Raycap PowerPlus System 100-3-1U Series Operation and maintenance manual

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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

INSTALLATION INSTRUCTION & OPERATION MANUAL PowerPlus System 100-3-1U
www.raycap.com
© Raycap | All rights reserved. •(320-1398) QRC | Rev.A
Page 1 of 34
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 ...................................................................................................................................5
5.1 Functionality ......................................................................................................................................5
5.2 Modes of Operation...........................................................................................................................5
5.3 System Topology ...............................................................................................................................6
 5.4 InstallationCongurations.................................................................................................................7
 5.5 ModuleCongurations .................................................................................................................8-12
6. System Management................................................................................................................................13
6.1 Modules...........................................................................................................................................13
6.2 Module Failure.................................................................................................................................14
6.3 Primary Failure................................................................................................................................14
7. Modules.....................................................................................................................................................15
7.1 Module Replacement ......................................................................................................................15
7.2 Cold Module Replacement..............................................................................................................16
7.3 Hot Module Replacement................................................................................................................16
7.4 Hot Module Replacement: Invalid Module Installation.....................................................................16
8. Module Settings........................................................................................................................................17
8.1 Settings Menus ...............................................................................................................................17
8.2 Initial Settings Menu........................................................................................................................17
8.3 Initial Settings Menu: Mode Selection .............................................................................................18
9. Parallel Mode Settings .............................................................................................................................18
10. Single Mode Settings...............................................................................................................................21
11. Live Settings Menu...................................................................................................................................24
12. Bus Bar......................................................................................................................................................26
13. Alarms .......................................................................................................................................................27

PowerPlus System 100-3-1U INSTALLATION INSTRUCTION & OPERATION MANUAL
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(320-1398) QRC | Rev.A •© Raycap | All rights reserved.
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1.0 Copyright
©Raycap, Inc. 2020 - All Rights Reserved
1.1 Disclaimer
Theinformationinthisdocumentissubjecttochangewithoutnoticeanddescribesonlytheproductdenedintheintroduction
of this documentation. This documentation is intended for the use of Raycap customers only for the purposes of the agreement
underwhichthedocumentissubmitted,andnopartmaybeused,reproduced,modiedortransmittedinanyformormeans
without 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 Warnings
Please 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
riskofre,electricshock,orinjurytopersons.
CAUTION – Do not operate the product if it has been damaged in any way. Return damaged products to their manufacturer for
repair or replacement.

INSTALLATION INSTRUCTION & OPERATION MANUAL PowerPlus System 100-3-1U
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© Raycap | All rights reserved. •(320-1398) QRC | Rev.A
Page 3 of 34
2.0 Introduction
In 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®SPDtechnologysignicantlyenhancethereliability&availabilityoftheRRHsitebyprovidingsuperiorelectrical
protection at the RRH and BBU. PowerPlus is Raycap’s solution for an intelligent and dynamic power transmission to the RRH
units of a DAS Telecommunication site. PowerPlus is a system installed at the PSU output that increases the voltage at the
base of a cellular site to compensate the voltage drop on the DC power cables that provide power to the RRHs.
3.0 Package Contents
1 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 Prerequisites
This document describes how to install the 100-3-1U on-site and how to program the modules.
InstallersofRaycap’sRRHber/powermanagementsolutionsmustbeindustryprofessionalswhohaveattendedtrainingon
theproperhandlingandinstallationofber-opticcable,andattendedtrainingontheinstallationoftheequipmentbyRaycap
and/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) 10mm wrenches

PowerPlus System 100-3-1U INSTALLATION INSTRUCTION & OPERATION MANUAL
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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.
4.5 Release the 4 push pins
and remove touch guard
as shown below.
1U

INSTALLATION INSTRUCTION & OPERATION MANUAL PowerPlus System 100-3-1U
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5. General Description
5.1 Functionality
• The PowerPlus 100-3-1U system is a dynamic smart system that can boost the voltage of a telecom
power supply in order to reduce the current on the power cables according to the power demands of
the radio.
• Thusthecablepowerlosesarereducedandthetotalsystembecomesmoreefcient.
• Additionally the PowerPlus 100-3-1U is very effective when backup batteries are supplying power
during a power outage. The PowerPlus 100-3-1U will increase the input voltage to the radio while the
battery voltage decreases due to discharging. Then the radio can operate for a longer period on the
battery supply.
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 may be connected to an individual load when the device is
conguredtooperateinSingle Mode.
• Theoutputsofthemodulesmaybeconnectedinparallelwhenthedeviceisconguredtooperatein
Parallel Mode.Inthisconguration,theloadissharedamongeachoftheinstalledmodules.
PowerPlus 100-3-1U Connection Diagram
AC/DC
Converter
-54Vdc -54Vdc-54Vdc + ∆V
Utility PowerPlus
Rack Mount
Unit Module
Raycap
OVP
(Base)
Raycap
OVP
(Tower Top)
Voltage Drop
on DC Cable
(∆V)
RRH
Battery
Bank

