Orbital Minotaur I User Manual

March 2014 Minotaur I User’s Guide

Release 3.0

Approved for Public Release
Distribution Unlimited

©2013 Orbital Sciences Corporation

All Rights Reserved.

Minotaur I User’s Guide Revision Summary

1.0

2.0

REVISION SUMMARY

VERSION DOCUMENT DATE CHANGE PAGE

TM-14025 Mar 2002 Initial Release All

TM-14025A Oct 2004 Changes throughout. Major updates include

• Performance plots

• Environments

• Payload accommodations

• Added 61 inch fairing option

3.0 TM-14025B Mar 2014 Extensively Revised All

All

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Minotaur I User’s Guide Preface

PREFACE

This Minotaur I User's Guide is intended to familiarize potential space launch vehicle users with the
Minotaur I launch system, its capabilities and its associated services. All data provided herein is for
reference purposes only and should not be used for mission specific analyses. Detailed analyses will be
performed based on the requirements and characteristics of each specific mission. The launch services
described herein are available for US Government sponsored missions via the United States Air Force
(USAF) Space and Missile Systems Center (SMC) Space Development and Test Directorate (SD),
Launch System Division (SDL).

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

[e-mail]
www.orbital.com/spacelaunch/Minotaur/I

[phone]

Orbital Suborbital Program - Mission Development
Orbital Sciences Corporation
Launch Systems Group
3380 S. Price Road
Chandler, AZ 85248

Additional information can be obtained from the USAF OSP Office at:

USAF SMC Space Development and Test Directorate (SMC/SD)
Launch Systems Division (SMC/SDL)
3548 Aberdeen Ave SE
Kirtland AFB, NM 87117-5778

[phone]
[phone]

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Minotaur I User’s Guide Table of Contents

PAGE

1. INTRODUCTION ................................................................................................................................. 1

1.1. Minotaur Family Performance and Capability ............................................................................... 2

2. MINOTAUR I CONFIGURATIONS ..................................................................................................... 4

2.1. Minotaur I Launch System Overview ............................................................................................ 4

2.2. Minotaur I Launch Service ............................................................................................................ 4

2.3. Minotaur I Launch Vehicle ............................................................................................................ 5

2.3.1. Lower Stack Assembly .............................................................................................................. 5

2.3.2. Upper Stack Assembly .............................................................................................................. 6

2.3.2.1. Avionics ............................................................................................................................... 6

2.3.2.2. Attitude Control Systems ..................................................................................................... 7

2.3.2.3. Telemetry Subsystem.......................................................................................................... 7

2.3.3. Payload Interface ....................................................................................................................... 8

2.3.4. Payload Fairing .......................................................................................................................... 8

2.4. Launch Support Equipment .......................................................................................................... 9

3. GENERAL PERFORMANCE ............................................................................................................ 11

3.1. Mission Profiles ........................................................................................................................... 11

3.2. Launch Sites ............................................................................................................................... 11

3.2.1. Western Launch Sites ............................................................................................................. 13

3.2.2. Eastern Launch Sites .............................................................................................................. 13

3.2.3. Alternate Launch Sites ............................................................................................................ 13

3.3. Performance Capability ............................................................................................................... 13

3.4. Injection Accuracy ....................................................................................................................... 18

3.5. Payload Deployment ................................................................................................................... 19

3.6. Payload Separation ..................................................................................................................... 19

3.7. Collision/Contamination Avoidance Maneuver ........................................................................... 19

4. PAYLOAD ENVIRONMENT .............................................................................................................. 20

4.1. Steady State and Transient Acceleration Loads......................................................................... 20

4.1.1. Transient Loads ....................................................................................................................... 21

4.1.2. Steady-State Acceleration ....................................................................................................... 22

4.2. Payload Vibration Environment................................................................................................... 23

4.3. Payload Acoustic Environment ................................................................................................... 23

4.4. Payload Shock Environment ....................................................................................................... 23

4.5. Payload Structural Integrity and Environments Verification ........................................................ 23

4.6. Thermal and Humidity Environments .......................................................................................... 24

4.6.1. Ground Operations .................................................................................................................. 24

4.6.2. Powered Flight ......................................................................................................................... 25

4.6.3. Nitrogen Purge (non-standard service) ................................................................................... 26

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Minotaur I User’s Guide Table of Contents

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4.7. Payload Contamination Control .................................................................................................. 26

4.8. Payload Electromagnetic Environment ....................................................................................... 26

5. PAYLOAD INTERFACES .................................................................................................................. 28

5.1. Payload Fairing ........................................................................................................................... 28

5.1.1. 50” Standard Minotaur I Fairing ............................................................................................... 28

5.1.1.1. Payload Dynamic Design Envelope .................................................................................. 28

5.1.2. Optional 61” Payload Fairing ................................................................................................... 29

5.1.2.1. Payload Dynamic Design Envelope (61” Payload Fairing) ............................................... 29

5.1.3. Payload Access Door .............................................................................................................. 30

5.2. Payload Mechanical Interface and Separation System .............................................................. 32

5.2.1. Minotaur Coordinate System ................................................................................................... 32

5.2.2. Orbital Supplied Mechanical Interface Control Drawing .......................................................... 34

5.2.3. Standard Non-Separating Mechanical Interface ..................................................................... 34

5.2.4. Optional Mechanical Interface ................................................................................................. 34

5.2.4.1. Dual and Multi Payload Adapter Fittings ........................................................................... 34

5.2.4.1.1. Load-Bearing Spacecraft ............................................................................................ 34

