GEI-24-SAPS-48 - Graywacke Engineering
Contents
1. GRAYWACKE ne User Technical Manual GEI 24 SAPS 48 PRC 152 Stay Alive Power System PRC 152 and PRC 148 battery storage and full charge modes adi GEI 24 SAPS Contents List GEI 24 SAPS 1 ea 15 Ft AC input power card 1 ea Trouble Shoot Guide 1 ea Tech User Manual 1 ea Repair Replacement Manual 1 ea Tech manual CD 1 ea Battery Removal Tool 1 ea GRAY WACKE Engineering loc General Operation Information The AN PRC 152 radio has a non rechargeable stay alive coin cell battery internal to the radio housing This coin cell provides constant power to maintain critical radio information when another power source is not available 1 e principle radio battery The replacement of the non rechargeable coin cell is not a trivial procedure and premature failure of this coin cell can present mission readiness problems In addition to the coin cell battery issues the AN PRC 152 radio battery also must be maintained over long storage periods The radios are stored both with and without their main batteries requiring a storage maintenance solution that works in both configurations The GEI 24 SAPS is the solution to the PRC 152 stay alive battery problem Operational Features Provides storage and maintenance for up to 24 PRC 152 radios User selectable storage or mission ready charge of 152 and 148 batteries Universal AC input 24 VDC inpu2. EXPENSES LOST SAVINGS OR LOST PROFITS OR ANY OTHER DAMAGES OF ANY KIND How to Get Warranty Service Call the Engineering Dept at Graywacke at 419 525 3888 prior to shipping Send the GEI 24 SAPS 48 and a written description of the problem to Graywacke Engineering 120 Industrial Drive Lexington OH 44904 Graywacke will return the repaired or replaced GEI 24 SAPS 48 at Graywacke s expense by the same delivery method used to send the GEI 24 S APS 48 to Graywacke THIS WARRANTY IS THE SOLE AND EXCLUSIVE REMEDY AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE
3. GEI 24 SAPS 48 EXTERIOR DIMENSIONS X v R ell GRAY WACKE Engineering Inc Radio Battery Interface Schematic A B P3 1 2 3 Header D 22K 1 10K 1 PBSS4350X 48 PBSS4350X Q RGSENS PBSS4350X R10 Q3 554350 5 SLOW P4 Ul VIN VOUT R23 10K 1 A VDC NC VSS 1801 1802 0 R24 511 1 Header 2 P1 R19 470 J12 BCHG J13 BTPOS2 BTPOS1 BTGNDI GND PBSS4350X QI J15 BTGND2 PBSS4350X 554350 Q9 12 5 220uF U3 VN OUT PGND FB SGND NC NC ON OFF NC NC 441 ne NC 2574 12 GND BCHG BCHG CHG GND GND U2 ROSS et PBO PDO PCINTI6 kf 142 PBI PCINTI OC1A PDI PCINTI7 555 31 PB2 PCINT2 SS OC1B PD2 INTO PCINTI8 912 MOSI I PCINT3 MOSI PCINT19 INT1 ENECHG PCINT4 MISO PD4 PCINT20 TO TE SCR gt PBS SCK PCINTS PDS 2 1 I 2 6 6 PD6 PCINT22 AINO Hm Eb r PB7 PCINT7 PD7 PCINT23 AIN1 ARVDC 23 9 LEDRE
4. Only by using Grounding Switch Radio Detected Turn on Red LED Failure Delay 2 sec Is Radio drawing at least 100uA Turn on Green LED Normal Condition Look for Battery Power to Battery Check for Charge Point Voltage Is there a Battery YES GRAYWACKE Estas Ine GEI 24 SAPS 48 Operational Flow Chart Cont Read Battle Ready Switch Charge Point Charge Point 55 HI gt 2550 Charge Point Charge Point Low 45 LOW 85 nomi GRAY WACKE Engineering Ine GEI 24 SAPS 48 Operational Flow Chart Cont YES Is the charge Point Voltage 0 9 LOW Turn On Charge Is the Charge Point Voltage HIGH Turn Off Charge Check Charge Flag Is Battery in Failed Mode Taking no charge Shorted FC NO Solid Green GRAY WACKE Engineering Inc Physical Specifications GEI 24 SAPS 48 Base Dimensions fj E a m A KY E 5 1 1 AS a imi GRAYWACKE Engimecring Ine INSERT SPECIFICATIONS ORS 224 MEN 639 Xr teg mm mE Gm DE me eij 9597 eis esl 16 3 S GRAY WACKE
