Princeton GTIB-30 Installation Manual
™
Clean power made simple.
GTIB-30
Installation Manual
www.princetonpower.com
4411-0011, Rev 2.0
April 1st , 2014
Copyright
The statements and information in this document must not be changed without special
notification from Princeton Power Systems Inc. Furthermore, Princeton Power Systems
Inc. does not commit to any further obligations with this document. Use and
reproduction is only permitted in accordance with the contractual agreements with
Princeton Power Systems. Under no circumstances may parts of this publication be
copied, reproduced, stored in a retrieval system or translated into another language,
except with written permission from Princeton Power Systems, Inc.
© Copyright 2014 Princeton Power Systems, Inc.
3175 Princeton Pike
Lawrenceville, NJ 08648
Tel: 609-955-5390
Fax: 609-751-9225
Email: info@princetonpower.com
Princeton Power Systems, and "Clean Power made simple" are registered trademarks
of Princeton Power Systems, Inc.
Specifications and descriptions in this document were in effect at the time of
publication. Princeton Power Systems, Inc. reserves the right to change
specifications, product appearance or to discontinue products at any time.
No patent infringement liability is assumed by Princeton Power Systems, Inc. with
regards to the use of information, circuits, equipment, or software described in this
manual.
The information contained in this manual is confidential and/or proprietary business
or technical data. Unauthorized copying, distribution or use of this manual, in whole
or in part, without receiving prior written consent from Princeton Power Systems,
Inc. is strictly prohibited.
About This Manual
Purpose
The purpose of this Installation Manual is to provide explanations and procedures for
installing and troubleshooting the GTIB-30.
Scope
This manual provides safety guidelines, detailed planning and setup information,
procedures for installing the inverter, as well as information about troubleshooting
the unit. It does not provide details about particular brands of batteries.
Audience
This manual is intended as guidance for installing the GTIB-30. Installers are
required to be certified technicians or electricians.
About this Manual
Abbreviations
Definition
AC
Alternating Current
ATS
Automatic Transfer Switch
BMS
Battery Management System
CEC
California Energy Commission
DC
Direct Current
DPDT
Double Pole Double Throw
ESD
Electro-Static Discharge
GFDI
Ground Fault Detector and Interrupter
GTIB
Grid-Tied Inverter and Battery Controller
HMI
Human/Machine Interface
I/O
Input/Output
Organization
This manual is organized into five chapters and two appendices.
Chapters
Chapter 1 Introduction welcomes the user and provides background information
about the GTIB-30 Inverter and Princeton Power Systems.
Chapter 2 System Overview and Configurations provides general information
about the GTIB-30 and introduces several of the important system components.
This section can also be found in the user manual of the GTIB-30.
Chapter 3 Pre-Installation provides important information regarding enclosure
transport, placement and dimensions.
Chapter 4 Wiring Instructions contains instructions on how to wire up the
GTIB-30.
Chapter 5 Commissioning Sequences provides a non-exhaustive wiring checklist
and commissioning sequence for the GTIB-30 inverter.
Appendices
Appendix A provides the technical specifications of the GTIB-30.
Appendix B, “Return Material Authorization, Product, and Contact Information”
This chapter provides instructions for obtaining a Return Material Authorization,
if the product needs to be returned to Princeton Power Systems or one of its
authorized service centers.
Abbreviations and Definitions
The following table provides a glossary of technical terms used in this manual. The
glossary also defines some common electrical terms and acronyms that may be used
in this manual.
4411-0011, Rev 2.0 v
About this Manual
Abbreviations
Definition
IEEE
Institute for Electrical and Electronics Engineers
MPPT
Maximum Power Point Tracking
NEC
National Electric Code
NEMA
National Electrical Manufacturers Association
PCB
Printed Circuit Board
PPS
Princeton Power Systems
PSU
Power Supply Unit
PV
Photovoltaic
SPDT
Single Pole Double Throw
SPST
Single Pole Single Throw
THD
Total Harmonic Distortion
UL
Underwriters Laboratories
VPC
Volts Per Cell
DC circuit
AC circuit
Phase indicator
Protective earth ground.
Other grounding conductor.