5.2.4.1.2. Non Load-Bearing Spacecraft – Dual Payload Adapter Fitting (DPAF) ..................... 35

5.2.5. Optional Separation Systems .................................................................................................. 36

5.2.5.1. Orbital 38” Separation System .......................................................................................... 37

5.2.5.2. Planetary Systems Motorized Lightband (MLB) ................................................................ 39

5.2.5.3. RUAG 937 Separation Systems ........................................................................................ 39

5.3. Payload Electrical Interfaces....................................................................................................... 40

5.3.1. Payload Umbilical Interfaces ................................................................................................... 40

5.3.2. Payload Interface Circuitry ...................................................................................................... 41

5.3.3. Payload Battery Charging ........................................................................................................ 41

5.3.4. Payload Command and Control .............................................................................................. 41

5.3.5. Pyrotechnic Initiation Signals ................................................................................................... 41

5.3.6. Payload Telemetry ................................................................................................................... 41

5.3.7. Payload Separation Monitor Loopbacks .................................................................................. 42

5.3.8. Telemetry Interfaces ................................................................................................................ 42

5.3.9. Non Standard Electrical Interfaces .......................................................................................... 42

5.3.10. Electrical Launch Support Equipment ................................................................................... 42

5.4. Payload Design Constraints........................................................................................................ 43

5.4.1. Payload Center of Mass Constraints ....................................................................................... 43

5.4.2. Final Mass Properties Accuracy .............................................................................................. 43

5.4.3. Pre-Launch Electrical Constraints ........................................................................................... 43

5.4.4. Payload EMI/EMC Constraints ................................................................................................ 43

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5.4.5. Payload Dynamic Frequencies ................................................................................................ 43

5.4.6. Payload Propellant Slosh ........................................................................................................ 44

5.4.7. System Safety Constraints ...................................................................................................... 44

6. MISSION INTEGRATION .................................................................................................................. 45

6.1. Mission Management Approach ................................................................................................. 45

6.1.1. SD/SDL Mission Responsibilities ............................................................................................ 45

6.1.2. Orbital Mission Responsibilities ............................................................................................... 45

6.2. Mission Planning and Development ........................................................................................... 46

6.2.1. Mission Assurance .................................................................................................................. 48

6.3. Mission Integration Process ........................................................................................................ 49

6.3.1. Integration Meetings ................................................................................................................ 49

6.3.2. Mission Design Reviews (MDR) .............................................................................................. 49

6.3.3. Readiness Reviews ................................................................................................................. 49

6.4. Documentation ............................................................................................................................ 50

6.4.1. Customer-Provided Documentation ........................................................................................ 50

6.4.1.1. Payload Questionnaire ...................................................................................................... 50

6.4.1.2. ICD Inputs ......................................................................................................................... 50

6.4.1.3. Payload Mass Properties .................................................................................................. 50

6.4.1.4. Payload Finite Element Model .......................................................................................... 50

6.4.1.5. Payload Thermal Model for Integrated Thermal Analysis ................................................. 51

6.4.1.6. Payload Drawings ............................................................................................................. 51

6.4.1.7. Program Requirements Document (PRD) Mission Specific Annex Inputs ....................... 51

6.4.1.7.1. Launch Operations Requirements (OR) Inputs .......................................................... 51

6.4.1.8. Payload Launch Site Integration Procedures .................................................................... 51

6.4.1.9. ICD Verification Documentation ........................................................................................ 51

6.4.2. Orbital Produced Documentation, Data, and Analyses ........................................................... 51

6.4.2.1. Launch Vehicle to Payload ICD ........................................................................................ 52

6.4.2.2. ICD Verification Documentation ........................................................................................ 52

6.4.2.3. Preliminary Mission Analyses ........................................................................................... 52

6.4.2.4. Coupled Loads Analyses (CLA) ........................................................................................ 52

6.4.2.5. Integrated Launch Site Procedures ................................................................................... 52

6.4.2.6. Missile System Pre-Launch Safety Package (MSPSP) Annex ......................................... 53

6.4.2.7. PRD Mission Specific Annex ............................................................................................. 53

6.4.2.8. Launch Operation Requirements (OR) ............................................................................. 53

6.4.2.9. Mission Constraints Document (MCD) .............................................................................. 53

6.4.2.10. Final Countdown Procedure ............................................................................................ 53

6.4.2.11. Post-Launch Analyses..................................................................................................... 53

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6.5. Safety .......................................................................................................................................... 54

6.5.1. System Safety Requirements .................................................................................................. 54

6.5.2. System Safety Documentation ................................................................................................ 54

7. GROUND AND LAUNCH OPERATIONS ......................................................................................... 55

7.1. Launch Vehicle Integration Overview ......................................................................................... 56

7.1.1. Planning and Documentation .................................................................................................. 56

7.1.2. Upper Stack Assembly Integration and Test Activities ............................................................ 56

7.1.3. Minuteman Motor Integration and Test Activities .................................................................... 57

7.1.4. Mission Simulation Tests ......................................................................................................... 57

7.1.5. Launch Vehicle Processing Facilities ...................................................................................... 57

7.2. Payload Processing/Integration .................................................................................................. 57

7.2.1. Payload to Minotaur I Integration............................................................................................. 58

7.2.2. Pre-Mate Interface Testing ...................................................................................................... 58

7.2.3. Payload Mating and Verification .............................................................................................. 58

7.2.4. Final Processing and Fairing Closeout .................................................................................... 58

7.2.5. Payload Propellant Loading ..................................................................................................... 58

7.3. Launch Operations ...................................................................................................................... 58

7.3.1. Booster Assembly Stacking/Launch Site Preparation ............................................................. 59

