figure 4-1 to determine the total payload
acceleration. Steady-state accelerations are
typically 8-Gs axial and 0.5-Gs lateral.

4.1.1. Transient Loads During powered flight, the maximum steady

Transient loads account for approximately
30% of the total vehicle load with the remainder
due to steady wind loads. Typical acceleration
values at the payload interface are 2-Gs lateral
and 4-Gs axial depending on the load case.
Transient lateral accelerations at Stage 2 ignition
are defined as a function of payload mass in
Figure 4-2. Preliminary and final CLAs will be
performed for each Minotaur IV payload. The
payload finite element model is coupled to the
vehicle model. Forcing functions have been
developed for different flight events or load cases.
Load cases include liftoff, transonic, max q and
stage and shroud separation.
4.1.2. Steady-State Acceleration
The steady-state vehicle accelerations are
determined from the vehicle rigid body analysis.
Drag, wind and motor thrust are applied to a
state accelerations are dependent on the payload
mass. The maximum level occurs during Stage 3
burn. Figure 4-3 depicts the axial acceleration at
burnout for Stages 3 and 4 as a function of
payload mass.
4.2. Payload Vibration Environment
The Minotaur IV payload vibration
environments are low frequency random and
sinusoidal vibrations created by the solid rocket
motor combustion processes and transmitted
through the launch vehicle structure. Additionally,
higher frequency aeroacoustics energy is created
by air flow over the surface of the vehicle. Some
of this aeroacoustic energy is transmitted via the
launch vehicle structure to the payload. However,
a majority of the aeroacoustic energy is
transmitted to the payload directly as acoustic
energy through the fairing.

TABLE 4-1. PAYLOAD CG PARAMETRIC DESIGN LIMIT LOADS

Payload Mass
1600 lbm (725.7 kg) 2400 lb (1089 kg) 3200 lb (1452 kg) 4000lb (8141 kg)
Axial (G) Lateral Axial (G) Lateral Axial (G) Lateral Axial (G) Lateral
(G) (G) (G) (G)
max/min max/min max/min max/min
Liftoff 3.83/0.27 0.62 3.93/0.15 0.46 3.90/0.16 0.41 4.01/0.12 0.37
Pre-Transonic
Resonant Burn 5.05/0.83 0.02 3.46/2.29 0.00 3.44/2.31 0.00 3.73/2.08 0.00
Transonic 5.13/1.52 1.23 3.95/2.71 0.97 3.89/2.75 0.90 4.07/2.49 0.89
Supersonic 3.41/3.40 1.96 3.38/3.38 1.61 3.36/3.36 1.40 3.34/3.34 1.26
Stage 2 Ignition 3.93/-0.35 4.05 3.95/-0.03 2.89 3.83/-0.02 2.74 3.66/0.01 2.13
Stage 3 Ignition 6.79/0.00 0.78 6.45/0.00 0.59 6.22/0.00 0.49 5.90/0.00 0.40
Stage 3 Burnout See Figure 4-3 TBS See Figure 4-3 TBS See Figure 4-3 TBS See Figure 4-3 TBS
Stage 4 Burnout See Figure 4-3 TBS See Figure 4-3 TBS See Figure 4-3 TBS See Figure 4-3 TBS

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Figure 4-2. Payload CG Net Transient Lateral Acceleration at Stage 2 Ignition with a Typical
Separation System

Figure 4-3. Minotaur IV Nominal Maximum Axial Acceleration as a Function of Payload Mass

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Minotaur IV User’s Guide
4.2.1. Random Vibration
Random vibration environments are produced
both by the structurally transmitted vibrations
through mechanical payload interface as well as
from the acoustic energy directly through the
fairing (Figure 4-4). However, the higher frequency
aeroacoustic-induced random vibration levels are
hard to accurately replicate for spacecraft of the
Minotaur IV class. Testing input levels are typically
hard to accurately specify because the response
at the LV-to-spacecraft interface is strongly
dependent on the unique spacecraft dynamics,
including its response to the acoustic field.
Therefore, structure-born random vibration
environments are only defined herein for
frequencies up to 250 Hz with the
recommendation that high frequency
environments be based on the acoustic levels
defined in Section 4.3. The acoustic environment
is defined starting at 20 Hz, allowing both
environments to be evaluated in the overlapping
region.
The structure-borne low frequency random
vibration environment for Minotaur IV is a flat
0.002 g2/Hz from 20 to 250 Hz, producing an
overall level of 0.68 gRMS (Figure 4-4). This level
is based on measured data from multiple
applicable Orbital launch vehicles. Vibration
produced by the PK Stage 1 motor was analyzed
based on data from three Taurus flights, which
utilized the PK Stage 1 motor. The random
vibration levels also cover the Orion 38 motor burn
observed on past Minotaur, Pegasus, and Taurus
flights. Detailed evaluation of the Stage 2 and 3
motor burn is still pending, but prior experience
indicates that their levels will be relatively benign
for the payload. The Minotaur IV structure-borne
vibration environment is enveloped by the MIL-
STD-1540E levels. OSP recommends that the
1540E level be used as guidance for minimum
levels for payload testing.
4.2.2. Sine Vibration
A known resonant burn characteristic of the
PK Stage 1 motor creates a sine vibration
requirement of Minotaur IV payloads. Orbital has
Release 1.1 January 2006
Section 4.0 – Payload Environment
reviewed test data from more than 30 static fire
tests and three Taurus flights. The sine vibration
level depends on payload weight and stiffness.
Orbital has developed forcing function to simulate
the Stage 1 motor resonance. The forcing
functions are used in a NASTRAN simulation to
predict peak sine vibration levels at different
vehicle locations. The simulation has been
validated using flight data. The sine vibration
varies between 45 and 75 Hz. The NASTRAN
simulation of the PK Stage 1 resonant burn is
analyzed for each payload as part of the CLA
discussed in Section 4.1. The results of this
mission-specific CLA are then used to refine the
SLV vehicle and payload sine vibration levels. A
parametric analysis of hypothetical payloads has
been conducted to provide guidance on expected
acceleration levels. The resulting levels are shown
in Figure 4-5.
4.3. Payload Acoustic Environment
The acoustic environments to which the
spacecraft will be exposed have been defined
based on measured acoustic data from previous
Taurus flights which utilized the Peacekeeper
Stage 1 motor and same 92 in. fairing. The data
was adjusted to account for differences in vehicle
trajectories and a 3 dB uncertainty was added per
MIL-STD-1540 guidelines. The resulting acoustic
level is shown in Figure 4-6.
4.4. Payload Shock Environment
The maximum shock response spectrum at
the base of the payload from all launch vehicle
events should not exceed the flight limit levels in
Figure 4-7 (clamp-band separation system).
Lower separation shock levels can be achieved by
the use of a Lightband separation system provided
by Planetary Systems Incorporated. The resulting
levels are also shown in Figure 4-7.
For missions that do not utilize an Orbital-
supplied payload separation system, the shock
response spectrum at the base of the payload
from vehicle events should not exceed the levels
in Figure 4-7 (non-separating shock).
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Figure 4-4. Minotaur IV Payload Random Vibration Environment

Figure 4-5. Minotaur IV Payload Sine Vibration Environment

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Figure 4-6. Minotaur IV Payload Acoustic Maximum Predicted Environment (MPE)

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Figure 4-7. Minotaur IV Payload Shock Maximum Predicted Environment (MPE) –

Launch Vehicle to Payload

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If the payload employs a non-Orbital
separation system, then the shock delivered from
the separation systems to the Stage 4 vehicle
interface must not exceed the limit level
characterized in Figure 4-8. Shock above this
level could require requalification of components
or an acceptance of risk by the Rocket Systems
Launch Program (RSLP).
4.5. Payload Structural Integrity and
Environments Verification
The primary support structure for the
spacecraft must possess sufficient strength,
rigidity, and other characteristics required to
survive the critical loading conditions that exist
within the envelope of handling and mission
requirements, including worst-case predicted
ground, flight, and post-boost loads. It must
survive those conditions in a manner that assures
safety and that does not reduce the mission
success probability. Spacecraft design loads are
defined as follows:
Figure 4-8. Payload Shock Environment – Payload to Launch Vehicle
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Section 4.0 – Payload Environment
a. Design Limit Load — The maximum
predicted ground-based, powered flight or
on-orbit load, including all uncertainties.
b. Design Yield Load — The Design Limit
Load multiplied by the recommended Yield
Factor of Safety (YFS). The payload
structure must have sufficient strength to
withstand simultaneously the yield loads,
applied temperature, and other
accompanying environmental phenomena
for each design condition without
experiencing detrimental yielding or
permanent deformation.
c. Design Ultimate Load — The Design
Limit Load multiplied by the recommended
Ultimate Factor of Safety (UFS). The
payload structure must have sufficient
strength to withstand simultaneously the
ultimate loads, applied temperature, and
other accompanying environmental
phenomena without experiencing any
fracture or other failure mode of the
structure.
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Minotaur IV User’s Guide Section 4.0 – Payload Environment

4.5.1. Recommended Payload Testing and

Analysis
Sufficient payload testing and/or analysis must
be performed to ensure the safety of ground crews
and to ensure mission success. The payload
structural design should comply with the testing
and design factors of safety in Figure 4-9.
Vibration testing should be based on the standard
margins defined in Figure 4-10. At a minimum, it
is recommended that the following tests be
performed:
a. Structural Integrity — Static loads, sine
vibration, or other tests should be
performed that combine to encompass the
acceleration load environment presented
in Section 4.1.
b. Random Vibration — The flight level
environment and recommended test level
is defined in Section 4.2.1.
c. Acoustics — Full scale acoustic testing is
recommended to verify higher frequency
Figure 4-9. Factors of Safety Payload
dynamics of the spacecraft are not Design and Test
adversely affected. The acoustic levels
are defined in Figure 4-6.
d. Shock – The payload separation event
should be simulated to verify the
spacecraft is not adversely effected.
Shock levels are defined in Section 4.4.

