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This document provides the standard Site Acceptance Test (SAT) procedure for the OP1400PR test bench. It only covers the unparalleled independent operation in three-phase 120 Vrms output configuration in voltage control mode. However, there may be other output configurations and modes tested on site, depending on your specific test bench model and risk assessment done prior to the visit of the OPAL-RT FAE.

It is recommended to continue with this procedure only after completing the installation of the test bench, to ensure proper functioning of all modules.

Validating the Electrical Wiring Inside the Cabinet

Ground Connections

The following checks should be made:

• Visually inspect ground connections of all the modules. Particular attention should be given to the ground connections of the OP8110 amplifiers as they are installed on site (see image below).

• Validate that all ground connections are properly fastened/tightened

• Using a multimeter, perform a continuity measurement between the test bench chassis (any bare metal part of a module or the cabinet) and the building ground (for example metal conduit, junction box, exposed ground wire), to ensure that the measured resistance is less than 1 Ohm.

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Location of the Protective Earth (PE) connection for OP8110

DC Supplies Power Connections

For each DC power supply, validate that:

• DC output cables are properly installed (black wire to the negative terminal, red wire to the positive terminal)

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• AC input cables are properly installed (red, black, blue wires present, green/yellow wire on to the ground screw)

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• Verify that all wires are properly secured by gently pulling each wire by hand. No movement should be observed.

• If 3 DC Power supplies are present, validate that line wires are interleaved such as in the image below (actual wire colors may vary from the image!).

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Interleaving of line wires when 3 DC Power supplies are present

OP8110 Amplifier Connections

Optical Synchronization cables

Test benches with more than one OP8110 unit require optical synchronization cables. If the test bench has more than one OP8110 unit inside it, validate that the optical synchronization cables are present and are installed the following way:

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OP14x0-30 models

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OP14x0-60 models

Auxiliary Supply

Visually check that every amplifier group has its auxiliary supply cable inserted into the associated ports shown in the images below. Verify by hand that the connectors are properly tightened.

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OP8110-3 Auxiliary supply connection

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OP8110-6 Auxiliary supply connections

High-voltage DC supply

Validate that the DC inputs of each amplifier group are connected and that polarity is respected (red on the left, black on the right), refer to table below, or OP1400PR-60 models, the two amplification groups of each OP8110 share a single DC cable. Red and black jumper cables are provided to interconnect the DC inputs of the two amplification groups.

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OP1400PR-10 models

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OP1400PR-20 models

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OP1400PR-30 models

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OP1400PR-60 models

Signal and Control Harnesses

Signal and control harnesses (connected between modules within the test bench) are installed and secured at the OPAL-RT factory before shipping and should not require any manipulation by the user. However, it is recommended to visually inspect the inside of the test bench to ensure that there are no free-hanging harness connectors. If there happens to be some, please contact your local OPAL-RT representative so we can assist you in correctly reconnecting them appropriately.

Validating the Control Equipment

Please refer to the Operation section of this manual if unexpected results are obtained.

Supplying the Control Equipment

The OP1400PR test benches are assembled with universal 100-240Vac power bars which supply the various control equipment in the test bench.

The power bars are located on the rear side of the cabinet, behind the rear door. Ensure that each power bar is plugged iinto a proper electrical outlet. Turn the power switch to the ON (I) position and validate that the light on the power bar turns on.

Validating the PDU

The PDU provides 24 V control power for various modules/boxes and 12 V auxiliary power for amplifier control circuits. When the power bars are turned ON, the “24V ON” LED light will turn ON.

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Validating the E-Stop Module

When the power bars are turned ON, the E-Stop Module “24V_ON” LED light will turn ON.

Validating the Start/Stop Buttons

Ensure the E-STOP (emergency stop) button on the E-STOP module is in the released (not pressed) position. If it's pressed in, rotate it clockwise to release it.

1. Press the Start button on the E-STOP Module to activate the PDU main contactor that supplies the ITECH DC power supplies:

   1. The light on the Start/Stop buttons should turn ON.

   2. The PDU main power contactor should close with an audible sound.

2. Press the Stop button:

   1. The light on the Start/Stop buttons should turn OFF.

   2. The PDU main power contactor should open with an audible sound.

Validating the Emergency Stop Button

Ensure the E-STOP (emergency stop) button on the E-STOP module is in the released (not pressed) position. If it's pressed in, rotate it clockwise to release it.