5. shall not be obligated under this Service Agreement to any end user for additional repair work if any invoice for prior repair work performed by Graywacke remains unpaid after the due date What This Service Agreement Does Not Cover This Service Agreement Does not cover non electrical components of the SAPS product IN NO EVENT SHALL GRAYWACKE BE LIABLE FOR ANY DIRECT SPECIAL INDIRECT CONSEQUENTIAL INCIDENTAL PUNITIVE OR EXEMPLARY DAMAGES EXPENSES LOST SAVINGS OR LOST PROFITS OR ANY OTHER DAMAGES OF ANY KIND How do I get Service Call the Engineering Dept at Graywacke at 419 525 3888 prior to shipping Send the 24 5 5 48 and a written description of the problem to Graywacke Engineering 120 Industrial drive Lexington OH 44904 Graywacke will return the repaired or replaced GEI 24 S APS 48 at Graywacke s expense by the same delivery method used to send the GEI 24 S APS 48 to Graywacke THERE ARE NO WARRANTIES EXPRESS OR IMPLIED WITH RESPECT TO REPAIR WORK COMPLETED UNDER THIS SERVICE AGREEMENT INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE GRAY WACKE Engineering loc LIMITED WARRANTY What does this Warranty Cover This warranty covers any defects in workmanship or materials of the GEI 24 S APS 48 under normal use and service How Long Does the Coverage Last This warranty runs for Two 2 years from the date of delivery What Will Gr
6. D ACHG PCO ADCO PCINTS PAO ADC6 PCINT24 LEDGRN Z PCI ADCI PCINTS ADC7 PCINT25 595 555 ADC2 PCINT10 PA2 PCINT26 ABCHG 1 PCINT27 a SATRDY PC4 ADCA SDAPCINTI2 RESET 285 PCS ADCS SCL PCINT13 E 550 PC6 RESET PCINT14 5 18 R21 GND AVCC BAUE 21 GND vec 22K 1 ATtiny48 AU GND Title Altium Limited 3 Minna Close e mmm Belrose Size A4 Number Revision NSW 2085 Date 6 13 2013 Time 1 29 12 PM Sheet of Australia File DAGWRADIOVI ASAPSVI 7 SchDoc BGND PBSS4350X R15 22K 1 RVDC 10K 1 51 1K 1 OP RGND 05 22K 1 554350 vec 2 1 2 3 4 22K 1 i PDA R20 ENCHG E PDS ENRVDC Header 6 m RD 22K 1 GRAY WACKE Engineering Inc Display Board Schematic DIR D2R D2G D3R D3G DSR DSG D6R D7R D7G DSR D amp G DOR DIG DIOR D10G DIIR DIR D12G N 0 8 Header 25 1 2 3 Pl A Header 25 DIR DIG D2R D2G D3R D3G D12G D4R D12R D4G DIG DSR DIIR D5G D10G D6R DIOR D6G DIG DOR 08 DSR ID7G 1 2 3 4 5 6 7 8 B LED R G LED LED R G LED R G LED LED LED R G
7. LED R G D7R NOTE DUAL ZENERS USED FROM LIBRARY ARE DUAL COLOR LEDS P3 vinee SE ISS ASE SE ROIS Header 25 D13R D13G D14R D14G DI5R D15G D24G DI6R D24R D16G D23G DI7R D23R D17G D22G DISR D22R D18G D21G ID21R D20G ID20R ID19G 13 15 16 17 18 19 20 LED R G LED RA LED R G LED R G LED RA LED LED R G LED R G D DI9R 1 2 3 nomi GRAY WACKE Engineering Ine Replacement Parts List Refer to Repair Replacement manual for detailed instruction G EI 152 SAPS 48 PART Un DESCRIPTION EN GEI 152 48 LEDPCB 2 LED PCB Board 4 73 152 48 5 2 Power Supply 152 48 7 5 1 7 5 Push Pull Breaker D GEI 152 48 15 1 15AMP Push Pull Breaker E GEI 152 48 CSA 1 Charge Station Assembly GEI 152 48 2818 0508 1 SAPS 152 48 Case G GEI 152 48 5 15PAC 1 15Ft AC Harness H GEI 152 48 SPSTSW 1 Single Pole Single Throw Switch I GEI 152 SAPS 48 PBPCB 24 PCB Board For PRC 152 148 Radio J GEI 152 48 RC 2 Ribbon Cable GEI 152 48 FLEDP 1 Front LED Plate L GEI 152 48 PMPC 1 Panel Mtg AC DC Power Connector M GEI 152 48 BT 1 Battery Removal Tool O GEI 152 48 FDP 1 Front Decal Plate P 1 GEI 152 48 CSD Charge Station Decal GRAY WACKE Engineering loc SERVICE AGREEMENT What Does This Service Agreement Cover This Service Agreement means that Graywacke Engineering Inc will provide the repair service described be
