CG-1152

REV B
SEP 2011

OPERATION AND MAINTENANCE MANUAL

for

GDST RAINBLOWERS

(SINGLE OR DUAL HEATER/BLOWER SYSTEMS)

General Dynamics SATCOM Technologies

3750 W. Loop 281
Longview, Texas 75604
 CAUTIONARY NOTICE
Although the manufacturer has attempted to detail in this manual all areas of
possible danger to personnel in connection with the use of this equipment, personnel
should use caution when installing, checking out, operating, and servicing this
equipment. Care should be taken to avoid electrical shock, whether the hazard is
caused by design or malfunction.

The manufacturer is specifically not liable for any damage or injury arising from the
technician's failure to follow the instructions contained in this manual or his failure to
exercise due care and caution in the installation, operation, checkout, and service of
this equipment.

PROPRIETARY NOTICE
All computer software, technical data, or other information pertaining to the
equipment covered by this manual is considered proprietary by GDST. Such
information is transmitted in this manual or related documents for the benefit of
GDST customers and is not to be disclosed to other parties verbally or in writing
without prior written approval of GDST. Additionally, this manual may not be
reproduced in whole or in part without written consent from GDST.

WARNING
THE CURRENTS AND VOLTAGES IN THIS EQUIPMENT ARE
DANGEROUS. PERSONNEL MUST AT ALL TIMES OBSERVE
SAFETY REGULATIONS.
 PLEASE READ THE FOLLOWING PRECAUTIONS

This manual is intended as a general guide for trained and qualified personnel who are
aware of the dangers of handling potentially hazardous electrical and electronic
circuits. This manual is not intended to contain a complete statement of all safety
precautions that should be observed by personnel in using this or other electronic
equipment.

The installation, operation, maintenance, and service of this equipment involves risks
both to personnel and equipment and must be performed only by qualified personnel
exercising due care. GDST shall not be responsible for injury or damage resulting from
improper procedures or from the use of improperly trained or inexperienced personnel
performing such tasks.

During installation and operation of this equipment, local building codes and fire
protection standards must be observed.

WARNING

ALWAYS DISCONNECT POWER BEFORE OPENING COVERS,

DOORS, ENCLOSURES, GATES, PANELS, OR SHIELDS.
ALWAYS USE GROUNDING STICKS AND SHORT OUT HIGH
VOLTAGE POINTS BEFORE SERVICING. NEVER MAKE
INTERNAL ADJUSTMENTS OR PERFORM MAINTENANCE OR
SERVICE WHEN ALONE OR FATIGUED.

Do not remove, short-circuit, or tamper with interlock switches on access covers,

doors, enclosures, gates, panels, or shields. Keep away from live circuits. Know your
equipment and don't take chances.

WARNING

IN CASE OF EMERGENCY BE SURE THAT POWER IS

DISCONNECTED.
 TABLE OF CONTENTS

TABLE OF CONTENTS

SECTION DESCRIPTION PAGE

1.0 INTRODUCTION
1.1 Scope ................................................................................ 1-1
1.2 Arrangement....................................................................... 1-1
1.3 System Configuration........................................................... 1-1
1.3.1 Blower Specifications ........................................................... 1-2
1.3.2 Operating Voltage................................................................ 1-2
1.3.3 Heater/Blower ..................................................................... 1-2
1.3.4 System Power Requirements................................................. 1-2
1.3.4.1 System Power Requirements (Single System) .......................... 1-2
1.3.4.2 System Power Requirements (Dual System) ............................ 1-3

2.0 REQUIRED EQUIPMENT SECTION

2.1 Tools And Test Equipment .................................................... 2-1

3.0 INSTALLATION
3.1 General .............................................................................. 3-1
3.2 Installation.......................................................................... 3-1
3.3 Preparation for Use .............................................................. 3-1
3.4 Preparation for Return Shipment ............................................ 3-1

4.0 OPERATION
4.1 General Operating Instructions............................................... 4-1
4.2 Theory of Operation ............................................................. 4-2
4.3 Controls and Indicators......................................................... 4-3
4.3.1 Rainblower Controller ........................................................... 4-3
4.3.2 Moisture Probe Control......................................................... 4-4

