Payload Users Guide

Falcon Launch Vehicle

Rev. 2 October 2004
 Payload Users Guide
Falcon Launch Vehicle

1. Introduction
The Company

Space Exploration Technologies (SpaceX) is developing a family of launch vehicles intended to

reduce the cost and increase the reliability of access to space ultimately by a factor of ten. The
company officially began operations in June 2002 and is located in the heart of the aerospace
industry in Southern California. The SpaceX technical staff was drawn from the top ranks of
leading aerospace firms, all with the common belief that a much better launch vehicle solution
could be built.

The Launch Vehicle

Our initial product, the Falcon I, is a mostly reusable, two stage, liquid oxygen and rocket grade
kerosene powered launch vehicle. The first stage is turbo-pump fed with high mass efficiency
monocoque aluminum tanks that use pressure assisted stabilization in flight. It is almost entirely
reusable and returns via parachute to a water landing.

The upper stage is pressure fed and constructed of the highest strength to weight aluminum-
lithium alloy available – the same material as used in the ‘super lightweight’ version of the Shuttle
external tank. It is capable of multiple restarts on orbit, limited only by onboard propellant.

Lift-off weight for the standard Falcon is approximately 27,000kg (60,000 lbs), length is just under
32m (70 ft) and diameter is 2.5m (5.5 ft). Note: A larger vehicle, Falcon V, will be available
starting in the fourth quarter of 2005 with 10,000 lb capability to the standard reference orbit. A
Falcon V User’s Guide will be available in late 2004.

Falcon is designed to achieve substantial improvements in reliability, cost and flight environment,
in that order of importance.

Why do we believe Falcon is a high reliability design?

The vast majority of launch vehicle failures in the past two decades can be attributed to three
causes: engine, avionics and stage separation failures. An analysis by Aerospace Corporation1
showed that 91% of known failures can be attributed to those subsystems.

It was with this in mind that we designed Falcon to have the minimum number of engines and
separation events. As a result, there is only one engine per stage and only one stage separation
event – the minimum pragmatically possible number. Moreover, the vehicle is not released until
the first stage engine is confirmed to be operating normally, allowing a safe shut-down if any off
nominal conditions occur.

Unlike most small launch vehicles, Falcon also has fully redundant flight computers and inertial
navigation, with a GPS overlay for additional orbit insertion accuracy. We have gone the extra

1
http://www.aero.org/publications/crosslink/winter2001/03.html
mile in building a first class avionics system in order to have minimal changes when we use this
system in our large vehicle development following Falcon I.

Cost and Operations

Our price per launch for the standard Falcon, which is the same for all customers, is set at $5.9
million (2004 dollars) plus range launch fees that vary by location. The only discounts offered are
for multi-launch contracts. Moreover, our goal is to make pre-launch operations as simple and
painless for you as possible. Your satellite needs to be brought to the launch site only 2 weeks
prior to launch and SpaceX provides clean room facilities for non-hazardous processing at no
charge.

Once the satellite arrives at the launch site, attachment and fairing encapsulation can be
completed in less than 24 hours.

Flight Environment

Most of a satellite’s design and a great deal of the weight are driven by the launch loads
experienced in the first ten minutes of its life. After separation, the satellite spends the rest of its
time in microgravity and does not experience such loads again during its useful life.

We have worked hard to minimize those launch loads, so that vibration and acoustic
environments are better than any other available launch vehicle. The fact that Falcon uses no
solid fuel boosters, has low thrust levels and a low thrust to weight all contribute to this.
2. Launch Vehicle Performance

Falcon is capable of delivering approximately 670 kg (1480 lb) payload into a reference low Earth
orbit with 200 km circular altitude, when launched due east from Cape Canaveral. With increasing
altitude, a two-impulse insertion provides more payload capability by inserting into a lower,
slightly eccentric orbit and performing a circularization burn at apogee. The following graphs show
performance for both types of orbit insertion (Figure 2.1, Figures 2.2) for a range of circular orbit
altitudes.

Launch from Vandenberg into Sun-Synchronous Orbit

600
Direct Insertion
Two Impulse Insertion 1200

500

1000

400
Payload (kg)

Payload (lb)
800

300
600

200
400

Rev. K SB150 8/5/03

100
200 300 400 500 600 700 800
Circular Orbit Altitude (km)

Figure 2.1 Falcon performance from the Western Range

 Launch from Cape Canaveral due East
700
Direct Insertion 1500
650 Two Impulse Insertion
1400
600
1300

550 1200

500 1100
Payload (kg)

Payload (lb)
450 1000

400 900

800
350
700
300
600
250
Rev. K SB150 8/4/03 500
200
200 300 400 500 600 700 800
Circular Orbit Altitude (km)

Figures 2.2 Performance from the Eastern Range to 28.5 °

For orbit inclinations other than provided above, certain azimuth limitations have to be taken into
account. The azimuth limits depend on the type of payload and orbit; Figure 2.3 shows the
payload performance as a function of inclination and circular orbit altitude for typical azimuth
limitations.
 Launch from Vandenberg into Circular Orbit
600
200 km 1300
500 km
Launch Azimuth Constraint 700 km

550
1200

500 1100
Payload (kg)

Payload (lb)
1000
450

900
400

800
Rev K SB 150 12/17/03
350
60 70 80 90 100 110 120
Inclination (deg)

Figure 2.3: Circular orbit performance from Western Range as a function of orbit
inclination

As a liquid vehicle, Falcon provides flexibility required for payload insertion into orbit with higher
eccentricity deploying multiple payloads into slightly different orbits. Target orbital insertion
accuracy is currently determined as follows:
• inclination +/- 0.1 deg
• perigee +/- 10 km
• apogee +/- 20 km

As for every new vehicle, insertion accuracy has to be verified during the first flights. The current
estimates are expected to improve since Falcon uses a GPS system for guidance correction.

Falcon can accommodate payloads with the following mass properties:

Characteristic Value
Mass Up to 1500 lbs
CG offset From centerline From separation plane
See Figure 2.4 See Figure 2.5
Stiffness Axial Lateral
> 25 Hz > 25 Hz
 Payload Lateral CG Offset

2.5
CG Lateral Centerline Offset

1.5
(in)

0.5

0
0 200 400 600 800 1000 1200 1400 1600
Payload We ight (lb)

Figure 2.4 Allowable Cg offset from Centerline

Axial CG Distance from Separation Ring

120

100
CG Axial Distance (in)

80

60

40

20

0
0 200 400 600 800 1000 1200 1400 1600
Payload Weight (lb)

Figure 2.5 Allowable Cg offset from Separation Plane

3. Launch Vehicle to Payload Interfaces

The Falcon coordinate system is shown in Figure 3.1

Figure 3.1 Launch vehicle coordinate system

Mechanical
Falcon baselines the Lightband separation system. SpaceX will provide the payload half of the
interface (this in not counted against the payload mass in performance curves) to the payload
provider. A drawing of the mechanical interface is shown in Figure 3.2. Figure 3.3 shows the
dynamic envelope for the Falcon fairing.
Figure 3.2 Falcon Mechanical Interface
Figure 3.3 Falcon Dynamic Envelope
The launch vehicle will provide a signal to the payload at separation to initiate payload power-up.
Alternate configurations for separation signals (break-wires, separation switches monitored
directly by the payload, or other configurations) can be negotiated as an option.

An access door is included in the fairing for contingency purposes only. Under nominal operating
conditions, all processing that requires access to the payload must be completed prior to fairing
installation. Payloads with consumables must include an on-pad de-tanking capability, which
must be accomplished through the fairing access door. The location of the fairing access door
can be modified, as an option, to allow access for payload de-tanking.

A GN2 purge is an optional service. The method for providing the purge (through a door in the
fairing or across the payload separation system interface) will be worked as part of the service.
Electrical

The electrical interface for Ground and Flight operations is shown in Figure 3.4. It is preferred that
the satellite is switched OFF during launch; if the satellite is on, it may not transmit and special
precautions with respect to interference have to be taken. Note that the distance between Mission
Control and the vehicle is significant and that the Ethernet data line is the only connection
between Mission Control and the launch pad.

