Riello UPS Master-HP 160 User manual

U
UN NI IN NT TE ER RR RU UP PT TI IB BL LE E P PO OW WE ER R S SU UP PP PL LY Y
160 to 250 kVA Three-Phase Output
MASTER HP
-
UL
USER MANUAL

page 2 / 85 0MLMHTM16RUENUB
RPS SpA
Viale Europa 7
37045 Legnago (VR) Italy
www.riello-ups.com

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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 160
160 kVA, 480 V input, 480 V output, 60 Hz, configured as wye-wye or delta-delta (see below); “00” may be
replaced with an alternate two character designator that denotes installed options as described in the order
documentation.
Master-HP 200
200 kVA, 480 V input, 480 V output, 60 Hz, configured as wye-wye or delta-delta (see below); “00” may be
replaced with an alternate two character designator that denotes installed options as described in the order
documentation.
Master-HP 250
250 kVA, 480 V input, 480 V output, 60 Hz, configured as wye-wye or delta-delta (see below); “00” may be
replaced with an alternate two character designator that denotes installed options as described in the order
documentation.
The wye output configuration that provides an output neutral connection is only permitted when an input neutral
is provided; that is, the delta-wye configuration is prohibited. The source must have a grounded neutral, even if
the neutral is not connected to the UPS; that is, a delta source may not be ungrounded or corner grounded.
Please refer to Section 4.4 for additional information.
Safety Warnings
IMPORTANT SAFETY INSTRUCTIONS
SAVE THESE INSTRUCTIONS
This manual contains important instructions for models 160, 200, 250kVA MASTER HP – UL that should be
followed during installation and maintenance of the UPS. Please read all instructions before operating the
equipment and save this manual for future reference.
READ AND FOLLOW ALL SAFETY INSTRUCTIONS
a. Do not use outdoors.
b. Do not route wiring across or near hot surfaces.
c. Do not install near gas or electric heaters.
d. Use caution when servicing batteries. Battery acid can cause burns to skin and eyes. If acid is spilled on
skin or in eyes, flush acid with fresh water and contact a physician immediately.
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.

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DANGER
This UPS contains LETHAL VOLTAGES. All repairs and service should be performed by
AUTHORIZED SERVICE PERSONNEL ONLY. There are NO USER SERVICEABLE PARTS
inside the UPS.
WARNING
To reduce the risk of fire or electric shock, install this UPS in a temperature and humidity
controlled, indoor environment, free of conductive contaminants. Do not operate near water or
excessive humidity (95% maximum).
Input and output over-current protection and disconnect switches must be provided by others.
High ground leakage current may be present. Do not operate the equipment without a proper
protective ground.
CAUTION
Batteries can present a risk of electrical shock or burn from high short circuit current. Observe
proper precautions. Servicing should be performed by qualified service personnel
knowledgeable of batteries and required precautions. Keep unauthorized personnel away from
batteries.
There is a risk of explosion if batteries are replaced by an incorrect type. Replace with same
type and rating only.
Proper disposal of batteries is required. Refer to your local codes for disposal requirements.
Never dispose of batteries in a fire
Definition
of
“
operator
”
and
“
specialized
technician”
The professional figure responsible for accessing the equipment for ordinary maintenance purposes is
defined with the term operator.
This definition covers personnel that know the operating and maintenance procedures for the
equipment, and that have been:
1. Trained to operate in accordance with the safety standards relating to the dangers that may arise where
electrical voltage is present;
2. Trained to use Personal Protective Equipment (PPE) and to carry out basic first aid.
The professional figure responsible for the installation and start-up of the equipment, and for any planned/
unplanned maintenance, is defined with the term specialized technician.
This definition covers personnel that, in addition to the requirements listed above for a general operator, must
also:
1. Have been trained by the manufacturers or their representative.
2. Be aware of installation, assembly, repair and service procedures, and have a specific technical
qualification.