8. and press in firmly Thread outer shell onto connector until hand tight Power ON OFF 2 9 24 CIRCUIT BREAKERS As PUSH RESET OR PULL TO DIS SS AECH The GEI 24 SAPS power can be cut via two push pull manual circuit breakers Pulling either circuit breaker will cut power to all pockets GRAY WACKE Engineering Inc Inserting Radio Battery The GEI 24 SAPS 48 accommodates 4 different configuration scenarios these include PRC 152 without a primary battery attached The PRC 152 with the primary battery attached and the PRC 152 primary battery alone PRC 148 primary battery alone In either radio scenario the HUB Stay Alive battery will be bypassed during long term storage When a primary battery alone is placed the GEI 24 SAPS 48 it will be maintained at the proper charge range for long term storage NOTICE The GEI 24 SAPS 48 15 designed to correct the HUB battery problem for the PRC 152 radio only The 24 5 5 48 is designed to charge 152 and 148 batteries only No other radio or To assure proper connection the battery radio has to nest inside the alignment plate which is located at the base of the pocket If the alignment is off you will see a red indicator light associated with that pocket Simply lift the battery or radio and reinsert it MOUNTING CONFIGURATIONS Radio with Battery Attached Radio Alone Battery Alone Storage at high temperatures perm
9. anently degrades battery capacity of all batteries Check the manufactures MSDS for proper storage and disposal information mif GRAYWACKE Engineering Ine BATTERY REMOVAL TOOL A removal tool has been proved for simple removal of the batteries LED STATUS CHART RADIO w BATTERY BATTERY ONLY GREEN Solid Light Hub Battery Is Bypassed Hub Battery Is Bypassed Battery at storage Charge 50 60 Full charge 90 Battery at storage Charge 50 60 Full charge 90 AMBER Solid Light Hub Battery is Bypassed Battery Charging Battery Charging RED Solid Light Radio Turned On power off radio Alignment Error Radio Turned on power off radio Battery Fault Service Battery Alignment Error Battery Fault Service Battery Alignment Error The SAPS 152 48 is a maintenance storage device and will charge the battery to optimum storage capacity of 50 60 state of charge Mission Ready state of charge is 90 Refer to the LED indicator charts located on the inside panel or the exterior case to determine the status of each pocket NOTE Due to different battery conditions charge times may vary Batteries in poor condition may show slight fluctuations from green to charge status GRAY WACKE Ine GEI 24 SAPS 48 Operational Flow Chart Power UP Initialize all Ports Registers and Variables No Radio Detected Test for Radio
10. aywacke Do Graywacke will at its option replace or repair any GEI 24 SAPS 48 product found by Graywacke to be defective at no charge The repaired or replaced GEI 24 SAPS 48 product will be shipped from Graywacke within 10 Business Days of receipt of the returned GEI 24 SAPS 48 product A written description of the problem must be included with the returned product from the end user Business Days mean Monday Tuesday Wednesday Thursday or Friday each a Weekday unless such date falls on a holiday observed by Graywacke in which case the next Weekday will apply All replaced GEI 24 SAPS 48 or parts will remain the property of Graywacke What Does This Warranty Not Cover Graywacke will not be responsible