Tech Drawing - Graywacke Engineering
Contents
1. BLK _ 24 VDC Power Supply Battery IN s Fan 120 240 ac in 24 vde 27 3 vdc out DS RED AC AC select DC wires Power Output Di Me I 40 Amp RED BLK RED BLK NEG Switch Sense wire POS IN 24 vdc POS IN 24 vdc WHT POS OUT RED POS OUT CONVERTER ON CONVERTER ON GRN NEG OUT BLK NEG OUT BLK BLK NEG IN 24 vde NEG IN 24 vde BLK POS IN 24 vdc POS IN 24 vde WHT POSOUT RED POSOUT SPST CONVERTER ON CONVERTER ON SWITCH BLK GRN NEG OUT BLR NEG OUT Le DE NEG IN 24 vdc NEG IN 24 vde NA WHT POS IN 24 vdc POS IN 24 vdc WHT POS OUT RED pos OUT SPST CONVERTER ON CONVERTER ON SWITCH bik GRN NEG OUT BLK NEG OUT Pe DE 24 vde NEG IN 24 vde NEG IN 24 vde BLK ut AC Breaker Power 15 Amp POS IN 24 vde POS IN 24 vde LED WHT POS OUT RED POS OUT ae BLK GRN NEGO BLK NEGOUT nem NEG IN 24 vdc NEG IN 24 vde WHT2. Isolation Voltage input to case amp output to case Isolation Resistance input to output Switching Frequency Fixed Minimum Load Weight Tower with accessory cables Dimensions Working Temperature Range Storage Temperature 12 24 VDC Accessory Outputs Pin Configuration INPUT SPECIFICATIONS Input AC Voltage Range Input DC Voltage Range Nominal DC Input Input Voltage Lockout Input Filter Input Reflected Ripple OUTPUT SPECIFICATIONS Output Current Output Voltage Tolerance External Output Trim Line Regulation Load Regulation Short Circuit Protection Over Voltage Protection Ripple Noise 20MHz BW Current Limiting Inception Thermal Overload 24 VDC BATTERY CHARGER SPECIFICATIONS 85 typical 1500VDC min 750VDC gt 100 M Ohms 400 kHz 10 none required 57 6 Ibs 23 50 Lx 14 00Wx16D O 51C 20 to 80C pin 1 pin 2 12 VDC Pin 4 pin 3 12 VDC 90 VAC 132 VAC 216 VAC 240 VAC 18 36 VDC 24 VDC lt 16 gt 38VDC Pi input filter 20mA p p pin 1 pin 2 4 amp Pin 4 pin 3 4 amp 1 max 10 0 1 0 1 Continuous approx 120 V out self resetting 1 5 V out approx 125 110 C base plate self resetting Note Specifications represent usage exclusively for the purpose of charging DC Output Voltage No Load Output Voltage Tolerance No Load Output Amperage Max Continuous Output Voltage Full Load approx Maximum Power Output Conti
3. replace or repair any electrical components in the GEI24 RPA t with new or rebuilt GEI24 RPA t electrical components at its then current hourly charge plus the cost of replacement parts If repair of the RPA electrical components will require estimated charges including the cost of replacement parts in excess of 400 00 Graywacke will contact the GEI24 RPA t end user to discuss alternatives The repaired GEI24 RPA t and an invoice for such repair work will be shipped from Graywacke within three Business Days of the date of receipt of the returned GEI24 RPA t 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 GEI24 RPA t s 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 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 RPA product INNO EVENT SHALL GRAYWACKE BE LIABLE FOR ANY DIRECT SPECIAL INDIRECT CONSEQ
4. on the radio and operate GEI 24 RPA T IQ Smart Charge Capabilities The IQ Smart Controller offers automatic charging control for the RPA T providing longer and safer use of your system s battery Ve GRAY WACKE Engineering Ine The IQ Controller allows the RPA T to operate as an automatic 3 stage smart charger This gives the customer the benefit of Bulk Absorption and Float stage charging increasing the charging capacity of the power supply and decreasing charge times insuring proper and safe battery charging and minimizing over charging This smart technology monitors the battery at all times If the RPA T voltage remains in the long term stage for more than seven days the IQ will automatically deliver a boost charge for a predetermined time and then automatically return to the normal float stage BULK CHARGE i Batteries are charge at the rr a full rated load of the battery Lo F reducing charge times SMART CHARGER Fra SBEARATIALI L A DE HE b F m 18 k kri A ni i ka Batteries are then held for a controlled period at the absorp tion phase to insure a full and complete charge FLOAT CHARGE The charge voltage is then dropped maintaining a full charge while minimizing gassing Reduced Charge Times The Bulk Stage allows the batteries to be charged from the full rated load of the battery During this stage the batteries are recharged quickly to reduce charge times Increased Batt