0MLMHTM16RUENUB page 5 / 85
3. Must have a background of technical training, or specific training relating to the procedures for the safe
use and maintenance of the equipment.
E
mergen
cy 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.
2. If exposed to heat or fire, some products may release toxic fumes into the
atmosphere. Always use a respirator when extinguishing a fire.
Symbols used in the manual
In this manual, some operations are shown by graphic symbols to alert the reader to the dangerous nature of the
operations:
Danger / Risk of Electric Shock
Possibility of serious injury or substantial damage to the device, unless adequate
precautionary countermeasures are taken.
Caution
This symbol indicates some important information which must be read with care.
Risk of Explosion
Note
“Ground Electrode Terminal”
Electrostatic Sensitive Device
It is recommended to read this part of the manual.

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Personal Protective E
quipment
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. Long hair must be
tied in such a way as to ensure that it is not a hazard.
The following signs show the protective equipment that should be worn. The various items of PPE must be
selected and sized according to the nature of the hazard (particularly electrical) posed by the equipment.
Accident prevention footwear
Use: always
Protective eyewear
Use: always
Protective clothing
Use: always
Helmet
Use: When there are suspended loads
Work gloves
Use: always
GENERAL PRECAUTIONS
This manual contains detailed instructions fo
r the use, installation
and start
-
up of the
UPS
.
Read the
manual carefully before installation. For information on how to use the UPS, the manual must be read and
understood before carrying out any operation on the device.
This device has been designed and manufactured in accordance with the standards for the product, for
normal use and for all uses that may reasonably be expected. It may under no circumstances be used for any
purposes other than those envisaged, or in any other ways than those described in this manual. Any operation
should be carried out in accordance with the criteria and the time-frames described in this manual.
No reproduction of any part of this manual, even partial, is permitted without the authorization of RPS S.p.A.
The RPS S.p.A. reserves the right to modify the product described herein, in order to improve it, at any time and
without notice.

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CONTENTS
1. LAYOUT..........................................................................................................9
2. PRELIMINARY OPERATIONS...........................................................................11
2.1 Removing the packaging and positioning the UPS.................................................... 11
2.2 Storage.....................................................................................................................11
2.3 Handling ..................................................................................................................11
3. INSTALLATION ENVIRONMENT ......................................................................12
3.1 Ambient conditions:..................................................................................................12
3.2 Dimensions of the premises ......................................................................................12
3.3 Cooling of the premises............................................................................................13
3.4 Ventilation for battery premises................................................................................13
4. ELECTRICAL CONNECTIONS..........................................................................14
4.1 UPS in single configuration......................................................................................15
1.1.1 Cable Entry.................................................................................................................................16
1.1.2 Connection of Power Cables for Single input Unit.......................................................................18
1.1.3 Connection of Power Cables for Dual input Unit.........................................................................20
4.2 Minimum Wire Size Requirements ............................................................................22
4.3 External Overcurrent Protection device and terminals .............................................24
1.1.4 Differential (GFI) .......................................................................................................................25
1.1.5 Backfeed protection.....................................................................................................................26
1.1.6 Emergency Power Off device (EPO)............................................................................................26
4.4 Mains, load and battery connections.........................................................................27
4.5 Connection of signals and remote commands............................................................28
1.1.7 Parallel (optional) ......................................................................................................................31
1.1.8 REMOTE COMMANDS, ALARMS AND EPO.............................................................................31
1.1.9 RS232.........................................................................................................................................32
1.1.10 SLOTS 2-1 , the following cards may be inserted (optional):........................................................33
1.1.11 REMOTE ALARMS (2 optional cards for the MASTER HP–UL PTCE version)...........................33
1.1.12 Battery temperature sensor (optional) .........................................................................................33
1.1.13 SWOUT and SWMB aux..............................................................................................................34
4.6 Start-up procedure ...................................................................................................35
1.1.14 Battery operation check...............................................................................................................36
4.7 Operating modes......................................................................................................36
1.1.15 On - line - factory setting -.........................................................................................................37
1.1.16 Standby-on / Smart active............................................................................................................37
1.1.17 Standby-off (with mains present the load is not supplied)............................................................37
1.1.18 Stabilizer (operation in on-line mode without battery) .................................................................38
4.8 Personalisation’s......................................................................................................38
4.9 Procedure to transfer the load from UPS onto maintenance bypass (only for
MASTER HP – UL MBY TCE version)...............................................................................38
4.10 UPS and load shutdown............................................................................................39
4.11 Block diagram..........................................................................................................40
4.12 Components of the block diagrams...........................................................................41
4.13 UPS in parallel configuration (Option).....................................................................42
1.12 Introduction..............................................................................................................42
4.14 Electrical system set-up............................................................................................43

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1.1.19 Input...........................................................................................................................................43
1.1.20 Ground Fault..............................................................................................................................43
1.1.21 Emergency power off device (EPO).............................................................................................44
1.1.22 External maintenance bypass. .....................................................................................................44
4.15 Mains, and load connections. ...................................................................................44
1.1.23 UPS AC input / output power connection.....................................................................................44
1.1.24 Connecting the Parallel Card (Option)........................................................................................45
4.16 Connection of signals ...............................................................................................46
4.17 Start-up procedure ...................................................................................................50
4.18 Operating modes......................................................................................................51
4.19 Mechanical Bypass (only for MASTER HP – UL PTCE version) .............................. 53
5. SIGNAL PANEL FUNCTIONS............................................................................56
1.1.25 Language setting menu (keys 1, 1)...............................................................................................61
1.1.26 Measurements menus (key 2).......................................................................................................62
1.1.27 Times Measurement. ...................................................................................................................62
1.1.28 Full page Measurements and output waveforms (key 2, 7)............................................................63
1.1.29 Controls Menu (key 3),................................................................................................................64
1.1.29.1 Keys menu 3, 2: battery test...............................................................................................64
1.1.29.2 CUSTOMIZING ................................................................................................................65
1.1.29.3 Keys menu 3, 5: CODE 436215..........................................................................................65
1.1.29.4 RATED OUTPUT VOLTAGE...........................................................................................66
1.1.29.5 BATTERY.........................................................................................................................66
1.1.29.6 PRE-ALARM ....................................................................................................................67
1.1.29.7 AUTO-OFF "VA"............................................................................................................69
1.1.29.8 AUTO-OFF Timer. ............................................................................................................69
1.1.29.9 BYPASS VOLTAGE RANGE ADJUSTMENT .................................................................70
1.1.29.10 BYPASS FREQUENCY RANGE ADJUSTMENT.............................................................70
1.1.29.11 MODEM............................................................................................................................70
1.1.29.12 "DIAL /SEND" MODEM...................................................................................................71
1.1.29.13 RS232................................................................................................................................71
1.1.29.14 ECHO................................................................................................................................71
1.1.29.15 IDENT...............................................................................................................................72
1.1.29.16 OPERATION IN STANDBY-ON ......................................................................................72
1.1.29.17 SMART ACTIVE OPERATION........................................................................................72
1.1.29.18 INVERTER-OFF/BYPASS................................................................................................72
1.1.29.19 TOTAL BLOCK................................................................................................................73
1.1.30 "RECORDER": RECORDED EVENTS (key 4)............................................................................73
1.1.30.1 RECORDED VOLTAGES MEASUREMENTS.................................................................73
1.1.30.2 RECORDED CODES.........................................................................................................73
1.1.30.3 RECORDED value on full page..........................................................................................74
1.1.31 DISABLING THE AUDIBLE ALARM (key 5) ..............................................................................75
1.1.32 "CLOCK": DATE/TIME (key 6)..................................................................................................75
1.1.33 "ARROW DOWN": Internal Codes, firmware ver.(key 7).............................................................75
6. MAINTENANCE .............................................................................................76
7. GENERAL CHARACTERISTICS.........................................................................77
8. APPENDIX AALARM MESSAGES ....................................................................81
9. APPENDIX B-OPTIONAL REMOTE COMMANDS .............................................84

