Verizon Wiring Manual PowerShift 10 January 2018
1. General DISCLAIMER: This document has been developed by CommScope, and is intended for the use of its customers and customer support personnel. The information in this document is subject to change without notice. While every effort has been made to eliminate errors, CommScope disclaims liability for any difficulties arising from the interpretation of the information contained herein. The information contained herein does not claim to cover all details or variations in equipment, nor to provide for every possible incident to be met in connection with installation, operation, or maintenance. This document describes the performance of the product under the defined operational conditions and does not cover the performance under adverse or disturbed conditions. Should further information be desired, or should particular problems arise which are not covered sufficiently for the purchaser s purposes, contact CommScope. CommScope reserves the right to change all hardware and software characteristics without notice. COPYRIGHT: Copyright 2016 CommScope Inc. All Rights Reserved. This document is protected by copyright. No part of this document may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical photocopying, recording, or otherwise without the prior written permission of CommScope. www.commscope.com TRADEMARKS All trademarks identified by or are registered trademarks or trademarks, respectively, of CommScope. Names of products mentioned herein are used for identification purposes only and may be trademarks and / or registered trademarks of their respective companies. CommScope, Inc. of North Carolina, December-2018 PowerShift units are Patent Pending TABLE OF CONTENTS 1. GENERAL 3 2. POWERSHIFT TECHNICAL SUPPORT 3 3. REFERENCES 3 4. INTRODUCTION 3 5. NEW CABINET WIRING 4 6. RETROFIT CABINET WIRING ERROR! BOOKMARK NOT DEFINED.5 7. RETROFIT SHELTER WIRING ERROR! BOOKMARK NOT DEFINED.6 8. TEST PROCEDURES: NEW EQUIPMENT CABINET 18 9. TEST PROCEDURES: RETROFIT CABINET OR SHELTER 18 10. HEAT LOAD & WEIGHT 19 11. SAFETY 20 PowerShift - Verizon Wiring 20 Jan 18 5-2-18 Page 2
1. General 1. General About CommScope CommScope is the foremost supplier of one-stop, end-to-end Wireless Product solutions. Part of the CommScope portfolio are complete solutions for wireless infrastructure from top-of-the-tower base station antennas to cable systems and cabinets, RF site solutions, signal distribution, DC Power and network optimization. For patents related to this, and other CommScope products, see www.cs-pat.com. CommScope has global engineering and manufacturing facilities. In addition, it maintains field service engineering offices throughout the world. The declaration of conformity for our products is available upon request from the local sales offices or directly from CommScope www.commscope.com. 2. PowerShift Technical Support For technical assistance and support, please contact the PowerShift technical support team. Website: https://www.commscope.com/wisupport/ Phone: +1-888-297-6433 Contact CommScope for the User Manual, Installation Bulletins, Site Reports, Site Survey form or assistance with generating Site Material Lists. 3. References It is important to review the applicable PowerShift specifications, installation documents and installation kits when using this document to plan for product installation and to understand product operation after installation. Refer to the following CommScope PowerShift product web page for more information: http://www.commscope.com/solutions/power-solutions/ 4. Introduction The purpose of this bulletin is to address the proper material and method of wiring PowerShift V2 in a shelter or a cabinet. Reference Document Verizon Network Standard NST47 Dated 202/15/17 and DC Power System Design, by Whitham D. Reeve. Assuming a maximum of 1320 watt RRU, 500 foot run of trunk cable and a Minimum battery voltage of 36 volts the maximum input current into PowerShift is 45 amps. Recommended DC circuit breaker size is 50 amps. PowerShift V2 output is electrically limited to 40 amps maximum in bypass mode (highest possible current mode) to assure flexible cords do not exceed NEC current limitations. If there are any deviations to this wiring permission is required from Verizon. PowerShift User Manual Page 3
5. New Cabinet Wiring Air Flow Direction ============ Air Flow Direction ============ Page 4 PowerShift User Manual
For other configurations contact CommScope Recommended Tools Type Manufacture Part Number Lug Crimper Burndy Y122CMR or Y1MRTC Wire Strippers Klein 11053 for 6 AWG to 12 AWG Wire Strippers Screw Driver Southwire Klein Insulated #2 Phillips S612STR for 6 AWG to 12 AWG 33532-INS Nut Driver Klein Insulated 7/16 646-7/16-INS 9 Cable Cutter Southwire CCP9 Scissors Southwire ES0001 Label Maker Dymo Dymo 160 Heat Gun Dewalt 26950 Jeweler's Screwdriver Generic Generic Wire Strippers 16-22 AWG Generic Generic PowerShift User Manual Page 5