5. the GEI24 RPA t 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 11 gt f Sigla GEI 24 RPA T Trouble Shooting Procedures Problem RPA Unit does not power on when plugged into AC outlet Check If power cord is not damaged and is connected to a 15 amp rated outlet Check If 15 amp AC circuit breaker on side panel of RPA unit is tripped push to reset Check If AC source is providing voltages in the following AC ranges 90 V 132 V 216 V 240 V Problem RPA Unit does not power on when connected to DC input Check If DC cable harness is not damaged and is connected to 24 VDC source only Check If 40 amp DC input circuit breaker is not tripped Check If DC input voltage falls within the following range 1 8 36 VDC Problem Individual shelf lights are flashing intermittently Check All input power connections are secure including radio cord Check If plugged into AC and DC source and DC source is below 18v switch off all loads and allow DC source to charge above 18v Check Be sure RPA unit is in a well ventilated area and vent holes are not obstructed Shut off unit and allow to cool 12 pr f pi A oi GEI 24 RPA T Trouble Shooting Procedures Cont Problem Main power indicator light is on but s
6. ER SWITCH 8A2R7 5 15 RPA CBK 15 15 AMP CIRCUIT BREAKER ARTZ S 40 RPA CBK 40 40 AMP CIRCUIT BREAKER 3A2R7 oo H RPA PWRIEC MAIN AC POWER INPUT CONNECTOR 3427 RERPAUNETSE 2500 BOAMP INPUT CABLE SET INCLUDES HARDWARE 1 AR O RPA DSTJKT ANDERSON STYLE DUST JACKET CW REALED gt s MANPOWER INDICATOR LIGHT GREEN sage 1 2 LIQUID TIGHT STRAIN RELIEF 3A2R7 X RPA 24VDCFN 24VDC EXAUST FAN 8A2R7 E PERSO UR SRE ME eee eae ddr 5 RPA SLF LBKT RADIO STABALIZING BRACKET P RPACONT SHELF CAGENGT eee J RPA 4CSC RADIO INPUT CORD 4CH4AWG ARR RPA SNFBRD SNG 110 220 VOLTAGE CONTROL BOARD SINGLE CHANNEL 3A2R7 L RPA SLV 20 SLAVE CALE 2C6AWG 25 FT WITH 50 AMP HOUSING 3A2R7 K_ RPAACCST AC POWER CORD RR A RPA CONVBD RPA CONVERTER CONTROL BOARD 3427 B RPA CVTR MTBKT _ CONVERTER CONTROL BOARD MOUNTING BRACKET 8A2R7 _ RPA MANUAL USER MANUAL ARR G RPA LED12 SHELF INDICATOR LIGHT GREEN 8A2R7 15 Ground AC Input Plug 120 240 ac CIL Select 1 WHT GEI 24 RPA T Wiring Diagram Power 1 AC INPUTS AC Input Voltage Control Board DPST Switch BLK BLK
7. UENTIAL 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 GEI24 RPA T and a written description of the problem to Graywacke Engineering 201 East 5 Street Suite 310 Mansfield OH 44902 Graywacke will return the repaired or replaced GEI24 RPA t at Graywacke s expense by the same delivery method used to send the GEI24 RPA t 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 10 pra GRAYWACKE Engineering Ine LIMITED WARRANTY What does this Warranty Cover This warranty covers any defects in workmanship or materials of the GEI24 RPA t under normal use and service How Long Does the Coverage Last This warranty runs for one 1 5 years from the date of delivery What Will Graywacke Do Graywacke will at its option replace or repair any GEI24 RPA t product found by Graywacke to be defective at no charge The repaired or replaced GEI24 RPA t product will be shipped from Graywacke within 10 Business Days of receipt of the returned GEI24 RPA t product A written description of the problem must be included with the returned product from the end user Business Days mean Monday Tuesd
8. Va uf GRAY WACKE Engineering Ine User Technical Manual GEI24 RPA T 24 volt Radio Povver Adaptor Va GRAYWACKE Engineering Ine GEI24 RPA T Contents list v RPA 24 4 shelf tower lea v 8 ft AC input power cord lea v 25 ft 6 awg DC mini NATO cable harness 1 ea v Neoprene rubber radio adaptor gaskets 4 ea v Battery Box extension ring 8 ea v Knurled 10 24 x shelf knob 8 ea v Shelf L securing bracket 8 ea v User Technical Manual lea v User Technical Manual CD lea v Trouble Shoot Guide lea ST GRAYWACKE Engineering Ine General Information The GEI 24 RPA produces power for the following 12 and 24 VDC radio equipment applications AN119 PRC113 PRC104 PRC150 PSC 5 gt SR PRC117 117G Included 12V SINCGARS without the use of communication batteries Instead it powers the radios using 110v 240 VAC shore power or generator and or 24v DC While GEI 24 RPA t will provide power to Harris Radios using either power source independently it is most effective when both AC and 24v DC are used together because that provides you with an uninterrupted power supply for your radios GEI 24 RPA t is designed to lie on its side back or stand upright Operational Features Main power rocker switch Individual accessory shelf power switch Main power lamp green Individual accessory shelf lamp green AC input resettable circuit protection 15
9. amps DC input resettable circuit protection 40 amps DC input battery style quick disconnect AC input cable 8 DC mini NATO style 6 ga cable harness 20 Color Tan Flexible low profile nylon carrying handles 5590 2590 style battery adaptor connectors Capabilities amp Power Requirements When the GEI24 RPA t is used with both 120 240v AC and 24DC it provides unmatched reliability In the event of a loss of AC power GEI24 RPA t will continue to power the radios using the 24v DC source To ensure the 24v battery is up to the task the GEI24 RPA t charges the battery as long as the AC is providing power but it will not over charge the battery When AC alone is used to power GEI24 RPA t it provides a clean DC output voltage It must be kept in mind that if AC is lost generator failure for example then power to the radios is lost until AC is restored Losing power like this will not harm the GEI24 RPA t although communications will be lost When 24v DC is used the GEI24 RPA t will continue to supply power as long as the battery is capable The battery can be installed in a vehicle or free standing The length of time the radios can be run on a battery without recharging is dependent on several factors e Condition of the battery e State of charge of the battery e Reserve Capacity RC of the battery e The amount of use of the nets each radio represents GENERAL SPECIFICATIONS Efficiency Isolation Voltage input to output
10. ay 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 GEI24 RPA t 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 GEI24 RPA t failure was A caused by misuse neglect accident abnormal condition of operation or handling including the failure to use the GEI24 RPA t in accordance with Graywacke instructions and observe the warnings on the GEI24 RPA t and the instruction manual alteration to the GEI24 RPA t 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 INNO 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 to Get Warranty Service Call the Engineering Dept at Graywacke at 419 525 3888 prior to shipping Send the GEI24 RPA t and a written description of the problem to Graywacke Engineering 201 East 5 Street Suite 310 Mansfield OH 44902 Graywacke will return the repaired or replaced GEI24 RPA t at Graywacke s expense by the same delivery method used to send