7.3.2. Final Vehicle Integration and Test ........................................................................................... 59

7.3.3. Launch Vehicle Arming ............................................................................................................ 59

7.3.4. Launch ..................................................................................................................................... 60

7.3.5. Launch Control Organization ................................................................................................... 60

7.3.6. Launch Rehearsals .................................................................................................................. 61

8. OPTIONAL ENHANCED CAPABILITIES .......................................................................................... 62

8.1. Separation System ...................................................................................................................... 62

8.2. Conditioned Air ........................................................................................................................... 62

8.3. Nitrogen Purge ............................................................................................................................ 62

8.4. Additional Access Panel ............................................................................................................. 62

8.5. Enhanced Telemetry ................................................................................................................... 63

8.6. Enhanced Contamination Control ............................................................................................... 64

8.6.1. Low Outgassing Materials ....................................................................................................... 64

8.6.2. High Cleanliness Integration Environment .............................................................................. 64

8.6.3. HEPA-Filtered Fairing Air Supply ............................................................................................ 64

8.6.4. Fairing Surface Cleanliness ..................................................................................................... 65

8.7. Secure FTS ................................................................................................................................. 65

8.8. Over Horizon Telemetry .............................................................................................................. 65

8.9. Increased Insertion Accuracy ...................................................................................................... 66

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8.10. Payload Isolation System ............................................................................................................ 66

8.11. Orbital Debris Mitigation .............................................................................................................. 67

8.12. Dual and Multi Payload Adapter Fittings ..................................................................................... 67

8.13. Minotaur I Launch Vehicle Enhanced Performance Configuration ............................................. 68

8.13.1. Minotaur I Commercial .......................................................................................................... 68

8.14. Large Fairing ............................................................................................................................... 68

8.15. Hydrazine Servicing .................................................................................................................... 68

8.16. Nitrogen Tetroxide Service ......................................................................................................... 70

8.17. Poly-Pico Orbital Deployer (P-POD) ........................................................................................... 71

8.18. Suborbital Performance .............................................................................................................. 71

8.19. Alternate Launch Location .......................................................................................................... 73

LIST OF FIGURES

Figure 1.1-1. The Minotaur Family of Launch Vehicles ............................................................................... 2

Figure 1.1-2. Space Launch Performance for the Minotaur Family Demonstrates a Wide Range of

Payload Lift Capability ............................................................................................................ 3

Figure 2.1-1. Minotaur I Launch Vehicle ...................................................................................................... 4

Figure 2.3-1. OSP Minotaur I Launch Vehicle Configuration ....................................................................... 5

Figure 2.3.1-1. Minotaur I LSA Being Lifted out of Transporter Erector ...................................................... 6

Figure 2.3.2-1. Minotaur I Upper Stack Assembly Processing at Orbital’s Vehicle Assembly Building

at VAFB ................................................................................................................................ 6

Figure 2.3.4-1. Minotaur I 50” Fairing and Handling Fixtures ...................................................................... 8

Figure 2.4-1. Minotaur I EGSE Configuration ............................................................................................ 10

Figure 3.1-1. Minotaur I Generic Mission Profile........................................................................................ 11

Figure 3.2-1. Flexible Processing and Portable GSE Allows Operations from Multiple Ranges or

Austere Site Options ............................................................................................................. 12

Figure 3.2-2. Launch Site Inclinations ........................................................................................................ 12

Figure 3.3-1. Minotaur I Performance Curves for VAFB Launches ........................................................... 14

Figure 3.3-2. Minotaur I Performance Curves for KLC Launches .............................................................. 15

Figure 3.3-3. Minotaur I Performance Curves for CCAFS Launches ........................................................ 15

Figure 3.3-4. Minotaur I Performance Curves for WFF Launches ............................................................. 16

Figure 3.3-5. Minotaur I with 61” Fairing Performance Curves for VAFB Launches ................................. 16

Figure 3.3-6. Minotaur I with 61” Fairing Performance Curves for KLC Launches .................................... 17

Figure 3.3-7. Minotaur I with 61” Fairing Performance Curves for CCAFS Launches............................... 17

Figure 3.3-8. Minotaur I with 61” Fairing Performance Curves for WFF Launches ................................... 18

Figure 4.1.1-1. Payload CG Net Transient Lateral Acceleration Envelope ............................................... 21

Figure 4.1.2-1. Minotaur I 3-Sigma Maximum Axial Acceleration as a Function of Payload Mass ........... 22

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Figure 4.3-1. Payload Acoustic Environment during Liftoff and Flight ....................................................... 23

Figure 4.2-1. Payload Random Vibration Environment during Flight ........................................................ 23

Figure 4.4-1. Maximum Shock Environment – Launch Vehicle to Payload ............................................... 24

Figure 4.4-2. Maximum Shock Environment – Payload to Launch Vehicle ............................................... 24

Figure 4.6.1-1. Minotaur I HVAC System Provides Conditioned Air to the Payload.................................. 25

Figure 4.6.2-1. Typical Minotaur I Fairing Pressure Profile ....................................................................... 26

Figure 5.1.1.1-1. 50” Payload Fairing Dynamic Envelope with 38” (97 cm) Diameter

Payload Interface ............................................................................................................ 29

Figure 5.1.2.1-1. 61” Payload Fairing Dynamic Envelope with 38” (97 cm) Diameter

Payload Interface ............................................................................................................ 30

Figure 5.1.3-1. 50” Payload Fairing Access Door Placement Zone .......................................................... 31

Figure 5.2.1-1. Minotaur Coordinate System ............................................................................................. 33