1. Press the Start button on the E-STOP Module to activate the PDU main contactor that supplies the ITECH DC power supplies:

   1. The light on the Start/Stop buttons should turn ON.

   2. The PDU main power contactor should close with an audible sound.

2. Press the Emergency Stop button:

   1. The light on the Start/Stop buttons should turn OFF.

   2. The “24V ON” LEDs on the LP Bus Bar and HP Bus Bar should turn OFF.

   3. The PDU main power contactor should open with an audible sound.

   4. Release the E-STOP by rotating it clockwise.

Validating the Bus Bars*

Ensure the 100-240 VAC power bars of the test bench are turned ON, and the 100-240 VAC entry module of the PDU is switched on. Then, make sure the E-STOP (emergency stop) button on the E-STOP Module is in the released (not pressed) position. If it's pressed in, rotate it clockwise to release it. Validate that the “24V ON” LEDs on the LP Bus Bar and HP Bus Bar are ON.

Validate the Enable button for each DUT:

1. Press the Start button - the light located between the Start and Stop buttons should start blinking

2. Press the Stop button - the light located between the Start and Stop buttons should turn OFF

*Note - The above section only applies to the OP1400PR test benches sold with a Bus Bar box (either LP or HP or both).

Validating the OP8110 units

With the 100–240 VAC entry module of the PDU still switched on, verify that every OP8110 unit is properly supplied by pressing the ON/OFF button and validating that the button turns to green.

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The functionality of the OP8110s' power circuits will be validated later in this document.

Validating Other Control Equipment (simulators, etc.)

For the remaining control equipment, please refer to the specific user manuals for these items in the Hardware Products Documentation.

Validating the High-Voltage Circuits

Please refer to OP1400PR PHIL Prime Test Bench Series Operation for the details on how to prepare and operate the OP1400PR test benches.

Please refer to the Troubleshooting section of this manual if unexpected results are observed.

Material Requirements

The following material must be provided to validate the high-voltage circuitry of the OP1400PR test bench:

• A three-phase resistive load -

  • The resistance and power rating of the load depend on the test bench model.
    However, just for validation purposes, a load between 100-200 ohms, with a power rating of 500W (the power rating depends on the output test voltage set during the test) would be sufficient.

• A basic multimeter

OP1400PR Bench Functional Test Procedure

1. Connect OP8110 Outputs
   Connect the first OP8110 group (outputs L1, L2, and L3) to the DUT1 Inputs of the Output Interface or the LP/HP Bus Bar (rear panel, inside the cabinet), using a three-phase 120 Vac topology.

2. Connect the Load
   Connect the resistive load to the DUT1 output of the Output Interface or the LP/HP Bus Bar (front panel).

3. Power on the three-phase mains

4. Power on the ITECH DC power supplies by first switching on the PDU (front panel switch) and then pressing the Start button on the E-STOP module.
   Set the ITECH DC power supply output voltage to 500 V, current to ±15 A and power to ±6kW. Trigger ON the output of the ITECH DC power supply at this point.

5. Build & Run the FAT model
   Verify that the provided FAT model is set for operating the OP8110 in three phase 120 Vrms, voltage mode control for Group 1 (L1, L2, L3 outputs) of the first OP8110 amplifier of the test bench. B

   1. Build and run the model in RT-LAB or HYPERSIM and using the model UI.

   2. Once the model is running, using the UI enable the DC Bus, turn on the amplifier outputs and then set the output voltage to 120 Vrms.

6. Voltage Validation at DUT1 (Before Enabling)

   • If connected directly to the Output Interface:
     Validate each of the three-line-to-neutral voltages are approximately 120 Vrms using a multimeter.

   • If connected through the LP or HP Bus Bar boxes:
     a. Press Start to locally enable DUT1—the Enable button should begin blinking.
     b. Enable DUT1 remotely (via digital IOs or Ethernet).
     The Enable button should turn solid ON (not blinking), and the internal contactors should close with an audible click.
     c. Validate that each of the three-line-to-neutral voltages is approximately 120 Vrms using a multimeter
     d. After the validation, disable DUT 1 (via digital IOs or Ethernet) and press the Stop button for DUT 1 on the bus bar box.

7. Shutdown
   Disable the OP8110 outputs from the UI of real-time simulation model, reset the model and then trigger off the ITECH DC power supply output.
   Switch off the PDU (front panel switch), the three-phase mains and then disconnect the load.

8. Repeat steps 1 to 5 using DUT2 and then DUT3 connection points of the Output Interface or LP/HP Bus Bar box.

9. Repeat steps 1 to 6 using the remaining untested output groups of OP8110 e.g.,

   • Outputs L4, L5, L6 of amplifier #1

   • Outputs L1, L2, L3 of amplifier #2

   • Outputs L4, L5, L6 of amplifier #2

   • Etc.