Important Safety Instructions
SAVE THESE INSTRUCTIONS– This manual contains important
instructions for the GTIB-30 that shall be followed during installation and
maintenance of the inverter.
Symbols
The following is a list of symbols used in this manual and on labels in the GTIB-30 kW.
vi 4411-0011, Rev 2.0
About this Manual
Warning Symbols used in this manual
Attention: This symbol identifies information about circumstances or practices that
could lead to personal injury, death, internal component damage, reduced product
life, equipment damage, economic loss, or other adverse effects.
Shock Hazard: This symbol identifies information about a condition or procedure
that could be potentially lethal or harmful to personnel or damaging to components
due to live voltages within the system, components holding stored energy, or
electrostatic discharge (ESD).
General Precautions
Maintenance by Qualified Personnel: Only personnel familiar with the Princeton
Power GTIB-30 Inverter and associated machinery should attempt installation,
commissioning, or maintenance of the system. Untrained or unauthorized personnel
run the risk of grave personal injury, death, or equipment damage. These servicing
instructions are for use by qualified personnel only. To reduce the risk of electric
shock, do not perform any servicing other than that specified in the operating
instructions unless you are qualified to do so. Use appropriate tools only and wear
appropriate protective gear. Remove all conductive jewelry when working on the
inverter (e.g. rings, watches and other metal objects). Ensure that all tools,
paperwork, and other foreign objects not designed for use in the Inverter are removed
from the enclosure prior to closing the door and re-energizing the equipment.
High Voltage Electric Shock Hazard: The Princeton Power GTIB-30 Inverter and
equipment connected to it, contains electrical components carrying potentially lethal
voltages and currents. Extreme caution should be exercised around the system,
especially when the cabinet door is open. Before opening the cabinet, all supply power
and loads, including all DC sources (batteries and PV arrays) should be disconnected
externally using a standard physical lock-out procedure and the service personnel should
wait 5 minutes prior to opening the enclosure door to allow internal components to
discharge. Note that a PV array must always be disconnected when performing
maintenance, even in no-light conditions. Avoid hazardous voltage situations that could
result from unsafe conditions such as, but not limited to, the following:
Back-feed from the utility
Improper grounding
Handling electrical leads or devices with wet hands or on wet ground
Frayed electrical leads
Working with or on an electrically hot system or component, or
when connected to an energized load
An ungrounded battery pack
Improper connection or re-connection of the terminal leads
Short circuits
Energized normal and emergency power sources
Installation to Code: The following instructions are merely a guide for proper
4411-0011, Rev 2.0 vii
About this Manual
installation. The National Electric Codes (NEC), local codes, and similar standards
outline detailed requirements for safe installation of electrical equipment. Installation
must comply with specifications for wire types, conductor sizes, electrical and
thermal insulation, branch circuit protection, grounding, and disconnect devices.
Princeton Power Systems cannot assume responsibility for compliance or
noncompliance to any national or local code. Princeton Power Systems cannot
assume responsibility for personal injury and/or equipment damage exists if codes are
ignored or misapplied during installation.
CAUTION: To reduce the risk of fire, connect each AC circuit of the inverter only
to a circuit provided with branch-circuit over-current protection in accordance with
the National Electrical Code, ANSI/NFPA 70 and the instructions in this manual.
(See Table 3: AC and DC Overcurrent Protection Rating Requirements in the
Wiring Instructions section of this manual).
Improper Use: Princeton Power Systems cannot assume responsibility for personal
injury and/or equipment damage as a result of improper installation, use,
maintenance, reconfiguration, reprogramming, or other improper actions. An
incorrectly serviced or operated Inverter system can cause personal injury,
component damage, or reduced product life. Malfunction may result from wiring
errors, an incorrect or inadequate DC supply or AC grid connection, excessive
ambient temperatures or obstructed ventilation, or incorrect software configuration.
Keep the door closed at all times when operating the system. Additionally, keep all
guards, screens, and electrical enclosures in place when the system is operating.
Close the inverter enclosure and put all guards and screens in place before energizing
the unit.
