Summary of Contents for Riello UPS MASTER HP-UL Series
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65 to 125 kVA Three-Phase Output MASTER HP-UL USER MANUAL Pag. 1 a 83 0MLMHTK65RUENUB...
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RPS SpA Viale Europa 7 37045 Legnago (VR) Italy www.riello-ups.com Pag. 2 a 83 0MLMHTK65RUENUB...
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Thank you for choosing our product. RPS S.p.A. is highly specialized in the development and production of uninterruptible power systems (UPS). The UPS’s of this series are high quality products, carefully designed and manufactured to ensure optimum performance. Applicability This manual applies to the following models: MASTER HP-UL 65-00 65 kVA, 480 V input, 480 V output, 60 Hz, configured as wye-wye or delta-delta (see below);...
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e. Equipment should be installed where it will not readily be subjected to tampering by unauthorized personnel. f. The use of accessory equipment not recommended by the manufacturer may cause an unsafe condition. g. Do not use this equipment for other than intended use. DANGER This UPS contains LETHAL VOLTAGES.
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EMERGENCY INTERVENTIONS The following information is of a general nature. First aid interventions Company regulations and traditional procedures should be followed for any first aid intervention that may be required. Fire fighting measures 1. Do not use water to put out a fire, but only fire extinguishers that are suitable for use with electrical and electronic equipment.
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PERSONAL PROTECTIVE EQUIPMENT No maintenance operations must be carried out on the device without wearing the Personal Protective Equipment (PPE) described below. Personnel involved in the installation or maintenance of the equipment must not wear clothes with wide sleeves or laces, belts, bracelets or other items that may be dangerous, especially if they are metallic.
Layout UPS 65-80 VA F RONT A Control panel with graphic display Door handle Ventilation grilles Communication area Front Cover panel with ventilation grilles Switch cover panel G Door SWIN: Input power switch SWOUT: Static switch output SWMB: Mechanical bypass switch SWBY: Static switch bypass input See single line diagram (page 17) for switch functions.
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UPS 100-125 VA F RONT A Control panel with graphic display Door handle Ventilation grilles Communication area Front Cover panel with ventilation grilles Switch cover panel G Door SWIN: Input power switch SWOUT: Static switch output SWMB: Mechanical bypass switch SWBY: Static switch bypass input See single line diagram (page 17) for switch functions.
Preliminary operations Removing the packaging and positioning the device On delivery, the packaging must be inspected to ensure that it is whole and that it has not been crushed or dented. Check in particular that neither of the two impact resistant devices on the packaging is red; if one of them is red; follow the instructions on the packaging.
Risk of overturning In order to avoid the risk of the device overturning, ensure that it is firmly secured to the fork-lift truck by means of appropriate ropes before moving it. When being moved the cabinet should be handled with care; shocks or drops can damage it. Once in position, remove the packaging carefully in order not to scratch the device.
Cooling of the premises The recommended operating temperature for the lifetime of the UPS and of the batteries is between 20 and 25°C. The lifespan of the battery depends on the operating temperature; with an operating temperature increase from 20°C to 30°C, the lifespan of the batteries is halved.
Electrical Connections CCESSING THE TERMINALS The following operations must be performed while the UPS is disconnected from the utility mains power, switched off and all the input and output power switches on the equipment are open. Before performing connection, open all the input and output power switches and check that the UPS is completely isolated from all power sources: battery and AC power line.
UPS in single configuration The UPS is designed to work as Single input Unit or as Dual input Unit. Schematic diagram: Single input Unit Schematic diagram: Dual input Unit Pag. 15 a 83 0MLMHTK65RUENUB...
1.1.1 Cable Entry The cables can enter in the UPS from the bottom or from the top with the ancillary Top Cable Entry cabinet (see related installation manual) Proceed as follows in order to open the UPS Open the door ...
1.1.2 Connection of Power Cables for Single input Unit Connect the input, output and battery cables to the terminals as shown in the figure below: UPS 65-80kVA Power connection Terminals Load Output Battery Input Neutral Output Ground Bond Neutral Input Mains / Bypass...