The payload organization must provide OSP with

a list of the tests and test levels to which the
payload was subjected prior to payload arrival at
the integration facility.
4.6. Thermal and Humidity Environments
The thermal and humidity environment to
which the payload may be exposed during vehicle
processing and pad operations are defined in the
sections that follow and listed in Figure 4-11.
4.6.1. Ground Operations
Upon encapsulation within the fairing and for
the remainder of ground operations, the payload
environment will be maintained by a Heating,
Ventilation and Air Conditioning (HVAC) system.
Figure 4-10. Recommended Payload Testing
Requirements
The HVAC provides conditioned air to the payload
in the PPF after fairing integration. The HVAC is
used at the launch pad after vehicle stacking
operations. Air Conditioning (AC) is not provided
during transport or lifting operations without the
enhanced option that includes High Efficiency
Particulate Air (HEPA) filtration. The conditioned
air enters the fairing at a location forward of the
payload, exits aft of the payload and is provided
up to 5 minutes prior to launch. Baffles are
provided at the air conditioning inlet to reduce
impingement velocities on the payload if required.

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Minotaur IV User’s Guide
Figure 4-11. Payload Thermal and Humidity Environment
Fairing inlet conditions are selected by the
customer, and are bounded as follows:
a. Dry Bulb Temperature: 55 to 85 °F (13 to
29 °C) controllable to ±4 °F (±2 °C) of
setpoint
b. Dew Point Temperature: 38 to 62 °F (3 to
17 °C)
c. Relative Humidity: determined by drybulb
and dewpoint temperature selections and
generally controlled to within ±15%.
Relative humidity is bound by the
psychrometric chart and will be controlled
such that the dew point within the fairing is
never reached.
d. Maximum Flow: 500 cfm
4.6.2. Powered Flight
The maximum fairing inside wall temperature
will be maintained at less than 200 °F (93 °C), with
an emissivity of 0.92 in the region of the payload.
As a non-standard service, a low emissivity
coating can be applied to reduce emissivity to less
Release 1.1 January 2006
Section 4.0 – Payload Environment
than 0.1. This temperature limit envelopes the
maximum temperature of any component inside
the payload fairing with a view factor to the
payload with the exception of the Stage 4 motor.
The maximum Stage 4 motor surface temperature
exposed to the payload will not exceed 350 °F
(177 °C), assuming no shielding between the aft
end of the payload and the forward dome of the
motor assembly. The Payload Adapter Module
(PAM), used with the fairing to provide
encapsulation of the payload during ground
processing, provides some level of shielding
between the payload and Stage 4 motor. Whether
this temperature is attained prior to payload
separation is dependent upon mission timeline.
The fairing peak vent rate is typically less than
0.6 psi/sec. Fairing deployment will be initiated at
a time in flight that the maximum dynamic
pressure is less than 0.01 psf or the maximum free
molecular heating rate is less than 0.1 BTU/ft2/sec,
as required by the payload.
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Minotaur IV User’s Guide
4.6.3. Nitrogen Purge (Non-Standard Service)
If required for spot cooling of a payload
component, Orbital will provide GN2 flow to
localized regions in the fairing as a non-standard
service. This option is discussed in more detail in
Section 8.3.2.
4.7. Payload Contamination Control
All payload integration procedures, and
Orbital’s contamination control program have been
designed to minimize the payload’s exposure to
contamination from the time the payload arrives at
the payload processing facility through orbit
insertion and separation. The payload is fully
encapsulated within the fairing and Payload
Adapter Module (PAM) at the payload processing
facility, assuring the payload environment stays
clean in a Class 100,000 environment. All SLV
assemblies that affect cleanliness within the
encapsulated payload volume include the fairing
and the payload cone assembly. These
assemblies are cleaned such that there is no
particulate or non-particulate matter visible to the
normal unaided eye when inspected from 2 to 4
feet under 50 ft-candle incident light (Visibly Clean
Level II). After encapsulation, the fairing envelope
is either sealed or maintained with a positive
pressure, Class 100,000 continuous purge of
conditioned air. If required, the payload can be
provided with enhanced contamination control as
an enhanced option, providing a Class 10,000
environment, low outgassing, and Visibly Clean
Plus Ultraviolet cleanliness (see Section 8.3.3).
Provisions exist in the fairing design accommodate
dry nitrogen purge as has been demonstrated on
the Taurus application.
With the enhanced contamination control
option, the Orbital-supplied elements will be
cleaned and controlled to support a Class 10,000
clean room environment, as defined in Federal
Standard 209. This includes limiting volatile
hydrocarbons to maintain hydrocarbon content at
less than 15 ppm and humidity between 35 to 60
Release 1.1 January 2006
Section 4.0 – Payload Environment
percent. Since the payload processing will be at a
GFP facility, it is assumed the Class 10,000 clean
room environment also adhering to these levels of
control will be provided by that facility.
Also with the enhanced contamination control
option, Orbital provides an Environmental Control
System (ECS) from payload encapsulation
through vehicle lift-off. The ECS continuously
purges the fairing volume with clean filtered air.
Orbital’s ECS incorporates a HEPA filter unit to
provide FED-STD-209 Class M5.5 (10,000) air.
Orbital monitors the supply air for particulate
matter via a probe installed upstream of the fairing
inlet duct prior to connecting the air source to the
payload fairing.
4.8. Payload Electromagnetic Environment
The payload Electromagnetic Environment
(EME) results from two categories of emitters: 1)
Minotaur IV onboard antennas and, 2) Range
radar. All power, control and signal lines inside
the payload fairing are shielded and properly
terminated to minimize the potential for
Electromagnetic Interference (EMI). The Minotaur
IV payload fairing is Radio Frequency (RF)
opaque, which shields the payload from external
RF signals while the payload is encapsulated.
Figure 4-12 lists the frequencies and
maximum radiated signal levels from vehicle
antennas that are located near the payload during
ground operations and powered flight. The
specific EME experienced by the payload during
ground processing at the PPF and the launch site
will depend somewhat on the specific facilities that
are utilized as well as operational details.
However, typically the field strengths experienced
by the payload during ground processing with the
fairing in place are controlled procedurally and will
be less than 2 V/m from continuous sources and
less than 10 V/m from pulse sources. The highest
EME during powered flight is created by the C-
Band transponder transmission, which results in
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Minotaur IV User’s Guide Section 4.0 – Payload Environment

peak levels at the payload interface plane of This EME should be compared to the payload’s
88 V/m at 5765 MHz (based on Taurus). Range RF susceptibility levels (MIL-STD-461, RS03) to
transmitters are typically controlled to provide a define margin.
field strength of 10 V/m or less inside the fairing.

