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OP1400PR PHIL Prime Test Bench Series Installation
Page Contents
- 1 Choosing an Appropriate Location
- 2 Unpacking
- 3 Installation Procedure - Physical Assembly
- 4 Installation Procedure - Electrical Wiring
- 4.1 Grounding all the boxes in the cabinet
- 4.2 Low-Voltage Wiring
- 4.3 High-Voltage Wiring
- 4.3.1 Installation of the customer Three-Phase Mains supply point
- 4.3.2 Connection from the Three-Phase Mains to the PDU
- 4.3.3 PDU AC supply to the DC Power Supplies
- 4.3.4 DC Supply Connection between the DC Power Supplies and OP8110 Amplifiers.
- 4.3.5 DC Supply connection from the PDU to the OP8110 Amplifiers
- 4.3.6 Synchronization cables on the OP8110 Amplifiers
- 4.3.7 Cable Routing
Choosing an Appropriate Location
Structural Requirements
The OP1400PR 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 is designed to support at least one metric ton (1000 kg) of weight.
Available Space
The final location for the OP1400PR test bench should take into account the dimensions of the cabinet (shown in the image above).
Please note that the two side panels and the rear panel are hinged doors that may need to be open from time to time to reconfigure 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.
The OP1400PR test bench cabinet is equipped with a fan installed at the top for ventilation. Therefore, the top of the cabinet must not be obstructed in any way that will disrupt the airflow from the fan. There must be at least 6 inches of free space between the ceiling and the top of the cabinet.
Environmental Conditions
OPAL-RT requires that the following environmental conditions be met at the installation site of the OP1400PR 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
Two dedicated single-phase power bars (100…240 Vac, 10 A).
Power terminals (3P + PE) for connection to a 380/400/415/480 Vac three-phase supply.
Refer to 3 Phase AC Mains Supply Line to the PDU (Power Distribution Unit) 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 OP1400PR 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.
In addition, please note that OP1400PR-10 and OP1400PR-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 any visible damage or evidence of impact sustained during transit, please inform OPAL-RT Technologies immediately for instructions on how to proceed. Do not continue unpacking/installation or attempt to power on any delivered equipment.
Contact Technical Support (login ou sign-up required).
OP1400PR Test Bench Crate
The test bench cabinet and included components will be received in a crate. The following procedure must be executed to safely unpack the test bench: Uncrating a Large OPAL-RT Hardware Product.
Once the crate has been disassembled, locate the following items and ensure that they are all are present and undamaged.
Please note that certain cables are already installed inside the cabinet based on the connections & signals overview of your test bench.
Item | Description | Part Number | Image | Qty |
|---|---|---|---|---|
Fiber-Optic Transmitters, Receivers SFP | Fiber-Optic Transceiver Module 4.25GBd 850 nm 3.3V for installation on OPAL-RT simulators to enable SFP communication with OP8110 units. | T00-0315 | | OP1400PR-10: 1 |
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 | | OP1400PR-10: 1 |
Ethernet cable | CAT6 (500 MHz) UTP Network Cable - Blue 10 ft | T00-0817 | | For OP8110 connection - (Pre-installed) Additionally, for all test bench models- |
Optical synchronization cable | POF Ind. Plastic Optical Fiber Patch Cords 0.65 m | T00-6615 | | OP1400PR-10: 0 |
Mini-USB cable | Cable USB A - Mini B Black R/A 3 ft | T00-0805 | | 1 |
Ring Terminals to PowerLok (DC) | Cable connecting the ITECH DC output to PDU DC_IN | 113-1729 | | OP1400PR-10: 1 |
PowerLok to banana | Cable connecting the PDU DC_OUT to the power amplifier | 113-1730 | | OP1400PR-10: 1 |
Ring Terminals to PowerLok (AC) | Cable connecting the PDU AC_OUT to the ITECH input power | 113-1731 | | OP1400PR-10: 1 |
Auxiliary power cable | Cable connecting from the PDU AUX to the amplifiers AUX | 113-1732 | | OP1400PR-10: 1 |
25 cm red banana cable | Banana cable connecting the amplifier DC+ inputs of group 1 and group 2 | T00-9659 | | OP1400PR-10: 0 |
25 cm black banana cable | Banana cable connecting the amplifier DC- inputs of group 1 and group 2 | T00-9658 | | OP1400PR-10: 0 |
25 cm white banana cable | SKL425-E/N 4 mm safety test lead 25 cm White | T00-7535 | | OP1400PR-10: 3 |
2m banana cable harness | SLK425-E/N 4 mm safety test lead 200 cm 4 cable harness (Red, Black, Blue and White) | 113-1371 | | OP1400PR-10: 2 |
VFEM cables | Remote measurement cables for the OP8110. | 113-1427 | | OP1400PR-10: 1 set |
ITECH Synch cable | On/Off synchronization cable | 113-1588 | | These cables are shipped with the ITECH connectors attached. The number of cables differs depending on the bench configuration: OP1400PR-10: 0 |
Cable E-STOP to PDU | PDU control cable | 113-1304 | | 1400PR-x0: 1 |
Additional components for test benches that have either the LP and/or the HP bus bar box.