Figure 5.2.4.1.1-1. COSMIC Spacecraft Configuration Utilized the Orbital MicroStar Bus to

Fly Six SVs ................................................................................................................... 35

Figure 5.2.4.1.1-2. JAWSAT Multiple Payload Adapter Load Bearing Spacecraft .................................... 35

Figure 5.2.4.1.1-3. Five Bay Multiple Payload Adapter Concept ............................................................... 36

Figure 5.2.4.1.2-1. DPAF Configuration ..................................................................................................... 36

Figure 5.2.5.1-1. Orbital 38” Separation System ....................................................................................... 38

Figure 5.2.5.2-1. 38” Planetary Sciences Motorized Lightband ................................................................ 39

Figure 5.2.5.3-1. RUAG 937S 38” Separation System ............................................................................. 39

Figure 5.3-1. Payload Electrical Interface Block Diagram Payload Interface Circuitry .............................. 40

Figure 5.3.1-1. Payload Umbilical 1:1 Pin Outs ......................................................................................... 41

Figure 6.1-1. Mission Integration Team ..................................................................................................... 45

Figure 6.2-1. Typical Minotaur Mission Integration Schedule .................................................................... 47

Figure 6.2-2. Typical Mission Field Integration Schedule .......................................................................... 48

Figure 7-1. Hardware Flow – Factory to Launch Site ................................................................................ 55

Figure 7.1-1. Launch Vehicle Processing Flow.......................................................................................... 56

Figure 7.1.5-1. Minotaur I Processing Is Performed at the MPF at VAFB ................................................. 57

Figure 7.3.4-1. Notional Minotaur Countdown Timeline ........................................................................... 60

Figure 7.3.4-2. Minotaur I Prepared for Launch ......................................................................................... 60

Figure 8.3-1. GN2 Purge Interface To Minotaur Fairing (Flyaway at Liftoff) .............................................. 62

Figure 8.4-1. Multiple Access Doors Were Demonstrated on the Optional Minotaur I Large Fairing ........ 63

Figure 8.6-1. Minotaur Team Has Extensive Experience in a Payload Processing

Clean Room Environment ..................................................................................................... 64

Figure 8.7-1. Orbital’s Secure FTS System Block Diagram ....................................................................... 65

Figure 8.8-1. TDRSS 20W LCT2 Transmitter and Cavity Backed S-band Antenna .................................. 66

Figure 8.8-2. TDRSS Notional Telemetry Flow.......................................................................................... 66

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Figure 8.10-1. Minotaur I SRSS Significantly Attenuates Peak LV Dynamic Environments ..................... 67

Figure 8.11-1. Operational and Disposal LEOs ......................................................................................... 67

Figure 8.13.1-1. Minotaur I Commercial Offers Exceptional Performance with Proven Reliability ............ 68

Figure 8.15-1. Typical Propellant Loading Schematic ............................................................................... 69

Figure 8.15-2. UPC Provides Reliable and Demonstrated Hydrazine Servicing for Minotaur ................... 70

Figure 8.18-1. Minotaur I Lite Ballistic Performance .................................................................................. 71

Figure 8.17-1. P-PODs Have Successfully Flown On Multiple Minotaur Missions .................................... 71

Figure 8.18-2. Minotaur I-Lite Replaces the Orion 38 with a Low Cost and Risk Simple

Aluminum Cylinder .............................................................................................................. 72

Figure 8.19-1. Minotaur IV Vehicles Have Successfully Launched From KLC .......................................... 73

Figure 8.19-3. Minotaur I Vehicles Have Successfully Launched Multiple Times From Wallops .............. 73

Figure 8.19-2. Launch Complex 46 at CCAFS Supports All Minotaur Configurations .............................. 73

LIST OF TABLES

Table 3.3-1. Common Mission Options and Associated Masses (These Masses Must Be Subtracted

from the LV Performance) ..................................................................................................... 14

Table 3.4-1. Minotaur I Injection Accuracy ................................................................................................. 18

Table 3.5-1. Typical Pre-Separation Payload Pointing and Spin Rate Accuracies ................................... 19

Table 4.8-1. Minotaur I Launch Vehicle RF Emitters and Receivers ......................................................... 27

Table 5.2.5-1. Minotaur I Separation System Options ............................................................................... 37

Table 5.4.2-1. Payload Mass Properties Measurement Tolerance ........................................................... 43

Table 8.9-1. Enhanced Insertion Accuracies ............................................................................................. 66

LIST OF APPENDICES

A. PAYLOAD QUESTIONNAIRE ..............................................................................................................A-1