Approved Material Lug Table Wire Table Wire Wrap Wax Twine String (or wrap around adhesive backed labels for new cabinets) Cable Marking Clearly mark power, return and ground conductors. -48, RTN, GRD and Circuit 1 through 12 DC Input 6 AWG 90C RHH/RHW PowerShift DC Output 6 AWG 90C RHH/RHW Raycap Panel OVP Raycap Panel OVP Note: Minimum bend radius of 6 AWG is 2.0 inches. When looking from the back of the cabinet - Dress the input cable to the right in such a way as to allow accessibility to the other equipment in the cabinet. Start from the edges (Circuits 1, 5 & 9) and work toward the middle. Page 6 PowerShift User Manual
Step 1 Install the alarms and data cables as shown below. Note: you may want to provide pigtail connections to the Ethernet and GP bus since getting to these ports may be difficult after the power conductors are installed. Label wires as PowerShift Alarm Major, PowerShift Alarm Minor, PowerShift LAN, PowerShift GP Bus and PowerShift RS485. Step 2 Wire Alarms as shown above to the normally open alarm contacts. Step 3 Install power cables to the back of the shelf. Starting from the outside and going towards the middle. It is recommended to wire the entire backplane with the appropriate bypass wired in for the RRU s that are not planned to use a module. The mapping should be CB 1 to Circuit input #1, CB 12 to Circuit 12. Label as -48 CB1, RTN CB1, etc. PowerShift User Manual Page 7
Connection and Label Details Page 8 PowerShift User Manual
First Column Wired and Labeled PowerShift User Manual Page 9
Distribution Connections for the First Row View of the Alarm and Data Connections Page 10 PowerShift User Manual
Step 4 - If Raycap panel mounts are included wire to those using the 6 AWG RHH 90C GR-347-CORE Gray color conductors. Use the wire mapping in the table below. If there are no Raycap Rack Mount OVP s then a bottom box will be used and the installer will be attaching the outdoor power cable to the output of the PowerShift. PowerShift Output Circuit 1 Circuit 2 Circuit 3 Circuit 4 Circuit 5 Circuit 6 Circuit 7 Circuit 8 Circuit 9 Circuit 10 Circuit 11 Circuit 12 Raycap 6 RRU Rack Mount Input RM1 OVP1 RM1 OVP2 RM1 OVP3 RM1 OVP4 RM1 OVP5 RM1 OVP6 RM2 OVP1 RM2 OVP2 RM2 OVP3 RM2 OVP4 RM2 OVP5 RM2 OVP6 PowerShift User Manual Page 11
Raycap Rack Mount OVP Wired and Labeled Page 12 PowerShift User Manual
PowerShift Output Wired and Labeled Two Raycap Rack Mount OVP s Wired and Labeled PowerShift User Manual Page 13
Step 5 - Ground PowerShift and Raycap Rack Mount Chassis to the Equipment Frame Ground using Burndy or Thomas & Betts Standard barrel two-hole Lug for ¼-20 studs, 5/8 hole spacing with inspection windows. All crimp tools and dies must be UL approved for use with the type of lug selected. PowerShift Completely Wired and Grounded for 12 RRU s Step 6 Test unit per the Test procedure at the end of this bulletin. Note: Wiring must include input power to circuit number 1 as a minimum, it is recommended to power up circuit 5 and circuit 9 for input power redundancy. Page 14 PowerShift User Manual
6. Retrofit Cabinet Wiring 6. Retrofit Cabinet Wiring Installing PowerShift in a retrofit cabinet is like the procedures for a new cabinet with the following exceptions: 1. To minimize site downtime plan as much pre-work as possible and make sure all the necessary material is available. A site survey is highly recommended. CommScope can assist in the material list generation for this type of site. 2. If possible, make sure that rack space and cable runs are planned or even installed ahead of time. Approved material Same as the material in the New Cabinet Section. There is a difference in wiring depending on whether an outdoor bottom box is used in lieu of a rack mount panel. Step 1 During approved downtime turn off power to the cabinet and place warning sticker on disconnect if out of view. Move the equipment if needed then install the PowerShift. Remove input cable from the circuit breakers to the OVP panel. Step 2 Install the alarms and data cables as shown below. Note: you may want to provide pigtail connections to the Ethernet and GP bus since getting to these ports may be difficult after the power conductors are installed. Step 3 Install power cables to the back of the shelf. Starting from the outside and going towards the middle. It is recommended to wire the entire backplane with the appropriate bypass wired in for the RRU s that are not planned to use a module. The mapping should be CB 1 to Circuit input #1, CB 12 to Circuit 12. Step 4 - If Raycap panel mounts are included wire to those using the 6 AWG RHH 90C GR-347-CORE Gray color conductors. Use the wire mapping in the table below: Step 5 - Ground PowerShift and Raycap Rack Mount Chassis to the Equipment Frame Ground using Dual Hole lug and minimum 6 AWG RHH conductors. Step 6 Install faceplate and bypass any planned unused slots. Step 7 Test unit per the Test procedure at the end of this bulletin. Step 8 Install proper labels into the GUI interface. PowerShift User Manual Page 15