Item | Description | Part Number | Image | Qty |
|---|---|---|---|---|
VFEM cable | VFEM_sensor_Banana_80inch used with the LP bus bar | 113-1428 | | -LP config : 2 sets |
VFEM cable | VFEM_sensor_Cosse_120inch used with the HP bus bar | 113-1429 | | -HP config: 2 sets |
50 cm single banana cable red | SKL425-E/N 4 mm Safety Test Lead 50 cm Red | T00-7239 | | -LP config: 4 |
50 cm single banana cable black | SKL425-E/N 4 mm Safety Test Lead 50 cm Black | T00-7240 | | -LP config: 4 |
ITECH fiber-optic cable | ITECH Optical fiber cable for IT6000 and IT8000 | T00-8856 (IT-E168) | | -LP config: 3 |
Bus Bar control power 24VDC | Brings 24VDC power from the E-Stop Module to the bus bar box. Multiple bus bar boxes will be connected in daisy chaining. | 113-1302 | | -LP config: 1 |
Notes:
1. -LP config refers to any OP1400PR PHIL Prime test bench that has an LP Bus Bar Box installed. For example, OP1400PR-10-LP, OP1400PR-20-LP and so on.
2.-HP config refers to any OP1400PR PHIL Prime test bench that has an HP Bus Bar Box installed. For example, OP1400PR-30-HP and OP1400PR-60-HP.
3. -LPHP config refers to any OP1400PR PHIL Prime test bench that has both an LP Bus Bar Box AND an HP Bus Bar box installed. For example OP1400PR-30-LPHP and OP1400PR-60-LPHP.
Separately Packaged Equipment
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:
| OP1400PR-10 models | OP1400PR-20 models | OP1400PR-30 models | OP1400PR-60 models |
|---|---|---|---|---|
OP8110-3 | 1 | - | 1 | - |
OP8110-6 | - | 1 | 1 | 3 |
IT6006C-500-30 | 1 | - | 3 | - |
IT6012C-500-60 | - | 1 | - | 3 |
Ensure that all these components have been received. Once unpacked, ensure that all items are undamaged.
Installation Procedure - Physical Assembly
There are two sections to the installation procedure:
Physically assembling the rack
Making the electrical connections
Please read each section in full before following the instructions. If any part is unclear or confusing, contact OPAL-RT for assistance.
Always install the boxes 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.
Physical Assembly - Mounting the DC Power supplies
Please follow the steps below:
Determine the mounting height for each DC power supply by referring to the diagrams below, specific to your OP1400PR bench model. The red rectangles indicate the correct locations for the units, where the mounting screws are located on the chassis side rails.
Remove the screws from the chassis side rails, reserve them for step 4.
Insert the power supplies in their appropriate locations, stacking the bottommost one on the pre-installed support brackets inside the chassis and stacking the remaining supplies (if any) on top of one another.
Install the previously removed screws on the side rails to fasten the power supply unit(s) in place.
OP1400PR-10 | OP1400PR-20 | OP1400PR-30 | OP1400PR-60 |
|---|---|---|---|
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Physical Assembly - Mounting the Power Distribution Unit (PDU)
The PDU is configured with removable slides to allow easy manipulation. Carefully align the PDU with the mating slides on the chassis. Once the slides are properly aligned, slide the PDU into the chassis, pushing on the lock buttons if necessary.
Secure the PDU to the chassis side rails using the screws that are already present on the side rails.
Physical Assembly - Mounting the OP8110 Amplifiers
The cabinet is configured with removable slides (as displayed below) to allow easy manipulation of the amplifiers. The following steps must be executed to install these slides on each OP8110 unit:
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.
Disassemble the inner portion of the slides by sliding them out and by pushing the lock button, reserve them for step 4.
Detach the mounting screws from both sides of the amplifier, reserve them for step 4.
Fasten the inner rail of the slides onto the amplifiers using the mounting screws.
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.
Mount the amplifiers to the chassis side rails using the screws that are already present on the side rails.
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 OP1400PR PHIL Prime Test Bench Series Important Safety Information for the detailed procedure.
OP1400PR-10 | OP1400PR-20 | OP1400PR-30 | OP1400PR-60 |
|---|---|---|---|
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Installation Procedure - Electrical Wiring
The electrical installation of the OP14xx products must be performed by qualified personnel only.
Recommended wiring sequence:
Grounding all the boxes in the cabinet
All the necessary grounding cables are located inside the cabinet and they are already connected to the cabinet ground busbar.
Grounding of PDU
The PDU has a dedicated grounding cable that must be connected to the ground terminal on the rear side of the unit. Locate the ground cable which has the following appearance:
Install it in the following location on the PDU:
Grounding of OP8110 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 in the following location on each OP8110 amplifier:
Grounding of E-Stop Module
The E-Stop Module has a dedicated grounding cable that must be connected to the ground terminal on the rear side of the module. Locate the ground cable which has the following appearance:
Install it on the following location on the E-Stop Module:
Grounding of Output Interface box
The Output Interface box has a dedicated grounding cable that must be connected to the ground terminal on the rear side of the box. Locate the ground cable which has the following appearance:
Install it in the following location on the Output Interface box:
Grounding of LP/HP Bus Bar boxes
The LP and HP Bus Bar boxes, each have a dedicated grounding cable that must be connected to the ground terminal on the rear side of the box. Locate the ground cable for each unit which has the following respective appearance:
Install the cable(s) on the following location on the LP/HP Bus Bar box(es), rear panel: