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Table of Contents



1. Choosing an Appropriate Location

1.1. Structural Requirements

The OP14xx test benches are fairly heavy sets of equipment (up to 600 kg for the heaviest models when incorporating optional equipment), thus care should be taken when choosing the installation location for the test bench. OPAL-RT highly recommends that the building structure where the bench will be sitting be designed to support at least one metric ton (1000 kg) of weight not to put stress on the building.

1.2. Available Space


The final location for the OP14xx test bench should take into account the dimensions of the chassis (shown on the image to the left).

Please note that the two side panels and the rear panel are hinged doors that may need to be opened from time to time to reconfigure the wiring or for maintenance reasons. Although it is not necessary to provide permanent clearance for the side and rear doors, it is recommended to at least confirm that there is enough space and enough loose wiring to roll the chassis in order to gain access to the doors.

Early versions of the OP1400 models had a reduced height of 1270 mm (50").

1.3. Environmental Conditions

OPAL-RT requires that the following environmental conditions be met at the installation site of the OP14xx test bench:

Parameter

Ideal

Mandatory

Site location

Inside a temperature controlled laboratory (or equivalent)

Indoors

Temperature

Regulated between 20°C and 30°C 

Between 5°C and 40°C

Site altitude

No more than 2000 m

No more than 2000 m

Relative humidity

Regulated to 50% RH or less

Maximum 80% RH up to 31°C decreasing linearly to 50% RH at 40°C

Pollution

IEC Pollution Degree 2 (or better)

IEC Pollution Degree 2 (or better)

1.4. Availability of Electrical Connections

1.4.1. EU models

• Two dedicated circuits for the monophasic power bars (220Vac 10A), except for OP1400-10 and OP1400-20 which have only one power bar.

• One four wire (3 phase + protective earth) cable to connect to the terminal block inside the test bench. This cable must be connected to a 380/400/415 Vac 3 phase circuit. Refer to 3 Phase AC Mains Supply Line to the PDU (Power Delivery Unit) for the circuit dimensioning requirements.

1.4.2. North American models

• Two dedicated circuits for the monophasic power bars (120Vac 15A), except for OP1400-10 and OP1400-20 which have only one power bar.

• One four wire (3 phase + protective earth) cable to connect to the terminal block inside the test bench. This cable must be connected to a 480 Vac 3 phase circuit. Refer to 3 Phase AC Mains Supply Line to the PDU for the circuit dimensioning requirements.


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Please note that it is theoretically possible to have a negative net power flow (energy fed back to the grid) on the 3 phase AC power line. This could be done using, for example, a PV system or a small wind turbine on a DER input of an OP14xx test bench. The user should note that not all electricity distribution companies will allow customers to feed energy to the grid and should contact their local electricity distributor before attempting to do so.

Please also note that OP14x0-10 and OP14x0-20 models will consume steady state unbalanced currents on its 3 phase AC input, which could lead to penalties being imposed to the user by the local electricity distributor.

Contact your local OPAL-RT sales representative for more information if required.


2. Unpacking

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This equipment has been packaged and shipped in secure conditions. However, when unpacking, check that the equipment has not been damaged during transportation.

If there is obvious damage or any signs of knocks which have occurred during transit, please inform OPAL-RT Technologies immediately. In this case, the equipment should not be powered ON before contacting OPAL-RT and getting instructions on how to proceed.

Contact Technical Support: https://www.opal-rt.com/contact-technical-support/


2.1. OP14xx Test Bench Crate

The test bench cabinet and included components will be received in a crate. The following procedure must be executed in order to safely unpack the test bench: Uncrating a Large OPAL-RT Hardware Product.