PowerPlus System 100-3-1U INSTALLATION INSTRUCTION & OPERATION MANUAL
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5.3 System Topology
-48VDC
OUT 1
-48VDC
OUT 2
-48VDC
OUT 3
-48VDC
IN
RTN OUT RTN IN GROUND

INSTALLATION INSTRUCTION & OPERATION MANUAL PowerPlus System 100-3-1U
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Page 7 of 34
5.4 Installation Congurations
PowerPlus100-3-1Usystemcongurations
SINGLE
-48VDC OUT 3
-48VDC OUT 2
-48VDC OUT 1
RTN OUT
-48VDC
RTN
GND
DC
PS
PARALLEL
-48VDC OUT
RTN OUT
DC
PS
-48VDC
RTN
GND

PowerPlus System 100-3-1U INSTALLATION INSTRUCTION & OPERATION MANUAL
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5.5 Single Module Conguration
PDU
RTMDC-5634-PF-48
RNSNDC-7771-PF-48
RTMDC-4983-RM-48
-48V
OUT
-48V
IN
Return
OUT
Return
IN
GROUND
Power Plus
Conguration 1 (For applications requiring 100 AMPS or less)
100 AMP
Breaker
Recommended Lugs
For 2 Gauge Use:
Panduit LCD2-14-Q
for Input & Output
For 6 Gauge Use:
Panduit LCD6-14A
for Ground
USE ONLY 2 GAUGE COPPER WIRE FOR INPUT & OUTPUT
100 AMP
Module
Installed
Trunk to
Upper OVP
Use 6 gauge
copper wire
for ground

INSTALLATION INSTRUCTION & OPERATION MANUAL PowerPlus System 100-3-1U
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5.6 2-Module in Single Conguration
PDU
Power Plus
-48V
OUT
-48V
IN
Return
OUT
Return
IN
GROUND
RTMDC-5634-PF-48
RNSNDC-7771-PF-48
RTMDC-4983-RM-48
Conguration 2 (For applications requiring 200 AMPS or less)
200 AMP
Breaker
Recommended Lugs
For 2 Gauge Use:
Panduit LCD2-14-Q
for Input & Output
For 6 Gauge Use:
Panduit LCD6-14A
for Ground
Use 6 gauge
copper wire
for ground
USE ONLY 2 GAUGE COPPER WIRE FOR INPUT & OUTPUT
100 AMP
Module
Installed
100 AMP
Module
Installed
Trunk to
Upper OVP

PowerPlus System 100-3-1U INSTALLATION INSTRUCTION & OPERATION MANUAL
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PDU
Power Plus
-48V
OUT
-48V
IN
Return
OUT
Return
IN
GROUND
RTMDC-5634-PF-48
RNSNDC-7771-PF-48
RTMDC-4983-RM-48
200 AMP
Breaker
Recommended Lugs
For 2 Gauge Use:
Panduit LCD2-14-Q
for Input & Output
For 6 Gauge Use:
Panduit LCD6-14A
for Ground
USE ONLY 2 GAUGE COPPER WIRE FOR INPUT & OUTPUT
Conguration 3 (For applications requiring 200 AMPS or less)
100 AMP
Module
Installed
100 AMP
Module
Installed
Trunk to
Upper OVP
5.7 2-Module in Parallel Conguration
Use 6 gauge
copper wire
for ground

INSTALLATION INSTRUCTION & OPERATION MANUAL PowerPlus System 100-3-1U
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Page 11 of 34
5.8 3-Module in Single Conguration
PDU
Power Plus
-48V
OUT
-48V
IN
Return
OUT
Return
IN
GROUND
RTMDC-5634-PF-48
RNSNDC-7771-PF-48
RTMDC-4983-RM-48
Conguration 4 (For applications requiring 300 AMPS or less)
300 AMP
Breaker
USE ONLY 1/Ø GAUGE COPPER WIRE FOR INPUT
USE ONLY 2 GAUGE COPPER WIRE FOR OUTPUT
100 AMP
Module
Installed
100 AMP
Module
Installed
100 AMP
Module
Installed
Trunk to
Upper OVP
Use 6 gauge
copper wire
for ground
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