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UPS 100-125kVA Power connection Terminals Load Output Battery Input Ground Bond Mains / Bypass Neutral Input Input Note: For the Input, Output and Battery connections, respect the order from the top to bottom, or right to left, as described in the boxes.
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1.1.3 Connection of Power Cables for Dual input Unit Connect the input, output and battery cables to the terminals as shown in the figure below: UPS 65-80kVA Power connection Terminals Remove the Bypass Jumpers Load Output Battery Input Neutral Output Ground...
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UPS 100-125kVA Power connection Terminals Remove the Bypass Jumpers Load Output Battery Input Bond Ground Bypass Input Mains Input A B C Neutral Input Remove the jumpers present between the SWIN and SWBY. Note: For the Input, Output and Battery connections, respect the order from the top to bottom, or right to left, as described in the boxes.
Minimum Wire Size Requirements Input (for single input unit) UPS models Phase and Neutral Conductor Ground Wire 65 kVA 6 AWG 80 kVA 6 AWG 100 kVA 6 AWG 250 kcmil 4 AWG 125 kVA Rectifier Input (for dual input unit only) UPS models Phase Conductor Ground Wire...
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Recommended cable lugs Bolt Size Wire Thomas & Betts Connectors 6 AWG 54136 5/16 4 AWG 54140 54109 54110 54112 250 kcmil 54172 54160 300 kcmil 54114 400 kcmil 54116 cables are to be connected to the field terminals through Listed cable lugs suitable for cable size. When using crimp type lugs, follow the manufacturer’s instructions for both crimp tool and lug Per NEC article 300-20(2), all three-phase conductors must be run in the same conduit. Neutral and ground must be run in the same conduit as the phase conductors.
External Over Current Protection device and terminals CAUTION to reduce the risk of fire, connect only to a circuit provided with branch circuit protection with maximum current rating per the table, below, in accordance with the National Electrical Code, ANSI/NFPA 70. Input (for single input unit) UPS models Nominal Current...
Battery UPS models Nominal Current Maximum Current OCP Device rating Bolt Size (in) 65 kVA 127@480Vdc 159.5A@400.8Vdc 160A 80 kVA 156A@480Vdc 196.4A@400.8Vdc 200A 100 kVA 195A@480Vdc 235.8A@400.8Vdc 250A 125 kVA 244A@480Vdc 294.8A@400.8Vdc 300A CAUTION: Input and output circuit protection must be provided by others as part of the UPS installation.
1.1.5 Backfeed protection The UPS is provided with a redundant device to prevent voltage backfeed on the input line due to an internal fault. This protection device works by switching off the inverter in case of the fault current on the bypass line during operation from the inverter.
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Schematic diagram: Single power line without neutral from the source SWMB SWBY 3P+G 3P+N+G 3P+N+G AC Input AC Output SWIN SWOUT DC Input 2W+G Note: AC and DC cables provided by others. Cable lugs provided by others. Schematic diagram: Main power supply and separate bypass without neutral from the source SWMB 3P+G 3P+N+G...
Connection of signals and remote commands In order to access the interface cards, open the door and remove the protection panel secured with screws (K) as shown in the drawing: REF. DESCRIPTION PARALLEL EPO (Emergency Power Off control) REMOTE COMMANDS AND ALARMS RS232-2 RS232-1 SLOT 2 (aux)
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Connector J1 of Aux signals isolation board NAME TYPE FUNCTION AUX SWBATT INPUT Normally open: dry contact used to indicate when SWBATT is closed AUX SWBATT RETURN INPUT AUX SWMB INPUT Normally close: dry contact used to indicate when the SWMB EXT is closed AUX SWMB RETURN INPUT AUX SWOUT...
1.1.7 Parallel (optional) -A- To be used for the connection of UPS’s in a parallel configuration. See the chapter “parallel version” on page 1.1.8 REMOTE COMMANDS, ALARMS AND EPO -C- The card is equipped with a 14 positions terminal board. SELV CIRCUIT PROVIDED.