11. d arcing can occur Allowing both the red and black leads to touch any conductive metal surface can also cause shorts and or arcing The leads should always be treated as if they are hot and carrying current e Connecting to 24V DC The GEI24 RPA t can be used with any 24V DC vehicle with an installed NATO style slave connection with a direct 24v DC hookup Connecting the GEI24 RPA t to a 24V battery installed in a 24V vehicle Use the supplied 6 gage cable with the NATO style slave connector Connect the grey Anderson style connector located on the side of the GEI24 RPA t with the mating end of the 6 gage NATO connector harness Note THE RPA is equipped with a safety Anderson style disconnect to prevent improper battery connection Simply plug the NATO style plug into any vehicle with the mating connector Notice while operating on 24v DC input alone the GEI24 RPA t main power switch will be bypassed and all power to the radios will be controlled via the individual shelf switches If no output is detected check connections to battery inside vehicle CAUTION If the 24v DC battery the GEI 24 RPA t is connected to is unserviceable the e GEI 24 RPA t external circuit breaker on the front of the GEI 24 RPA t will pop out disconnect when the AC is plugged in WARNING Connecting the GEI24 RPA 24 to a vehicle installed battery incorrectly can result in damage to the GEI24 RPA t and the radios e GEI24 RPA t is now prepared for use Turn
12. ery Capacity After the Bulk Stage the batteries are held in the Absorption Stage for a controlled period insuring a full and complete charge Reduced Battery Stress During the Float Stage the RPA T charge voltage is reduced This minimizes gassing while maintaining a full charge at the nominal rate of the battery Weekly Equalization for Longer Battery Life If the batteries have not received a smart charge during a seven day period the IQ Controller will switch the RPA T charger into a pre programmed equalization stage to top off the batteries dissolving any sulfate layer on the battery s internal plates and avoiding stratification Charging Voltages The charging voltages used to charge the battery during the three stages differ depending on the voltage of the battery being charged Charging Phase Voltage Charge per Cell Bulk Charge 2 46 Absorption Charge 2 36 Float Charge 2 26 pra GRAY WACKE Engineering Ine SERVICE AGREEMENT What Does This Service Agreement Cover This Service Agreement means that Graywacke Engineering Inc will provide the repair service described below to the product end user on the GEI24 RPA t product at Graywacke Engineering at 201 East 5th Street Suite 310 Mansfield OH 44902 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 GEI24 RPA t product What Will Graywacke Do Graywacke will at its option
13. helf switches do not power on No shelf indicator light Check If RPA unit is plugged into AC and or DC power and the cables are not damaged or AC and or DC circuit breakers are tripped Check If radio connector cable is plugged into the Radio device properly Check If connected to DC input only that DC input voltage falls within the following range 18 36 V Problem RPA unit shuts down during operation Check If RPA unit is in a well ventilated area and vent holes are not blocked Shut off unit and allow to cool Check If powered by DC alone Be sure DC input voltage is above 18v switch off all loads and allow DC source to charge above 18v Check If the RPA is plugged into a good quality surge protector and is providing power within 90 VAC 132 VAC 13 GEI 24 RPA T Parts List pu A 14 GEI 24 RPA T Parts List IMTEM DESCRIPTION L CAGE NSN Y_ RPA CHS RPA 4 Shelf Metal Chassis Tan 184287 Q RPA SHLF RPA METAL SHELF REPLACEMENT TAN 3A2R7 oo E RPA TOP RPA METAL VENT TOP REPLACEMENT TAN 3A2R7 o Z RPA LID RPAMETALLIDREPLACEMENTTAN _ 3427 M_ RPA SLFKT RPA SHELF HARDWARE KIT TKNOB T NUT L BRACKET 3A2R7 O RPA GSKT RPA RADIO GASKET KIT GASKET RETENTION RING 8A2R7 R RPA HND RPA NYLON HANDLE SET 4EA sf S8A2R7 F RPA MNS RPA INDIV SHELF MINI SWITCH sf S8A2R7 OO RPAMS RPA MAIN POWER ROCK