Figure 4-12. Minotaur IV Launch Vehicle RF Emitters and Receivers

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Minotaur IV User’s Guide
5. PAYLOAD INTERFACES
This section describes the available
mechanical, electrical and Launch Support
Equipment (LSE) interfaces between the Minotaur
IV launch vehicle and the payload.
5.1. Payload Fairing
Orbital’s flight-proven Taurus 92-inch diameter
payload fairing is used to encapsulate the payload,
provide protection and contamination control
during ground handling, integration operations and
flight. The fairing is a bi-conic design made of
graphite/epoxy face sheets with aluminum
honeycomb core. The two halves of the fairing are
structurally joined along their longitudinal interface
using Orbital’s low contamination frangible joint
system. An additional circumferential frangible
joint at the base of the fairing supports the fairing
loads. At separation, a gas pressurization system
is activated to pressurize the fairing deployment
thrusters. The fairing halves then rotate about
external hinges that control the fairing deployment
to ensure that payload and launch vehicle
clearances are maintained. All elements of the
deployment system have been demonstrated
through test to comply with stringent
contamination requirements.
5.1.1. Payload Dynamic Design Envelope
The fairing drawing in Figure 5-1 shows the
maximum dynamic envelope available for the
payload during powered flight. The dynamic
envelope shown account for fairing and vehicle
structural deflections only. The payload contractor
must consider deflections due to spacecraft design
and manufacturing tolerance stack-up within the
dynamic envelope. Proposed payload dynamic
envelope violations must be approved by OSP via
the ICD.
No part of the payload may extend aft of the
payload interface plane without specific OSP
approval. Incursions below the payload interface
plane may be approved on a case-by-case basis
after additional verification that the incursions do
not cause any detrimental effects. Vertices for
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Section 5.0 – Payload Interfaces
payload deflection must be given with the Finite
Element Model to evaluate payload dynamic
deflection with the Coupled Loads Analysis (CLA).
The payload contractor should assume that the
interface plane is rigid; Orbital has accounted for
deflections of the interface plane. The CLA will
provide final verification that the payload does not
violate the dynamic envelope.
5.1.2. Payload Access Door
Orbital provides one 18 in. by 24 in. (45.7 cm
by 61.0 cm) payload fairing access door to provide
access to the payload after fairing mate. The door
can be positioned according to payload
requirements within the cylindrical section of the
fairing, providing access to the payload without
having to remove any portion of the fairing or
break electrical connections. The specific location
is defined and controlled in the payload ICD.
Additional access doors can readily be provided
as an enhanced option (see Section 8.1.2).
5.2. Payload Mechanical Interface and
Separation System
Minotaur IV provides for a standard non-
separating payload interface and an optional
Orbital-provided payload separation system.
Figure 5-1. Standard 92 in. Fairing Envelope
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Minotaur IV User’s Guide
Orbital will provide all flight hardware and
integration services necessary to attach non-
separating and separating payloads to Minotaur
IV. Payload ground handling equipment is
typically the responsibility of the payload
contractor. All attachment hardware, whether
Orbital or customer provided, must contain locking
features consisting of locking nuts, inserts or
fasteners.
5.2.1. Standard Non-Separating Mechanical
Interface
Orbital’s payload interface design provides a
standard interface that will accommodate multiple
payload configurations. Figure 5-2 illustrates the
standard, non-separating payload mechanical
interface. This is for payloads that provide their
own separation system or payloads that will not
separate. The interface is a standardized circular
bolted interface common with the Evolved
Expendable Launch Vehicle (EELV). The
interface is a 62.01-inch diameter bolted interface.
A butt joint with 121 holes (0.265-inch diameter)
designed for ¼-inch fasteners is the payload
mounting surface as shown in Figure 5-2.
Alternate or multiple payload configurations can
also be accommodated with the use of a bulkhead
which allows flexibility in mounting patterns and
configurations.
5.2.2. Orbital Supplied Mechanical Interface
Control Drawing
Orbital will provide a toleranced Mechanical
Interface Control Drawing (MICD) to the payload
contractor to allow accurate machining of the
fastener holes. The Orbital provided MICD is the
only approved documentation for drilling the
payload interface.
5.3. Payload Electrical Interfaces
The payload electrical interface supports
battery charging, external power, discrete
commands, discrete telemetry, analog telemetry,
serial communication, payload separation
indications, and up to 16 separate ordnance
discretes. If an optional Orbital-provided
Release 1.1 January 2006
Section 5.0 – Payload Interfaces
separation system is utilized, Orbital will provide
all the wiring through the separable interface
plane. If the option is not exercised the customer
will be responsible to provide the wiring from the
spacecraft to the separation plane.
5.3.1. Payload Umbilical Interfaces
The payload umbilical connector provides 60
wires from the ground to the spacecraft via a
dedicated payload umbilical within the vehicle, as
shown in Figure 5-3. The length of the internal
umbilical is approximately 25 ft (7.62 m). The
cabling from the LEV to the launch vehicle is
approximately 130 ft (39.6 m). This umbilical is a
dedicated pass through harness for ground
processing support. It allows the payload
command, control, monitor, and power to be easily
configured per each individual user’s
requirements. The umbilical wiring is configured
as a one-to-one from the Payload/Minotaur IV
interface through to the payload EGSE interface in
the Launch Equipment Vault, the closest location
for operating customer supplied payload EGSE
equipment.
It is a Launch Vehicle requirement that the
payload provide two (2) separation loopback
circuits on the payload side of the separation
plane. These are typically wired into different
separation connectors for redundancy. These
breakwires are used for positive separation
indication telemetry and initiation of the CCAM
maneuver.
Figure 5-4 details the pin outs for the standard
interface umbilical. All wires are twisted, shielded
pairs, and pass through the entire umbilical
system, both vehicle and ground, as one-to-one to
simplify and standardize the payload umbilical
configuration requirements while providing
maximum operational flexibility to the payload
provider.
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Minotaur IV User’s Guide Section 5.0 – Payload Interfaces

Figure 5-2. Standard, Non-separating Payload Mechanical Interface

Figure 5-3. Payload Electrical Interface Block Diagram, With No Orbital Supplied
Separation System

Figure 5-4. Payload 1:1 Umbilical Pin Outs

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Minotaur IV User’s Guide Section 5.0 – Payload Interfaces

5.3.2. Payload Interface Circuitry

Standard interface circuitry passing through
the payload-to-launch vehicle electrical
connections are shown in Figure 5-5. This figure
details the interface characteristics for launch
vehicle commands, discrete and analog telemetry,
separation loopbacks, pyro initiation, and serial
communications interfaces with the launch vehicle
avionics systems.

5.3.3. Payload Battery Charging

Orbital provides the capability for remote
controlled charging of payload batteries, using a
customer provided battery charger. This power is
routed through the payload umbilical cable. Up to
5.0 amperes per wire pair can be accommodated.
The payload battery charger should be sized to
withstand the line loss from the LEV to the
spacecraft.

5.3.4. Payload Command and Control

The Minotaur IV standard interface provides
discrete sequencing commands generated by the
launch vehicle’s Ordnance Driver Module (ODM)
that are available to the payload as closed circuit
opto-isolator command pulses of 5 A in lengths of
35 ms minimum. The total number of ODM
discretes is sixteen (16) and can be used for any
combination of (redundant) ordnance events
and/or discrete commands depending on the
payload requirements. Figure 5-5. Minotaur IV Payload Electrical
Interface Block Diagram
5.3.5. Pyrotechnic Initiation Signals
5.3.6. Payload Telemetry
Orbital provides the capability to directly
The baseline telemetry subsystem capability
initiate 16 separate pyrotechnic conductors
provides a number of dedicated payload discrete
through two dedicated MACH Ordnance Driver
(bi-level) and analog telemetry monitors through
Modules (ODM). Each ODM provides for up to
dedicated channels in the vehicle encoder. Up to
eight drivers capable of a 5 A, 100 ms, current
24 channels will be provided with type and data
limited pulse into a 1.5 ohm resistive load. All
rate being defined in the mission requirements
eight channels can be fired simultaneously with an
document. In addition, a GCI610 will be utilized in
accuracy of 1 ms between channels. In addition,
the encoder stack for serial data ranging up to 600
the ODM channels can be utilized to trigger high
Kbs if required. The GCI610 utilizes an IRIG
impedance discrete events if required. Safing for
standard RS422 driver interface for simplicity in
all payload ordnance events will be accomplished
payload interface definition. The payload serial
through an Arm/Disarm (A/D) Switch.
and analog data will be embedded in the baseline
vehicle telemetry format. For discrete monitors,