Heat Hazard: The cabinet should not be mounted on a combustible surface nor
should combustible materials be placed on or against the cabinet. The system should
not be installed in a confined space that prevents proper ventilation or allows the
build-up of excessive heat. A minimum of 12 inches of spacing clearance must exist
for proper cooling airflow into and out of ventilation openings. Keep vents and air
outlets clear of debris and provide proper airflow. Do not place or store any objects
on the enclosure roof
ESD Sensitive Components: The inverter contains Electrostatic Discharge (ESD)
sensitive components. Standard ESD control precautions must be followed when
installing, commissioning, testing, servicing, or repairing the system. Component
damage, component degradation, or an interruption in control system operation may
occur upon an electrostatic discharge event. Use anti-static wristbands when
servicing electronic components.
Locked Doors: The inverter enclosure should remain locked at all times during
normal operation and should only be unlocked for maintenance by qualified
personnel. Enclosure keys should be stored in a safe place and should be accessible
to appropriate personnel only.
Electrical Connections: Be sure that all electrical connections and connectors are
properly installed and connected with proper torque.
viii 4411-0011, Rev 2.0
About this Manual
Safety Check
Fuses: For continued protection against risk of fire, only use replacement fuses of the
same type and rating as the original fuse. Replacing of fuses should be done by
knowledgeable and trained personnel only.
Tipover: Tip over hazard. Do not move this equipment without mechanical
assistance.
Performing a routine safety check before energizing the Inverter will minimize the
risk of injury to the operator and minimize the potential for damaging the unit.
Before operating the unit, check for obvious signs of damage or concern. The
following is a list of suggested items to be checked before operating the unit:
1. Check the enclosure for obvious signs of damage.
2. Verify that all inlet and outlet vents are clear of debris.
3. Check external wires and cables for signs of damage, such as fraying or
cracked insulation.
4. Check room for potential hazards, such as standing water on the floor or on
the GTIB-30 Inverter.
Note: Additional safety checks may be necessary depending on the particular
installation of the unit. The safety checklist above is not intended to be all-inclusive.
Terms of Use
Resolve all issues before operating the inverter. Contact Princeton Power Systems if
necessary.
Because of the wide variety of uses for power electronics equipment, this manual
does not describe every possible application or configuration. All technicians
responsible for installing, commissioning, and operating this equipment must satisfy
themselves of the suitability and proper implementation of the intended application of
this power conversion product.
In no event will Princeton Power Systems, Inc., its subsidiaries, partners, employees,
or affiliates be responsible or liable for any damages, indirect or direct, resulting from
the misuse or incorrect application of this equipment.
The examples and diagrams in this manual are for illustrative purposes only.
Because of the wide variety of uses, applications, peripheral equipment, and facility
configurations particular to each installation, Princeton Power Systems, Inc. cannot
assume responsibility or liability for actual use based on the information provided
herein.
4411-0011, Rev 2.0 ix
Battery Information
This system is designed to be operated with a variety of battery types and voltage.
Battery voltage and current ratings must comply with the DC port ratings outlined in
Appendix A.
WARNING: The battery charge control function has adjustable battery charging
settings. The user must confirm that the charge control profile used in this inverter is
appropriate and safe for the type of battery used and that all battery charging settings
are set correctly for the battery voltage, current, and temperature ratings. Setting
these settings incorrectly may damage the battery and the inverter and may cause a
hazardous condition that puts personnel at risk of grave injury or death.
WARNING: Consult the battery manufacturer for information regarding safe
transport, storage, operation and maintenance of batteries. Although this manual
contains some information regarding battery safety but it is by no means exhaustive.