Falcon Electrical Interface to Payload

Mission
Control Falcon Vehicle
Upper Stage Satellite
Mission Control
Flight 4 Relay Commands
Computer (Config.)
Relay Board
Router
2 Digital I/O

Telemetry Option: RS 422 or 232

< 34800 baud

Ethernet LAN 10 Mb/s

15 Pass Through
(AWG 22 < 3 amp)

Test Connector to Breakwire

the spacecraft for
checkout and
battery charging

Pad Computer
Relay Board
(4 Relays) Notes:
- 4 Relay Commands can be configured as
pyrotechnic initiation. The power for
pyrotechnic initiation originates from the
Falcon vehicle (5 Amp 25 msec)
- The serial RS 422/232 option allows only
Launchpad J-Box downlink; for uplink, use the faster Ethernet
on the ground.
- 15 Pass through can be extended to 50
upon request as an optional service

Space Exploration Proprietary (HJK)

Figure 3.4 Falcon electrical interface to the payload

The electrical interface provides all flexibility on the ground through Ethernet, not hardwire. The
Ethernet is a shared resource, and the payload should therefore not saturate the network. For
remote control of battery chargers located at the launch pad and other ground equipment, up to 4
relays are available with a maximum load of 3 Amps at 28 V, through the pad computer.

As a standard service, 15 pass-through connections with a capacity of up to 3 amps are available

between the launch pad and the integrated payload.

As a standard service during the flight, 4 relay commands and 2 uni-directional (configurable)
digital TTL signals are available. The user provides Space Exploration Technologies with a
sequence description if and how these commands are being used, including the direction of the
digital signal (payload to Launch Vehicle or vice versa). If pyrotechnics are initiated through the
relay commands, vehicle power is being used to provide adequate inhibits.

A break wire is mounted on the payload side of the connector; if desired, a separation switch can
be provided for the payload. As an option, a telemetry serial data stream is available for the
payload with up to 34800 baud. Data reception depends on ground station visibility during ascent
and might not be reliable for certain orbits as the vehicle approaches the horizon.

With the standard interface, two connectors are used between Falcon and the payload,
configured as follows (Table 3.1):

Table 3.1 Connector pin identification

Connector/Pin Designation AWG

A1 Relay 1 22
A2 Relay 2 22
A3 Relay 3 22
A4 Relay 4 22
A5 Relay GND 22
A6 Digital 1 22
A7 Digital 2 22
A8 Digital GND 22
A9 TX+ 22
A10 TX- 22
A11 RX+ 22
A12 RX- 22
A13 Breakwire + 22
A14 Breakwire Return 22
A15 Spare 22
B1 User Configurable (to Pad) 22
B2 User Configurable (to Pad) 22
B3 User Configurable (to Pad) 22
B4 User Configurable (to Pad) 22
B5 User Configurable (to Pad) 22
B6 User Configurable (to Pad) 22
B7 User Configurable (to Pad) 22
B8 User Configurable (to Pad) 22
B9 User Configurable (to Pad) 22
B10 User Configurable (to Pad) 22
B11 User Configurable (to Pad) 22
B12 User Configurable (to Pad) 22
B13 User Configurable (to Pad) 22
B14 User Configurable (to Pad) 22
B15 User Configurable (to Pad) 22

Grounding

The satellite mounting interface must be conductive. The electrical resistance will be verified prior
to the assembly of the Payload on the separation system.
4.0 Facilities
SpaceX has launch facilities at Space Launch Complex 3W at Vandenberg Air Force base for
high inclination missions, Launch Complex 46 at Cape Canaveral Air Force Station for mid
inclination missions, and the Reagan Test Site on the Kwajalein Atoll for very low inclination
missions.

Facilities for Payload Preparation

The Space Exploration Technologies Payload processing facility will be made available for non-
hazardous Payload operations for up to 3 weeks prior to launch from each of our sites. If
additional time is needed, then the Payload must procure a processing facility independently.

