PowerPlus System 100-3-1U Series - Raycap · 2020. 7. 14. · The PowerPlus 100-3-1U will increase...

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INSTALLATION INSTRUCTION & OPERATION MANUAL PowerPlus System 100-3-1U

INSTALLATION INSTRUCTION & OPERATION MANUAL

PowerPlus System 100-3-1U Series

100-3-1U-3

100-3-1U-2


www.raycap.com© Raycap | All rights reserved. • (320-1398) QRC | Rev.B

Page 1 of 30

Table of Contents

1. Copyright ............................................................................................................................................................ Page 2

1.1 Disclaimer .........................................................................................................................................2

1.2 Warnings ...........................................................................................................................................2

2. Introduction ................................................................................................................................................................... 3

3. Package Contents ......................................................................................................................................................... 3

3.1 Prerequisites .....................................................................................................................................3

3.2 Tools ..................................................................................................................................................3

4. Mounting .......................................................................................................................................................................4

5. General Description ...................................................................................................................................6

5.1 Functionality ......................................................................................................................................6

5.2 Modes of Operation ...........................................................................................................................6

5.3 System Topology ...............................................................................................................................7

5.4 InstallationConfigurations .................................................................................................................8

5.5 ModuleConfigurations .................................................................................................................9-13

6. System Management ................................................................................................................................14

6.1 Modules ...........................................................................................................................................14

6.2 Module Failure .................................................................................................................................15

6.3 Primary Failure ................................................................................................................................15

7. Modules .....................................................................................................................................................16 7.1 Module Replacement ......................................................................................................................16

7.2 Cold Module Replacement ..............................................................................................................17

7.3 Hot Module Replacement ................................................................................................................17

7.4 Hot Module Replacement: Invalid Module Installation .....................................................................17

8. Module Settings ........................................................................................................................................18

8.1 Settings Menus ...............................................................................................................................18

8.2 Initial Settings Menu ........................................................................................................................18

8.3 Initial Settings Menu: Mode Selection .............................................................................................19

9. Parallel Mode Settings .............................................................................................................................20

10. Single Mode Settings ...............................................................................................................................21

11. Live Settings Menu ...................................................................................................................................22

12. Bus Bar ......................................................................................................................................................24

13. Alarms .......................................................................................................................................................25

PowerPlus System 100-3-1U INSTALLATION INSTRUCTION & OPERATION MANUAL

www.raycap.com(320-1398) QRC | Rev.B • © Raycap | All rights reserved.

Page 2 of 30

1.0 Copyright© Raycap, Inc. 2021 - All Rights Reserved

1.1 DisclaimerTheinformationinthisdocumentissubjecttochangewithoutnoticeanddescribesonlytheproductdefinedintheintroductionof this documentation. This documentation is intended for the use of Raycap customers only for the purposes of the agreement underwhichthedocumentissubmitted,andnopartmaybeused,reproduced,modifiedortransmittedinanyformormeanswithout the prior written permission of Raycap. The documentation has been prepared to be used by professional and properly trained personnel, and the customer assumes full responsibility when using it. Raycap welcomes customer comments as part of the process of continuous development and improvement of the documentation.

Raycap has made all reasonable efforts to ensure that the instructions contained in this document are adequate and free of material errors and omissions. Raycap will, if deemed necessary explain issues which may not be covered by this document.

The contents of this document are subject to revision without notice due to continued progress in methodology, design and manufacturing. Raycap shall have no liability for any error damage of any kind resulting from the use of this document.

1.2 WarningsPlease read this manual prior to use to become familiar with the product’s numerous features and operating procedures. To maintain the maximum degree of safety, follow the sequences as outlined. Before using the product, read all instructions and cautionary markings on the product and on any equipment connected to the product.

CAUTION – Unless otherwise noted, product usage that is not recommended or sold by the product manufacturer can result in riskoffire,electricshock,orinjurytopersons.

CAUTION – Do not operate the product if it has been damaged in any way. Return damaged products to their manufacturer for repair or replacement.

CAUTION – A) Elevated Operating Ambient - if installed in a closed or multi-unit rack assembly, the operating ambient temperature of the rack environment may be greater than room ambient. Therefore, consideration should be given to installing the equipment in an environment compatible with the maximum ambient temperature of 55°C.