Once the crate has been unassembled, locate the following items:

Item

Description

Part Number

Image

Qty

Fiber Optic Transmitters, Receivers SFP

Fiber Optic Transceiver Module 4.25GBd 850nm 3.3V for installation on OPAL-RT simulators to interface through SFP interface

T00-0315

1 for each included OP8110 unit

Fiber optic cable

Multimode Dplx Fiber Cable 62.5/125 LC-LC 2M to connect OPAL-RT simulators to OP8110 through SFP interface

T00-0797

1 for each included OP8110 unit

Ethernet cable

CAT6 (500 MHz) UTP Network Cable - Blue 10FT

T00-0817

1 for each included OP8110 unit

Optical synchronization cable

POF Ind. Plastic Optical Fiber Patch Cords 0.65M

T00-6615

OP14x0-10: 0

OP14x0-20: 1

OP14x0-30: 1

OP14x0-60: 2

Mini-USB cable

Cable USB A - Mini B Black R/A 3FT

T00-0805

1

2m banana cable harness

SLK425-E/N 4 mm safety test lead 200 cm 4 cable harness (Red, Black, Blue and White)

113-1371

OP1400-10: 2

OP1400-20: 4

OP1400-30: 6

OP1400-40: 8

OP1400-60: 12

OP1420 models: 4

25 cm white banana cable

SKL425-E/N 4 mm safety test lead 25 cm White

T00-7535

(or T00-8896)

OP14x0-10: 3

OP14x0-20: 6

OP14x0-30: 9

OP1400-60: 18

VFEM cables

Remote Sense cables used for improving the Current Control mode operation.

113-1427

2 sets for each OP8110-6

1 set for each OP8110-3

ITECH Synch cable

On/Off synchronization cable

113-1588

These cables are shipped with the ITECH connectors attached.

The number of cables change depending on the bench configuration:

  • OP14xx-10 and OP14xx-20 : x0

  • OP14xx-30 and OP1400-60: x2

  • OP1400-40: x3

Additional components for OP1400-60 with an OP1450 (Applicable for projects delivered after September 1st, 2024)
VFEM cableVFEM_sensor_Banana_80inch113-1428

2 sets
VFEM cableVFEM_sensor_Cosse_120inch113-1429

2 sets
OP1450 power cableOP1450 power cable set to client system113-1383

1 set
OP1450 jumper cableOP1450 jumper cable set113-1384

1 set
50 cm banana cable setSLK425-E/N 4 mm safety test lead 50 cm 4 cable harness (Red, Black, Blue and White)113-13776 sets
50 cm single banana cable redSKL425-E/N 4 mm Safety Test Lead 50 cm RedT00-7239

6
50 cm single banana cable blackSKL425-E/N 4 mm Safety Test Lead 50 cm BlackT00-7240

6
ITECH fiber optic cableITECH Optical fiber cable for IT6000 and IT8000

T00-8856

(IT-E168)

3
External bus barCopper bus bar for shorting110-3261

1 (Installed inside the OP1450 depending on project configuration)
Grounding cableGrounding cable (60inch) to shorting bus bar - 8AWGT00-6657

1
1 (Installed inside the OP1450 depending on project configuration)

Ensure that all items are present and undamaged.

2.2. Separately Packaged Equipment

In order to minimize the risk associated with shipping and handling, the following components are removed from the test bench before shipping and are packaged separately:

OP8110 PHIL 4Q Power Amplifier

DC Power supplies

The following quantities of each item should be expected depending on the purchased test bench model:


OP14xx-10 models

OP14xx-20 models

OP14xx-30 models

OP1400-40

OP14xx-60

OP8110-3

1

-

1

-

-

OP8110-6

-

1

1

2

3

IT6006C-500-30

1

-

3

4

-

IT6012C-500-60

-

1

-

-

3

Ensure that all these components have been received. Once unpacked, ensure that all items are undamaged.

3. Installation Procedure - Physical Assembly

There are two sections to the installation procedure: physically assembling the rack and the making the electrical connections. In the physical assembly, the OP8110 amplifiers and I-Tech DC power supplies are mounted on the chassis, and the red, PDU disconnector switch is installed. After the assembly is complete, the electrical connections between the chassis' components are made. 

3.1. Physical Assembly - Mounting the DC Power supplies

The DC power supplies must be stacked inside the chassis and screwed onto the rails. Please follow the steps below:

1. Find the appropriate height to mount the DC power supply. For your particular OP14xx bench please refer to the diagrams below, the sections indicated with the red rectangles are where the DC power supplies ought to be placed. The mounting screws for the power supply unit(s) can be found on the chassis side rails at this height.