The payload processing room at SLC 3W (Figure 4.1) consists of 1200 square feet of floor space.
The processing room consists of a high bay 60 ft long, 20 ft wide, 20 ft high. Personnel access
doors provide access to the processing room from the launch vehicle/payload checkout control
room. The outside cargo entrance door is 16 ft wide by 16 ft high which leads into a 20 ft wide,
20 ft long, 20 ft high anti-room. A bridge crane with an 18 ft hook height and 5 ton capacity is
available for handling spacecraft and associated equipment. The processing room provides a
class 100,000 laminar flow cleanroom 40 ft long, 20 ft wide, 20 ft high. Temperature of 60° - 80°
F ± 2° (controlled) and humidity 30% - 60% (monitored only) with a differential pressure of .05
inches of water minimum with all doors and pass-throughs closed.

The Payload processing facilities will be consists of a common work area (anti-room) and the
clean room bay. The common work area of the processing facility is dedicated for spacecraft
ground support equipment unloading, unpacking/packing and intermediate storage of empty
cargo container. The working area shall be equipped with a crane to lift the Payload onto the
adapter.

SpaceX will monitor relative humidity, temperature and cleanliness in the payload processing
facility. This is true with the exception of periods when the satellite is mated to the launcher
second stage. Monitoring data will be made available to the payload customer. In order to ensure
this, satellite preparation will be performed using clean processes.

The processing facility has the following characteristics:

„ Smooth, continuous floor surface (anti-static)
„ Illumination equals 300 Lux (with localized capability up to 1000 Lux)
„ Uninterrupted power supply for satellite control and test equipment
„ Fire protection
„ Emergency exit and illumination
„ Controlled access and security
Figure 4.1 Space Exploration Technologies SLC 3W payload processing facility
layout
Service and Equipment
The services and equipment provided for satellite processing in the clean area are shown in
Table 4.1.

Table 4.1 Services and equipment for satellite processing

Constraints User provided support

• No installed GN2 or GHe systems • GN2 and He pressure carts
• Non-hazardous processing only • Electrical interfaces to processing area

Capability type Capability

Space/access Design Floor Loading:
- 100 psf on checkout floor cell
- 75 psf plus a 4000 load on four casters
Work space 20 ft by 20 ft
Cell door opening 16 ft wide, 16 ft high
Adjacent to launch vehicle and control rooms

Handling 5-ton overhead bridge crane

Hook height:
- 16 ft

Speeds
- Hoist 10 fpm
- Bridge N/S 10 fpm
- Trolley E/W 5 fpm

Micro Drive
- Hoist 0.5 fpm
- Bridge 0.5 fpm
- Trolley 0.5 fpm
Electrical Utility and Technical Power 120/208, 408 VAC
Multipoint grounding per MIL-STD-1542
Liquids Cleaning water supply
- 50 gpm at 80 psig
- 1 inch hose bib with 1 inch male thread
Pneumatics Compressed air at 125 psi
3/8 inch QD’s at 2 locations in processing room
Environment 100,000 clean room capability
- Temp 60° - 80° F ± 2° (controlled)
- RH 30% - 60% (monitored only)

Safety All electrical equipment is hazard-proof as defined in the National Electrical Code
Fire detection and suppression system

Security Access control

- KeyCard/cipher system
- Intrusion detection system
- Lockable personnel doors
Communications Administrative phone
Area Warning System
Paging System
Electrical Power Supply
The electrical power supplied in the payload processing area is shown in Table 4.1. Customer
shall provide the necessary cables to interface GSE to payload processing room power.
Customer shall state power requirements in the payload to launcher interface control document.

Fueling—no fueling or other hazardous operation can be performed in the SpaceX payload
processing area. Please contact Astrotech, Spaceport Systems International, or another facility
provider if such services are required.

Administrative & Payload Monitoring and Control Space

Near the payload processing facility, one office area will be provided that contains two desks
(approximately 2 ft by 3.5 ft), four office chairs, one class A telephone line, and high speed
internet connectivity (via a commercial source). Fax service is available in the nearby SpaceX
office. Portable units will supply sanitation needs for both SpaceX and payload support personnel
at the launch pad. Payload support personnel are welcome to share small amounts of
refrigerator space, coffee machines, microwaves, and other conveniences that may be available.