The position of the contacts as shown is without the alarm present. The contacts rating is 24Vac - 1A. Please refer to APPENDIX A for the list of alarms and commands that can be programmed. The change of function can be made by authorized technical support personnel. 1.1.9 RS232 SELV CIRCUIT PROVIDED.
Modem male female female male maschio femmina DB9 male RS232-2 femmina maschio RS232-2 - E - For connection with a modem use a cable standard. See the diagram for connection with a modem. Computer male female female male maschio femmina femmina maschio RS232-2...
1.1.11 REMOTE ALARMS (2 optional cards) SELV CIRCUIT PROVIDED. CONNECT TO SELV CIRCUIT ONLY. - H, I - 6 output (relays): Form C dry contacts for alarms, rating 30 VAC/DC, 1A max, (programmable by display panel), 2 inputs (programmable by display panel) and 1x 12V DC 100mA max auxiliary input. 1.1.12 MODEM (optional) -L- Model compatible with the communication standards between the UPS and the software provided.
Note: MASTER HP-UL series have input terminals (for acquiring the status of aux contacts) isolated from the internal circuits of the UPS. This will result in to be sufficient a single aux contact electrical connection of the External switch brought to each UPS of the parallel system.
Start-up procedure mains power supply The mains power supply must be present in order to start up the UPS The UPS output terminals will be powered in this step and all loads connected will receive voltages. All users must therefore be warned before carrying out the start-up procedure. BATTERY CABINET (if present) The battery cabinet must be provided with a disconnect device for it to be connected to the UPS.
SWMB The mechanical bypass switch SWMB must not be closed during normal operation of the UPS. SWMB should only be closed during UPS maintenance operations in order to keep the load powered (see the instructions on page 37). When the UPS is first started up, it is in on-line mode (see page 36 ). See pages 36 and 72 to set Standby-on / Smart active operating mode.
1.1.18 On - line - factory setting - Load is always powered by the inverter, in the event of an input mains failure the load continues to be powered from the inverter using the energy stored by the batteries. On – line: The load is always powered by the inverter, with stabilized voltage and frequency, using the energy from the mains power supply (INPUT).
Standby-Off: If there is a mains power supply, UPS output is zero. The RECTIFIER remains on and keeps the battery charged. The output voltage is only present when the mains power supply fails. The system remains with output voltage = 0V while the voltage and the input frequency are within an acceptable range.
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connect to the bypass input. As a part of backfeed protection, it is necessary that several signal wire connections exist between the UPS an external optional Maintenance Bypass Cabinet (MBS). The proper wiring of these connections shall be described in the User’s manual for the MBS. These connections carry signals that avoid operation of the MB breakers such that backfeed is prevented.
Components of the block diagrams The UPS is made up of the following sub-assemblies: IGBT RECTIFIER This represents the input stage and its function is to convert the AC voltage of the power supply line into DC voltage. Rectifier start-up can be programmed from the display panel.
INVERTER This is the output stage, its function is to convert the DC voltage from the RECTIFIER or from the BATTERY into stabilized sinusoidal AC voltage. The inverter output is isolated from the input and from the batteries by a galvanic isolation transformer.
Electrical system set-up All the information contained in the section on electrical system set-up in relation to the UPS remains valid with the addition of the information set out below. 1.1.23 Input The instructions showed in the first part of the manual for a single UPS remain valid; each unit must be protected with equivalent fuses or switches.
1.1.25 Emergency power off device (EPO) When several devices are connected in parallel, the EPO command must be sent to all UPS’s simultaneously, as shown in the figure below: UPS 8 UPS 2 UPS 1 a - EPO terminal board on the UPS b - EPO switch with auxiliary contacts (not provided).
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Parallel connect the UPS as follows: - Connect the mains power supply phases L1, L2, L3, N to the corresponding input phases of each UPS L1, L2, L3, and N. - Connect the load phases L1, L2, L3, N to the corresponding output phases of each UPS L1, L2, L3, and N. MAINS (A) The figure shows an example of three units connected in parallel.
