service manual ITYS

6-10 kVA
 Document: MSMITYTWXX30-GB_00
Date: 25.07.2008

INDEX

1. Introduction……………………………………………………………….……..4

2. Schematics and functioning principle…………………………………….……6

3. Troubleshooting………………………………………………………………...18

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PURPOSE.
This Service Manual provides the informations to ease the maintenance and/or repairs by qualified
technical personnel authorized by SOCOMEC UPS.

APPLICABILITY.
Every information included in this Service Manual is related only to ITYS 6 kVA and ITYS 10
kVA UPSs.

IMPORTANT.
After the shutdown of the UPS, isolate it and wait 5 minutes before removing the protection panels
and work on parts under dangerous voltage.
Please, refer to the Technical Logistic Guide for the code of spare parts.

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1. Introduction

Legend.

A Operation and led Display H Input and output terminal board

B Ventilation grid I Cable couplings

C Wheel front cover L Slot for optional communication board

D RS232serial port (JBUS protocol) M Output socket for external battery
cabinet connection (LB models only)
E Fan
N Manual by-pass
F Fan (10kVA only)
O Wheels with safety locking system
G Imput protection (magneto-thermal)

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MODEL: ITYS 6kVA MODEL: ITYS 10kVA

ITEM DESCRIPTION QTY ITEM DESCRIPTION QTY
A BATTERY 12V 7.2AH 20 A BATTERY 12V 9.0AH 20
B FAN 1 B FAN 2
C CNTL PCB 1 C CNTL PCB 1
D PSDR PCB 1 D PSDR PCB 1
E CHGR PCB 1 E CHGR PCB 1
F I/P EMI PCB 1 F I/P EMI PCB 1
G O/P EMI PCB 1 G O/P EMIPCB 1

Please, refer to the Technical Logistic Guide for the code of spare parts.

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2. Schematics and functioning principle

The simplified schematics in figure illustrate the overall system.

How the major assemblies are connected.

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Wiring Diagram of ITYS 6kVA

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Wiring Diagram of ITYS 10kVA

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POWER STAGE (PSDR)

The Power Stage (PSDR) consists of DC Power Supply for controlling circuits, Power Factor
Correction (PFC), Booster, DC/AC Inverter, and output circuits.
Pictures and system diagram of the PSDR is as below.

PSDR of ITYS 6kVA

PSDR of ITYS 10kVA

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• Jumper Settings of the PSDR

The connecting JUMPER wires must be connected on between P27 and P28, as well as
between CN111 and CN112. Please pay attention on these jumper settings while replacing of
the PSDR.

ITEM LOCATION DESCRIPTION

1 P27, P28 Connected with a jumper
2 CN111, CN112 Connected with a 2-pin wire set

• Fuses Configuration on the PSDR

FUSE LOCATION
MODEL MAINS INPUT BATTERY INPUT
F301 F302 F303 F304
6kVA NC 30A600V 30A600VDC NC
10kVA 30A600V 30A600V 30A600VDC 30A600VDC

Notes: 1. NC means no fuse is required.

2. The fuses of F301 and F302 must be in the same type if necessary.
3. The fuses of F303 and F304 must be in the same type if necessary.

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Following are the descriptions of the major circuits on PSDR.

a) DC Power Supply:

The input of DC Power Supply is connected to the battery BUS + and -or the output of the
charger. DC Power Supply provides 5VDC, 12VDC, ±15VDC for the controlling, driver and
others circuits.

b) Power Factor Correction (AC/DC Converter):

The purpose of Power Factor Correction (P.F.C) circuit is to make the input current and voltage
in phase and therefore achieve a high input power factor.
The PWM signals of the PFC are controlled by DSP (Digital Signal Processor) from CNTL.

c) Booster (DC/DC Converter):

In AC mode (Utility Power mode), the AC power goes through noise filter to the pre-charging
circuit. The ±DC BUS capacitors will be pre-charged. When the DC voltages on the DC BUS
capacitors reach the peak value level of the input AC power, then the input SCR will be
turned on. After turning on the input SCR, the charger will work to charge the batteries and
the ±DC BUS capacitors will present voltages at about 1.4 times of input RMS voltage.
By pressing the POWER ON button on the front panel to power up the UPS, the ±DC BUS
voltages are regulated at 345VDC, and in few seconds, the UPS will transfer from BYPASS
mode to INVERTER mode.
In Battery Mode, the major function of the UPS is to deliver accurate AC power to the loads
connected to it whenever the utility power is abnormal or fails. In this system, the batteries
release the stored energy to supply the INVERTER immediately. The battery voltage is
transformed through the booster (DC/DC converter) to achieve ±345VDC BUS voltages for the
INVERTER.
In the event of any abnormality of the utility power, the DC source of ±345VDC buses is caught
up from the batteries to supply the power needed by the INVERTER immediately.

d) Inverter sub-system:

The UPS converts ±DC BUS voltages to AC output voltage through a DC/AC converter,
called INVERTER. The INVERTER is of half bridge configuration at normal operation.
To construct a high frequency (19.2KHz) PWM inverter, the drivers receive switching signals
from CPU PWM generation circuit through a pair of IGBT Drive modules to trigger the upper
and the lower IGBT alternately. The output of IGBT is filtered by an LC circuit to reduce
harmonic distortion of the output voltage.