B)ReducedAirFlow-Installationoftheequipmentinarackshouldbesuchthattheamountofairflowrequiredforsafeoperation of the equipment is not compromised.

C) Mechanical Loading - Mounting of the equipment in the rack should be such that a hazardous condition is not achieved due to uneven mechanical loading.

D) Circuit Overloading - Consideration should be given to the connection of the equipment to the supply circuit and the effect that overloading of the circuits might have on overcurrent protection and supply wiring. Appropriate consideration of equipment nameplate ratings should be used when addressing this concern.

E) Reliable Earthing - Reliable earthing of rack-mounted equipment should be maintained. Particular attention should be given to supply connections other than direct connections to the branch circuit (e.g. use of power strips).

F) The supply input voltage ranges between -58Vdc to -40 Vdc (+/- 0%).

G) Rated Output Power (kW) = Input Voltage (Vdc) *275 (A).



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2.0 IntroductionIn a split Radio Base Station (RBS) architecture the typical RBS consists of a Base Band Unit (BBU) and Remote Radio Heads (RRH) connected by cabling. Power to the RRH is provided through copper cables traveling from the base station to the top of the tower or roof top. This creates a conductive path, making the active equipment at the top and the base of the site vulnerable to damage by direct lightning strikes. Protection systems installed in front of both the BBU and the RRH must be able to withstand direct lightning currents in order to protect the sensitive equipment. Raycap’s RRH solutions featuring Strikesorb®SPDtechnologysignificantlyenhancethereliability&availabilityoftheRRHsitebyprovidingsuperiorelectrical protection at the RRH and BBU. PowerPlus is Raycap’s solution for power transmission to the RRH units of a DAS Telecommunication site. PowerPlus is a system installed at the PSU output that boosts the voltage at the base of a cellular site to overcome the voltage drop on the DC power cables that provide power to the RRHs.

3.0 Package Contents1 each

(1) 1U PowerPlus System(1) Rack Extension Kit for 23" racks(4) 12-24 screws (for use with rack mount brackets)(1) Bridge output busbar(1) Lug mounting hardware set(1) Touch guard set(1) Cable Kit

3.1 PrerequisitesThis document describes how to install the 100-3-1U on-site and how to program the modules.

InstallersofRaycap’sRRHfiber/powermanagementsolutionsmustbeindustryprofessionalswhohaveattendedtrainingontheproperhandlingandinstallationoffiber-opticcable,andattendedtrainingontheinstallationoftheequipmentbyRaycapand/or the mobile operator. Installers are required to read this installation guide thoroughly prior to installation of the Raycap RRH management equipment.

3.2 Tools

#2 Phillips screw driver(2) 7/16" wrenches



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4. Mounting

4.1 Select a suitable position for the installation of the unit. You will need 1U vertical space.

4.2 The unit ships with a Rack Extension Kit to mount into a 23" rack.

4.4 Mount the unit on the rack.



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4.4.1 Mounting Distance from 19" rack

Note:Mountingearpositionsofferthefollowingmountingconfigurations

4.5 Release the 4 push pins and remove touch guard as shown below.

Mounting Position A1



0.59

0.94

0.93

0.36

0.94

0.94

2.742.14




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5. General Description

5.1 Functionality

• The PowerPlus 100-3-1U system is intended to boost the voltage of a telecom power supply to reduce the current on the power cables. The output voltage of the system remains constant to a value that is userconfigurableduringitsinstallation.

• By reducing the current, the cable power losses are reduced, and the total system becomes more efficient.

• Additionally,thePowerPlus100-3-1Uisbeneficialwhenoperatingonbatterybackuppowerduringapoweroutage.ThePowerPlus100-3-1Uwillmaintainaconstantoutputvoltage(asconfigured)totheradio while the battery discharges. This allows the radio to operate for a longer period of time while the batteries discharge.

5.2 Modes of Operation

• The PowerPlus 100-3-1U system is composed of a mounting rack and up to three pluggable modules.

• The PowerPlus 100-3-1U system may operate in one of two modes. The Single Mode and the Parallel Mode.

• The voltage output of each module is intended to be connected to individual loads when the device is configuredtooperatein Single Mode.

• ThemoduleoutputsmaybeconnectedinparallelwhenthedeviceisconfiguredtooperateinParallel Mode.Inthisconfiguration,theloadissharedbetweentheinstalledmodules.

PowerPlus 100-3-1U Connection Diagram

AC/DCConverter

-54Vdc -58Vdc

UtilityPowerPlus

Rack MountUnit Module

RaycapOVP

(Base)

RaycapOVP

(Tower Top)

Voltage Dropon DC Cable

(∆V)

RRH

BatteryBank



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5.3 System Topology

-48VDC

OUT 1

-48VDC

OUT 2

-48VDC

OUT 3

-48VDC

IN RT

N O

UT

RT

N IN

GR

OU

ND



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5.4 Installation Configurations

PowerPlus100-3-1Usystemconfigurations

SINGLE MODE

-48VDC OUT 3

-48VDC OUT 2

-48VDC OUT 1

RTN OUT

-48VDC

RTN

GND

DCPS

PARALLEL MODE

-48VDC OUT

RTN OUT

DCPS

-48VDC

RTN

GND



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5.5 Single Module Configuration

PDU

RTMDC-5634-PF-48RNSNDC-7771-PF-48RTMDC-4983-RM-48

-48VOUT

-48VIN

ReturnOUT

ReturnIN

GROUNDPower Plus

Configuration 1 (For applications requiring 100 AMPS or less)

100 AMPBreaker

Recommended Lugs

For 2 Gauge Use:Panduit LCD2-14-Qfor Input & Output

For 6 Gauge Use:Panduit LCD6-14A

for Ground

Torque:

All PowerPlus terminal connections are

¼-20 studs.

Torque to 65 in-lbs.

THE WIRE GAUGE SHOULD BE A MINIMUM OF 2AWG OR 1/O COPPER WIRE FOR INPUT & OUTPUT

LARGER DIAMETER CONDUCTORS IS ACCEPTABLE.

100 AMPModule

Installed

Trunk toUpper OVP

Use #6 AWG copper wire for ground



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5.6 2-Module in Single Configuration

PDU

Power Plus-48VOUT

-48VIN

ReturnOUT

ReturnIN

GROUND



200 AMPBreaker


100 AMPModule

Installed

100 AMPModule

Installed

Trunk toUpper OVP

Recommended Lugs



for Ground

Torque:


¼-20 studs.






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PDU

Power Plus-48VOUT

-48VIN

ReturnOUT

ReturnIN

GROUND


200 AMPBreaker


100 AMPModule

Installed

100 AMPModule

Installed

Trunk toUpper OVP

5.7 2-Module in Parallel Configuration


Recommended Lugs



for Ground

Torque:


¼-20 studs.






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5.8 3-Module in Single Configuration

PDU

Power Plus-48VOUT

-48VIN

ReturnOUT

ReturnIN

GROUND



300 AMPBreaker

100 AMPModule

Installed

100 AMPModule

Installed

100 AMPModule

Installed

Trunk toUpper OVP


Recommended Lugs

For 1/O Gauge Use:Panduit LCD1/O-14A-X

for Input

For 2 Gauge Use:Panduit LCD2-14A-Q

for Output

For 6 Gauge Use:Panduit LCD6-14A-L

for Ground

Torque:


¼-20 studs.






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5.9 3-Module in Parallel Configuration

PDU

Power Plus-48VOUT

-48VIN

ReturnOUT

ReturnIN

GROUND



300 AMPBreaker

Recommended Lugs

For 1/O Gauge Use:Panduit LCD1/O-14A-X

for Input

For 2 Gauge Use:Panduit LCD2-14A-Q

for Output

For 6 Gauge Use:Panduit LCD6-14A-L

for Ground

100 AMPModule

Installed

100 AMPModule

Installed

100 AMPModule

Installed

Trunk toUpper OVP


Torque:


¼-20 studs.






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6. System Management

6.1 Modules

• There is always a Primary module in the rack which controls the proper operation of the complete system.

• When a failure occurs, the Primary module will coordinate the response to this event.

• When the Primary module fails, another Secondary module will take over control of the system and become the new Primary.

• All modules will display the input and output voltage of the system. The Primary module is indicated by an “P”characterwhichislocatedattheendoftheinputvoltagevalue(firstlineofthedisplay).