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Minotaur IV User’s Guide
the payload customer must provide the 5 Vdc
source and the return path. The current at the
payload interface must be less than 10 mA.
Separation breakwire monitors can be specified if
required. The number of analog channels
available for payload telemetry monitoring is
dependent on the frequency of the data. Payload
telemetry requirements and signal characteristics
will be specified in the Payload ICD and should not
change once the final telemetry format is released
at approximately L-6 months. Orbital will tape,
archive, and reduce the data into a digital format
for delivery to the payloaders for review.
Due to the use of strategic assets, Minotaur IV
telemetry is subject to the provisions of the
Strategic Arms Reduction Treaty (START).
START treaty provisions require that certain
Minotaur IV telemetry be unencrypted and
provided to the START treaty office for
dissemination to the signatories of the treaty. The
extent to which START applies to the payload
telemetry will be determined by RSLP.
Encrypted payload telemetry can be added as a
non-standard service pending approval by RSLP
and the START treaty office.
5.3.7. Payload Separation Monitor Loopbacks
Separation breakwire monitors are required on
both sides of the payload separation plane. With
the Orbital provided separation systems, Minotaur
IV provides three (3) separation loopbacks on the
launch vehicle side of the separation plane for
positive payload separation indication.
Minotaur IV also requires two (2) separate
loopbacks on the payload side of the separation
plane. These are used for telemetry indication of
separation and also the initiation of the Stage 4
CCAM maneuver.
5.3.8. Telemetry Interfaces
The standard Minotaur IV payload interface
provides a 16Kbps RS-422/RS-485 serial interface
for payload use with the flexibility to support a
variety of channel/bit rate requirements, and
provide signal conditioning, PCM formatting
Release 1.1 January 2006
Section 5.0 – Payload Interfaces
(programmable) and data transmission bit rates.
The number of channels, sample rates, etc. will be
defined in the Payload ICD.
5.3.9. Non-Standard Electrical Interfaces
Non-standard services such as serial
command and telemetry interfaces can be
negotiated between OSP and the payload
contractor on a mission-by-mission basis. The
selection of the separation system could also
impact the payload interface design and will be
defined in the Payload ICD.
5.3.10. Electrical Launch Support Equipment
Orbital will provide space for a rack of
customer supplied EGSE in the LCR, or either of
the on-pad equipment vaults. The equipment will
interface with the launch vehicle/spacecraft
through either the dedicated payload umbilical
interface or directly through the payload access
door. The payload customer is responsible for
providing cabling from the EGSE location to the
launch vehicle/spacecraft.
Separate payload ground processing
harnesses that mate directly with the payload can
be accommodated through the payload access
door(s) as defined in the Payload ICD.
5.4. Payload Design Constraints
The following sections provide design
constraints to ensure payload compatibility with
the Minotaur IV system.
5.4.1. Payload Center of Mass Constraints
Along the Y and Z-axes, the payload CG must
be within 1.0 inch (3.8 cm) of the vehicle
centerline. Payloads whose CG extend beyond
the 1.0 inch lateral offset limit will require Orbital to
verify the specific offsets that can be
accommodated.
5.4.2. Final Mass Properties Accuracy
The final mass properties statement must
specify payload weight to an accuracy of at least
1 lbm (0.5 kg), the center of gravity to an accuracy
of at least 0.25 inch (6.4 mm) in each axis, and the
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Minotaur IV User’s Guide
products of inertia to an accuracy of at least 0.5
slug-ft2 (0.7 kg-m2) (see Figure 5-6). In addition,
if the payload uses liquid propellant, the slosh
frequency must be provided to an accuracy of 0.2
Hz, along with a summary of the method used to
determine slosh frequency.
Figure 5-6. Payload Mass Properties
Measurement Tolerance
5.4.3. Pre-Launch Electrical Constraints
Prior to launch, all payload electrical interface
circuits are constrained to ensure there is no
current flow greater than 10 mA across the
payload electrical interface plane. The primary
support structure of the spacecraft shall be
electrically conductive to establish a single point
electrical ground.
5.4.4. Payload EMI/EMC Constraints
The Minotaur IV avionics share the payload
area inside the fairing such that radiated
emissions compatibility is paramount. OSP places
no firm radiated emissions limits on the payload
other than the prohibition against RF
transmissions within the payload fairing. Prior to
launch, Orbital requires review of the payload
radiated emission levels (MIL-STD-461, RE02) to
verify overall launch vehicle EMI safety margin
(emission) in accordance with MIL-E-6051.
Payload RF transmissions are not permitted after
fairing mate and prior to an ICD specified time
after separation of the payload. An EMI/EMC
analysis may be required to ensure RF
compatibility.
Payload RF transmission frequencies must be
coordinated with Orbital and range officials to
ensure non-interference with Minotaur IV and
range transmissions. Additionally, the customer
Release 1.1 January 2006
Section 5.0 – Payload Interfaces
must schedule all RF tests at the integration site
with Orbital in order to obtain proper range
clearances and protection.
5.4.5. Payload Dynamic Frequencies
To avoid dynamic coupling of the payload
modes with the natural frequency of the vehicle,
the spacecraft should be designed with a
structural stiffness to ensure that the lateral
fundamental frequency of the spacecraft, fixed at
the spacecraft interface is typically greater than 25
Hz (based on Taurus). However, this value is
effected significantly by other factors such as
incorporation of a spacecraft isolation system
and/or separation system. Therefore, the final
determination of compatibility must be made on a
mission-specific basis.
5.4.6. Payload Propellant Slosh
A slosh model should be provided to Orbital in
either the pendulum or spring-mass format. Data
on first sloshing mode are required and data on
higher order modes are desirable. The slosh
model should be provided with the payload finite
element model submittals.
5.4.7. Payload-Supplied Separation Systems
If the payload employs a non-Orbital
separation system, then the shock delivered to the
Stage 4 vehicle interface must not exceed the limit
level characterized in Section 4.3 (Figure 4-6). As
stated in that section, shock above this level could
require a requalification of components or an
acceptance of risk by RSLP.
5.4.8. System Safety Constraints
OSP considers the safety of personnel and
equipment to be of paramount importance. EWR
127-1 outlines the safety design criteria for
Minotaur IV payloads. These are compliance
documents and must be strictly followed. It is the
responsibility of the customer to ensure that the
payload meets all OSP, Orbital, and range
imposed safety standards.
Customers designing payloads that employ
hazardous subsystems are advised to contact
OSP early in the design process to verify
compliance with system safety standards.
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6. MISSION INTEGRATION
6.1. Mission Management Approach
The Minotaur IV program is managed through
U.S. Air Force, Space and Missile Systems
Center, Rocket Systems Launch Program (RSLP).
RSLP serves as the primary point of contact for
the payload customers for the Minotaur IV launch
service. A typical integrated OSP organizational
structure is shown in Figure 6-1. Open
communication between RSLP , Orbital, and the
customer, emphasizing timely transfer of data and
prudent decision-making, ensures efficient launch
vehicle/payload integration operations.
6.1.1. RSLP Mission Responsibilities
The program office for all OSP missions is the
RSLP . They are the primary Point of Contact
(POC) for all contractual and technical
coordination. RSLP contracts with Orbital to
provide the Launch Vehicle and launch integration
and separately with commercial Spaceports and/or
Government Launch Ranges for launch site
facilities and services. Once a mission is
identified, RSLP will assign a Mission Manager to
Figure 6-1. Typical Integrated OSP Organizational Structure
Release 1.1 January 2006
Section 6.0 – Mission Integration
coordinate all mission planning and contracting
activities. RSLP is supported by Northrop
Grumman and other associate contractors for
technical and logistical support, particularly
utilizing their extensive expertise and background
knowledge of the Peacekeeper booster and
subsystems.
6.1.2. Orbital Mission Responsibilities
As the launch vehicle provider, Orbital’s
responsibilities fall into four primary areas:
a. Launch Vehicle Program Management
b. Mission Management
c. Engineering
d. Launch Site Operations
Orbital assigns a Mission Manager to manage
the launch vehicle technical and programmatic
interfaces for a particular mission. The Orbital
Mission Manager is the single POC for all aspects
of a specific mission. This person has overall
program authority and responsibility to ensure that
payload requirements are met and that the
appropriate launch vehicle services are provided.
The Orbital Mission Manager will jointly chair the
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Minotaur IV User’s Guide
Mission Integration Working Groups (MIWGs) with
the RSLP Mission Manager. The Mission
Managers responsibilities include detailed mission
planning, payload integration services, systems
engineering, mission-peculiar design and analyses
coordination, payload interface definition, launch
range coordination, integrated scheduling, launch
site processing, and flight operations.
6.2. Mission Planning and Development
OSP will assist the customer with mission
planning and development associated with
Minotaur IV launch vehicle systems. These
services include interface design and configuration
control, development of integration processes,
launch vehicle analyses, facilities planning, launch
campaign planning to include range services and
special operations, and integrated schedules.
The procurement, analysis, integration and
test activities required to place a customer’s
payload into orbit are typically conducted over a
20 month standard sequence of events called the
Mission Cycle. This cycle normally begins
18 months before launch, and extends to 8 weeks
after launch.
Once contract authority to proceed is received,
the Mission Cycle is initiated. The contract option
designates the payload, launch date, and basic
mission parameters. In response, the Minotaur IV
Program Manager designates an Orbital Mission
Manager who ensures that the launch service is
supplied efficiently, reliably, and on-schedule.
The typical Mission Cycle interweaves the
following activities:
a. Mission management, document
exchanges, meetings, and formal reviews
required to coordinate and manage the
launch service.
b. Mission analyses and payload integration,
document exchanges, and meetings.
c. Design, review, procurement, testing and
integration of all mission-peculiar
hardware and software.
Release 1.1 January 2006
Section 6.0 – Mission Integration
d. Range interface, safety, and flight
operations activities, document
exchanges, meetings and reviews.
Figure 6-2 details the typical Mission Cycle for
a specific launch and how this cycle folds into the
Orbital vehicle production schedule with typical
payload activities and milestones. A typical
Mission Cycle is based on an 18 month interval
between mission authorization and launch. This
interval reflects the OSP contractual schedule and
has been shown to be an efficient schedule based
on Orbital’s Minotaur, Taurus and Pegasus
program experience. However, OSP is flexible to
negotiate either accelerated cycles, which take
advantage of the Minotaur IV/Pegasus/Minotaur/
Taurus multi-customer production sets, or
extended cycles required by unusual payload
requirements, such as extensive analysis or
complex payload-launch vehicle integrated
designs or tests or funding limitations.
6.3. Mission Integration Process
6.3.1. Integration Meetings
The core of the mission integration process
consists of a series of Mission Integration and
Range Working Groups (MIWG and RWG,
respectively). The MIWG has responsibility for all
physical interfaces between the payload and the
launch vehicle. As such, the MIWG creates and
implements the Payload-to-Minotaur IV ICD in
addition to all mission-unique analyses, hardware,
software, and integrated procedures. The RWG is
responsible for the areas of launch site operations;
range interfaces; safety review and approval; and
flight design, trajectory, and guidance.
Documentation produced by the RWG includes all
required range and safety submittals.
Working Group membership consists of the
Mission Manager and representatives from
Minotaur IV engineering and operations
organizations, as well as their counterparts from
the customer organization. While the number of
meetings, both formal and informal, required to
develop and implement the mission integration
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Minotaur IV User’s Guide
Figure 6-2. Typical Mission Integration Schedule
process will vary with the complexity of the
spacecraft, quarterly meetings are typical.
6.3.2. Mission Design Reviews (MDR)
Two mission-specific design reviews will be
held to determine the status and adequacy of the
launch vehicle mission preparations. They are
designated MDR-1 and MDR-2 and are typically
held 6 months and 13 months, respectively, after
authority to proceed. They are each analogous to
Preliminary Design Reviews (PDRs) and Critical
Design Reviews (CDRs), but focus primarily on
mission-specific elements of the launch vehicle
effort.
6.3.3. Readiness Reviews
During the integration process, reviews are
held to provide the coordination of mission
participants and management outside of the
regular contact of the Working Groups. Due to the
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Section 6.0 – Mission Integration
variability in complexity of different payloads and
missions, the content and number of these
reviews can be tailored to customer requirements.
As a baseline, Orbital will conduct two readiness
reviews as described below.
a. Mission Readiness Review —
Conducted within 1 month of launch, the
Mission Readiness Review (MRR)
provides a pre-launch assessment of
integrated launch vehicle/payload/facility
readiness prior to committing significant
resources to the launch campaign.
b. Launch Readiness Review — The
Launch Readiness Review (LRR) is
conducted at L-1 day and serves as the
final assessment of mission readiness
prior to activation of range resources on
the day of launch.
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Minotaur IV User’s Guide
6.4. Documentation
Integration of the payload requires detailed,
complete, and timely preparation and submittal of
interface documentation. As the launch service
provider, RSLP is the primary communication path
with support agencies, which include—but are not
limited to—the various Range support agencies
and U.S. Government agencies such as the U.S.
Department of Transportation and U.S. State
Department. Customer-provided documents
represent the formal communication of
requirements, safety data, system descriptions,
and mission operations planning. The major
products and submittal times associated with
these organizations are divided into two areas—
those products that are provided by the customer,
and those produced by Orbital.
6.4.1. Customer-Provided Documentation
Documentation produced by the customer is
detailed in the following paragraphs.
6.4.1.1. Payload Questionnaire
The Payload Questionnaire is designed to
provide the initial definition of payload
requirements, interface details, launch site
facilities, and preliminary safety data to OSP. The
customer shall provide a response to the Payload
Questionnaire form (Appendix A), or provide the
same information in a different format, in time to
support the Mission Kickoff Meeting. The
customer’s responses to the payload
questionnaire define the most current payload
requirements and interfaces and are instrumental
in Orbital’s preparation of numerous documents
including the ICD, Preliminary Mission Analysis,
and launch range documentation. Additional
pertinent information, as well as preliminary
payload drawings, should also be included with
the response. Orbital understands that a definitive
response to some questions may not be feasible.
These items are defined during the normal mission
integration process.
6.4.1.2. Payload Mass Properties
Payload mass properties must be provided in
a timely manner in order to support efficient launch
vehicle trajectory development and dynamic
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Section 6.0 – Mission Integration
analyses. Preliminary mass properties should be
submitted as part of the MRD at launch vehicle
authority to proceed. Updated mass properties
shall be provided at predefined intervals identified
during the initial mission integration process.
Typical timing of these deliveries is included in
Figure 6-2.
6.4.1.3. Payload Finite Element Model
A payload mathematical model is required for
use in Orbital’s preliminary coupled loads
analyses. Acceptable forms include either a
Craig-Bampton model valid to 120 Hz or a
NASTRAN finite element model. For the final
coupled loads analysis, a test verified
mathematical model is desired.
6.4.1.4. Payload Thermal Model for Integrated
Thermal Analysis
An integrated thermal analysis can be
performed for any payload as a non-standard
service. A payload thermal model will be required
from the payload organization for use in Orbital’s
integrated thermal analysis if it is required. The
analysis is conducted for three mission phases:
a. Prelaunch ground operations;
b. Ascent from lift-off until fairing jettison; and
c. Fairing jettison through payload
deployment.
Models must be provided in SINDA format.
There is no limit on model size although turn-
around time may be increased for large models.
6.4.1.5. Payload Drawings
Orbital prefers electronic versions of payload
configuration drawings to be used in the mission
specific interface control drawing, if possible.
Orbital will work with the customer to define the
content and desired format for the drawings.
6.4.1.6. Program Requirements Document
(PRD) Mission Specific Annex Inputs
To obtain range support, a PRD must be
prepared. This document describes requirements
needed to generally support the Minotaur IV
launch vehicle. For each launch, an annex is
submitted to specify the range support needed to
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Minotaur IV User’s Guide
meet the mission’s requirements. This annex
includes all payload requirements as well as any
additional Minotaur IV requirements that may arise
to support a particular mission. The customer
completes all appropriate PRD forms for submittal
to Orbital.
6.4.1.6.1. Launch Operations Requirements
(OR) Inputs
To obtain range support for the launch
operation and associated rehearsals, an OR must
be prepared. The customer must provide all
payload pre-launch and launch day requirements
for incorporation into the mission OR.
6.5. Safety
6.5.1. System Safety Requirements
In the initial phases of the mission integration
effort, regulations and instructions that apply to
spacecraft design and processing are reviewed.
Not all safety regulations will apply to a particular
mission integration activity. Tailoring the range
requirements to the mission unique activities will
be the first step in establishing the safety plan.
OSP has three distinctly different mission
approaches affecting the establishment of the
safety requirements:
a. Baseline mission: Payload integration and
launch operations are conducted at VAFB,
CA
b. Campaign/VAFB Payload Integration
mission: Payload integration is conducted
at VAFB and launch operations are
conducted from a non-VAFB launch
location.
c. Campaign/Non-VAFB Payload Integration
mission: Payload integration and launch
operations are conducted at a site other
than VAFB.
For the baseline and VAFB Payload
Integration missions, spacecraft prelaunch
operations are conducted at Government
Furnished Property (GFP) Payload Processing
Facility (PPF). For campaign style missions, the
spacecraft prelaunch operations are performed at
the desired launch site.
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Section 6.0 – Mission Integration
Before a spacecraft arrives at the processing
site, the payload organization must provide the
cognizant range safety office with certification that
the system has been designed and tested in
accordance with applicable safety requirements
(e.g. EWR 127-1 Range Safety Requirements for
baseline and VAFB Payload Integration missions).
Spacecraft that integrate and/or launch at a site
different than the processing site must also comply
with the specific launch site’s safety requirements.
Orbital will provide the customer coordination and
guidance regarding applicable safety
requirements.
It cannot be overstressed that the applicable
safety requirements should be considered in the
earliest stages of spacecraft design. Processing
and launch site ranges discourage the use of
waivers and variances. Furthermore, approval of
such waivers cannot be guaranteed.
6.5.2. System Safety Documentation
For each Minotaur IV mission, OSP acts as
the interface between the mission and Range
Safety. In order to fulfill this role, OSP requires
safety information from the payloader. For
launches from either the Eastern or Western
Ranges, EWR 127-1 provides detailed range
safety regulations. To obtain approval to use the
launch site facilities, specified data must be
prepared and submitted to the OSP Program
Office. This information includes a description of
each payload hazardous system and evidence of
compliance with safety requirements for each
system. Drawings, schematics, and assembly and
handling procedures, including proof test data for
all lifting equipment, as well as any other
information that will aid in assessing the respective
systems should be included. Major categories of
hazardous systems are ordnance devices,
radioactive materials, propellants, pressurized
systems, toxic materials, cryogenics, and RF
radiation. Procedures relating to these systems as
well as any procedures relating to lifting operations
or battery operations should be prepared for safety
review submittal. OSP will provide this information
to the appropriate safety offices for approval.
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Minotaur IV User’s Guide Section 7.0 – Ground and Launch Operations
7. GROUND AND LAUNCH OPERATIONS
7.1. Minotaur IV/Payload Integration Overview
The processing of the Minotaur IV utilizes
many of the same proven techniques developed
for the Pegasus, Taurus and Minotaur launch
vehicles. This minimizes the handling complexity
for both vehicle and payload.
7.2. Ground And Launch Operations
Ground and launch operations are conducted
in three major phases:
a. Launch Vehicle Integration — Assembly
and test of the Minotaur IV vehicle
b. Payload Processing/Integration —
Receipt and checkout of the satellite
payload, followed by integration with
Minotaur IV fairing and Payload Adapter
Module (PAM) and verification of
interfaces
c. Launch Operations — Includes transport
to the launch pad, final integration,
checkout, arming and launch.
7.2.1. Launch Vehicle Integration
Orbital will process all Minotaur IV vehicles
according to a flow similar to that implemented for
the Minotaur and Taurus vehicles. All launch
vehicle motors, parts and completed
subassemblies are delivered to the launch Vehicle
Processing Facility (VPF) from Orbital’s Chandler
production facility, the assembly/motor vendor or
the Government. Figure 7-1 depicts the typical
flow of hardware from the factory to the launch
site. Flowcharts of the field processing are shown
in Figure 7-2.
7.2.1.1. Planning and Documentation
Minotaur IV integration and test activities are
controlled by a comprehensive set of Work
Packages (WPs) that describe and document
every aspect of integrating and testing Minotaur IV
and its payload. All testing and integration
activities are scheduled by work package number
on a daily activity schedule updated and
distributed daily during field operations. This
schedule is maintained by Orbital and serves as
Release 1.1 January 2006
the master document communicating all activities
planned at the field site. The schedule contains
notations regarding the status of the work package
document and hardware required to begin the
operation. Mission-specific work packages are
created for mission-unique or payload-specific
procedures. Any discrepancies encountered are
recorded on a Discrepancy Report and
dispositioned as required. All activities are in
accordance with Orbital’s ISO 9001 certification.
7.2.1.2. GCA/Orion 38 Integration and Test
Activities
The GCA will undergo subsystem level testing
at Orbital’s Chandler facility prior to being shipped
to the field site. The GCA and the Stage 4 Orion
38 motor are then delivered to the launch vehicle
processing facility located at VAFB. Upon arrival
at VAFB these components/sub-assemblies will
undergo a thorough inspection and subsystem
level checkout. At this time range certification of
Range Tracking System (RTS) and Flight
Termination System (FTS) devices will be
performed. The components will be reinstalled
and in-vehicle testing of the RTS and FTS
systems will be performed. After the completion of
subsystem level testing the Orion 38 motor is
integrated into the GCA to form the Stage 4
assembly.
7.2.1.3. PK Motor Integration and Test
Activities
The PK Stage 1, 2 and 3 motors are delivered
to the launch vehicle processing facility where they
undergo checkout and testing. Once integration is
complete, a booster confidence test will be
conducted.
7.2.1.4. Mission Simulation Tests
Orbital will run three Mission Simulator Tests
(MST) to verify the functionality of launch vehicle
hardware, and software. The Mission Simulation
Tests use the actual flight software and simulate a
“fly to orbit” scenario using simulated Inertial
Navigation System (INS) data. This will allow the
test to proceed throughout all mission phases
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Minotaur IV User’s Guide Section 7.0 – Ground and Launch Operations

Figure 7-1. Hardware Flow – Factory to Launch Site

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Minotaur IV User’s Guide Section 7.0 – Ground and Launch Operations

Figure 7-2. SLV Processing Flow

recording vehicle performance data. The data will
be compared to simulations performed in the
factory software laboratory using an identical copy
of the flight software. Orbital will use GFP PK
nozzle assembly simulators to perform all mission
simulations. These components will provide a
realistic assessment of booster performance
during the testing operations. After a thorough
data review of all telemetry parameters, the test
configuration is disassembled and setup for
payload integration begins.
7.2.1.5. Booster Assembly Stacking/Launch
Pad Preparation
After completion of the MST, the booster
assembly (Stages 1, 2 and 3) and the stage 4
assembly (Orion 38 integrated with the GCA) are
transported to the launch facility. Figure 7-3
shows a pictorial representation of the processing
flow.
Prior to the arrival of the PK boosters, the site
is prepared for launch operations with the
installation of the launch stool. This stool is the
same design used for Orbital’s Taurus SLV. It
supports a flat pad launch of a full PK booster
assembly with front section and fourth stage motor
options. After stool installation, the fixed
scaffolding installation is performed. This
scaffolding provides access to the base ring of the
PK Stage 1 motor during integration activities.
Once the booster arrives at the launch site, it
is then lifted and emplaced onto the launch stool.
Each motor assembly will be individually stacked
using a process developed for handling Taurus
Stage 0 motors. Scaffolding integration continues
as the booster stages are mated.
The Stage 4 assembly is shipped in the
vertical configuration to the launch facility for
payload integration.
7.2.2. Payload Processing/Integration
Payloads normally undergo initial checkout
and preparation for launch at an Air Force payload

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Figure 7-3. Minotaur IV Processing Flow

processing facility (PPF) or commercial facilities at
VAFB. After arrival at the PPF, the payload
completes its own independent verification and
checkout prior to beginning integrated processing
with Minotaur IV fairing and Payload Adapter
Module (PAM). The Minotaur IV fairing and PAM
will be delivered to the payload processing facility
for encapsulation of the payload. The fairing and
PAM provide a sealed enclosure which protects
the payload and provides a structure to facilitate
transportation to the launch facility. After
enclosure of the payload in the fairing, the
assembly is shipped in the vertical configuration to
the launch facility for a pre-installation verification
test.
7.2.2.1. Payload Propellant Loading
Payloads utilizing integral propulsion systems
with propellants such as hydrazine can be loaded
and secured through coordinated Orbital and
contractor arrangements for use of the propellant
loading facilities in the VAB. This is a non-
standard service.
7.2.2.2. Final Vehicle Integration and Test
After successful completion of payload
mate/fairing closeout the completed front section
assembly (Minotaur IV Stage 4 assembly
integrated with the payload assembly) will then be
lifted in vertical configuration atop the booster
assembly. Figure 7-4 illustrates the vertical lifting
operation performed on a Taurus front section.
Final post mates checks of the booster assembly
and front section assembly interface are then
conducted. A final systems verification test,
similar to the previous MST, is then performed. At
this point the vehicle is ready for final Range
interface tests and launch readiness.

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Figure 7-4. Minotaur IV Upper Stack Assembly
will be Vertically Integrated to Minotaur IV
Booster Assembly in a Similar Manner to
Taurus Upper Stack
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7.3. Launch Operations
7.3.1. Launch Control Organization
The Launch Control Organization is split into
two groups: the Management group and the
Technical group. The Management group consists
of senior range personnel and Mission
Directors/Managers for the launch vehicle and
payload. The Technical Group consists of the
personnel responsible for the execution of the
launch operation and data review/assessment for
the Payload, the Launch Vehicle and the Range.
The Payload’s members of the technical group are
engineers who provide technical representation in
the control center. The Launch Vehicle’s
members of the technical group are engineers
who prepare the Minotaur IV for flight, review and
assess data that is displayed in the Launch
Control Room (LCR) and provide technical
representation in the LCR and in the Launch
Operations Control Center (LOCC). The Range’s
members of the technical group are personnel that
maintain and monitor the voice and data
equipment, tracking facilities and all assets
involved with RF communications with the launch
vehicle. In addition, the Range provides personnel
responsible for the Flight Termination System
monitoring and commanding.
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Minotaur IV User’s Guide Section 8.0 – Optional Enhanced Capabilities
8. OPTIONAL ENHANCED CAPABILITIES
The OSP launch service is structured to
provide a baseline vehicle configuration which is
then augmented with optional enhancements to
meet the unique needs of individual payloads.
The baseline vehicle capabilities are defined in the
previous sections and the optional enhanced
capabilities are defined below. The enhanced
options allow customization of launch support and
accommodations to the Minotaur IV designs on an
efficient, “as needed” basis.
8.1. Mechanical Interface and Separation
System Enhancements
8.1.1. Separation Systems
Various separation systems can be provided
or accommodated to meet mission-unique
requirements. As a baseline option, Orbital offers
an optional payload separation system that is flight
proven on Taurus. The separation system is
manufactured for Orbital by SAAB Ericson Space
(SES). SES has extensive experience in supplying
separation systems for a wide range of launch
vehicles and payloads. This system is based on a
design that has flown over 30 times with 100%
success. The baseline separation system, shown
in Figure 8-1, has a standardized 38.81 inch bolt
pattern. It is a marmon clamp design employing
two aluminum interface rings that are clamped by
dual, semi-circular stainless steel clamp bands
with aluminum clamp shoes. Each of the two
retention bolts is severed by a redundantly
initiated bolt cutter.
The separation ring to which the payload
attaches is supplied with through holes and the
separation system is mated to the spacecraft
during processing at the PPF. The weight of
hardware separated with the payload is
approximately 8.7 lbm (13.95 kg). Orbital-
provided attachment bolts to this interface can be
inserted from either the launch vehicle or the
payload side of the interface (NAS630xU, dash
number based on payload flange thickness). The
weight of the bolts, nuts, and washers connecting
Release 1.1 January 2006
the separation system to the payload is allocated
to the separation system and included in the
launch vehicle mass.
Separation velocity is provided by up to eight
matched spring actuators. The spring assemblies
may be tailored to mitigate the effects of payload
CG offset, controlling tip-off within 5 deg/sec. Tip-
off rates are highly dependent on payload mass
properties, but are typically on the order 1
deg/sec. Preliminary and final mission-specific tip-
off analyses are conducted for each payload using
Orbital’s computer simulation dynamic analysis
tools. If non-standard separation velocities are
needed, different springs may be substituted on a
mission-specific basis as a non-standard service.
Other separation systems can also be
supplied on a mission-specific basis.
8.1.2. Additional Fairing Access Doors
Additional access doors can be provided to
accommodate unique payload requirements. The
standard door size is 18 in. by 24 in. (45.7 cm by
61.0 cm). Access doors of non-standard size can
also be provided as necessary. Orbital performs
structural analyses to verify the acceptability of the
mission-specific door configuration. Other fairing
access configurations, such as small circular
access panels, can also be provided as negotiated
mission-specific enhancements.
8.1.3. Payload Isolation System
OSP offers a flight-proven payload isolation
system as a non-standard service. The Softride
for Small Satellites (SRSS) was developed by Air
Force Research Laboratory (AFRL) and CSA
Engineering. It was successfully demonstrated on
the two initial Minotaur missions and six Taurus
missions. The typical Minotaur configuration is
shown in Figure 8-2. This mechanical isolation
system has demonstrated the capability to
significantly alleviate the transient dynamic loads
that occur during flight. The isolation system can
provide relief to both the overall payload center of
gravity loads and component or subsystem
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Figure 8-1. 38-in. Separation System Option

responses. Typically the system will reduce 8.2. Performance Enhancements

transient loads to approximately 50% of the level
they would be without the system. The exact
results can be expected to vary for each particular
spacecraft and with location on the spacecraft.
Generally, a beneficial reduction in shock and
vibration will also be provided. The isolation
system does impact overall vehicle performance
(by approximately 20 to 40 lb [9 to 18 kg]) and the
available payload dynamic envelope by up to 4
inches (10.16 cm) axially and up to 1.0 inch (2.54
cm) laterally.
8.2.1. Insertion Accuracy
Enhanced insertion accuracy or support for
multiple payload insertion can be provided as an
enhanced option utilizing the Hydrazine Auxiliary
Propulsion System (HAPS). The common usage
of the Orion 38 makes the flight proven HAPS
design directly applicable to the Minotaur IV
usage, as shown in Figure 8-3. Orbital insertion
accuracy can typically be improved to ±10 nmi
(±18.5 km) or better in each apse and ±0.05 deg in
inclination. For orbits above 324 nmi (600 km), the