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1. Layout
MASTER HP –UL -FRONT VIEW
AControl panel with graphic display
BDoor handle
CVentilation grilles
DCommunication area
EFront Cover panel with ventilation grilles
FSwitch cover panel
GDoor
1SWIN: Input power switch
2SWBY: Static switch bypass input
3SWOUT: Static switch output
A
B
D
F
C
E
1
2
3
G
G
D

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MASTER HP –ULMBY TCE -FRONT VIEW
AControl panel with graphic display
BDoor handle
CVentilation grilles
DCommunication area
EFront Cover panel with ventilation grilles
FSwitch cover panel
GDoor
1. SWIN: Input power switch
2. SWBY: Static switch bypass input
3. SWOUT: Static switch output
4. SWMB: Mechanical bypass switch
A
B
D
F
C
E
1
3
4
2
G
G

0MLMHTM16RUENUB page 11 / 85
2. Preliminary operations
2.1 Removing the packaging and positioning the UPS
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 indicator devices on the packaging is red; if one of
them is red; follow the instructions on the packaging.
The relevant data of the UPS are provided on the shipping document. The marking, weight and dimensions of
the different items making up the packing list are shown.
Check the state of the UPS by means of a visual inspection of both the inside and the outside. Any dents noticed
mean that the UPS has suffered shocks during shipping, which could compromise the normal operation.
2.2 Storage
In the following situations:
- installation not immediately after delivery;
- de-installation and storage while awaiting relocation,
Place the device in covered premises that are protected from direct contact with atmospheric agents and dust.
The following environmental values are those allowed in the storage area:
Temperature: -13°F to +167°F ( -25 to + 75 °C)
Relative humidity: 30-95 % max.
For the installation of a battery cabinet, if provided with the uninterruptible power supply, follow the
instructions given in the specific manual.
The list of material provided may vary depending on the order specifications. As a general rule, the packaging
should include the following: the manual, the installation drawing, the warranty and the accessories if requested.
2.3 Handling
The equipment must only be handled by trained personnel. It can be unloaded from the vehicle and put into place
by lifting the box or the wooden deck to which the equipment is secured with a fork-lift truck. A fork-lift truck
should be used for the permanent positioning of the equipment, in accordance with the instructions provided
below.
1Insert the forks of the fork-lift truck in the lower part of the device, from the front or back, and
ensure that they stick out about 12 inches on the other side.
2Secure the device to the fork-lift before moving it.
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.

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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.
The packaging should be removed as follows:
1. Cut the bands
2. Slide away the carton from above.
3. Remove the screws securing the cabinet to the wooden base.
3. Installation environment
The UPS and the battery cabinet have been designed for indoor installation. The chosen of premises for
installation should comply with the points set out below.
3.1 Ambient conditions:
ensure that the floor can support the weight of the MASTER HP - UL and of any battery cabinet that
may be used
avoid dusty environments (the indoor area must be free of conductive contaminations)
avoid narrow environments that could hinder normal maintenance operations
avoid placing the device in areas exposed to direct sunlight or heat
ensure that the ambient temperature conforms to the following:
- minimum operating temperature: +32°F ( 0 °C)
- maximum temperature for 8 hours a day: +104°F (+ 40°C)
- average temperature for 24 hours: +95°F (+ 35°C)
3.2 Dimensions of the premises
For the mechanical dimensions of the cabinets, refer to the “INSTALLATION DRAWINGS” supplied with the
UPS and with the battery cabinet, if present. These drawings provide the following data:
the position of the holes in the base to secure the device to the floor, if applicable;
a view of the floor support for the sizing of a structure to raise the cabinet, if applicable;
the position of cable entry;
the position of the fans on the top of the UPS, for the positioning of a structure to convey the air
flow outgoing the equipment outside the premises, if applicable;
the input, output and battery cables section;
Power loss by the equipment (kW).