Release 3.0 March 2014 x

Minotaur I User’s Guide Glossary

6DOF

Six Degrees of Freedom

A/D

Arm/Disarm

AADC

Alaska Aerospace Development
ACAT-1

Acquisition Category 1

ACS

Attitude Control System

AFRL

Air Force Research Laboratory

ait

Atmospheric Interceptor
AIT

Assembly Integration Trailer

AODS

All-Ordnance Destruct System

BCM

Booster Control Module

BER

Bit Error Rate

C/CAM

Collision/ Contamination
C/D

Command/Destruct

CBOD

Clamp Band Opening Device

CCAFS

Cape Canaveral Air Force Station

CDR

Critical Design Review

CG

Center of Gravity

CLA

Coupled Loads Analysis

CLF

Commercial Launch Facility

CVCM

Collected Volatile Condensable

DIACAP

DoD Information Assurance

DoD

Department of Defense

DPAF

Dual Payload Adapter Fitting

ECU

Electronic Control Unit

EGSE

Electrical Ground Support
EMC

Electromagnetic Compatibility

EME

Electromagnetic Environment

EMI

Electromagnetic Interference

ER

Eastern Range

FAA

Federal Aviation Administration

FRR

Flight Readiness Review

FTLU

Flight Termination Logic Unit

FTS

Flight Termination System

GFE

Government Furnished Equipment

GFP

Government Furnished Property

GN2

gaseous nitrogen

GPB

GPS Positioning Beacon

GPS

Global Positioning System

GTO

Geosynchronous Transfer Orbit

HAPS

Hydrazine Auxiliary Propulsion

HVAC

Heating, Ventilation, and Air
I&T

Integration and Test

I/O

Input/Output

ICD

Interface Control Document

INS

Inertial Navigation System

IRRT

Independent Readiness Review

IV&V

Independent Verification and
IVT

Interface Verification Test

KLC

Kodiak Launch Complex

KSC

Kennedy Space Center

LCR

Launch Control Room

LEO

Low Earth Orbit

LEV

Launch Equipment Vault

LITVC

Liquid Injection Thrust Vector
LOCC

Launch Operations Control Center

LRR

Launch Readiness Review

LSA

Lower Stack Assembly

LSA

Launch Stool Assembly

LSE

Launch Support Equipment

LV

Launch Vehicle

MA

Mission Assurance

MACH

Modular Avionics Control
MARS

Mid-Atlantic Regional Spaceport

MDR

Mission Design Review

MDR

Mission Dress Rehearsal

MGSE

Mechanical Ground Support

MICD

Mechanical Interface Control
MLB

Motorized Lightband

MM

Minuteman

MODS

Mechanical Ordnance Destruct
MPA

Multiple Payload Adaptor

MPE

Maximum Predicted Environment

MPF

Minotaur Processing Facility

MRD

Mission Requirements Document

MRR

Mission Readiness Review

MST

Mission Simulation Test

System

Corporation

Technology

Avoidance Maneuver

Mass

Conditioning

Team

Validation

Control

Certification and Accreditation
Process

Equipment

Hardware

Equipment

Drawing

System

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Minotaur I User’s Guide Glossary

MTO

Medium Transfer Orbit

NASA

National Aeronautics and Space
NCU

Nozzle Control Unit

NRE

Non-Recurring Engineering

NTO

Nitrogen Tetroxide

ODM

Ordnance Driver Module

OR

Operations Requirements

OSP-3

Orbital Suborbital Program 3

PAF

Payload Attach Fitting

PCM

Pulse Code Modulation

PDR

Preliminary Design Review

PEM

Program Engineering Manager

PPF

Payload Processing Facility

P-POD

Poly-Pico Orbital Deployer

PRD

Program Requirements Document

RAAN

Right Ascension of Ascending
RCS

Roll Control System

RF

Radio Frequency

RWG

Range Working Group

S/A

Safe and Arm

SCAPE

Self-Contained Atmospheric

SD

Space Development and Test
SDL

SD Launch Systems Division

SEB

Support Equipment Building

SLC-8

Space Launch Complex 8

SLV

Space Launch Vehicle

SMC

Space and Missile Systems Center

SRSS

Softride for Small Satellites

SSI

Spaceport Systems International

START

Strategic Arms Reduction Treaty

SV

Space Vehicle

TDRSS

Telemetry Data Relay Satellite
TLI

Trans-Lunar Injection

TML

Total Mass Loss

TVC

Thrust Vector Control

UPC

United Paradyne Corporation

USA

Upper Stack Assembly

USAF

United States Air Force

VAFB

Vandenberg Air Force Base

WFF

Wallops Flight Facility

WP

Work Package

Administration

Node

Protective Ensemble

Directorate

System

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Minotaur I 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 3 (OSP-3) Minotaur I Space Launch
Vehicle (SLV) launch service. This document provides an
overview of the Minotaur I system design and a
description of the services provided to our customers.
Minotaur I offers a variety of enhanced options to allow for
maximum flexibility in satisfying the objectives of single or
multiple payloads.

The user’s handbook is not intended as a design
document but rather it is to be used to select a launch
vehicle that meets the requirements of the payload. This
document describes typical environments seen on
previous missions. Each spacecraft is unique and will
require detailed analysis early in the program.

The primary mission of Minotaur I is to provide low cost,
high reliability launch services to government-sponsored
payloads. Minotaur I accomplishes this by using flight
proven components with significant flight heritage. The
philosophy of placing mission success as the highest
priority is reflected in the success and accuracy of all
Minotaur missions to date.

The Minotaur I launch vehicle system is composed of a
flight vehicle and ground support equipment. Each
element of the Minotaur I 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 I 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 I mission
integration process.

The Minotaur I 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 Launch
Complex (KLC). This User’s Guide describes Minotaur I­unique integration and test approaches (including the
typical operational timeline for payload integration with the

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Minotaur I User’s Guide Section 1.0 – Introduction

Minotaur I vehicle) and the existing ground support equipment that is used to conduct Minotaur I
operations.

1.1. Minotaur Family Performance and Capability

Figure 1.1-1 shows the Minotaur family of launch vehicles, which is capable of launching a wide range of
payload sizes and missions. Representative space launch performance across the Minotaur fleet is
shown in Figure 1.1-2 to illustrate the relative capability of each configuration. In addition to space launch
capabilities, the Minotaur I Lite and Minotaur IV Lite configurations are available to meet suborbital
payload needs for payloads weighing up to 3000 kg. This User’s Guide covers the Minuteman-based
Minotaur I. Please refer to the Minotaur IV – V – VI User’s Guide for information on the Peacekeeper­based Minotaur vehicles.