• The primary module in the parallel mode will display the input and output voltage of the system. The Secondary modules will display the “Module 1” and “Module 2” messages.

Primary Secondary

Parallel Mode – Primary Module Parallel Mode – Secondary Module



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6.2 Module Failure

• When a Secondary module fails, the Primary module will disable this module and will raise an alarm. The front panel’s LED will change from GREEN to in RED, the remote contact will change to Failed and the new Primary module will display the “MODULE FAILURE” message.

• After removing the failed Secondary module, the Primary module will search for a newly installed module.Whenthisisfound,thePrimarymodulewilltransfertheoriginallyconfiguredoutputvoltagetothis new Secondary module.

• The alarm is reset after pressing the ‘ENTER’ button on the Primary module for more than 3 seconds.

6.3 Primary Failure

• When the Primary module fails another Secondary module will overtake the role of Primary and raise an alarm. The front panel’s LED will change from GREEN to RED, the remote contact will change to Failed and the new Primary module will display the “PRIMARY FAILURE” message.

• After removing the module, the newly assigned Primary module will search for a replacement module to be installed. When this occurs, the current Primary module will transfer output voltage to the new module.ThenewmodulewillbeconfiguredasanewSecondarymodule.

• The alarm will disappear after pressing the ‘ENTER’ button on the current Primary module for more than 3 seconds.

ENTER



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7. Modules

7.1 Module Replacement

• Unscrew the thumb screws on both sides of the module.

• Release the side levers.

• Extract the module.



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7.2 Cold Module Replacement

• Cold Module Replacement is the replacement of a module when the system is powered OFF.

• Everymodulestoresthesettings(configuredoutputvoltage)ofallothermoduleswhichparticipateinthe system.

• When the system boots, all the modules will exchange their stored settings. If the settings between the modules disagree, the system will change to settings mode and will request new settings to be entered. This is the starting point of the initial settings menu. All the modules will display the “SETTINGS” message.

• Initially, in an empty system (empty slots), 1, 2 or 3 modules may be plugged in, these may have random stored settings (Cold Module Replacement). After power on the modules will exchange their stored settings, if the settings between modules are different, the system will change to settings mode and it will wait for new settings. This is also a starting point of the initial settings menu.

7.3 Hot Module Replacement

• Hot Module Replacement is the replacement of a module when the system is powered ON and operational.

• Every module stores the settings of all other modules in the system.

• When a module fails (Primary module or Secondary module failure) it must be replaced. The replacement may occur while the system is running. The settings of the replaced module will be transferred automatically to the new module and the system will continue to operate normally.

• The Hot Module Replacement is recommended instead of Cold Module Replacement because in Cold Module Replacement the system will prompt for initial settings. Also during Hot Module Replacement the system operation will not be interrupted.

7.4 Hot Module Replacement: Invalid Module Installation

• Ifasystemisconfiguredandhas1or2emptyslots,anyhot module installation in any empty slot is invalid. The invalid module will display the “REMOVE MODULE” message, and the invalid module must be removed.

• If there is a cold module installation in open slot(s), then the system will prompt for initial settings during power ON.



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8. Module Settings

8.1 Settings Menus

• There are two different settings menus. The initial settings menu and the live settings menu.

• The initial settings menu will appear when the system detects differences between the current module settings and previous module settings during system boot.

• The live settings menu is enabled when the ‘UP’ and ‘DOWN’ buttons of the Primary module are pressed simultaneously for more than 3 seconds.

• The initial settings menu and the live settings menu are very simple menus.

8.2 Initial Settings Menu

• The initial settingsmenuwillappearwhenthesystemdetectsconflictingsettingduringsystemboot,or at initial power up. Each module will display the “SETTINGS” message.

• The Primary module is selected by pressing the ‘ENTER’ button of any module (e.g. Slot 1 module). ThismodulewillbecometheprimarymoduleandtheothermoduleswillbeconfiguredasSecondarymodules.

ENTER

UP

DOWN

Slot 1 Slot 2 Slot 3



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8.3 Initial Settings Menu: Mode Selection

• The next step is the Mode Selection. The mode is changed by pressing the ‘UP’ or ‘DOWN’ buttons of the Primary module. The selection is applied by pressing the ‘ENTER’ button on the Primary module.