0MLMHTM16RUENUB page 13 / 85
3.3 Cooling of the premises
The recommended operating temperature for the lifetime of the UPS and of the batteries is from 20 to 25°C. The
lifespan of the battery depends on the operating temperature; with a rise
temperature of 10°C above 20°C , the lifespan of the batteries is halved.
A heat dissipation system is required to keep the temperature of the
premises where the units are placed within the range of 20-25°C.
The heat dissipation needed for the correct operation of the UPS is by the
air flow generated by the fans located inside the UPS (forced convection)
and by the air surrounding (natural convection).
In order to ensure proper air motion, and therefore the correct operation of
the UPS, countermeasures must be taken during installation to avoid any
obstructions to the free circulation of air. These include the following:
Ensure a distance of at least 24 inches from the ceiling, so as not to
hinder free circulation of air.
Leave a free space of at least 36 inches on the front of the equipment
to ensure both the free circulation of the air and installation and
maintenance operations;
With natural convection the heat is dissipated by temperature
gradients to the outside through the walls; thus a cabinet placed
against a wall or in a recess dissipates less heat than one located in a
free environment.
The following rule must be observed:
Leave at least one of the three side walls free: right, left or back.
The bottom side kick panels must not be mounted for installations where cabinets are lined up.
3.4 Ventilation for battery premises
The premises housing the battery cabinet must have adequate ventilation to prevent the concentration of
hydrogen issued during battery charging and keep it below the danger limit.
The air flow in the premises should preferably be provided by natural ventilation, otherwise by forced
ventilation.
The standard EN 50272-2 for ventilation requires that the minimum opening must satisfy the following equation:
A = 28 x Q = 28 x 0.05 x n x Igas x C10 (1/10³) [cm²]
where: A = free opening for air intake and outlet
Q = flow of air to be removed [m³/h]
n = number of battery elements;
C10 = battery capacity over 10 hours [Ah]
Igas = current that produces gas [mA//Ah]
In accordance with the standard: Igas = 1 VRLA type battery (*)
(*) for open vase or nickel batteries, contact the battery manufacturer.
When the equation is applied for 240 elements (40 batteries) sealed lead acid batteries:
A = 336 x C10 / 10³ [cm²]
When using 120Ah batteries, the minimum opening should be approximately:
A = 41 [cm²] or (multiplied by .155) = 6.36 in2
The
ventilation grates for
in
let
and outlet
air
must
be positioned to
ensure
the
best possible
circulation
of
air; for example: - on opposite walls,
- minimum distance of 6 ft. when they are on the same wall.

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4. Electrical Connections
ACCESSING THE UPS 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. In particular, check that:
- the UPS input line is completely isolated;
- that the battery circuit breaker/disconnect is open;
- all the UPS power and load connection switches (SWIN, SWBY, SWOUT
and SWMB if present) are in the open position;
- no dangerous voltages are present (use a multimeter).
The first connection to be performed is the protective wire (ground cable) which
has to be inserted into the terminal labelled “Grounding Electrode Terminal”. The
UPS must operate with the grounding system connected.
CAUTION: Do not connect the output neutral to the input neutral.
CAUTION:
If the input connection is
D
elta the UPS can supply only
D
elta load.
The output neutral must not be connected unless the UPS is the Wye version
supplied with an input neutral.
TRANSFORMER CABINETS (optional) are available for converting the distribution
systems from 3 to 4 wires.
CAUTION: If a three
-
phase
non
-
linear
load is connected to the output, the current on
the neutral conductor can reach a value equal to 1.5 times the value of the phase
current. Dimension the input/output neutral cable appropriately taking this data into
account.
CAUTION: The UPS cannot feed from a corner ground or mid
-
point grounded delta
supply source.
CAUTION: Use only lugs or cables with tin-plated eyes for the connections.
CAUTION: Ensure correct phase rotation at the input and output terminals
Ensure correct polarity battery connections
Each model can be configured for a delta input source with a de
lta connected load or
for a wye input with a wye connected load. If the load requires a neutral connection
(i.e. wye), then an input neutral must be provided. Refer to the Power Connection
terminals diagrams later in this section for details concerning configuration of the
neutral to ground bond.