Figure 1.1-1. The Minotaur Family of Launch Vehicles

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Minotaur I User’s Guide Section 1.0 – Introduction

Figure 1.1-2. Space Launch Performance for the Minotaur Family Demonstrates a Wide Range of

Payload Lift Capability

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Minotaur I User’s Guide Section 2.0 – Minotaur I Configurations

2. MINOTAUR I CONFIGURATIONS

2.1. Minotaur I Launch System Overview

The Minotaur I launch vehicle, shown in
Figure 2.1-1, was developed by Orbital for the
United States Air Force (USAF) to provide a cost
effective, reliable and flexible means of placing
small satellites into orbit. Orbital is the launch
vehicle developer and manufacturer under the
Orbital Suborbital Program 3 (OSP-3) 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.

Minotaur I has been designed to meet the needs
of United States Government-sponsored
customers at a lower cost than commercially
available alternatives through the use of surplus
Minuteman boosters. OSP-3 requirements
emphasize system reliability, transportability, and
operation from multiple launch sites. Minotaur I
draws on the successful heritage of Orbital’s
space launch vehicles and the Minuteman II system of the USAF to meet these requirements. Orbital has
built upon these legacy systems with enhanced avionics components and advanced composite structures
to meet the payload-support requirements of the OSP-3 program. Combining these improved subsystems
with the long and successful history of the Minuteman II boosters has resulted in a simple, robust, self­contained launch system with a proven success record that is fully operational to support government­sponsored small satellite launches.

The Minotaur I system also includes a complete set of transportable Launch Support Equipment (LSE)
designed to allow Minotaur I to be operated as a self-contained satellite delivery system. The Electrical
Ground Support Equipment (EGSE) has been developed to be portable and adaptable to varying levels of
infrastructure. While the Minotaur I system is capable of self-contained operation at austere launch sites
using portable vans, typical operations occur from permanent facilities on established ranges.

The Minotaur I system is designed to be capable of launch from four commercial Spaceports (Alaska,
California, Florida, and Mid-Atlantic), as well as from existing U.S. Government facilities at VAFB and
CCAFS. A Launch Control Room (LCR) serves as the control center for conducting a Minotaur I 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 I Launch Service

The Minotaur I Launch Service is provided through the combined efforts of the USAF and Orbital, along
with associate contractors and Commercial Spaceports. The primary customer interface will be with the
USAF Space and Missile Systems Center, Space Development and Test Directorate, Launch Systems

Figure 2.1-1. Minotaur I Launch Vehicle

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Division (SDL). Orbital is the launch vehicle
provider. This integrated team will be referred to
collectively as “OSP” throughout the User’s Guide.
Where necessary, interfaces that are associated
with a particular member of the team will be
referred to directly (i.e., Orbital or SDL).

OSP provides all of the necessary hardware,
software and services to integrate, test and launch
a payload into its prescribed orbit. In addition,
OSP will complete all the required agreements,
licenses and documentation to successfully
conduct Minotaur I operations. The Minotaur I
mission integration process completely identifies,
documents, and verifies all spacecraft and
mission requirements.

2.3. Minotaur I Launch Vehicle

The Minotaur I vehicle, shown in expanded view
in Figure 2.3-1, 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 I payload
accommodations and interfaces have been
designed to satisfy a wide range of potential
payload requirements.

2.3.1. Lower Stack Assembly

The Lower Stack Assembly (LSA), shown in
Figure 2.3.1-1, consists of the refurbished
Government Furnished Equipment (GFE)
Minuteman Stages 1 and 2. Only minor
modifications are made to the boosters, including
harness interface changes and conversion from
All-Ordnance Destruct System (AODS) to Modular
Mechanical Ordnance Destruct System (MMODS)
Flight Termination System (FTS).

The first stage consists of the Minuteman II
M55A1 solid propellant motor, Nozzle Control
Units (NCU), Stage 1 Ignition Safe/Arm, S1/S2
Interstage and Stage 1 MMODS FTS. Four
gimbaled nozzles provide three axis control during
first stage burn. The second stage consists of a refurbished Minuteman II SR19 motor, Liquid Injection

Figure 2.3-1. OSP Minotaur I Launch Vehicle

Configuration

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Processing Facility at VAFB

Thrust Vector Control (LITVC) subsystem, S2
ignition safe/arm device, a Roll Control System
(RCS), and the Stage 2 MMODS FTS
components. Attitude control during second stage
burn is provided by the operational LITVC and hot
gas roll control.

2.3.2. Upper Stack Assembly

The Minotaur I Upper Stack is composed of the
Stage 3 and 4 motors, their associated
interstages, the avionics assembly, and,
ultimately, the payload and payload fairing. The
Stage 3 and 4 motors are the Orion 50 XL and
Orion 38, respectively. These motors were
originally developed for Orbital’s Pegasus
program and are used in a similar manner on the
ground-launched Minotaur I vehicle. Common
design features, materials and production
techniques are applied to both motors to
maximize reliability and production efficiency. The
motors are fully flight qualified based on their
heritage, conservative design, ground static fires
and over 60 launches. Processing of the
Minotaur I Upper Stack is conducted at the
Minotaur Processing Facility (MPF), as shown in
Figure 2.3.2-1.