7. Retrofit Shelter Wiring 7. Retrofit Shelter Wiring Installing PowerShift in a retrofit shelter is like the procedures for a new cabinet with the following exceptions: 1. To minimize site downtime plan as much pre-work as possible and make sure all the necessary material is available. A site survey is highly recommended. CommScope can assist in the material list generation for this type of site. 2. If possible, make sure that rack space and cable runs are planned or even installed ahead of time. 3. If you can separate each conductor from the others by one diameter, then 6 AWG RHH 90C conductors can be used. (copied from dc Power System Design for Telecommunications, Author Whitham D. Reeve.) Page 16 PowerShift User Manual
7. Retrofit Shelter Wiring Approved material Same as the material in the New Cabinet Section. Step 1 During approved downtime turn off power to the cabinet and place warning sticker on disconnect if out of view. Move equipment if needed then install PowerShift. Remove input cable from the circuit breakers to the OVP panel. Step 2 Install the alarms and data cables as shown below. Note: you may want to provide pigtail connections to the Ethernet and GP bus since getting to these ports may be difficult after the power conductors are installed. Label as. Step 3 Install power cables to the back of the shelf. Starting from the outside and going towards the middle. It is recommended to wire the entire backplane with the appropriate bypass wired in for the RRU s that are not planned to use a module. The mapping should be CB 1 to Circuit input #1, CB 12 to Circuit 12. Label as. Step 4 - If Raycap panel mounts are included wire to those using the 6 AWG RHH 90C GR-347-CORE Gray color conductors. Use the wire mapping in the table below: Step 5 - Ground PowerShift and Raycap Rack Mount Chassis to the Equipment Frame Ground using Dual Hole lug and minimum 6 AWG RHH conductors. Step 6 Test unit per the Test procedure at the end of this bulletin. PowerShift User Manual Page 17
8. Test Procedures: New Equipment Cabinet 8. Test Procedures: New Equipment Cabinet Test Material -Ohmmeter Test purpose Assure the system is wired correctly. Step 1 Use ohmmeter to check all connections and proper polarity from distribution panel to the input to PowerShift. If there is a Raycap rack mount OVP check all connections and polarities. 9. Test Procedures: Retrofit Cabinet or Shelter Test Material Test purpose Assure the system is wired correctly. CommScope Cabinet Test Set-up Laptop Computer Ohmmeter, Voltmeter Step 1 Remove the input power connector to each RRU and make sure, if there are any exposed wires they are rendered safe. Step 2 Turn on CB 1 and 2. Verify V1 and V2 appear on the proper RRU readouts in the GUI. Turn Circuit breaker 1 and 2 off. Record values. Step 3 Turn on CB 3 and 4. Verify V3 and V4 appear on the proper RRU readouts in the GUI. Turn Circuit breaker 3 and 4 off. Record values. (do not install module but test if faceplate is in slot but check voltages to make sure the proper RRU voltages appear). Step 4 Install special Module and fail circuit one. Check that the major and minor alarm contacts close and red LED lights up on module. Step 5 Turn site up and monitor traffic for a minimum of 30 minutes. Page 18 PowerShift User Manual
10. Heat Load The PowerShift Circuitry is 97% efficient at typical loads and rectifier voltage levels. The efficiency be affected by input voltage and temperature. The efficiency for 95% at 43-volt input voltage. Configuration Heat Load 1320W Heat Load 1440W Heat Load 1600W 3 RRU - 200' 128 140 157 6 RRU - 200' 255 280 314 9 RRU - 200' 383 420 471 12 RRU - 200' 511 561 628 3 RRU - 500' 141 156 177 6 RRU - 500' 282 312 353 9 RRU - 500' 423 468 530 12 RRU - 500' 564 624 706 Chart shows heat generation in watts based on RRU DC Power Consumption and Length of 6 AWG Trunk 11. Weight Empty Shelf 29 lbs. Circuit Module 4 lbs. Bypass Module 2 lbs. Controller 1 lb. RS485 Card 1 lb. Configuration Populated Weight (lbs.) 3 RRU 45 6 RRU 51 9 RRU 63 12 RRU 69
12. Safety 1. Equipment room/cabinet cooling may be required based on Section 10. 2. Do not install equipment over combustible surfaces. 3. Follow all national and local rules and regulations for field connections. 4. Use listed/certified compression connectors to terminate listed/certified field wire conductors. 5. Install, service, and operate equipment only by professional skilled and qualified personnel. 6. Grounding-connect the equipment chassis directly to ground, in enclosed equipment cabinets connect to the cabinet AC service ground bus, in huts, vaults, and central office connect to the system bonding network. 7. Connections with shielded cabling must be grounded at both ends. Page 20 PowerShift User Manual