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HAPS also permits injection of shared payloads

Figure 8-2. Soft Ride Payload Isolation System
as Integrated on Minotaur LV
into different orbits. HAPS, which is mounted
inside the Avionics Structure, consists of a
hydrazine propulsion subsystem and a Stage 4
separation subsystem. After burnout and
separation from the Stage 4 motor, the HAPS
hydrazine thrusters provide additional velocity and
both improved performance and precise orbit
injection. The HAPS propulsion subsystem
consists of a centrally mounted tank containing
approximately 130 lbm (59 kg) of hydrazine,
helium pressurization gas, and three fixed, axially
pointed thrusters. The hydrazine tank contains an
integral bladder which will support multiple
restarts.

HAPS can also increase payload mass by 8.2.2. Star 48 Stage 4

approximately 50 to 250 lbm (22.7 to 113 kg), The modular design of Orbital’s GCA and
depending on the orbit. Specific performance integrating structures provides great flexibility in
capability associated with the HAPS can be accommodating alternative Stage 4 propulsion
provided by contacting the OSP program office. systems. As one low risk example, a optional

Figure 8-3. Hydrazine Auxiliary Propulsion System (HAPS) Used to Provide Insertion Accuracy

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configuration using the more powerful ATK Thiokol
Star-48 motor is shown in Figure 8-4. The only
modifications required to accommodate this
change are a modified Motor Adapter Cone (MAC)
with the Star 48 forward interface and a longer 3/4
interstage to allow room for the increased motor
length. Other alternative motors can be similarly
adopted.
Figure 8-4. Orion 38 Stage 4 Motor can be
Replaced with a Star-48 to Provide Increased
Performance
8.3. Environmental Control Options
8.3.1. Conditioned Air
Conditioned air can be provided within the
fairing volume using an Environmental Control
System (ECS) via a “fly-out” duct that is retracted
at launch. Temperature and humidity is regulated
within the limits specified in the Payload ICD. A
filter is installed to provide a Class 100,000
environment, typically. The Nitrogen Purge
(Section 4.6.3) and Enhanced Contamination
Control (Section 4.7 and 8.3.3) enhancements
complement this capability. Upon exercise of the
Enhanced Cleanliness option, a certified HEPA
filter is used in the input duct to assure the
necessary low particulate environment (Class
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100,000 or Class 10,000). Nitrogen purge is used
in conjunction with the Conditioned Air option to
provide mission-specific localized cooling and/or
dry nitrogen environments to satisfy unique
payload environmental requirements.
8.3.2. Nitrogen Purge
Continuous clean dry nitrogen inside the
shroud during vehicle processing from payload
encapsulation to launch is available as an option.
Dry clean nitrogen purge can be provided to the
payload at a Class 10,000 environment for
continuous purge of the payload after fairing
encapsulation until lift-off. The capability was
demonstrated on the Minotaur MightySat mission
with the exception of purge during transportation.
A nitrogen cooling system is already provided on
every SLV mission to spot-cool sensitive electronic
boxes. Flow adjustments for cooling versus purge
would be changed back and forth to accommodate
both. If nitrogen purge is required during
transport, the only additional items needed would
be a minor addition of a nitrogen bottle, regulator,
and mounting hardware.
The system distribution lines are routed across
the payload interface plane and/or along the inner
surface of the shroud or fairing. If required for
spot cooling of a payload component, Orbital will
provide GN2 flow to localized regions in the
fairing. The GN2 will meet Grade B specifications,
as defined in MIL-P-27401C and can be regulated
to at least 5 scfm. The system’s regulators are set
to a desired flow rate during pre-launch
processing. Payload purge requirements are
controlled and documented via the launch vehicle
to payload ICD.
Payload purge requirements must be
coordinated with Orbital via the ICD to ensure that
the requirements can be achieved.
8.3.3. Enhanced Contamination Control
Understanding that some payloads have
requirements for enhanced cleanliness, OSP
offers a contamination control option, which is
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composed of the elements in the following upstream of the fairing inlet duct prior to
sections (which is also discussed in Section 4.7). connecting the air source to the payload fairing.
Minotaur IV customers can also coordinate
combinations of the elements listed below to meet 8.3.4. Launch Pad Environmental Control
the unique needs of their payloads. For launch sites without gantries for
environmental control or vehicle access, optional
8.3.3.1. High Cleanliness Integration Quick Erect Scaffold® (QES) will protect the
Environment (Class 10K or 100K) vehicle from the environments, maintain
With enhanced contamination control, a soft temperatures within 60 to 100 °F (in conjunction
walled clean room can be provided to ensure a with a thermal blanket) and provide access to the
FED-STD-209 Class M6.5 (100,000) or Class vehicle for launch pad operations (see Figure 8-5).
M5.5 (10,000) environment during all payload As the name implies, QES can be rapidly
processing activities up to fairing encapsulation. assembled and is highly adaptable for
The soft walled clean room and anteroom(s) utilize accommodating different vehicle configurations.
HEPA filter units to filter the air and hydrocarbon This scaffolding has been previously
content is maintained at 15 ppm or less. The demonstrated on Minotaur.
payload organization is responsible for providing
the necessary clean room garments for payload 8.3.4.1. Booster Temperature Control
staff as well as vehicle staff that need to work The thermal blanket design successfully used
inside the clean room. during Minotaur missions can be used to maintain
the PK booster operating temperature within the
8.3.3.2. Fairing Surface Cleanliness Options limits of 60 to 100 °F. The thermal blanket is
The inner surface of the fairing and payload
cone assemblies can be cleaned to cleanliness
criteria which ensures no particulate matter visible
with normal vision when inspected from 6 to 18
inches under 100 ft-candle incident light. The
same will be true when the surface is illuminated
using black light, 3200 to 3800 Angstroms (Visibly
Clean Plus Ultraviolet). In addition, Orbital can
ensure that all materials used within the
encapsulated volume have outgassing
characteristics of less than 1.0% TML and less
than 0.1% CVCM. Items that do not meet these
levels can be masked to ensure they are
encapsulated and will have no significant effect on
the payload.

8.3.3.3. High Cleanliness Fairing Environment

With the enhanced contamination control
option, Orbital provides an ECS from payload
encapsulation until just prior to vehicle lift-off. The
ECS continuously purges the fairing volume with
clean filtered air. Orbital’s ECS incorporates a
HEPA filter unit to provide FED-STD-209 Class Figure 8-5. Mobile Scaffolding for
M5.5 (10,000) air. Orbital monitors the supply air Environmental Control Demonstrated on
for particulate matter via a probe installed Minotaur Missions

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constructed of outer PVC material with an inner provides better than 100 m position accuracy with
insulating liner. It is a four piece cover with Velcro 10 Hz data rate. This capability was successfully
seams running along the length of the boosters. demonstrated on the inaugural Minotaur mission.
Integral inflatable manifold tubes space the
blanket away from the booster and provide space 8.5. Shared Launch Accommodations
for ducting conditioned air for the boosters. The Minotaur IV is uniquely capable of providing
baseline blanket design only covers the Stage 1, 2 launches of multiple satellite payloads, leveraging
and 3 boosters. RSLP and Orbital’s extensive experience in
integrating and launching multiple payloads.
8.4. Enhanced Telemetry Options Multiple spacecraft configurations have been flown
OSP can provide mission specific on many of Orbital’s Pegasus, Taurus and
instrumentation and telemetry components to Minotaur missions to date. A number of different
structural configurations have been developed for
support additional payload or experiment data
dual payloads, one is shown in Figure 8-6.
acquisition requirements. Telemetry options
Because of the modular nature of the structures,
include additional payload-dedicated bandwidth
dual payload configurations can be easily
and GPS-based precision navigation data.
accommodated by the Minotaur IV structural
design.
8.4.1. Enhanced Telemetry Bandwidth
Enhanced mission specific instrumentation
and telemetry can be provided, supplying a
dedicated telemetry link to support additional
payload or experiment data acquisition
requirements. A baseline data rate of 1 Mbps is
available, however, maximum data rates depend
on the mission coverage required and the launch
range receiver characteristics and configuration.
The enhanced telemetry option was demonstrated
on both inaugural Minotaur TLV and SLV
missions.