2.3.2.1. Avionics

The Minotaur I avionics system has heritage and
commonality across the Minotaur fleet. The flight
computer is a 32-bit multiprocessor architecture. It
provides communication with vehicle subsystems,
the LSE, and if required, the payload via standard
RS-422 serial links and discrete I/O. The avionics
system design incorporates Orbital’s innovative,
flight proven Modular Avionics Control Hardware
(MACH). The MACH consists of standardized,
function-specific modules that are combined in
stacks of up to 10 modules to meet mission
requirements. The functional modules from which
the MACH stacks are created include power
transfer, ordnance initiation, booster interface,
communication, and telemetry processing. These
modules provide an array of functional capability
and flexibility.

Figure 2.3.1-1. Minotaur I LSA Being Lifted out

of Transporter Erector

Figure 2.3.2-1. Minotaur I Upper Stack

Assembly Processing at Orbital’s Minotaur

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2.3.2.2. Attitude Control Systems

The Minotaur I Control System provides three-axis attitude control throughout boosted flight and coast
phases. Stages 1 and 2 utilize the Minuteman Thrust Vector Control (TVC) systems. The Stage 1 TVC is
a four-nozzle hydraulic system, while the Stage 2 system combines liquid injection for pitch and yaw
control with hot gas roll control. Stages 3 and 4 utilize the same TVC systems as Minotaur IV. They
combine single-nozzle electromechanical TVC for pitch and yaw control with a three-axis cold-gas
Attitude Control System (ACS) resident in the avionics section providing roll control.

Attitude control is achieved using a three-axis autopilot. Stages 1 and 2 fly a pre-programmed attitude
profile based on trajectory design and optimization. Stage 3 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 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 a modular object oriented software design, 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 I 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 I
vehicle. This data is used by both Orbital and the range safety personnel to evaluate system
performance. The Minotaur I baseline telemetry subsystem provides a number of dedicated payload
discrete (bi-level) and analog telemetry monitors through dedicated channels in the launch vehicle
encoder. The baseline telemetry system has a 1.5 Mbps data rate for both payload and Minotaur launch
vehicle telemetry. To allow for flexibility in supporting evolving mission requirements, the output data rate
can be selected over a wide range from 2.5 kbps to 10 Mbps (contingent on link margin and Bit Error
Rate (BER) requirements). The telemetry subsystem nominally utilizes Pulse Code Modulation (PCM)
with a RNRZ-L format. Other types of data formats, including NRZ-L, S, M, and Bi-phase may be
implemented if required to accommodate launch range limitations. Furthermore, the launch vehicle
telemetry system has the capability to take payload telemetry as an input, randomize if required, and
downlink that dedicated payload link from launch through separation. That capability is available as a
non-standard option.

The Enhanced Telemetry option as described in the Enhancements section 8.5 augments the existing
baseline telemetry system by providing a dedicated telemetry link with a baseline data rate of 2 Mbps.
This Enhanced Telemetry link is used to provide further insight into the mission environment due to
additional payload, LV, or experiment data acquisition requirements. Supplementary instrumentation or
signals such as strain gauges, temperature sensors, accelerometers, analog, or digital data can be
configured to meet payload mission-specific requirements.

An Over the Horizon Telemetry option can also be added to provide real-time telemetry coverage during
ground-based telemetry receiving site blackout periods. The Telemetry Data Relay Satellite System
(TDRSS) is used for this capability, and has been successfully demonstrated on past Minotaur missions.
Close to the time when telemetry coverage is lost by ground based telemetry receiving sites, the LV
switches telemetry output to the TDRSS antenna and points the antenna towards the designated satellite.

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The TDRSS then relays the telemetry to the ground where it is routed to the Launch Control Room for
real-time telemetry updates. Reference Enhancements Section 8.8 for further details on this Over the
Horizon Telemetry option.

Minotaur telemetry is subject to the provisions of the Strategic Arms Reduction Treaty (START). START
treaty provisions require that certain Minotaur I telemetry be unencrypted and provided to the START
treaty office for dissemination to the signatories of the treaty.

2.3.3. Payload Interface

Minotaur provides for a standard non-separating payload interface, with the option of adding an Orbital­provided payload separation system. Orbital will provide all flight hardware and integration services
necessary to attach non-separating and separating payloads to the Minotaur launch vehicle. Additional
mechanical interface diameters and separation system configurations can readily be provided as an
enhanced option as described in Section 5.0. Further detail on payload electrical, mechanical and launch
support equipment interfaces are detailed in Section 5.0.

Because of its design flexibility, Minotaur can accommodate and has flown missions with multiple
spacecraft. This capability, described in more detail in Section 5.0 of this User’s Guide, permits two or
more smaller payloads to share the cost of a Minotaur I launch, resulting in a lower launch cost for each
as compared to other launch options. Furthermore, Orbital can accommodate small payloads when there
is excess payload and/or mass capability.

2.3.4. Payload Fairing

The baseline Minotaur I 50” fairing, shown in
Figure 2.3.4-1, is identical to the Pegasus fairing
design and has been successfully deployed in
over 40 Pegasus and Minotaur I missions. Due to
differences in vehicle loads and environments, the
Minotaur I implementation allows for a larger
payload envelope than Pegasus. The Minotaur I
payload fairing consists of two composite shell
halves, a nose cap integral to one shell half, and a
separation system. Each shell half is composed of
a cylinder and ogive sections.

Options for payload access doors and enhanced
cleanliness are available. A larger 61” diameter
fairing is also available. Further details on both
fairings are included in Section 5.1.

Figure 2.3.4-1. Minotaur I 50” Fairing and

Handling Fixtures

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2.4. Launch Support Equipment

The Minotaur I 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 and Telemetry Data Reduction consoles are located in the Launch Control Room (LCR),
or mobile launch equipment van depending on available launch site accommodations. The Vehicle
Interface consoles are located at the launch pad in a permanent structure, typically called a Launch
Equipment Vault (LEV). Fiber optic connections from the Launch Control to the Vehicle Interface consoles
are used for efficient, high bandwidth communications, eliminating the need for copper wire between
locations. The Vehicle Interface consoles provide the junction from fiber optic cables to the cables that
directly interface with the vehicle. Figure 2.4-1 depicts the functional block diagram of the LSE. All
Minotaur EGSE is compliant with the Department of Defense Instruction 8510.01, DoD Information
Assurance Certification and Accreditation Process (DIACAP). Some launch sites have a separate
Support Equipment Building (SEB) that can accommodate additional payload equipment.

The LCR serves as the control center during the launch countdown. The number of personnel that can be
accommodated is 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 payload consoles and equipment can
be supported in the LCR and payload equipment at the launch pad can be supported in the LEV or SEB,
if available, within the constraints of the launch site facilities. Interface to the payload through the
Minotaur I payload umbilicals provides the capability for direct monitoring of payload functions. Payload
personnel accommodations will be handled on a mission-specific basis.

All of the Mechanical Ground Support Equipment (MGSE) used to support the Minotaur integration, test
and launch is currently in use and launch demonstrated. MGSE fully supports all Minotaur configurations
and are routinely static load tested to safety factors in compliance with Orbital internal and Range
requirements.

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Figure 2.4-1. Minotaur I EGSE Configuration

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3. GENERAL PERFORMANCE

3.1. Mission Profiles

Minotaur I 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 I launch system. A generic mission profile
to a sun-synchronous orbit is shown in Figure 3.1-1. All performance parameters presented within this
User’s Guide are typical for most expected payloads. However, performance may vary depending on
unique payload or mission characteristics. Specific requirements for a particular mission must be
coordinated with OSP. Once a mission is formally initiated, the requirements will be documented in the
Mission Requirements Document (MRD). The MRD is the requirement kick off document that initiates the
contractual agreement and flows the payload requirements to Orbital. The MRD establishes the data
required to begin formal trajectory analysis as well as Coupled Loads Analyses (CLAs). Further detail will
be captured in the Payload-to-Launch Vehicle Interface Control Document (ICD).

Figure 3.1-1. Minotaur I Generic Mission Profile

3.2. Launch Sites

Depending on the specific mission, Minotaur I can operate from East and West Coast launch sites as
illustrated in Figure 3.2-1. The corresponding range inclination capabilities are shown in Figure 3.2-2.
Specific performance parameters are presented in Section 3.3. The baseline launch site for Minotaur I is
VAFB.

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Figure 3.2-1. Flexible Processing and Portable GSE Allows Operations from Multiple Ranges or

Austere Site Options

Figure 3.2-2. Launch Site Inclinations

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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, as shown in Figure 3.2-2. Inclinations below 72° from VAFB are possible,
but require an out-of-plane dogleg, thereby reducing payload capability. Minotaur I is nominally 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,
including past launches of Minotaur IV.

3.2.2. Eastern Launch Sites

For easterly launch azimuths to achieve orbital inclinations between 28.5° and 55°, launches can be
conducted from facilities at Cape Canaveral Air Force Station, FL (CCAFS) or Wallops Island, VA (WFF).
Launches from Florida will nominally use the Space Florida launch facilities at LC-46 on CCAFS. Typical
inclinations are from 28.5° to 50°; however, higher inclination trajectories may be accommodated by using
northerly ascent trajectories. These would need to consider the potential of European overflight and
require range safety assessment. The Mid-Atlantic Regional Spaceport (MARS) facilities at the WFF may
be used for inclinations from 37.8° to 55°. Some inclinations and/or altitudes 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 I 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 for launch operations as
an unpriced option. The mobile equivalent of the LCR is the Launch Support Van (LSV), and the mobile
LEV is the Launch Equipment Van.

3.3. Performance Capability

Minotaur I performance curves for circular orbits of various altitudes and inclinations are detailed in Figure

3.3-1 through Figure 3.3-8 for launches from all four Spaceports in metric and English units. These
performance curves provide the total mass above the standard, non-separating interface. The mass of
the separation system and any Payload Attach Fitting (PAF) that is attached to the 38.81” interface, is to
be accounted for in the payload mass allocation. Table 3.3-1 shows a number of common options and the
mass associated with each.

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Table 3.3-1. Common Mission Options and Associated Masses

(These Masses Must Be Subtracted from the LV Performance)

Option

Total Mass (kg)

(These Masses Must Be

Subtracted from the LV

Performance)

Portion of Total Mass

That Remains with SV

Post Separation (kg)

Enhanced Telemetry 9.85 0

TDRSS 8.54 0

38” Orbital Separation System1 12.24 4.0

38” RUAG Low Shock Separation System (937S)1 19.89 6.16

38” Lightband1 8.85 2.52

38” Softride and Ring2 9 to 18 0

Notes:

1. For more information on these separation system options, refer to Table 5.2.5-1.

2. A range is provided for the softride option; actual mass is based on payload requirements.

Figure 3.3-1. Minotaur I Performance Curves for VAFB Launches

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Figure 3.3-2. Minotaur I Performance Curves for KLC Launches

Figure 3.3-3. Minotaur I Performance Curves for CCAFS Launches

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Figure 3.3-4. Minotaur I Performance Curves for WFF Launches

Figure 3.3-5. Minotaur I with 61” Fairing Performance Curves for VAFB Launches

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Figure 3.3-6. Minotaur I with 61” Fairing Performance Curves for KLC Launches

Figure 3.3-7. Minotaur I with 61” Fairing Performance Curves for CCAFS Launches

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