1.1.28 Connecting the Parallel Card (option) The UPS is supplied with the parallel control cards on request or the parallel kit is provided. For all details about installations of parallel card and parallel signal card RJ45 refer to the manual “Parallel kit UL” Connection of signals The signals of several parallel UPS’s are connected in a closed loop configuration;...
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- RJ45-flat-adapter signals parallel card. Note: The UPS may be provided with one of two versions of the parallel card which differ in the type of switch used (type 1 or type 2). The difference between the two switches is the position of the control lever. J1 RJ45 type connector J2 RJ45 type connector start position...
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UPS 1 UPS 2 LED (D) SW1 (E) START CONT Note: 2 RJ45 cables are required for loop configuration. System will not start up unless 2 cables are installed. UPS 2 UPS 1 Pag. 47 a 83 0MLMHTK65RUENUB...
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-Three UPS in parallel UPS 1 UPS 2 UPS 3 LED (D) SW1 (E) START CONT CONT Note: 3 RJ45 cables are required for loop configuration. System will not start up unless 3 cables are installed. UPS 2 UPS 2 UPS 1 UPS 3 To add other parallel UPS’s, a “UPS PARALLEL CABLE”...
Start-up procedure Before starting up the whole system for the first time, some tests have to be performed to check that the UPS’s are connected to each other correctly. A) Open all the switches and disconnects on the UPS’s (SWIN, SWBY, SWOUT and SWMB) and on the battery cabinets.
Operating modes Several UPS units connected in parallel share the current absorbed by the load between them. In a system with several UPS’s connected in parallel, there is a single MASTER unit and the remaining units will be SLAVES. The UPS’s are all exactly the same and the MASTER is chosen on start-up. The MASTER unit is shown on the display panel by the capital letter “P”...
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Example of parallel operation For the sake of simplicity, the instructions shown below refer to a system with three UPS’s, but are equally valid for more complex systems. Let us assume that the signal cable is not damaged and that the UPS’s are in the following state: UPS STATUS 1) Normal operation, Master unit 2) Normal operation, Slave unit...
Mechanical Bypass follows these precautions when operating SWMB SWMB must not be closed on a UPS that is off and that is connected in parallel with other units operating normally. This operation may cause a fault on the UPS’s which may create a dangerous voltage at the output.
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Procedure b) The bypass line is out of the acceptable range; the following message is showed on the display panel: BAD BYPASS VOLTAGE or SWBY OFF and the green LED 1 will flash 1. Open all the switches on the UPS (SWIN, SWOUT, SWBY and the battery cabinet circuit breaker/disconnect).
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With the lever of SW1 in the start position in one UPS only and the lever in the cont position on all the others, check that all the UPS’s are operating normally and that the system is sharing the output power. Example of hot removal With hot removal, it is not necessary to shut down all the UPSs of the system in order to remove one.
Frequency Converter Setup RPS MASTER HP-UL series products are designed to operate from 480 volt, 60Hz input and can be set through front panel settings to provide 400 volt, 50Hz output. The power rating is reduced 20% in frequency converter mode.
Signal panel functions Control Panel View LED Bypass line indicator LED Mains line indicator LED Battery powering the load LED Load on bypass LED Normal output LED Alarm for internal fault Graphic display F1, F2, F3, F4, F5, F6, F7, F8 = FUNCTION KEYS.
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Led status indicators Indicator Symbol Color Function State Meaning Input Bypass line is present and correct Bypass Green line Flashing Input Bypass line is present but not correct indicator Input Bypass line is not present Mains is present and correct Mains Green line...
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RAPHIC DISPLAY A wide graphic display is present on the UPS door, which allows the user to have a close-up, detailed overview in real time of the status of the UPS. The user can switch the UPS on and off, check electrical mains, output, battery measurements etc.
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Picture of the UPS display having all items OFF, Table of diagram items Shapes Active Inactive Meaning Input converter Output inverter Bypass line switch Battery Manual bypass line switch Bypass line input switch Battery switch Output switch Main line input switch Output load (40%VA or 0%VA) Battery(70%Ah or 0%Ah) Table with keys numbers and Icons...