under this warranty if Graywacke determines that 1 upon examination that the GEI 24 SAPS 48 failure was A caused by misuse neglect accident abnormal condition of operation or handling including the failure to use the GEI 24 S APS 48 in accordance with Graywacke instructions and observe the warnings on the GEI 24 SAPS 48 and the instruction manual alteration to the GEI 24 S APS 48 other than the movement of the carrying straps or an alteration which Graywacke determines does not affect electrical components or function or other conditions beyond the control of Graywacke or B damaged in transit to Graywacke IN NO EVENT SHALL GRAYWACKE BE LIABLE FOR ANY DIRECT SPECIAL INDIRECT CONSEQUENTIAL INCIDENTAL PUNITIVE OR EXEMPLARY DAMAGES
11. low to the GEI 24 S APS 48 product end user on the 24 5 5 48 product at Graywacke Engineering at 120 Industrial Drive Lexington OH 44904 How Long Does The Service Agreement Last This Service Agreement will remain in effect for five 5 years from the date of delivery of the GEI 24 SAPS 48 product What Will Graywacke Do Graywacke will at its option replace or repair any electrical components in GEI 24 S APS 48 with new or rebuilt GEI 24 SAPS 48 electrical components at its then current hourly charge plus the cost of replacement parts If repair of the GEI 24 SAPS 48 electrical components will require estimated charges including the cost of replacement parts in excess of 1200 00 Graywacke will contact the GEI 24 SAPS 48 end user to discuss alternatives The repaired GEI 24 SAPS and an invoice for such repair work will be shipped from Graywacke within three Business Days of the date of receipt of the returned f GEI 24 SAPS 48 from end user with a written description of the problem unless further information is needed from the end user Business Days mean Monday Tuesday Wednesday Thursday or Friday each a Weekday unless such date falls on a holiday observed by Graywacke in which case the next Weekday will apply All replaced GEI 24 S APS 48 or parts will remain the property of Graywacke By accepting this Service Warranty the end user agrees to pay such invoice within thirty 30 days of the date of such invoice Graywacke
12. t via NATO style connector Internal and External LED status display 15 AC NEMA style input cable 15 DC Mini NATO style input cable sold separately Independent and simultaneous radio bay operation Integrated ruggedized storage and transit case Circuit protected AC and DC input Current limiting protection 4 External Tie down brackets GRAY WACKE Engineering loc General Specifications Weight Dimensions Input Voltage Input Frequency Inrush Current Input Current Hold Up Time Input Protection Efficiency Operating Temperature Storage Temperature Minimum Load Line Regulation Load Regulation Ripple amp Noise AC Overload Protection Adjustment 42 165 without Radios Batteries 31 5 x 21 55 x 13 5 Universal 90 264 VAC 20 30 VDC 47 63Hz 30 115 VAC 60A 230 VAC 32 5A Max 2 4 115 VAC 2 0A 230 VAC Max 19ms typ 115 amp 80ms 230 VAC Full Load External Fuse 15A vac 7 5 A 24 vdc 86 typical 30 to 70 C Full Load 40 C to 80 C 10 95 RH n a 5 typical 2 typical 1 typ pk pk 20MHz 110 150 of rated output power Fixed GRAY WACKE Operating Instructions Connecting AC or DC Power cords Attention Prior to connecting input cable to the GEI 24 SAPS be certain the input cord is not plugged into the AC or DC power source Locate circular connector on side of case Align top key notch
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