• ThebuttonsontheSecondarymodules(Slot2,Slot3)aredisableduntilslot1configurationiscomplete, and display the “SETTINGS” message.

Up/Down

Slot 1Primary

Slot 2 Slot 3



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9.2 Initial Settings Menu: Parallel Mode Finish-Output Voltage Selection Finish

• Whenallmoduleshavebeenconfigured,thesystemstartsthesinglemodeoperationcycle.

Slot 1Up/Down +/- 1V

Slot 2 Slot 3

Slot 1Primary

Main Single Mode Operation

Slot 1Primary

Slot 2

Slot 2

Slot 3

Slot 3

9. Parallel Mode Settings

9.1 Initial Settings Menu: Parallel Mode Output Voltage Selection

• The Output Voltage selection is from -58V to -54V and can be selected by pressing the ‘UP’ and ‘DOWN’ buttons on the Primary module in increments of 1V. The maximum target voltage for the RRUis typically set to -58V.



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10. Single Mode Settings

10.1 Initial Settings Menu: Single Mode Output Voltage Selection

• The Output Voltage selection is from -58V to -54V and can be selected by pressing the ‘UP’ and ‘DOWN’ buttons on the Primary module in increments of 1V. The maximum target voltage for the RRUis typically set to -58V.

10.3 Initial Settings Menu: Single Mode Output Voltage Selection All Modules are Set Finish

• Whenallmoduleshavebeenconfigured,thesystemstartstheoperatinginSinglemode.

10.2 Initial Settings Menu: Single Mode Output Voltage Selection Next Module Setting

• ThesameconfigurationprocedureshouldberepeatedforeachoftheSecondarymodules.

Slot 1Primary

Main Single Mode Operation

Slot 1Primary

Slot 2

Slot 2

Slot 3

Slot 3





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11. Live Settings Menu

11.1 Live Settings

• The live settings menu is displayed by pressing ‘UP’ and ‘DOWN’ buttons of the Primary module simultaneously for more than 3 seconds while the system is running in the main operation cycle. In this menu the modules in each slot are displaying the “SETTINGS” message.

• The Primary module is selected by pressing the ‘ENTER’ button on any module (e.g. Slot 1 module). ThismodulewillbecomethePrimarymoduleandtheothermoduleswillbeconfiguredasSecondarymodules.

Slot 1 Slot 2 Slot 3

UP

DOWN

11.2 New/Previous Configuration Selection

• Next step is the New/Previous Configurationselection.Theconfigurationselectionischangedbypressing the ‘UP’ or ‘DOWN’ buttons on the Primary module. The selection is applied by pressing the ‘ENTER’ button on the Primary module.

Slot 2 Slot 3

Up/Down

Slot 1Primary



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Slot 1Primary

Slot 2 Slot 3

11.4 New/Previous Configuration Selection Previous Configuration in Single Mode

• If the previous configuration is selected and the system was operating in Single Mode, then the

next step for the Secondary modules is the New/Previous Configuration selection and the next step for the Primary modules is the Mode selection.

• Atthisstagethemodulescanbeconfiguredindependentlywiththesameproceedingstepsasfortheinitial settings menu.

Slot 1Primary

Slot 2 Slot 3

11.3 New/Previous Configuration Selection Previous Configuration in Parallel Mode

• If the previous configuration is selected and the system is operating in Parallel Mode, then the

live settings menu is complete.

Slot 1Primary

Slot 2 Slot 3

Slot 2 Slot 3Slot 1Primary



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11.5 New/Previous Configuration Selection New Configuration

• If the new configuration is selected the next step is the initial settings menu regardless of the

previousconfigurationmode(single/parallel).

Slot 1Primary

Slot 1Primary

Slot 2

Slot 2

Slot 3

Slot 3

Initial Settings

12. Bus Bar

12.1 Bus Bar Detection

• Afterenteringallconfigurationsettings,thesystemwillsenseifthebusbarisinstalledontherearoutput terminals.

• If the system is operating in Parallel Mode and the bus bar is not installed, the “PLACE BUS BAR” message will be displayed.

• The bus bar must be installed when the Parallel Mode is selected.

Bus Bar IS installed (Parallel Mode) Bus Bar IS NOT installed (Single Mode)

• If the system is operating in Single Mode and the bus bar is installed, the “REMOVE BUS BAR” message will be displayed.