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Basic menu (text lines area) If no commands have been inserted, the first text line shows messages to inform about status of operation. First text line NORMAL OPERATION U125A OUT=100%VA, BATT=100%Ah, 5=ON Second text line In each operating condition, the display returns to the "basic menu" after two minutes from the last command inserted with the keys.
The message OUT changes to BY when the load is not powered from the inverter (normal operation) but from the mains through the bypass line. The message OUT=100%VA changes to OUT= SWMB when the load is powered through the mechanical bypass switch, and the output current cannot be provided.
1.1.30 Measurements menus (key 2) The measurements with two line displayed, are selected from the basic menu by pressing key 2 IN=100,100,100%V, 60.2Hz OUT=277,277,277Vln Measurement of the three voltages, neutral phase and input Measurement of the three output phase voltages of frequency.
1.1.32 Full page Measurements and output waveforms (key 2, 7) The full page measurements and output voltage and current waveform are selected by pressing key 7 from the two line measurement menu. Basic Menu IN=100,100,100%V; 101,101,101%A; 60.1Hz BY=277,277,277Vln (480V); 60.1Hz; 125kVA 277V 3L 60Hz [15:35:55] _________________________________ [[1; V L‐L] L1‐2 L2‐3 L3‐1 Freq. MAINS VOLTAGE 480V 480V 480V 60.0Hz BYPASS VOLTAGE 480V 480V 480V 60.0Hz OUTPUT VOLTAGE 480V 480V 480V 60.0Hz BATTERY VOLTAGE 530V BATTERY CURRENT ‐ 10.0A...
1.1.33 Controls Menu (key 3), BATTERY TEST Menu 3, 2 DISPLAY CONTRAST: 6 Keys 8 and 7 to increase ADJUSTMENT: 7=-, 8=+ and decrease the contrast. Code ? ………………. 2=BATTERY TEST 4=DISPLAY CONTRAST Menu 3, 5 5=PERSONALIZ. 6=BYPASS 7=TOTAL BLOCK INVERTER OFF/BYPASS Menu 3, 6 Menu 3, 7...
1.1.33.2 CUSTOMIZING The "CUSTOMIZING" menu is accessed by means of key 5 from the COMMANDS menu; an intermediate menu will then be displayed in which a CODE has to be entered. Access by CODE ensures that unauthorized persons cannot modify the operating parameters of the equipment.
1.1.33.4 RATED OUTPUT VOLTAGE. Press the following sequence of keys to access the menu: 3, 5, 436215, 2 Keys 7 and 8 can be used to decrease or increase the rated output voltage. The value displayed is the voltage between phase and neutral "Vln". The value set modifies the operation of the inverter, during normal operation.
Recharging at two voltage levels (configurable): This type of recharging is effected with two current levels (EN 50272-2); the first step comprises rapid charging (U1) with limited current, while in the second step charging is with float voltage (U2). NOTE: this type of recharging may be configured on site and is mainly used for special type batteries such as vented and NiCd.
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Type “0” Battery With the battery set to type 0, the following menu is displayed: (420Vmin,480Vp,540Vs) Prealarm : 5min Adjustment: (4=setV), 7=-,8=+ When key 4 is pressed, the program proposes the setting of the three voltage values. Vbat.test: Vmin., Vp, Vs: 420, 480, 540V Adjustment: 3-4+, 5-6+, 7-8+ Preset value...
[the value must be multiply for 40, number of batteries] battery voltage with discharge at 90% of the total time (3). 1.1.33.7 AUTO-OFF "VA" Press the following sequence of keys to access the menu: 3, 5, 436215, 6: Automatic Switch-OFF when Output < 0%VA Adjustment: (5=Toff,Ton) 7=-,8=+ Press key 1 to exit the menu.
The "end of discharge pre-alarm" contact for remote alarms is also switched. In this case the system remains active for the next 4 minutes, after which the system switches onto the bypass line and then deactivates. There is no output voltage after deactivation. The interval between the start of the alarm and deactivation is equal to the interval selected as PRE-ALARM.