For monitoring of spacecraft telemetry during test and launch operations, one console is provided
for the payload customer in the SpaceX command van, and stations for up to five other payload
support personnel will be available either in the payload processing area or in other facilities
(during launch ops). These additional stations will consist of a connection to the SpaceX
telemetry server – payload customers should bring computers for these stations (PC systems).
All stations will be able to monitor any telemetry received through the Falcon vehicle telemetry
stream or via the payload Ethernet connection. Currently, two stations in off pad locations will
include communications consoles, as will the console in the Command Van. Any commanding of
the spacecraft that is required during launch operations (if available) will have to be physically
implemented by the SpaceX launch controller, but is authorized only by the payload customer.
5. Payload Integration and Flight Profile
Falcon missions and associated operations have been designed for minimal complexity and
minimal time at the pad. The payload will be integrated horizontally to the launcher
approximately 4 days prior to launch. Once integrated, the vehicle is moved to the pad and is
erected using the Falcon transporter. Final system close-out, fueling and testing is then
completed. Twenty four hours prior to launch, the launch readiness review is held. Once the
launch approval is given, the 24 hour countdown begins. The flight profile is shown in Figure 5.1.

Figure 5.1 Falcon sample flight profile—direct injection

Payload Integration
Payload arrival is expected not more than 3 weeks prior to flight. During this time, SpaceX
provides a payload processing facility for non hazardous operations only. Top level summary of
the launch site operations is described below. Note that during hazardous operations, the pad
(including the payload processing facility) must be cleared of personnel.

Note that if hazardous operations or longer payload processing time is required, a separate
facility must be procured by the customer.

At approximately launch minus 4 days, the integration process begins and includes the following:

• Payload is vertically integrated with payload fairing and encapsulated in the payload
processing facility.
 • The encapsulated payload is then driven to the launch deck
• Payload is rotated horizontally and prepared for integration to booster.
• Encapsulated payload and booster are integrated by lifting the payload and placing it on
the mobile erector forward platform.
• Payload is then positioned and mated to the booster.
• Umbilical connections are made
• Booster umbilical connections are made in the horizontal position
• Payload and booster are erected as a single unit
• Final connections and installations are completed

Figure 5.2 Operations with launch vehicle and payload in mobile erector

Once Falcon is launched it follows the profile described in Figure 5.1. Note this profile will vary
for various trajectories. For direct injected missions, payload separation occurs at approximately
570 seconds. For two burn missions, the payload is released approximately 3270 seconds into
the mission.

Payload Separation

Payload separation is a timed event referenced to the second stage burnout. A command is sent
initiating the Lightband system. Separation is initiated non-explosively. Separation springs then
impart separation velocity. The system maintains tip off rates below 1 degree per second. Once
the two halves of the system separate, a signal is sent to the payload using either a Breakwire or
Microswitch. If the payload desires, it can be spun at separation up to approximately 6 RPM.

Almost any attitude can be accommodated at separation. However, it may take up to 10 minutes
to obtain some attitudes prior to separation. The second stage attitude and rate accuracies at
separation are:

„ Roll +/- 2 degrees

„ Pitch/Yaw +/- 0.5 degrees
„ Body rates +/- 0.1 deg/sec/axis

Collision Avoidance

Ten seconds post separation, Falcon performs a collision avoidance maneuver using the heated
helium pressurant and the RCS thrusters. The thrusters are positioned to minimize gas
impingement on the spacecraft yet still provide adequate separation.
6.0 Payload Environments
This section provides details on the maximum predicted environments (MPE) the payload will
experience during Falcon ground ops, integration, flight, and initial orbital operations. The
environmental design and test criteria presented here have been calculated using the most
sophisticated and accurate methods available and, where possible, have been correlated and
scaled with data from vehicles with similar engine types, materials, construction, and size.
Because all data is mostly calculation based and in the process of being verified through ground
testing, appropriate margins are added and indicted (additional margins over those presented
here are not recommended but up to user discretion).