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CNTL

The CNTL (Control Board Assembly) is of the brain of the UPS system. The CNTL consists
of DSP (Digital Signal Processor), CPU, signaling and sensing circuits, controlling circuits
and comunication port.

• Default Setting of CN100 and CN101

There are two jumpers preset between Pin-2 and Pin-3 on CN100, and between Pin-1
and Pin-2 on CN101. Please DO NOT try to change this factory default setting.

CN100 CN101

Pin 1 & 2 Pin 2 & 3 Pin 1 & 2 Pin 2 & 3

JUMPER - CLOSE CLOSE -

• Model settings
The CNTL is applicable to the models of 6kVA and 10kVA, but the jumper setting of JP01
on CNTL varies from their model number.
Please refer to the following for the model settings of JP01.

MODEL JP01 settings

Pin 9 & Pin 11 & Pin 13 &
Pin 1 & 2 Pin 3 & 4 Pin 5 & 6 Pin 7 & 8
10 12 14
ITYS
CLOSE - - - - - -
6kVA
ITYS
CLOSE - - - - CLOSE -
10kVA

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CHGR

• The input of DC charger is connected to ±DC BUS. The output voltage of the charger is
274VDC with a maximum charging current of 2A. Adjust the VR901 on the Charger Board
to obtain the expected output voltage.

NOTES:

• The UPS system cannot be powered up if there is no battery bank connected to, or the
voltage of the battery bank is extremely low, even though the AC input power is normal, the
UPS system simply provides bypass output.
• Tips of adjusting the output voltage of the charger: Switch the INPUT breaker of the UPS in
ON position, when the UPS is normally working in BYPASS mode, or in INV mode in
Utility Power mode, then disconnect the connecting jumper wire of the battery bank and
then check the DC output voltage of the charger. If necessary, adjust VR901 on the CHGR
to obtain the expected output voltage of the charger.

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I/P EMI

Input EMI Board is connected between mains and the input of PSDR.

O/P EMI

Output EMI Board is connected between the output of PSDR and output terminal block.

O/P EMI 6kVA O/P EMI 10kVA

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COMMUNICATION PORT

A DB-9 port and an intelligent slot interface are equipped on the rear panel of the UPS for
communications with the computers.

a) RS232 Interface (DB-9)

PIN# DESCRIPTION I/O

2 TX Output
3 RX Input
5 GND GND

b) NET-VISION (Intelligent Slot):

Net-Vision can get hold of the status from and issue commands to the UPS. User can use SNMP
managers or Web browsers to manage the UPS through an Ethernet.
Net-Vision also provides shutdown programs for different operating systems.
It issues a shutdown command in the event of such as mains failure, battery low condition, UPS
overload, UPS over temperature and scheduled shutdown. All shutdown events are
configurable. The shutdown software will proceed to the automatic orderly shutdown to prevent
the abnormal shut off of the clients or the servers. For a complete description, refer to the Net
Vision documentation.

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c) Dry Contact (Intelligent slot):

Dry contact pcb have 5 relay with the following pin assignment.
The maximum voltage that can be applied to the contacts is 24 Vdc and the maximum current is
500 mA.

Notes: Remote shutdown command is received by leaving the contact closed for 3 consecutive
seconds. The external contact MUST be dedicated and at zero potential; if this condition is
not respected, permanent damage may be caused to the UPS.

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ALIGNMENTS

TEST TEST POINT TEST AND EXPECTED RESULT

ADJUSTMENT

±DC BUS ± BUS CAP. Connect DVM (DC) to test +DC BUS=
or on PSDR points and supply input 345VDC±4V
+DC BUS: mains, - DC BUS=
P20/21, P13/14 then press the Power ON 345VDC±4V
- DC BUS: button The voltage differentials
P13/14, P24/25 on the front panel of the UPS. between ±DC BUS
voltages should be or
less than 6VDC

Charger +, - of the output of 1. Supply input mains to the 274VDC±0.5V

the battery bank UPS
2. Batteries disconnected.
3. Connect DVM (DC) to test
points
4. Adjust VR901 on CHGR
board to obtain the expected
voltage

Output Terminal block of the Connect DVM (AC) to the 220VAC±1%

Voltage AC output of the UPS test (217.8 ~ 222.2VAC)
points

Voltage Terminal block of AC 1. Connect the measurement ± 1VDC.

Balance output of the UPS tool as below circuit to the
output of the UPS
2. Connect the DVM to the
test points
3. Input mains and turn on the
UPS

Measurement Tool for test of output balance

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3. Troubleshooting
For the reason of safety, you must turn off the mains and disconnect the batteries.
Check the components to confirm which part of the circuit is out of order and follow the procedures
listed thereafter.
It is not recommended to repair the PCB assemblies. Just replace the whole set of CNTL and PSDR,
or other PCB assemblies if any, for the unit in the event of any failure of the UPS.

CAUTION: DO NOT supply the UPS with the mains unless you are sure that you have replaced
all defective components or assemblies.