14. nuous Typical Efficiency Max Inrush Current Single Cycle Short Circuit Protection Overload Protection Load Regulation Fan Control Thermal Protection approx 27 2 V DC or 5 40 Amps gt 27 0 V DC 1100 Watts gt 80 50 Amps Yes gt 100 lt 1 PROPORTIONAL YES Va GRAYWACKE Engineering Ine Connecting the Radios WARNING Ensure switches that supply power to the individual radio power cords are set to the OFF position before installing the radios 1 Battery box should be installed on the back of the radio prior to installation Fig A 2 See Fig A Open the clamshell door that normally houses the BA 5590 Plug one of the connectors from RPA T into the battery connector The connector will slide on easily when the connector key is properly aligned Fig B Fig C 3 See Fig B amp C Place the supplied rubber gasket in between the battery box doors with the cutout aligned with the top of the radio on the side of the battery box that has the binder posts on it Place the power cord through the cutout and close the box ST f GRAYWACKE Engineering ne Fig D Fig E 4 See Fig D amp E Fasten the twist style retainer on the side opposite the binder post using the supplied extension clip The clip will allow you to use the retainers in the normal fashion while compensating for the additional thickness of the gasket On the binder post side
15. of the battery box the retaining clip that prevents the two pieces of the clamshell from separating from one another will compensate for the thickness of the gasket On this side you do not fasten the retainer at all The connector on the side opposite the binder posts holds everything in place 5 If Harris remotes are to be used run the slash wire through the hole in the side of the GEI24 RPA t then connect them to the binder posts in accordance with the Harris Technical Manual 6 See Fig E a Slide the Harris into the GEI24 RPA t and secure it with the supplied thumb screw and retaining brackets 7 Repeat 1 6 for each radio to be installed ok f GRAY WACKE Engineering bne Carrying the GEI24 RPA t Fig F See Fig F This illustrates how the GEI24 RPA t unit can be lifted by the web handles The web handles can also be moved to accommodate individual unit preferences Connecting Power to the GEI24 RPA t Input Connections AC input NOTICE DC input NOTICE Be sure main power switch is in the off position prior to connecting power cord Allow 1 2 seconds for power up after main power switch has been turned On Green indicator lamp will illuminate when powered up Prior to powering On the tower be sure all output loads are off or disconnected Connect mini NATO style connector cable harness to unit via quick connection on side of the tower Green indicator lamp will illuminate when powe
16. red up Prior to powering On the tower be sure all output loads are off or disconnected When connecting to DC input only The RPA tower will power on regardless of position of main power switch Charging via NATO cable The RPA tower when used exclusively as a charging devise will provide charging capabilities to a 24 VDC battery bank Connect the AC power plug to the AC source Connect the NATO style connector cable to the vehicle you want to charge Depending on state of charge of the battery bank the green light will illuminate when connected Turn the main power switch to the on position Va nesti GRAY WACKE Engineering Ine NOTICE To prevent unnecessary power surge to connected equipment be sure all accessory shelf switches are in the off position prior to powering on the tower Connecting to 120 240v AC Plug GEI24 RPA t into any standard 3 prong grounded 110v AC outlet It will operate using military generator or shore power If the 120 240v power switch is in the on position when GEI24 RPA t is plugged in the lamp will illuminate and the radio cooling fan will activate At this time GEI24 RPA t will power up to 4 Harris radios through the individual power cords WARNING Whenever GEI24 RPA t is plugged into AC and turned on the 6 gauge battery cables are carrying 24 volts of DC current Care must be used to ensure the red positive and black negative cable leads do not touch one another or an electrical short an
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