5.0 MAINTENANCE
5.1 Scope ................................................................................ 5-1
5.2 Operational Checkout........................................................... 5-1
5.2.1 System Operational Checkout Procedure................................. 5-1
5.3 Inspection and Preventive Maintenance .................................. 5-4
5.4 Troubleshooting .................................................................. 5-4
5.4.1 Air Pressure Switch Adjustment ............................................ 5-5
5.5 Repair and Replacement ....................................................... 5-6
5.6 System Spares .................................................................... 5-6

6.0 ENGINEERING DRAWINGS.................................................... 6-1

7.0 VENDOR INFORMATION

7.1 General .............................................................................. 7-1

i
 TABLE OF CONTENTS

LIST OF TABLES

1-1 Blower Specifications ........................................................... 1-2

4-1 Rainblower Controller Controls .............................................. 4-3
4-2 Moisture Probe Control Switch Functions................................ 4-4
5-1 Inspection and Preventive Maintenance .................................. 5-4
5-2 Troubleshooting .................................................................. 5-4

LIST OF FIGURES

4-1A Basic Rainblower System...................................................... 4-1

4-1B Basic Rainblower System (Skid Unit) ...................................... 4-2
4-2 Rainblower Controller ........................................................... 4-3
4-3 Moisture Probe.................................................................... 4-4

ii
 INTRODUCTION

1.0 INTRODUCTION
This manual includes the information required to operate and maintain the General
Dynamics SATCOM Technologies (GDST) Rainblower Systems.

1.1 Scope

The instructions and information contained is limited to that required for the
rainblower systems as provided by GDST. It does not include the operation or
maintenance of the antenna or other systems or components that interface to the
antenna.

1.2 Arrangement

Information is presented in seven sections, which are:

 Section 1.0 -Introduction and General Information: provides information about

the purpose, scope, contents, and use of the manual. Also includes warranty
information.

 Section 2.0 - Required Equipment: lists the special tools and test equipment
required to operate and maintain the rainblower system.

 Section 3.0 - Installation: instructions for installation of a rainblower system on

existing antennas, preparing the system for use, and preparation of component
parts for shipment.

 Section 4.0 - Operation: procedures for the proper operation of the rainblower
system. Also includes a general theory of operation.

 Section 5.0 - Maintenance Instructions: includes preventive maintenance,

inspection, troubleshooting, repair, and test procedures.

 Section 6.0 – Engineering Drawings: included are the drawings and diagrams
required for installing and maintaining the rainblower system.

 Section 7.0 -Vendor Information: includes various documentation supplied with

GDST purchased equipment.

1.3 System Configurations

Specifications for the rainblower systems are dependent on certain equipment used
in each model. The equipment used varies with the antenna configuration that the
system is installed on. The following paragraphs cover the major factors
determining the rainblower system configuration.

1-1
 INTRODUCTION

1.3.1 Blower Specifications

Different blowers are used in the systems designed for antennas operating in the C
and Ku-bands. Their specifications are listed in Table 1-1.

TABLE 1-1 BLOWER SPECIFICATIONS

FREQ FUJI BLOWER MAX. PRESS. FREE DELIVERY OPER TEMP THERMAL OPER
BAND MODEL (in H 2 O)3 FLOW PROTECTOR RESET
C-Band VFC404P 53 94 cfm 40°C 135±5°C 88±15°C
104°F 275±9°F 190±27°F
Ku-Band VFC304P 49 56 cfm 40°C 135±5°C 88±15°C
104°F 275±9°F 190±27°F

1.3.2 Operating Voltage

The rainblower system is designed for operation on either 120 VAC or 220 VAC,
dependent upon which controller and heater boxes are used. These components
are designed specifically for operation on one of these two voltages. Refer to the
rainblower installation drawings in Section 6.

1.3.3 Heater/ Blower

A rain blower can be ordered as a single Blower/Heater system. It is equipped with

one set of heater elements which warm the air and a blower that blows across the
feed window. The dual system has a set of two heaters & blowers.
Refer to the installation drawings in Section 6.