2. Remove the screws from the chassis side rails, reserve them for step 4.

3. Insert the power supplies in their appropriate locations, stacking the bottommost one the pre-installed support brackets inside the chassis and stacking the remaining supplies (if any) on top of another.

4. Install the screws on the side rails to fix the power supply unit(s) in place.

OP1400-10

OP1400-20

OP1400-30

OP1400-40

OP1400-60

OP1420-10

OP1420-20

OP1420-30






3.2. Physical Assembly - Mounting the OP8110 Amplifiers

The cabinet is configured with removable slides (as displayed bellow) to allow easy manipulation of the amplifiers. These slides must be reinstalled on the amplifier units in order to reassemble the units on the cabinet. The following steps must be executed:

1. Locate the installation height of the amplifier units using the diagrams below (OP8110-6 amplifiers must be placed on top of OP8110-3 amplifiers if both models are present). The slides are preinstalled on the chassis.

2. Disassemble the inner portion of the slides by sliding them out and by pushing the lock button, reserve them for step 4.

3. Detach the mounting screws from the both sides of the amplifier, reserve them for step 4.

4. Fix the inner rail of the slides onto the amplifiers using the mounting screws.

5. One amplifier at a time, carefully align the amplifier with the mating slides on the chassis. Once the slides are properly aligned, slide the amplifier into the chassis, pushing on the lock buttons if necessary.

6. Mount the amplifiers to the chassis side rails using the screws that are already present on the side rails.

Slides for OP8110 mounting

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titleWhen removing the OP8110 (RMA or maintenance)

In the case that an OP8110 unit needs to me removed from the rack either for an RMA or maintenance, ensure to shut down the PDU before opening the cabinet and starting to unscrew the cables. Refer to OP1400 PHIL Test Bench Series Important Safety Information - Accessing the Inside of the Cabinet for detailed procedure.

The OP8110 and DC power supplies will isolate themselves as soon as the PDU is unpowered, eliminating any risk of electric shock. 


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Always install the amplifier units one at a time, never having more than one unit hanging on its slides. Failure to do so could cause tilting of the cabinet which could result in serious injury.



OP1400-10

OP1400-20

OP1400-30

OP1400-40

OP1400-60

OP1420-10

OP1420-20

OP1420-30





3.3. Installing the PDU disconnector switch cap and knob

The disconnector switch knob of the Power Distribution Unit (or PDU) must be reinstalled. The PDU is located on the rear face of the cabinet. The knob must simply be aligned with the existing disconnector switch holes as in the images below. Ensure the alignement of the "ON" and "OFF" labels are as in the final image. Finally, use a flathead screwdriver to fix the switch into place.









Location of the disconnector switch holes on the PDU

Final alignment of disconnector switch knob

Screw the knob to secure it into place


4. Installation Procedure - Electrical Wiring

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The electrical installation of the OP14xx products must be performed by qualified personnel only.


The steps for wiring the cabinet are fairly straightforward, the main connections between the test-bench components will be done in the same order as the power flows through the OP1400 test-bench. But before the cabinet is wired the Three-Phase AC Mains to the PDU must be installed. Thus, the steps are as follows:

  1. Installation of the Three-Phase Main, and connection to the PDU

  2. Connection from the Three-Phase Main to the PDU

  3. PDU → I-tech DC power supplies

  4. I-tech DC power supplies → OP8110 Amplifiers

  5. Auxiliary AC Supply Lines for the OP8110 Amplifiers

  6. Grounding the OP8110 Amplifiers

  7. Synchronization cables between the Amplifiers

  8. Cable Routing

4.1. Three-Phase AC Main Supply to the PDU

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The electrical installation of the 3 phase AC mains supply line must be performed by qualified personnel only (Certified Electrician or Lab Technician contracted by the customer) and must be in accordance with local electrical codes which typically include (but is not necessarily limited to) requirements such as:

  • Installation of a certified overcurrent protection device (circuit breaker or fuse) on the AC mains line supplying the equipment

  • Dimensioning the electrical wiring and overcurrent protection device with a 25% margin over the maximum specified current of the equipment

  • Installation, on the AC mains line supplying the equipment, of a clearly identified physical disconnect means (such as a disconnect switch or a circuit breaker) within reach of the equipment

Failure to do so could result in risks of fire or electric shock.