NOTE: for correct operation, use a modem that has already been configured to recognize "HAYES" type commands and that is able to dial the telephone number using pulses or tones as required by the telephone line that is to be used.
1.1.33.15 IDENTIFICATION. Press the following sequence of keys to access the menu: 3, 5, 436215, 7, 7: Press key 1 to exit the menu. Keys 7 and 8 can be used to decrease or increase the number used for the identification of a single unit in systems with several UPS connected to a single RS232 serial line.
1.1.33.19 TOTAL BLOCK Press the following sequence of keys to access the menu: 3, 7: Total System Shut-OFF Command = 47263 WARNING, the Output Voltage will be OFF Exit the menu by pressing key 8 or any other key with a sequence other than the one described here. Pressing keys 4, 7, 2, 6, 3 in succession as shown on the display activates the command for TOTAL BLOCK of the system.
The "RECORDED CODES" menu is accessed with key 6 from menu 4 "RECORDED EVENTS" and menus 4, 2; 4, 2, 2; 4,2,2,2 that is, the recorded measurement menus. Return to the basic menu by means of key 1. Apart from key 6, the other keys have the same functions as those described for menu 4, and the messages on the lower line also remain the same.
1.1.35 DISABLING THE AUDIBLE ALARM (key 5) Press the following sequence of keys to access the menu: 5 During operation from the basic menu, the operator can permanently disable or re-enable the audible alarm (buzzer) by pressing key 5. "5=ON" is shown in the basic menu when the audible alarm is enabled and "5=OFF" when the audible alarm is disabled.
Maintenance The Uninterruptible Power System is designed and produced to last a long time, even in the most severe service conditions. It should be remembered however that this is electronic power equipment, which requires periodic maintenance. Moreover, some components have a limited lifespan and as such must be periodically checked and replaced: in particular the batteries, the fans and in some cases the electrolytic capacitors.
General characteristics 65 kVA UPS models 80 kVA 100 kVA 125 kVA MECHANICAL DATA Width (inches [mm]) 31.50 [800] Depth / height (inches [mm]) 33.46 [850] / 74.80 [1900] Ventilation Forced Max current dispersion 300mA max Noise at 1m from front (0÷100% load) (dBA) Applicable Standards UL Standard 1778 2nd Edition National Electrical Code (NFPA-70)
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65 kVA UPS models 80 kVA 100 kVA 125 kVA INVERTER Rated power Pf 0.9 (kVA) inductive Active power Pf 1 (kW) 58.5 112.5 Power derating (kVA/kW) for Pf =0.8/0.9 0.85/0.89 capacitive Rated voltage 480Vac 3-phase + N Rated frequency 60Hz Voltage range adjustment +5% -10%...
Appendix A Alarm messages Below is a list of the alarm messages that are shown on the first line of the display panel, the “A=” column shows the number that is also displayed on the right in the lower row . ALARMS EVENT MESSAGE DESCRIPTION...
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Alarm present when the system has been deactivated and switched onto the bypass, by means of a specific command inserted via the keyboard. The command remains stored BYPASS COMMAND also during shutdown due to a mains power supply failure. The system does not return ACTIVE;...
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Brake circuit Overload The optional brake circuit has an overload Rectifier switched OFF by The input converter stage is switched off by a remote command. Remote command WAIT starting: NOT connect the The input converter is starting, it needs to wait before connecting the battery BATTERY UPS SERVICE The unit operation time exceeded the set time to require service.
Appendix B - Optional remote commands Technical support personnel may modify the COMMAND that can executed from the standard “INV.OFF” remote input or from the optional remote input/output card. COMMAND Name Description Typical application Disables the recharging of the battery, keeping the When there is a generator, this Battery charge recharge current to a minimum, independently of the...
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UPS conform to: This device has been designed and manufactured in accordance with the standards for the product. - General and safety requirements: EN 62040-1 - Electromagnetic compatibility (EMC) requirements: EN 62040-2 (category C3) - Methods of specifying the performance and test requirements: EN 62040-3 The conformity to these Standards allows to bear the mark.
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