NOTES:
After replacing PSDR and CNTL or other major assemblies, please examine the UPS step by step.
Firstly, check the UPS functions in Battery mode, if all the functions are okay and the parameters
comply with the specifications, then power off the UPS before supplying utility power.

1. Wait for at least 3 seconds after connecting the battery bank to the unit, then simply press the
Power ON button on the front panel for less than 1 second to perform the self-diagnosis function
and pay attention to the LED display and the audible alarm warning.
The LEDs on the panel will be lit on and then off, and no other alarming signal, that means self
test is OK, it is possible by pressing the Power ON button for more than 1 second to power up
the UPS for further checkup, such as ±DC BUS voltages, O/P voltage and frequency, Balance
voltage in Battery mode.

2. Make sure the unit is normal in Battery mode, then power off the UPS before supplying the
utility power to the UPS.

3. Switch ON the INPUT breaker of the UPS and pay attention to the LED panel and audible alarm
warning, if self diagnosis is OK and LED display in normal state, to examine ±DC BUS
voltages, Input voltage and bypass output voltage as well as charge voltage, then by pressing
the Power ON button to power up the UPS for further checkup in Utility Power mode and then
to confirm all the parameters in AC mode, such as ±DC BUS voltages, O/P voltage and
frequency, Balance voltage, charge voltage, etc. are within specifications.

4. If all the parameters comply with the specifications both in Battery mode and in Utility Power
mode, switch OFF and ON the input breaker of the UPS or the breaker of the mains distribution
panel for at least 3 ~ 5 time to ensure that the UPS is functionally normal transferring from
Battery mode to Utility Power mode and vice versa, without any problem and no interruption to
the output.

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LED DISPLAY PANEL

Led 6 Led 5 Led 4 Led 3 Led 2

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• POWER ON / SILENCE BUZZER

To power up the UPS system simply by pressing this button continuously for more than 1
second. Pressing this button again if the UPS is normally working in utility power mode, the
UPS system will perform self test. In Battery mode, press the ON button again will stop the
audible alarm warning of beeping every four seconds, and press the button once again to resume
the audible alarm warning.
In Alarm Silence mode, the audible alarm warning will automatically resume when the battery
voltage reaches battery low level.

Notes: If simply pressing this ON button for less than 1 second, the UPS system is just to
perform self diagnosis, the system can not be powered up.

• POWER OFF
Press this OFF button for 1 second to power off the UPS. The UPS system will transfer to
BYPASS mode after pressing this OFF button in Utility Power mode.

• MAIN PRESENT LED

Whenever this led is on, it shows that the input voltage and frequency of the UPS are normal.

• BYPASS MODE LED

Whenever this led is on, it shows the loading current is directly supplied from the utility power
via internal filters.

• INVERTER MODE LED

Whenever this led is on, it shows the inverter of the UPS is working normally.
The UPS system provides complete protection to the load if the Inverter Mode LED is lit and
the Bypass mode LED is off.

• BATTERY MODE LED

Whenever this led is on, it shows the loading current is powered from batteries via the inverter.

• GENERAL ALARM LED

Whenever this led is on, it means the UPS is in abnormal condition and usually comes with an
audible alarm warning.

• LED BAR
This Led Bar indicate the loading percentage of the output power in Inverter mode or the level
of battery capacity in Battery mode.
The combination of these leds in presence of an alarm is used to do diagnosis.

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CORRESPONDING LED DISPLAY & ALARM WARNING IN CERTAIN FAULT

CONDITIONS

LED DISPLAY
General alarm

LED BAR
By-pass mode
Mains present
Inverter mode
BUZZER POSSIBLE CAUSE

Battery mode
6 5 4 3 2

Twice every
z z z z z z z z Inverter overload
second
Twice every Inverter overload and load
z z z z
second transfer on by-pass mode
Overload on battery mode and
z z Continuosly
cut off output
z z * * Continuosly Internal overtemperature
Inverter fault (Vinv ≥276V or
z z * * Continuosly
≤140V for 128ms)
z z z * * Continuosly Output short circuited

z z * * Continuosly ±DC BUS fault

CHGR fault (Overvolt or Bat
z z z z z Continuosly
SCR fault)
CHGR fault (Vbatt<240V for 1hr
z z z › Continuosly
on Inverter mode)
z z z z z Continuosly Battery SCR fault

z z z Continuosly Cooling Fan fault

z z z * * Continuosly Inverter relay (RY1 & 2) fault

Internal CPU communications
z z z * * Continuosly
error
z z z z Continuosly Inverter or S.S. fault

z Led ON › Led blinking * Led status depending on if there is utility

power supplied or not.

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OVERVIEW

• Power Stage Board (PSDR)

- Input part
- DC Power Supply.
- Power Factor correction (P.F.C.).
- Booster sub-system.
- Inverter sub-system.

• Control Board (CNTL)

• DC Charger Board

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REFERENCE VALUE FOR CHECKING

A. Power Stage (PSDR)

(A-1) RECTIFIER

(A-2) PFC & BOOSTER/DC-DC CONVERTER

(A-3) DC-AC INVERTER

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B. Charger Board

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