Hazardous voltage levels may be present inside the PDU unit. The supply lines (including monophasic power bars) must be completely disconnected before opening the PDU door.


After the PDU is connected to the Three-Phase Main, while the PDU is not energized, make sure that the qualified electrician sets the disconnect switches inside the PDU to “ON.” If this step is not done even when energized the PDU will not allow power to flow to the DC power supplies. Refer to the “PDU Connections with the Three-Phase AC Main” section on how the connections need to be made.


A 4 wire (3 line conductors + 1 protective earth conductor) cable must be connected inside the PDU box of the test bench. The circuit must provide the following voltage levels and frequency:


European models

North-American models

Line to line voltage (RMS)

380 V / 400 V / 415 V

480 V

Frequency

47 Hz to 63 Hz

The circuit must be dimensioned for the following maximum load current:


Maximum line current (RMS)

OP140xx model

European version

North-American version

OP1400-10*

17.5 A

14 A

OP1400-20*

30 A

24 A

OP1400-30

30 A

24 A

OP1400-40*

48 A

38 A

OP1400-60

60 A

48 A

OP1420-10*

17.5 A

14 A

OP1420-20*

30 A

24 A

OP1420-30

30 A

24 A

*Phase currents are unbalanced for these models, worst line current is thus specified

Refer to the ratings label on the equipment in case of doubt.

4.2. PDU AC supply to the DC Power Supplies

The AC supply cables must be screwed on the AC input terminals of all DC power supplies. Locate the AC supply cables inside the chassis which have the following appearance:

AC electrical connections from the PDU

Install them on the following locations on the DC power supplies. Be sure to respect the color schemes as in the images (actual wire colors may vary from image). For OP14x0-30 and OP14x0-60 models, ensure that the AC phases are properly interleaved between the 3 power supplies (as in the image) in order to balance out the currents of the three phases:

OP14x0-10/20 models

OP14x0-30/60 models


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The AC supply lines carry high current, the connections must be properly tightened to avoid resistive connections that could overheat.



Also, make sure to reinstall the plastic covers on top of the connections to provide protection against electric shock:

4.3. DC Supply Connection between the DC Power Supplies and OP8110 Amplifiers.

Now that the PDU has been connected to the DC power supplies, it is now necessary to connect the high power cables between the DC power supplies and the amplifiers. The #113-1277 cable is used to connect these two components. For the DC power supplies the cable uses ring connectors which will be screwed onto the DC terminals. The opposite end of the cable will interface with OP8110 amplifiers via banana plugs. Locate the DC-end of the DC supply cables inside the chassis, they have the following appearance:



Install the DC-end of the 113-1277 cable on the DC power supply terminals, the terminals are indicated by the red circles in the images below. Be sure to not invert the polarity of the cables; red must be on right side, black on left side.

For OP14x0-30 and OP14x0-60 models, ensure that the labels on the DC cables match with the intended numbering scheme, note that the number scheme for some newer benches may be different. If you need clarification please contact OPAL-RT support.

OP14x0-10/20 models

OP14x0-30/60 models

Note: for OP14x0-60 models, there are two DC cables per DC power supply


Use a 5mm Allen key to tighten the DC connections.

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The DC supply lines carry high current, the connections must be properly tightened to avoid resistive connections that could overheat.


Also, make sure to reinstall the plastic covers on top of the connections to provide protection against electric shock:

Newer power supply models have electrode protection cases as indicated below:

4.4. DC Supply connection to the OP8110 Amplifiers

After securing the DC supply cable to the DC power supplies, each OP8110 group (OP8110-3 has 1 group, OP8110-6 has 2 groups) must have its dedicated DC supply lines connected. Locate the DC supply lines inside the chassis which have the following appearance:


Install them on the following locations on the OP8110 amplifiers. Be sure to not invert the polarity of the cables (red must be on left side, black on right side). For OP14x0-30 and OP14x0-60 models, ensure that the labels on the DC cables match with the intended numbering scheme. The numbering scheme may be different on newer PHIL test-benches:

OP14x0-10 models

OP14x0-20 models




OP14x0-30 models

OP14x0-60 models



4.5. Auxiliary Supply Lines on the OP8110 Amplifiers

Each OP8110 group (OP8110-3 has 1 group, OP8110-6 has 2 groups) must have its dedicated Auxiliary supply cable connected. Locate the auxiliary supply cables inside the chassis which have the following appearance:


Install them on the following locations on the OP8110 amplifiers:

OP8110-3 Auxiliary supply connection

OP8110-6 Auxiliary supply connections

Please be careful and align the connectors and auxiliary terminal receptors, if you attempt to force the connection, the amplifier will be severely damaged and will require repair.