1.3.4 System Power Requirements

1.3.4.1 System Power Requirements (Single System)

Blower Ku-Band 1/2 HP, 120 VAC, 1 PHASE, 60 Hz., FLA 5.0
1/2 HP, 220 VAC, 1 PHASE, 50 Hz., FLA 2.7

C-Band 1 HP, 120 VAC, 1 PHASE, 60 Hz., FLA 8.6

1 HP, 220 VAC, 1 PHASE, 50 Hz., FLA 4.7

Heater 1000 WATTS, 120 VAC, 1 PHASE 8.3 Amps,

1000 WATTS, 220 VAC, 1 PHASE 4.5 Amps,

Standard systems consist of the appropriate blower and heater assembly. The
customer supplied power feeder normally should terminate at the hub mounted
controller. The recommended power feeder is 30 amp, 1 phase, 120 VAC, 60 Hz.,
2 wire plus ground or 20 amp, 1 phase, 220 VAC, 50 Hz., 2 wire plus ground
dependent upon available site voltage.

1-2
 INTRODUCTION

1.3.4.2 System Power Requirements (Dual System)

Blower Ku-Band 1/2 HP, 120 VAC, 1 PHASE, 60 Hz., FLA 5.0 (2 Ea)
1/2 HP, 220 VAC, 1 PHASE, 50 Hz., FLA 2.7 (2 Ea)

C-Band 1 HP, 120 VAC, 1 PHASE, 60 Hz., FLA 8.6 (2 Ea)

1 HP, 220 VAC, 1 PHASE, 50 Hz., FLA 4.7 (2 Ea)

Heater 1000 WATTS, 120 VAC, 1 PHASE 8.3 Amps, (2 Ea)

1000 WATTS, 220 VAC, 1 PHASE 4.5 Amps, (2 Ea)

The dual system consists of the two appropriate blowers and two heater
assemblies. The customer supplied power feeder normally should terminate at the
hub mounted controller. The recommended power feeder is 50 amp, 1 phase, 120
VAC, 60 Hz., 2 wire plus ground or 30 amp, 1 phase, 220 VAC, 50 Hz., 2 wire
plus ground dependent upon available site voltage.

1-3
 REQUIRED EQUIPMENT

2.0 REQUIRED EQUIPMENT

2.1 Tools and Test Equipment

Only common tools and a volt-ohm-ampere meter are required to maintain the
rainblower system.

2-1
 INSTALLATION

3.0 INSTALLATION

3.1 General

This section contains the instructions for installing the rainblower system to
existing antennas or removing and replacing components. The procedure for
preparing component parts for shipment to repair facilities is also included.

3.2 Installation

Refer to the installation drawings in Section 6 for installation instructions. Most

installations are provided with a factory assembly and a minimal field installation.

3.3 Preparation for Use

Prior to system operation after installation or replacement of electrical component

parts the wiring connections should be checked to confirm that they conform to
the wiring schematic shown on the installation drawing located in Section 6.
Particular care should be taken to confirm that the jumpers and the motor lead
wires are connected properly for the site voltage available.

3.4 Preparation for Return Shipment

Parts to be shipped should be packed in the original shipping containers if available.

If not available, package in a manner that will prevent damage to the part. Use
standard commercial practices for the mode of transportation to be used.

3-1
 OPERATIONS

4.0 OPERATIONS

4.1 General Operating Instructions

This section includes the basic theory of operation of the rainblower system as
shown in Figures 4-1A and 4-1B. The system is used to keep the antenna feed
window clear of moisture from precipitation. This prevents any significant
degrading of system performance during inclement weather.

4-1
 OPERATIONS

4.2 Theory of Operation

When the moisture probe senses precipitation it provides a contact closure to the
controller for any given temperature. When the moisture probe no longer senses
precipitation, the contact to the controller will open up after two minutes. The
moisture probe contains a switch that can be set to MANUAL or AUTOMATIC.
The MANUAL position is used for system testing, or operation if the automatic
mode fails. The AUTOMATIC position is used for normal operation. If left in the
MANUAL position for 40 hours the control will revert to AUTOMATIC.

When the controller receives the signal from the moisture probe it activates the
blower. The air from the blower is filtered and passes through the heater and air
duct tube to the nozzle, which vents the air across the feed window to keep the
window free of precipitation.

A pressure switch in the heater closes when it senses pressure in the air chamber
and sends a voltage signal to the controller, which then activates the heater.

4-2
 OPERATIONS

4.3 Controls and Indicators

4.3.1 Rainblower Controller

The controls of the rainblower controller are shown in Figure 4-2 and explained in
Table 4-1.