About this Manual
x 4411-0011, Rev 2.0
About this Manual
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4411-0011, Rev 2.0 xi
Contents
About This Manual ............................................................................................................................... iv
Purpose .............................................................................................................................................. iv
Scope ................................................................................................................................................. iv
Audience ............................................................................................................................................ iv
Organization ....................................................................................................................................... v
Abbreviations and Definitions ............................................................................................................ v
Important Safety Instructions ................................................................................................................ vi
Symbols ............................................................................................................................................. vi
Warning Symbols used in this manual .............................................................................................. vii
General Precautions .......................................................................................................................... vii
Safety Check ...................................................................................................................................... ix
Terms of Use...................................................................................................................................... ix
Battery Information............................................................................................................................. x
1 Introduction 16
1.1 Congratulations ............................................................................................................................. 17
1.2 PPS Company information ........................................................................................................... 17
2 System Overview and Configurations 18
2.1 System Overview .......................................................................................................................... 19
2.1.1 Power Ports .............................................................................................................................. 19
2.1.2 Isolation Transformer............................................................................................................... 20
2.1.3 Functional Power Block Diagram ............................................................................................ 21
2.1.4 Main System Components ....................................................................................................... 22
2.2 Power Format ............................................................................................................................... 28
2.2.1 Three-phase Power Format ...................................................................................................... 28
2.3 GTIB-30 Configuration Options ................................................................................................... 29
2.4 Important System Specifications .................................................................................................. 30
2.4.1 Isolation Transformer............................................................................................................... 30
3 Pre-Installation 31
3.1 Unpacking, Inspection, and Storage ............................................................................................. 32
3.2 Dimensions ................................................................................................................................... 32
3.2.1 Outer Dimensions .................................................................................................................... 32
3.2.2 Pad Mounting ........................................................................................................................... 33
3.3 Inverter Placement Considerations ............................................................................................... 34
4 Wiring Instructions 37
4.1 Preparing for the Installation ........................................................................................................ 38
4.1.1 Installation Tools and Materials Tools Required ..................................................................... 38
4.2 Safety ............................................................................................................................................ 39
4.3 External disconnect and overcurrent protection requirements ...................................................... 40
4.3.1 AC Disconnect switch requirements ........................................................................................ 40
4.3.2 DC Disconnect switch requirements ........................................................................................ 40
4.4 Opening the enclosure .................................................................................................................. 41
4.4.1 Opening enclosure door ........................................................................................................... 41
4.5 Wire Sizing and Ratings ............................................................................................................... 42
4.5.1 Power Conductor Sizing and Ratings ...................................................................................... 42
4.5.2 Control Wire Sizing and Ratings ............................................................................................. 42
Contents
4.6 Wiring Terminals .......................................................................................................................... 43
4.7 Earth Wiring ................................................................................................................................. 45
4.7.1 AC Circuit and DC Port earth wire requirements .................................................................... 45
4.7.2 Grounding in Grid-Tied configuration ..................................................................................... 46
4.7.3 Connecting to the Grounding terminal ..................................................................................... 46
4.8 Torque Specifications of Power Terminal Blocks ........................................................................ 46
4.9 Utility Grid (Source) Port Wiring ................................................................................................. 47
4.10 Load Port Wiring (if option is installed) ................................................................................ 48
4.11 DC Port Wiring ...................................................................................................................... 49
4.11.1 DC Port grounding ............................................................................................................. 49
4.12 PV Ground Wiring ................................................................................................................. 50
4.13 Signal wiring .......................................................................................................................... 51
4.13.1 Digital Inputs ...................................................................................................................... 51
4.13.2 Digital Outputs ................................................................................................................... 53
4.13.3 External Control Interface Connection ............................................................................... 54
4.13.4 Other Communication Ports ............................................................................................... 55
5 Commissioning Sequences 57
5.1 Wiring Checklist ........................................................................................................................... 58