8.4.2. Enhanced Telemetry Instrumentation

To support the higher data rate capability in
Section 8.4.1, enhanced telemetry instrumentation
can be provided. The instrumentation can include
strain gauges, temperature sensors,
accelerometers, analog data, and digital data
configured to mission-specific requirements. This
capability was successfully demonstrated on the
inaugural OSP-SLV mission. Figure 8-6. Modular Minotaur IV Structural
Design Easily Accommodates Multiple
8.4.3. Navigation Data Payloads
Precision navigation data using an
independent Global Positioning System (GPS)
receiver and telemetry link is available as an
enhanced option. This option utilizes Orbital’s
flight proven GPS Position Beacon (GPB) to
provide missile state data for range safety and

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APPENDIX A

PAYLOAD QUESTIONNAIRE

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SATELLITE IDENTIFICATION

FULL NAME:

ACRONYM:

OWNER/OPERATOR:

INTEGRATOR(s):

ORBIT INSERTION REQUIREMENTS*

SPHEROID Standard (WGS-84, Re = 6378.137 km)

Other:
ALTITUDE Insertion Apse: Opposite Apse:
nmi nmi
___ ± __ km ± km
or... Semi-Major Axis: Eccentricity:
nmi
___ ± __ km ≤e≤
INCLINATION
±
deg
ORIENTATION Argument of Perigee: Longitude of Ascending Node (LAN):

± deg ± deg
Right Ascension of Ascending Node (RAAN):

± deg ...for Launch Date:

* Note: Mean orbital elements

LAUNCH WINDOW REQUIREMENTS

NOMINAL LAUNCH DATE:

OTHER CONSTRAINTS (if not already implicit from LAN or RAAN requirements, e.g., solar beta angle, eclipse
time constraints, early on-orbit ops, etc):

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GROUND SUPPORT EQUIPMENT

Describe any additional control facilities (other than the baseline Support Equipment Building (SEB) and
Launch Equipment Vault (LEV)) which the satellite intends to use:

SEB Describe (in the table below) Satellite EGSE to be located in the LSV.
[Note: Space limitations exist in the SEB, 350 ft umbilical cable length to spacecraft typical]
Equipment Name / Type Approximate Size (LxWxH) Power Requirements

.................................................................. ............................................... ................................

.................................................................. ............................................... ................................

.................................................................. ............................................... ................................

.................................................................. ............................................... ................................

.................................................................. ............................................... ................................

Is UPS required for equipment in the SEB? Yes / No
Is Phone/Fax connection required in the SEB? Yes / No Circle: Phone / FAX
LEV Describe (in the table below) Satellite EGSE to be located in the LEV.
[Note: Space limitations exist in the SEB, 150 ft umbilical cable length to spacecraft typical]
Equipment Name / Type Approximate Size (LxWxH) Power Requirements

.................................................................. ............................................... ................................

.................................................................. ............................................... ................................

.................................................................. ............................................... ................................

.................................................................. ............................................... ................................

.................................................................. ............................................... ................................

Is UPS required for equipment in the LEV? Yes / No
Is Ethernet connection between SEB and LEV required? Yes / No

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EARLY ON-ORBIT OPERATIONS

Briefly describe the satellite early on-orbit operations, e.g., event triggers (separation sense, sun acquisition, etc), array
deployment(s), spin ups/downs, etc:

SATELLITE SEPARATION REQUIREMENTS

ACCELERATION Longitudinal: = g’s Lateral: = g’s

VELOCITY Relative Separation Velocity Constraints:

ANGULAR RATES
Longitudinal: Pitch: ± deg/sec
(pre-separation)
± deg/sec Yaw: ± deg/sec
ANGULAR RATES
Longitudinal: Pitch: ± deg/sec
(post-separation)
± deg/sec Yaw: ± deg/sec
ATTITUDE Describe Pointing Requirements Including Tolerances:
(at deployment)

SPIN UP Longitudinal Spin Rate: ± deg/sec

OTHER Describe Any Other Separation Requirements:

SPACECRAFT COORDINATE SYSTEM

Describe the Origin and Orientation of the spacecraft reference coordinate system, including its orientation with
respect to the launch vehicle (provide illustration if available):

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SPACECRAFT PHYSICAL DIMENSIONS

STOWED Length/Height: Diameter:

CONFIGURATION in cm in cm

Other Pertinent Dimension(s):

Describe any appendages/antennas/etc which extend beyond the basic satellite

envelope:

ON-ORBIT Describe size and shape:

CONFIGURATION

If available, provide dimensioned drawings for both stowed and on-orbit configurations.

SPACECRAFT MASS PROPERTIES*

PRE-SEPARATION Inertia units: lbm-in2 kg-m2

Mass: lbm kg
Ixx:
Xcg: in cm Iyy:
Izz:
Ycg: in cm Ixy:
Iyz:
Zcg: in cm Ixz:
POST-SEPARATION Inertia units: lbm-in2 kg-m2
(non-separating Mass: lbm kg
adapter remaining with Ixx:
launch vehicle)
Xcg: in cm Iyy:
Izz:
Ycg: in cm Ixy:
Iyz:
Zcg: in cm Ixz:
* Stowed configuration, spacecraft coordinate frame

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ASCENT TRAJECTORY REQUIREMENTS

Free Molecular Heating at Fairing Separation: Btu/ft2/hr

(Standard Service: = 360 Btu/ft2/hr) FMH = W/m2
Fairing Internal Wall Temperature deg F
(Standard Service: = 200°F) T = deg C
Dynamic Pressure at Fairing Separation: lbf /ft2
(Standard Service: = 0.01 lbf /ft2) q = N/m2
Ambient Pressure at Fairing Separation: lbf /in2
(Standard Service: = 0.3 psia) P = N/m2
Maximum Pressure Decay During Ascent: lbf /in2/sec
(Standard Service: = 0.6 psia) ΔP = N/m2/sec
Thermal Maneuvers During Coast Periods:
(Standard Service: none)

SPACECRAFT ENVIRONMENTS

THERMAL Spacecraft Thermal Dissipation, Pre-Launch Encapsulated: Watts

DISSIPATION
Approximate Location of Heat Source:

TEMPERATURE Temperature Limits During Max deg F deg C

Ground/Launch Operations: Min deg F deg C
(Standard Service is 55°F to 80°F)
Component(s) Driving Temperature Constraint:
Approximate Location(s):

HUMIDITY Relative Humidity: or, Dew Point:

Max % Max deg F deg C
Min % Min deg F deg C
(Standard Service is 37 deg F)
NITROGEN Specify Any Nitrogen Purge Requirements, Including Component Description, Location,
PURGE and Required Flow Rate:

(Nitrogen Purge is a Non-Standard Service)

CLEANLINESS Volumetric Requirements (e.g. Class 100,000):
Surface Cleanliness (e.g. Visually Clean):
Other:
LOAD LIMITS Ground Transportation Load Limits: Axial = g’s Lateral = g’s

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ELECTRICAL INTERFACE

Bonding Requirements:

Are Launch Vehicle Supplied

Pyro Commands Required? Yes / No If Yes, magnitude: amps for msec
(Standard Service is 10 amps for 100 msec)
Are Launch Vehicle Supplied If Yes, describe:
Discrete Commands Required? Yes / No

Is Electrical Access to the Satellite Required... After Encapsulation? Yes / No

at Launch Site Yes / No
Is Satellite Battery Charging Required... After Encapsulation? Yes / No
at Launch Site? Yes / No
Is a Telemetry Interface with the Launch Vehicle Flight Computer Required? Yes / No

If Yes, describe:

Other Electrical Requirements:

Please complete attached sheet of required pass-through signals.

RF RADIATION

Time After Separation Until RF Devices Are Activated:

(Note: Typically, no spacecraft radiation is allowed from encapsulation until 30 minutes after liftoff.)

Frequency: MHz Power: Watts

Location(s) on Satellite (spacecraft coordinate frame):

Longitudinal in cm Clocking (deg), Describe:

Longitudinal in cm Clocking (deg), Describe:

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REQUIRED PASS-THROUGH SIGNALS

Max Total Line
Item
Current Resistance
# Pin Signal Name From LEV To Satellite Shielding
(amps) (ohms)
1

10

11

12

13

14

15

16

17

18

19

20

21

22

23

24

25

26

27

28

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MECHANICAL INTERFACE

DIAMETER Describe Diameter of Interface (e.g. Bolt Circle, etc):

SEPARATION Will Launch Vehicle Supply the Separation System? Yes / No

SYSTEM
If Yes approximate location of electrical connectors:

special thermal finishes (tape, paint, MLI) needed:

If No, provide a brief description of the proposed system:

SURFACE Flatness Requirements for Sep System or Mating Surface of Launch Vehicle:
FLATNESS

FAIRING Payload Fairing Access Doors (spacecraft coordinate frame):

ACCESS
Longitudinal in cm Clocking (deg), Describe:

Longitudinal in cm Clocking (deg), Describe:

Note: Standard Service is one door

DYNAMICS Spacecraft Natural Frequency:

Axial Hz Lateral Hz

Recommended: > TBD Hz > TBD Hz

OTHER Other Mechanical Interface Requirements:

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