Figure 4-2. RAINBLOWER CONTROLLER

TABLE 4-1 RAINBLOWER CONTROLLER CONTROLS

CONTROL NAME TYPE POSITION USE
Power Circuit Breaker On Applies power to the rainblower system.
Off Removes power from the rainblower
system
Mode Select Switch Man Establishes manual control of the
rainblower
Off Disables the rainblower system
Auto Establishes automatic control of the system
(activated by moisture probe)

4-3
 OPERATIONS

4.3.2 Moisture Probe Control

Refer to Figure 4-3 for the location of the moisture control test switch. Table 4-2
on the following page describes the switch use.

Figure 4-3 MOISTURE PROBE

TABLE 4-2 MOISTURE PROBE CONTROL SWITCH FUNCTIONS

CONTROL NAME TYPE POSITION USE
Test Switch Switch AUTOMATIC Allows the probe to operate automatically
(react to rainfall)

STANDBY/RESET Deactivates the probe

MANUAL ON Bypasses the sensing function. Feeds signal

to controller as if precipitation has been
sensed. Automatically resets to
AUTOMATIC mode after 40 hours if
inadvertently left in the MANUAL ON
position.

4-4
 MAINTENANCE

5.0 MAINTENANCE

5.1 Scope

This section contains the instructions for maintaining the rainblower system in an
operational status. It is not intended to cover the overhaul or repair of the
component parts except for the replacement of fuses or common electrical parts
that can be accomplished using standard practices by a qualified technician.

5.2 Operational Checkout

An operational checkout of the rainblower system is required after installation of

the system or after replacement of the controller, blower, heater, or moisture
probe. It should also be conducted after 30 days of inactivity due to the lack of
precipitation.

5.2.1 System Operational Checkout Procedure

Perform an operational checkout of the rainblower system as follows:

A) Ensure that the POWER switch of the controller is in the ON position.

B) Place the MODE SELECT switch of the controller to the MANUAL position.
The rainblower system should operate with warm air being blown across the
feed window.

C) Place the MODE SELECT switch of the controller to the AUTO position and
the moisture probe control switch to the MANUAL ON position. The
rainblower system should operate with warm air being blown across the feed
window.

D) Place the MODE SELECT switch of the controller to the AUTO position and
the moisture probe control switch to the AUTOMATIC position. Using a
hose or water can, spray or pour water on the moisture probe. The
rainblower system should operate with warm air being blown across the feed
window.

E) Stop the water flow and dry any moisture from the probe. The rainblower
should cease operation after 1 hour. Leave the MODE SELECT switch of the
controller in the AUTO position and the moisture probe control switch in the
AUTOMATIC position.

5-1
 MAINTENANCE

CUSTOMER COPY

Rainblower System Test Data Sheet

Job No: _______________________________

Date: _______________________________

Site: _______________________________

_______________________________

_______________________________

Rainblower Model No: ______________________________

Rainblower Serial No. _______________________________

Controller Model No. ________________________________

Controller Serial No. _________________________________

Installation has been performed in accordance with drawings

and equipment O&M manual ____(Check)

Operational checkout has been successfully performed according

to test procedure ____(Check)

Signatures:

Performed By __________________________________________
(GDST)

Witnessed By __________________________________________
(Customer)

5-2
 MAINTENANCE

GDST COPY

Rainblower System Test Data Sheet

Job No: _______________________________

Date: _______________________________

Site: _______________________________

_______________________________

_______________________________

Rainblower Model No: ______________________________

Rainblower Serial No. _______________________________

Controller Model No. ________________________________

Controller Serial No. _________________________________

Installation has been performed in accordance with drawings

and equipment O&M manual ____(Check)

Operational checkout has been successfully performed according

to test procedure ____(Check)

Signatures:

Performed By __________________________________________
(GDST)

Witnessed By __________________________________________
(Customer)

5-3
 MAINTENANCE

5.3 Inspection and Preventive Maintenance

Inspection and preventive maintenance to be performed is listed in Table 5-1.

TABLE 5-1 INSPECTION AND PREVENTATIVE MAINTENANCE

FREQUENCY ITEM PROCEDURE
Every 30 days Blower Clean outside of the ring compressor (particularly
the air path of the cooling fan)

Every 30 days of in-activity due to dry System Perform operational checkout (Section 5.2)
weather conditions

5.4 Troubleshooting

Troubleshooting can be performed using a volt-ohm-ampere meter and standard

troubleshooting procedures using the schematics found in Section 6.0. Table 5-2
offers probable causes and troubleshooting steps for the most common problems.