5.2 Commissioning Checklist ............................................................................................................. 59
A GTIB 30 kW Specifications 62
A.1 System Specifications ................................................................................................................... 63
B Return Material Authorization, Contact, and Product
Information 66
B.1 Return Material Authorization Policy ......................................................................................... 67
B.2 Out of Warranty Service .............................................................................................................. 67
B.3 Contact Information ...................................................................................................................... 67
B.4 Information About This System .................................................................................................. 68
Figures
Figure 1: Symbolic single line diagram of GTIB-30. ................................................................................. 20
Figure 2: Symbolic representation of the GTIB-30 with isolation transformer. ......................................... 20
Figure 3: Functional power diagram of the GTIB-30. ................................................................................ 21
Figure 4: Closed GTIB-30 metal enclosure. ............................................................................................... 22
Figure 5: Touch Screen HMI mounted in front door of GTIB-30 enclosure. ............................................. 22
Figure 6: View of GTIB-30 enclosure when front door is opened. ............................................................ 23
Figure 7: Picture of GTIB-30 Control Panel showing optional Grid Overcurrent Switch. ........................ 23
Figure 8: Integrated 15kW AC Breaker. ..................................................................................................... 24
Figure 9: Picture of GTIB-30 control Panel showing DC switch in the tripped position. .......................... 25
Figure 10: GTIB-30 Wiring tray. ................................................................................................................ 26
Figure 11: DC Bus fuse ............................................................................................................................... 26
Figure 12: GTIB-30 Wiring Tray fuses. ..................................................................................................... 26
Figure 13: Main Power Connection terminal blocks .................................................................................. 27
Figure 14: Picture of GTIB-30 showing air flow (bottom front panel removed to show filter). ................ 28
4411-0011, Rev 2.0 13
Contents
Figure 15: Single line diagram of GTIB-30 in Grid-Tied configuration. ................................................... 29
Figure 16: Position of the internal isolation transformer in the GTIB-30 enclosure. ................................. 30
Figure 17: Outer dimensions of GTIB-30 inverter ..................................................................................... 32
Figure 18: Front view of GTIB-30 Mounting plate and Bottom view of Enclosure (showing position and
dimensions of mounting holes). .............................................................................................. 33
Figure 19: Suggested Mounting Pad Layout for GTIB-30 Installation. ..................................................... 33
Figure 20: GTIB-30 View showing ventilation louvers. ............................................................................ 34
Figure 21: Enclosure with lockable handle. ................................................................................................ 41
Figure 22: View of Terminal blocks for DC (PV/Battery) and AC power wiring. ..................................... 43
Figure 23: External wire routing into the GTIB-30 .................................................................................... 44
Figure 24: Main earth terminals inside enclosure with earth wire connected. ............................................ 46
Figure 25: Grid port wiring connections. .................................................................................................... 47
Figure 26: Load port wiring connections. ................................................................................................... 48
Figure 27: DC port wiring connections. ...................................................................................................... 49
Figure 28: PV ground wiring connections. ................................................................................................. 50
Figure 29: Signal connectors. ..................................................................................................................... 51
Figure 30: Location of digital inputs. .......................................................................................................... 51
Figure 31: Digital input connector pin outs ................................................................................................ 52
Figure 32: Functional diagram of SPDT relay on optional GTIB-30 client input/output PCB .................. 53
Figure 33: Connection points for BMS. ...................................................................................................... 54
Figure 34: RS 485 Pin outs. ........................................................................................................................ 54
Figure 35: RS 232 (3-pin) Pin outs. ............................................................................................................ 55
Figure 36: RS 232 (Male DB-9) Pin outs. .................................................................................................. 55
Figure 37: Location of the USB connection. .............................................................................................. 55
Figure 38: Location of the Ethernet RJ-45 receptacle. ............................................................................... 55
Tables
Table 1: GTIB-30 Fuse List ........................................................................................................................ 26
Table 2: Summary of three-phase power format......................................................................................... 28
Table 3: AC and DC Overcurrent Protection Rating Requirements ........................................................... 40
Table 4: Minimum power port wire requirements ...................................................................................... 42
Table 5: User I/O wire requirements........................................................................................................... 42
Table 6: Ethernet port wire requirements ................................................................................................... 43
Table 7: Ground Wire Size Chart ............................................................................................................... 45
Table 8: Digital Input parameters of GTIB-30 Client I/O device. .............................................................. 52
Table 9: Digital input connectors on optional GTIB-30 Client I/O device. ................................................ 52
Table 10: Digital output relay contact specifications of the optional GTIB-30 Client I/O device. ............ 53
Table 11: GTIB-30 Key Specifications. ..................................................................................................... 63
14 4411-0011, Rev 2.0
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4411-0011, Rev 2.0 15
1
Introduction
1.1 Congratulations
Congratulations on purchasing one of the most advanced inverters in the world, from
one of the leading power electronics companies in the world. The GTIB-30 Inverter
meets Underwriter’s Labs’ standard 1741 to allow power export to the North
American electric grid. It is compatible with multiple input sources, including solar
arrays with advanced maximum power point tracking (MPPT), battery banks, and
generators.
The GTIB-30 is highly reliable, efficient, and flexible. It is backed by a world-class
team of engineers at Princeton Power Systems that can ensure the technical and
financial success of your application.