PowerPlus System 100-3-1U INSTALLATION INSTRUCTION & OPERATION MANUAL
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5.9 3-Module in Parallel Conguration
PDU
Power Plus
-48V
OUT
-48V
IN
Return
OUT
Return
IN
GROUND
RTMDC-5634-PF-48
RNSNDC-7771-PF-48
RTMDC-4983-RM-48
Conguration 5 (For applications requiring 300 AMPS or less)
300 AMP
Breaker
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
USE ONLY 1/Ø GAUGE COPPER WIRE FOR INPUT
USE ONLY 2 GAUGE COPPER WIRE FOR OUTPUT
100 AMP
Module
Installed
100 AMP
Module
Installed
100 AMP
Module
Installed
Trunk to
Upper OVP
Use 6 gauge
copper wire
for ground

INSTALLATION INSTRUCTION & OPERATION MANUAL PowerPlus System 100-3-1U
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Page 13 of 34
6. System Management
6.1 Modules
• There is always a primary module in the rack which controls the proper operation of the whole
system in parallel mode or in single mode.
• When a failure occurs the primary module will coordinate the response to this event.
• When the primary module fails, another secondary module will overtake control of the system as
primary.
• All modules in single mode will display the input and output voltage of the system. The primary
moduleisindicatedbyan“P”characterwhichislocatedattheendoftheinputvoltagevalue(rstline
of the display).
• The primary module in the parallel mode will display the input and output voltage of the system. The
secondary modules will display “Module 1” and “Module 2” messages.
Single Primary Single Secondarys
Parallel Primary Parallel Secondarys

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6.2 Module Failure
• When a secondary module fails the primary module will disable this secondary module and will
raise an alarm. In this case the panel LED will change from GREEN to in RED, the remote contact
state will change to Failed and the primary will display “MODULE FAILURE” message.
• After removing the failed secondary module, the primary module will search for a new module to be
installed.Whenthisoccurs,theprimarymodulewilltransferallnecessarydata(systemconguration,
cable resistance etc.) to the new secondary module.
• The alarm will be 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 all the necessary data
(systemconguration,cableresistanceetc.)tothenewmodule.Thenewmodulewillbecongured
as a new secondary module.
• The alarm will disappear after pressing the ‘ENTER’ button on the current Primary module for more
than 3 seconds.
ENTER

INSTALLATION INSTRUCTION & OPERATION MANUAL PowerPlus System 100-3-1U
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7. Modules
7.1 Module Replacement
• Unscrew the thumb screws on both
sides of module.
• Release the side levers out.
• Pull out the device.

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7.2 Cold Module Replacement
• Cold Module Replacement is the replacement of a module when the system is off.
• Every module stores the settings of all other modules which participate in the 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 waiting for new settings to be
input. This is the start 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 start point of the initial settings menu.
7.3 Hot Module Replacement
• Hot Module Replacement is the replacement of a module when the system is running.
• 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
• Ifasystemisconguredandhas1or2emptyslots(ineitheroperationalmodei.e.parallel/single),
any hot module installation in any empty slot is invalid. The invalid module will display
“REMOVE MODULE” and the invalid module must be removed.
• If there is a cold module installation inopenslot(s)(ineitheroperationalmodei.e.parallel/single),
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 settingsmenuwillappearwhenthesystemdetectsconictingsettingduringsystemboot,
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).
Thismodulewillbecometheprimarymoduleandtheothermoduleswillbeconguredassecondary
modules.
Slot 1 Slot 2 Slot 3
ENTER
UP
DOWN

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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 of the Primary module.
• The buttons of the secondary modules (Slot 2, Slot 3) are disabled in this stage. The secondary
modules also are displaying the “SETTINGS” message.
9. Parallel Mode Settings
9.1 Initial Settings Menu:
Parallel Mode System Units Selection
• In Parallel Mode selection the next step is the System Units selection. There are two types of
system units “Imperial” and “Metric”. The system units are changed by pressing the ‘UP’ or ‘DOWN’
buttons of the primary module. The selection is applied by pressing the ‘ENTER’ button of the primary
module.
• The secondary modules (Slot 2, Slot 3) in this stage will display “SETTINGS OK” since they are
waiting for common settings from the primary module.
Up/Down
Slot 1
Primary
Slot 2 Slot 3
Up/Down
Slot 1
Primary
Slot 2 Slot 3