TABLE 5-2 TROUBLESHOOTING

PROBLEM PROBABLE CAUSE/STEP
Rainblower (1) No power to system: - Check for voltage to the controller. Refer to drawings in
Inoperable- Section 6.
Precipitation
falling (2) Switch in wrong position: Set switches as follows:
(a) Controller POWER: ON, (b) Controller MODE SELECT: AUTO,
(c) Moisture Probe: AUTOMATIC

(3) Controller Breaker Tripped: Reset Breaker. Refer to drawings in section 6.

4) Faulty moisture probe: Place controller MODE SELECT switch in the MAN
position. If the system operates normally replace the moisture probe.

(5) Controller contactor faulty: Replace contactor. Refer to drawings in section 6.

(6) Blower failed: Replace blower.

(7) Faulty wiring: Check wiring. Refer to drawings in section 6.

Blower air cool (1) Controller breaker(s) tripped: Reset breaker(s). If problem continues check system
out for fault condition. Refer to drawings in section 6.

(2) Air pressure switch out of adjustment: Adjust air pressure switch. Refer to
Paragraph 5.4.1.

(3) Heater contactor failed: Replace heater contactor. Refer to drawings in section 6.

(4) Heater assembly failed: Replace heater assembly.

(5) Leaks in air duct system: Locate leak and repair duct.

5-4
 MAINTENANCE

5.4.1 Air Pressure Switch Adjustment

The air pressure switch in the heater box assembly is adjustable for a range of 5 -
30 in. H O. The adjustment is a hex head adjusting screw located on the bottom
of the switch (refer to item (c) in Section 6 - VENDOR DATA). Adjustment is as
follows: 2

A. Remove the cover of the Heater Box Assembly.

B. Place the system switches in the following positions:

1) Main Controller POWER circuit breaker: ON

2) Heater circuit breaker: OFF
3) Blower circuit breaker: OFF
4) Moisture Probe circuit breaker: ON
5) Moisture Probe selector switch: MANUAL ON
6) Controller MODE SELECT switch: MAN

C. Check for normal system voltage at terminal point AS1(Refer to drawings in

section 6. If normal system voltage is detected, check for normal system
voltage at terminal point AS2. If normal system voltage is not detected at
AS2 then go to step (D) below, otherwise use a 1/16-inch hex key wrench
and turn the Pressure Switch adjustment screw clockwise until normal
system voltage is not detected at AS2. If adjustment screw bottoms out and
system voltage is still detected at AS2, then remove all power and replace
the Pressure Switch. Repeat steps A through C with new switch installed.

D. Turn the blower circuit breaker on. The blower motor should be running (If
not check out blower system control circuit). Check for normal system
voltage at AS2. If system voltage is detected go to step (E) below otherwise
use a 1/16-inch hex key wrench and turn the Pressure Switch adjustment
screw counter-clockwise until normal system voltage is detected at AS2
then go to step E. If the adjustment screw backs completely out of the
pressure switch before system voltage is detected at AS2, remove all power
and replace the pressure switch. Repeat steps A through D with new switch
installed.

E. Reset controller MODE SELECT switch, moisture probe CONTROL SWITCH,

and system breakers to normal operating positions.

5-5
 MAINTENANCE

5.5 Repair and Replacement

There is no field repair of the components of the rainblower system. Refer to the
appropriate drawing in Section 6 of this manual when removing and replacing
components. Whenever a component is replaced perform the operational check
outlined in Section 5.2.1.

5.6 System Spares

Spare parts can be ordered from GDST. Spares for each standard system
configuration are available. Please identify the unit model number and serial
number, part description, and quantity.

5-6
 ENGINEERING DRAWINGS

6.0 ENGINEERING DRAWINGS

This section contains the following drawings in the order listed:

800561 Rainblower Controller Box Layout and Details (120V)

800572 Rainblower Controller Box Layout and Details (220V)
800790 Dual Rainblower Controller 120/220VAC, 1 Phase

6-1
 VENDOR DATA

7.0 VENDOR DATA

7.1 General

Vendor data for the following rainblower components are included for reference
after this page:

Automated Systems Engineering DS-2 Rain/Ice Sensor Controller

7-1