Choosing an Appropriate Location
Structural Requirements
The OP14xx test benches are heavy 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.
Available Space
The final location for the OP14xx test bench should take into account the dimensions of the cabinet (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 cabinet in order to gain access to the doors.
Early versions of the OP1400 models had a reduced height of 1270 mm (50").
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) |
Availability of Electrical Connections
The following electrical connections must be made available:
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 for the circuit dimensioning requirements.
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.
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.
Unpacking
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/
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 0.5M | T00-0823 |
| 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 OP1400-60: 12 OP1420 models: 4 |
25 cm white banana cable | SKL425-E/N 4 mm safety test lead 25 cm White | T00-7535 |
| OP14x0-10: 2 OP14x0-20: 4 OP14x0-30: 6 OP1400-60: 12 OP1420-60: 6 |
PDU Disconnect switch knob | SWITCH Padlockable Selector handle for door mounted disconnect switch - must be reinstalled (see instructions bellow) | T00-7159 |
| 1 |
VFEM cables | Remote Sense cables used for improving the Current Control mode operation. | 113-1427 |
| 1 set for each included OP8110 unit |
ITECH Synch cable | On/Off synchronization cable | 113-1588 |
| 1 for each system including more than one ITECH power supply |
Ensure that all items are present and undamaged.
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:
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.
Reassembling the Rack
Installing the DC Power supplies in the rack
The DC power supplies must be stacked inside the cabinet and screwed onto the rails. Simply execute the following steps:
Locate the installation height (using the diagrams below), the mounting screws for the power supply unit(s) will be assembled on the cabinet side rails at this height
Unscrew the screws off the cabinet side rails, reserve them for step 4
Insert the power supplies in their appropriate locations, stacking the bottommost one the pre-installed support brackets inside the cabinet and stacking the other ones (if any) one on top of the other
Install the screws on the cabinet side rails to permanently hold the power supply unit(s) in place
OP1400-10 | OP1400-20 | OP1400-30 | OP1400-40 | OP1400-60 |
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OP1420-10 | OP1420-20 | OP1420-30 | ||
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Installing the OP8110 Amplifiers in the Rack
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:
Locate the installation height of the amplifier units using the diagrams below (-6 amplifiers must be on top of -3 amplifier if both models are present). The slides are preassembled on the cabinet at this height.
Disassemble the inner portion of the slides by sliding them out and by pushing the lock button, reserve them for step 4
Unscrew the mounting screws on the two sides of the amplifier, reserve them for step 4
Assemble the inner portion of the slides onto the amplifiers using the screws
One amplifier at a time, carefully align the amplifier with the mating slides on the cabinet. Once the slides are properly aligned, slide the amplifier into the cabinet, pushing on the lock buttons if necessary.
Screw the amplifiers to the cabinet side rails using the screws that are already present on the side rails.
Slides for OP8110 mounting
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 |
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OP1420-10 | OP1420-20 | OP1420-30 | ||
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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.
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Location of the disconnector switch holes on the PDU | Final alignment of disconnector switch knob | Screw the knob to secure it into place |
Electrical Installation
The electrical installation of the OP14xx products must be performed by qualified personnel only.
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:
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| Optical synchronization cable | Synchronization connectors on OP8110 (rear face) |
The optical synchronization cables must be installed the following way:
| 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 may result in both damage to the amplifier and voiding of the warranty.
OP14x0-10 and OP14x0-20 models don't need synchronization cables since they only have one OP8110 unit.
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 |
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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 rack 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 |
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DC Supply Lines on the OP8110 Amplifiers
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 rack 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:
OP14x0-10 models | OP14x0-20 models |
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OP14x0-30 models | OP14x0-60 models |
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DC Supply Lines on the DC Power Supplies
The DC output cables must be screwed on the DC outputs of all DC power supplies. Locate the DC supply lines inside the rack which have the following appearance:
Install them on the following locations on the DC power supplies. 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:
OP14x0-10/20 models | OP14x0-30/60 models Note: for OP14x0-60 models, there are two DC cables per DC power supply |
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Use a 5mm Allen key to tighten the DC connections.
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:
AC Supply Lines on 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 rack which have the following appearance:
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:
3 Phase AC Mains Supply Line to the PDU
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.
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.
PDU Setup
The customer power cable must be routed through the rear door of the OP14xx rack.
It must then be routed inside the PDU through the pre-installed cable gland.
The OP1400/1420 test bench may be equipped with one of the following PDU models depending on manufacturing date and test bench power:
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):
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):
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):
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.
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.
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.
PDU Electrical Schematic