4.6. Grounding of OP8110 4Q Amplifiers

Each OP8110 unit has a dedicated grounding cable that must be connected to the ground terminal on the rear side of the unit. Locate the ground cables which have the following appearance:

Install them on the following locations on the OP8110 amplifiers:

OP8110-3 Ground terminal

OP8110-6 Ground terminal

4.7. Synchronization cables on the OP8110 Amplifiers

The OP14x0-30 and OP14x0-60 test benches come with optical synchronization cables that must be installed on the rear face of the OP8110 units:

Optical synchronization cable

Synchronization connectors on OP8110 (rear face)

The optical synchronization cables must be installed the following manner:

OP14x0-30 models

OP14x0-60 models


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The fiber optic synchronization cables cannot be flexed or folded. If they are too long and must be wrapped, the user should gently wrap them in a circle and tie them without applying excessive pressure.

Additionally, the OP8110's synchronization cables should neither be connected nor removed during amplifier operation.

Doing so mayresult in both damage to the amplifier and voiding of the warranty.



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OP14x0-10 and OP14x0-20 models don't need synchronization cables since they only have one OP8110 unit.


4.8. Cable Routing

The customer power cable must be routed through the rear door of the OP14xx chassis.

It must then be routed inside the PDU through the pre-installed cable gland.

4.9. PDU Electrical Schematic

4.9.1. PDU Connections with the Three-Phase AC Main

The OP1400/1420 test bench may be equipped with one of the following PDU models depending on manufacturing date and test bench power:


Expand
titleLow Power PDU (Pre-Aug. 2021)

The early models of OP1400/1420 test benches have a slightly different wiring scheme of the PDU. For these models, the 3 line wires must be connected to the top portion of the disconnect switch attached to the door (see image below):


Expand
titleLow Power PDU (Aug. 2021-Nov. 2022)

This PDU version has a slightly different wiring scheme. The 3 line wires must be connected to the top portion of the circuit breaker inside the PDU. The protective ground wire must be connected to the bottom-most connector hole of terminal box located on the lower right corner of the PDU box. Take note that this connector hole is shared with another protective ground wire, (see image below):


Expand
titleLow Power PDU (current model)

This Low Power PDU version has been introduced after Nov. 2022. The 3 line wires must be connected to the top portion of the circuit breaker inside the PDU. The protective ground wire must be connected to the top of the ground terminals located on the lower side of the PDU box, (see image below):


Expand
titleMedium Power PDU (current model)

The OP1400-40 models require the Medium Power PDU version. This setup provides over current protection fuses for the Itech cables.

For these models, the 3 lines plus the ground wires must be connected to the bottom of the customer power terminals.

Attention! This PDU model is rated maximum 60A, continuous duty. The customer must provide over current protection not exceeding 60A!

The AC Input cable and the Itech Power Supplies cables pass via cable clamps located at the bottom of the box.


Expand
titleHigh Power PDU (Door Mounted)

The OP1400-60 models require the High Power PDU version. This setup has the PDU installed attached to the rear cabinet door.

For these model, the 3 line wires must be connected to the top of the power breaker.

The AC Input cable and the Itech Power Supplies cables pass via cable clamps located at the bottom of the box.


Expand
titleHigh Power PDU (current model)

The OP1400-60 models require the High Power PDU version. This setup provides over current protection fuses for the Itech cables.

For these models, the 3 lines plus the ground wires must be connected to the bottom of the customer power terminals.

Attention! This PDU model is rated maximum 80A, continuous duty. The customer must provide over current protection not exceeding 80A!

The AC Input cable and the Itech Power Supplies cables pass via cable clamps located at the bottom of the box.