0MLMHTM16RUENUB page 15 / 85
4.1 UPS in single configuration
The UPS is designed to work as Single input Unit or as Dual input Unit.
Schematic diagram: Single input Unit
(*) SWMB only in MASTER HP – UL TCE version.
Schematic diagram: Dual input Unit
(*) SWMB only in MASTER HP – UL TCE version.
(*)
(*)

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1.1.1 Cable Entry
The cables can enter in the UPS from the bottom in the MASTER HP – UL version, from the top or the bottom
with the MASTER HP – UL MBY TCE version
Proceed as follows in order to open the UPS
Open the door
Remove the switch cover panel
Remove the bottom cable entry cover plates
Drill or punch conduit holes in the cover plates
Route the power cable through the bottom to the UPS terminals in base to your configuration (see the
next paragraphs)
MASTER HP – UL
-Cables can enter in the UPS from the bottom-
FRONT
REAR
External Control
Cable Entry
Power Battery
Cable Entry
UPS Bottom
View
Power AC Cable
Entry

0MLMHTM16RUENUB page 17 / 85
MASTER HP – UL MBY TCE
- Cables can enter in the UPS from the top or from the bottom-
FRONT
External Control
Cable Entry
Power AC Cable
Entry
Power Battery
Cable Entry
UPS Bottom

page 18 / 85 0MLMHTM16RUENUB
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:
MASTER HP – UL Power connection Terminals
Note: For the Input, Output and Battery connections, follow the order from the top to bottom, or right to left, as
described in the boxes. The label marked “N” present on the terminal identifies the neutral terminal.
The single input is a factory default configuration. Do not remove the bypass jumper. The input phase
connections are made using bolts to one of the three holes in the bus bar. Do not loosen the bolts that attach the
bus bar.
Bond: The UPS is provided with a separate bus bar that connects the Neutral Output to the frame Ground for
delta input connection. This is required to meet NEC grounding code for separately derived neutrals. When a
Neutral is provided in a Wye configured input connection the bus bar should be removed.
Refer to NEC article 250 (Grounding and Bonding) for identify system of grounding and size of equipment
grounding conductor
Once installation has been completed inside the equipment, put the switch cover panel back and close the door.

0MLMHTM16RUENUB page 19 / 85
MASTER HP – UL MBY TCE Power connection Terminals
Note: For the Input, Output and Battery connections, follow the order from the top to bottom, or right to left, as
described in the boxes. The label marked “N” present on the terminal identifies the neutral terminal.
The single input is a factory default configuration. Do not remove the bypass jumper. The input phase
connections are made using bolts to one of the three holes in the bus bar. Do not loosen the bolts that attach the
bus bar.
Bond: The UPS is provided with a separate bus bar that connects the Neutral Output to the frame Ground for
delta input connection. This is required to meet NEC grounding code for separately derived neutrals. When a
Neutral is provided in a Wye configured input connection the bus bar must be removed.
Once installation has been completed inside the equipment, put the switch cover panel back and close the door.

page 20 / 85 0MLMHTM16RUENUB
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:
MASTER HP – UL Power connection Terminals
Remove the jumpers present between the SWIN and SWBY.
The input phase connections attach using bolts through the holes that were previously used to attach the bus bars.
The main (rectifier) input is located on the left and the bypass input is on the right. The neutral input comes
from the bypass source; no neutral is to run from the rectifier input source, although the rectifier source must be
a grounded wye.
Note: For the Input, Output and Battery connections, follow the order from the top to bottom, or right to left, as
described in the boxes. The label marked “N” present on the terminal identifies the neutral terminal.
Bond: The UPS is provided with a separate bus bar that connects the Neutral Output to the frame Ground for
delta input connection. This is required to meet NEC grounding code for separately derived neutrals. When a
Neutral is provided in a Wye configured input connection the bus bar must be removed.
Once installation has been completed inside the equipment, replace the switch cover panel and close the door.