1.2 PPS Company information
Princeton Power Systems designs and manufactures advanced power conversion
products and systems to provide customers with cost-effective, reliable, smart
distributed generation. Our patented technologies, including AC-link
clean electric power simply and efficiently, and our capable and flexible engineering
team works closely with our customers to solve their problems. Customer solutions
include grid-integrated distributed generation, renewable energy, energy storage, and
military power supplies for Navy and Army applications.
GTIB-30 Installation Manual-UL
TM
, produce
4411-0011, Rev 2.0 17
2
System Overview and Configurations
1
2.1 System Overview
The GTIB-30 is an extremely versatile state of the art multi-port energy management
converter system. The GTIB-30 can be connected to batteries, solar PV arrays, and
utility grids. Unlike most conventional inverters and renewable energy systems, the
GTIB-30 is designed to support and strengthen the utility grid instead of being a
burden on it. It is therefore compatible with next generation smart and micro grids.
These new power systems enable a much higher penetration of renewable energy
than conventional inverter systems would allow and therefore the GTIB-30 helps to
facilitate technical solutions to some of the world’s most urgent environmental
problems.
In an on-grid application, the loads connected to the GTIB-30 Load Port are supplied
directly from the utility (as long as the grid is available). When the GTIB-30’s DC port is
configured for bi-directional power exchange with a DC power source or DC energy
system, it charges its batteries from the utility grid. When the batteries are full, the
GTIB-30 supplies all of the energy to the loads. At any stage, the operator can request the
GTIB-30 to provide additional energy and supplement the utility grid by feeding energy
from the batteries into the grid. (See User Manual) When the DC Port is configured for
PV operation, the GTIB-30 can draw power from a connected PV array and supply it to
the loads or optionally export it to the grid.
GTIB-30 Installation Manual-UL
2.1.1
Additionally, the GTIB-30 also allows solar PV energy to be supplemented with
combustion generators and other AC sources.
Power Ports
The GTIB-30 Inverter has one DC port (battery or PV) and one or two (optional) AC
power ports (grid and load) giving the GTIB-30 a total of three power ports. In this
manual, the GTIB-30 is often symbolically represented by a diagonally divided
square where one half represents the AC ports and the other half represents the
DC port (battery or PV). This symbolic representation of the GTIB-30 is shown in
the center of Figure 1.
2.1.1.1 DC Port
The DC port can be either used for a battery bank or for connecting a PV array to the
GTIB-30. The battery port is a two wire DC port used to connect a battery bank to
the GTIB-30. The PV Port is a two wire DC port used to connect a PV array to the
GTIB-30.
4411-0011, Rev 2.0 19
GTIB-30 Installation Manual-UL
2.1.1.2 Load Port (Optional)
The load port is a four-wire AC port with three phases and a neutral line. This port is
used to connect local loads to the GTIB-30. For example, by connecting to this port,
the system may limit the loading on the utility supply (peak load shaving) by
supplementing power from energy stored in batteries connected to the DC Port.
2.1.1.3 Grid (Source) Port
The grid port is a four-wire AC port with three phases and a neutral line. This port
can be connected to the utility grid. If no utility grid is available, suitable AC
generators can also be connected to this port.
Figure 1: Symbolic single line diagram of GTIB-30.
2.1.2 Isolation Transformer
The GTIB-30 comes equipped with an internal isolation transformer. The isolation
transformer provides electrical isolation between the DC and AC ports. The isolation
transformer does not provide electrical isolation between the two AC ports if the load
port option is installed.
Figure 2: Symbolic representation of the GTIB-30 with isolation transformer.
20 4411-0011, Rev 2.0
2.1.3 Functional Power Block Diagram
A functional block diagram of the GTIB-30 power circuit is shown in Figure 3. This
diagram provides information to the interested reader but does not need to be
understood for successful installation.
The GTIB-30 consists of a single bi-directional DC-AC stage. An optional internal
manual utility switch can be provided. (Figure 7) This internal switch is not the same
as an external utility grid disconnect switch. An internal switch is provided on the DC
port. (Figure 8) This is not the same as the external disconnect switch.
External disconnects are required on the battery bank or PV array.
GTIB-30 Installation Manual-UL
Figure 3: Functional power diagram of the GTIB-30.
4411-0011, Rev 2.0 21
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