Falcon was designed to have the most benign payload environments possible to reduce interface
complexity and risk. The vehicle is all liquid with a single staging event, low thrust to weight, and
low dynamic pressure flight. In addition, a low shock (non pyrotechnic) separation system and a
vibration + shock damping and isolation system is baselined at the payload interface. The
environments presented here are intended to reflect typical mission levels; mission specific
analyses are to be performed and documented in the ICD per payload needs. Specific individual
environments are defined in the following sections.

Throughout pre-flight and flight operations various environmental contributions become more or
less important. Certain events, such as pyrotechnic firings and stage burnout, add specific quasi-
static or dynamic loads for specified durations which may or may not need to be added to other
environments experienced at the same time. Table 6.1 below specifies the relative periods of
loading events and detailed information about specific loads can be found in subsequent
sections. Because Falcon is a new vehicle, these environments will be updated as new data
becomes available.

Table 6.1: Summary of environmental conditions at various flight events.

Flight Event Typical Flight Steady / Quasi- Transient or Acoustic Loads Random
Time (s) Static Loading Shock Loads Vibration
Liftoff 0-5 Low Yes Yes Yes
Subsonic 5-50 Yes Low Very Low Low
Transonic 50-65 Yes Yes Low Low
Max q 65-80 Yes Yes Yes Yes
Stage I Burnout 170 Yes Yes Low Low
Stage Separation 172 Low Yes Very Low Low
Stage II Burn 174-540 Yes Low No Low
Stage II Burnout 542 Yes Low No Very Low
Payload Separation 560 Yes Yes No No

Quasi-Static Loads

During flight, payload will experience a range of axial and lateral acceleration. Axial acceleration
is determined by the vehicle thrust history and drag, while max. lateral accelerations are primarily
determined by wind gusts, engine gimbal maneuvers, and other short-duration events.
Conservative loads used for payload design are summarized in table 6.2 and axial acceleration
vs. time is plotted in Figure 6.1 for a nominal trajectory. Mission specific loads will be determined
approximately four months prior to launch with the coupled loads analysis (including specific
trajectory details and payload mass properties). These results should only be used to validate
that the design loads envelope the mission specific loads.
Table 6.2: Summary of payload design C.G. limit load factors for nominal Falcon

Quasi-static Load Factors

Axial (g): Steady ± Dynamic (Total) Lateral (g)
Flight Event
Ground Handling 0.5 2.0
Lift Off 1.2 ± 0.4 (0.8 / 1.6) 0.50
Max qα 2.0 ± 1.0 (3.0 / 1.0) 0.75
Stage I burnout 6.4 ± 1.25 (7.7 / 5.2) 0.75
Stage II Ignition 3.2±.25 (3.0/3.4)* to 6.0±.25 (5.75/6.25)* 0.25
Stage II burnout 4.5 ± 0.5 (5.0 / 4.0)* to 6.5 ± 0.5 (7.0 / 6.0)* 0.25

*Payload weight and trajectory dependent. Please contact SpaceX for further details.

Axial Acceleration v Time

7.00

6.00

5.00
Acceleration (g )

4.00

3.00

2.00

1.00

0.00
0 100 200 300 400 500 600
Time (s)

Figure 6.1 Nominal steady state axial acceleration time history for Falcon.

Random Vibration Environment

The payload vibration environment is generated by acoustic noise in the fairing and also by
engine and aero-induced vibration that is transmitted through the vehicle structure. Because
random vibration is very difficult to predict analytically, preliminary Falcon environment was
calculated using empirical correlations coupled with scaling data from vehicles of similar size
(physical and thrust), materials, and construction. The generation and transmission of random
vibrations scales closely with the acoustic power generation of the engine, the materials
comprising the skin, tanks, and fairing, and the type of joints used respectively. Based on this
analysis, Falcon’s random vibration Maximum Predicted Environment is shown below in Figure
6.2. Note that these values include appropriate margins due to uncertainty and that this data will
be continuously refined as additional engine tests are performed. The corner frequencies and
slope values are summarized in table 6.3.

Table 6.3. Summary of random vibration PSD values.

Frequency (Hz) PSD (g2/Hz) Frequency Range (Hz) PSD Slope

20 0.0043 0 – 20 0
100 0.020 20-100 +3 dB/oct
800 0.020 100-800 0
2000 0.0019 800-2000 -9 dB/oct

Predicted Random Vibration Level

-2
10
PSD (g /Hz)
2

grms = 5.3

-3
10
1 2 3
10 10 10
Frequency (Hz)

Figure 6.2 Falcon random vibration spectra

Shock Environment

There a four events during flight that are characterized as shock loads: 1) vehicle hold-down
release at lift-off, 2) stage separation, 3) fairing separation, and 4) payload separation. The
baseline separation system for Falcon is the Lightband® motorized ring system, which provides a
very low shock load (negligible compared pyrotechnic events). Data from Lightband is shown in
Figure 6.3.a (shock response spectrum (SRS)) below with a typical pyrotechnic shock spectrum
shown for reference. Of the other shock events, (1) and (2) are negligible for the payload relative
to (3) due to the large distance and number of joints over which shocks (1) and (2) will travel and
dissipate. Max shock loading (3) is modeled using by assuming an initial SRS given by the
typical pyrotechnic curve in Figure 6.3.a and scaling down via standard correlations based on
distance from source and joints. The resulting max. shock environment predicted at payload
interface is shown in Figure 6.3.b.

It should be noted that vibration test data of the Lightband system suggests very low response at
the high frequencies associated with shock events which will likely add considerable attenuation
to any shock acceleration loads. In addition, a damping and isolation system is being design at
the payload interface which will further reduce any shock loads. These systems are not modeled
here and hence the SRS presented should be treated as very conservative.

4
Shock Response Spectrum at Payload Interface
10

Reference Pyrotechnic

Maximum Acceleration (g)

3
10

Payload Interface

2
10
2 3 4
10 10 10
Frequency (Hz)

Figures 6.3 a & b Falcon shock response at separation plane due to payload
separation system and other ordnance events

Acoustic Environment
During flight, the payload will be subjected to a varying acoustic environment. Levels are highest
at lift off and during transonic flight due to aerodynamic excitation. Falcon will make use of
acoustic blanketing to reduce the acoustic environment and a nominal (minimal) 2” thick blanket
configuration is assumed for predicted environment. Spectral energy methods were used to
predict worst-case acoustic environment below. A 1.5 dB margin is typically added for
qualification and a 3 dB margin is typically added for testing, but this is left to the discretion of the
user. A summary of acoustic MPE is shown in Table 6.4 and plotted in Figure 6.4.
Table 6.4. Summary of Falcon payload acoustic environment assuming nominal 2”
acoustic blankets.

1/3 Octave Frequency (Hz) SPL (dB) 1/3 Octave Frequency (Hz) SPL (dB)

20.0 104 1000 112

25.0 107 1250 107
31.5 110 1600 104
40.0 113 2000 102
50.0 115 2500 101
63.0 117 3150 100
80.0 119 4000 101
100 120 5000 101
125 121 6300 100
160 122 8000 100
200 122 10000 100
250 122
315 121
400 119 OASPL 131
500 117
630 115
800 115

Falcon Predicted Acoustic Environment

125

120
1/3 Octave SPL (dB)

115

110

105

100

95
10 100 1000 10000
1/3 Octave Frequency (Hz)

Figure 6.4. SPL spectrum for Falcon assuming 2” acoustic blankets.

RF Environment
Payload customers must ensure that spacecraft materials or components sensitive to an RF
environment are compatible with both the launch pad environment and the RF environment
during flight.

Vandenberg AFB guarantees an RF environment not greater than 24.2 dbm (pulsed) at SLC-3W.
This environment could be experienced by the payload during transport to the launch site and
during spacecraft preparations and integration with the adaptor and fairing. When the spacecraft
and launch vehicle are vertical on the pad, the fairing will attenuate most of the RF environment.
The RF environment at our other sites are expected to be similar.

The Falcon fairing attenuates the launch vehicle transmissions during launch pad operations and
flight, up to fairing separation. After fairing separation, the C-band transmissions will not exceed
3.38 dbm (pulsed) at the CG of the fairing. The S-band transmissions at this time will not exceed
-4.87 dbm (continuous) at the CG of the fairing.

Table 6.5. Summary of transmitter RF characteristics.

Transmitter 1 Transmitter 2 Transmitter 3

Characteristics Characteristics Characteristics
Transmitter Telemetry Video Xponder

Nominal frequency S Band S Band C Band

Power output 10 W (40 dbm) 10 W (40 dbm) 400 W (56 dbm)

Humidity, Cleanliness and Thermal Control

Relative humidity will be controlled to 40-60%. The payload will be exposed to thermal
environments and cleanliness levels for the various mission phases summarized in table 6.7.
Table 6.6. Summary of thermal and humidity environments.

Location Temperature Cleanliness Level Humidity Level

Heating Level
Clean room Customer desired with a 100K 30-60 % Condensation
of water inside the
range of 60° - 80° F ± 2°
Payload compartment
will not occur.
Encapsulated Air purge at payload Visibly clean 30-60 %
during transport desired temperature Condensation of water
between 60° - 80° F ± 2° inside the Payload
compartment will not
occur.
Encapsulated Air purge at payload Visibly clean 30-60 % Condensation
and stacked desired temperature Filtered (3-5 micron) of water inside the
between 60° - 80° F ± 2° purified air purge Payload compartment
Positive pressure will keep will not occur.
fairing environment clean.
Launch Radiated environment: 15- Positive pressure will keep N/A
150° C TBD fairing environment clean
Conducted environment:
15-150° C TBD
Time history will be
provided.
Fairing separated when N/A N/A
aero-thermal heating is
less than 1135 W/m2

Flight Pressure Profile

The fairing flight pressure profile is defined in the Figure 6.5

W orst Case Pressure and Pressure Rates Inside the Fairing

15 0
Depressurization Rate (psi/sec)

10 -0.1
Pressure (psi)

5 -0.2

Rev K vb002
0 -0.3
0 20 40 60 80 100 120 140 160 180
Time since Lift-Off (sec)

Figure 6.5 Depressurization environment and depressurization rates

7. The Integration Process & Schedule

The standard launch integration process consists of the following:

• Contract signing and authority to proceed (Launch – 8 months or more)

o Estimated Payload mass, volume, mission, operations and interface
requirements
o Safety information (Safety Program Plan; Design information: battery, ordnance,
propellants; and operations)
o Mission analysis summary provided to the Customer within 30 days of contract

• Final payload design, including: mass, volume, structural characteristics, mission,

operations, and interface requirements (Launch – 6 months)
o Payload to provide test verified structural dynamic model

• Payload readiness review for Range Safety (Launch – 4 months)

o Launch site operations plan
o Hazard analyses

• Verification (Launch – 3 months)

o Review of Payload test data verifying compatibility with Falcon environments
o Coupled Payload and Falcon loads analysis completed
o Confirm Payload interfaces as built are compatible with Falcon
o Mission safety approval

• Pre-shipment review (Launch -1 month)

• Payload arrival at launch location (Launch – 2 weeks)

• Payload encapsulation (Launch – 3 days)

• Payload stacking (Launch – 2 days)

• Launch readiness Review (Launch – 1 day); Launch

User Documentation Requirements

The payload customer is responsible for generating their own range safety, range, and FAA
documentation. SpaceX will facilitate the required discussions, however and will coordinate
submittals with the appropriate organizations. At a minimum, the following documents must be
provided:

• Program introduction to the Range

• Spacecraft design overview with graphics.
• Safety documentation including: hazard analyses and reports, vehicle break up models
(debris data) and detailed design and test information for all hazardous systems (batteries,
pressurized systems or other hazardous or safety critical materials, propellant data,
• Launch site operations plan and detailed procedures (note hazardous procedures must be
approved by range safety)
• Interface verification plan and report
• Application for a payload determination (for non US gov’t payloads only)
• Environmental statement

In addition to these documents, input is required to support development of the Interface Control
Document, launch countdown procedures, and the launch readiness review package.