• The bus bar must be removed when the Single Mode is selected.



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NOTE: Primary Module Failure and Secondary Module Failure is detailed in the System Management section of this document.

13. Alarms

13.1 Front Panel LED and Remote Contact

• Whenever an abnormal condition is encountered, the system will raise an alarm. The front panel’s LED will change from GREEN to RED and the remote contacts will change to the failed position. The maximum rated current of the remote contacts is 2A.

Alarm LED(Green/Red)

RemoteContact Alarm

Alarm Condition

CommonAlarm Condition ClosedAlarm Condition Open

Normal Operation

CommonNormally Open

Normally Closed



Page 26 of 30

Halted Secondary Module

Primary Module

13.2 Overcurrent

• When the current of a Secondary module exceeds the maximum rated current (110A) for more than 3 seconds, the Secondary module will switch to its bypass mode and display the “HIGH CURRENT” message. The Primary module will detect the overcurrent condition of the Secondary module and raise the “MODULE FAILURE” alarm.

Halted Primary Module New Primary Module

• When the current of a Primary module exceeds the maximum rated current (110A) for more than 3 seconds, the Primary will switch to its bypass mode and display the “HIGH CURRENT” message. The Secondary module will detect the overcurrent condition of the Primary module and take control so as to become the Primary module. This new Primary module will raise a “PRIMARY FAILURE” alarm.

13.3 Low Input Voltage

• When the system input voltage is below the minimum voltage (usually the minimum battery voltage), the system will raise an alarm. The Primary module will display the “IN VLT LOW” message if this condition is sustained for more than 3 seconds. The alarm is automatically cleared when the input voltage returns to its normal operation level.

13.4 High Input Voltage

• When the system input voltage is above the maximum voltage, the system will raise an alarm. The Primary module will display the “IN VLT HIGH” message if this condition is sustained for more than 3 seconds. The alarm is automatically cleared when the input voltage returns to its normal operational level.



Page 27 of 30

13.5 Extra Low Input Voltage

• If the system input voltage drops below -38V for more than 200msec, each module in the system will go to bypass and remain in this condition until the input voltage returns to its normal operational level. All modules will display the “EXTRA LOW Vin” message.

13.6 High Secondary Module Temperature

• If while operating in Parallel Mode, the temperature of a Secondary module exceeds its maximum rated internal temperature for more than 3 seconds, the Primary module will detect this condition and isolate the overheated Secondary module (by switching it into its bypass mode). The Secondary module will display the “HIGH TEMP” message and the Primary module will display the ”MODULE FAILURE” message and raise an alarm.

• If while operating in Single mode the temperature of a Secondary module exceeds its maximum rated internal temperature for more than 3 seconds, the module will go to bypass and display the “HIGH TEMP” message. The Primary module detects this condition and raises the “MODULE FAILURE” alarm.

• If while operating in either Parallel mode or Single mode the temperature of a Primary module exceeds its maximum rated internal temperature for more than 3 seconds, the module will go to bypass and will display the “HIGH TEMP” message. The Secondary module will detect the failed Primary module and take over control as the new Primary module and raise the “PRIMARY FAILURE” alarm.


Primary Module


Primary Module

Halted Primary Module New Primary Module



Page 28 of 30

13.7 System Low Temperature

• When the temperature of the system falls below the minimum rated operating temperature (-35ºC) for more than 250 seconds, the modules will go to bypass and remain in this condition until the temperature returns to its normal operating level, and the modules will display the “LOW TEMP” message.

13.9 Module DC/DC Converter Communication Failure

• If a failure of the internal DC/DC converter occurs, the module will halt its output and display the “DC/DC COM FAIL” message.

13.10 Forced By-Pass Condition

• When the system goes to by-pass mode without the control of the module, the module will display the “FORCED BY-PASS” message.

13.8 Module DC/DC Converter Failure

• When a short circuit at the output of a module occurs for more than 20 msec, the module will display the “DC/DC ALERT” message, and halt to prevent any damage to the device.



Page 29 of 30

Notes



Page 30 of 30

PowerPlus System 100-3-1U Series - Raycap · 2020. 7. 14. · The PowerPlus 100-3-1U will increase...

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