ITYS-E 6-10KVA

Service Manual
2 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 TABLE OF CONTENT
Purpose - Applicability - Safety - Warranty ........................................................................... 4
Warranty: ............................................................................................................................. 4
1. Introduction ..................................................................................................................... 5
1.1 Technical Specifications. ........................................................................................ 5
1.2 Function and Features.......................................................................................... 6
1.3 Operation Principle. .............................................................................................. 7
1.4 PCBs UPS. ........................................................................................................... 8
1.5 PCB explanation. .................................................................................................. 9
1.5.1 Power supply circuit (SPS) ........................................................................... 9

1.5.2 PFC/Boost circuit ....................................................................................... 10

1.5.3 Inverter circuit............................................................................................. 10

1.5.4 Charger ...................................................................................................... 11

1.5.5 EMI Board .................................................................................................. 11

1.6 Wiring diagram .................................................................................................... 12

1.7 Internal view. ...................................................................................................... 14
2. Hardware replace.......................................................................................................... 15
2.1 Electronic cabinet and battery cabinet swap. ..................................................... 15
3. Communication ............................................................................................................. 16
3.1 RS232 Port. ........................................................................................................ 16
3.2 USB port. ............................................................................................................ 17
3.3 Emergency Power Off (EPO). ............................................................................ 17
4. Battery .......................................................................................................................... 18
5. Troubleshooting ............................................................................................................ 19
5.1 Trouble shooting according to warning indication ............................................... 19
5.2 Trouble shooting according to fault indication ..................................................... 20

3 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 PURPOSE – APPLICABILITY - SAFETY

Purpose - Applicability - Safety - Warranty

Purpose:
This service manual provides the information to ease the maintenance and/or repairs
by qualified technical personnel authorised by SOCOMEC.

Applicability:
Any information included in this Service Manual is related only to UPS ITYS-E 6-10
kVA models.

Safety:
All operations must be done in the optimum and usual conditions of safety.
• personal protective equipment wearing (PPE)
• machine in manual by-pass with all breakers open and wait 5 minutes for
discharge capacitors.

Battery:
A battery can present a risk of electrical shock and high short circuit current.
The following precautions should be observed when working on batteries:
a) Remove watches, rings or other metal objects.
b) Use tools with insulated handles.
c) Wear rubber gloves and boots.
d) Do not lay tools or metal parts on top of batteries.
e) Disconnect the charging source prior to connecting or disconnecting battery
terminals.
f) Determine if battery is inadvertently grounded. If inadvertently grounded,
remove source from ground.
Contact with any part of a grounded battery can result in electrical shock.
The likelihood of such shock can be reduced if such grounds are removed during
installation and maintenance (applicable to equipment and remote battery
supplies not having a grounded supply circuit).

Warranty:
• The warranty shall not apply in case of opened of the equipment.
• The faulty power modules must be shipped back to factory with
appropriate packaging as per the return shipment instructions provided
each time a replacement is request.
• It’s strictly recommended to use the original package of the new replacing
module to ship back the faulty one. Costs of transportation damages will
be not covered by the warranty.

4 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 1. Introduction

1. Introduction

1.1 Technical Specifications.

5 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 1. Introduction

1.2 Function and Features.

True double-conversion online UPS

DSP technology guarantees high performance
Output power factor 0.8
Active input power factor correction 0.99
50Hz/60Hz frequency converter mode

6 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 1. Introduction

1.3 Operation Principle.

As a true online UPS, the product employ a double conversion topology, comprise
following functional block, as shown in the figure below.

Fig 1-1 Function block Diagram

The CNTL block control the action of the UPS system, the CNTL also provides the
communication interface for receiving and executing command from user via the panel or
other communication protocol.

The Rectifier and PFC blocks are the input stage of the UPS, The blocks converse the AC
input power into two stable DC power storing on the BUS capacitor. In means time,
PFC(Power Factor Correction) is performed, the input current tracking the input voltage
waveform, and the input power factor can be corrected to 1, achieve maximum efficiency
and product lowest power pollution to the utility.
The PFC block in battery mode, called also Booster, used to converse the low voltage DC
power into higher voltage and more stable DC power, storing on the BUS capacitor also.
The Inverter block is the output stage of the UPS, used to converse the DC power from
the BUS capacitor into sine waveform output power.
The Charger charges the battery when the utility is normal. The charger converse the AC
input power into DC power for recharging the battery.
The Input or Output EMI section provides EMI filter function. The input EMI filter and
output EMI filter can prevent the UPS being interference by external electronic/magnetic
noise which generated by the other electronic system, and it can prevent the noise
generated inside the UPS system interference other system too.
The SPS generates DC power supply needed by operation of the circuit of the UPS itself.
The Bypass provides a path that utility can power the output directly when the Inverter
didn’t work.

7 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 1. Introduction
1.4 PCBs UPS.

PCB list of 6kVA UPS:

Name Quantity Description

PFC 1 PFC Boost PCB 6K
INV 1 INVERTER PCB 6K
CHGR 1 CHARGER PCB 6K 10K
CNTL 1 PCB Controller 6K 10K
COMMU 1 Communication PCB 6K 10K

Table 1-1

PCB list of 10kVA UPS:

Name Quantity Description

PFC 1 PFC Boost PCB 10K
INV 1 INVERTER PCB 10K
CHGR 1 CHARGER PCB 6K 10K
CNTL 1 PCB Controller 6K 10K
COMMU 1 Communication PCB 6K 10K

Table 1-2

8 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 1. Introduction

1.5 PCB explanation.

1.5.1 Power supply circuit (SPS)

The Power Supply (SPS) module supplies DC power for UPS operation. The input of the
SPS is the line, or battery when the line is loss.

Figure 1-2 Basic circuit of power supply

This is a flyback converter topology. When Q1 is on, all rectifier diodes(D1/D2/D3) are
reverse-based and all output capacitors(C1/C2/C3) supply currents to the load. The
primary wire of the transformer acts like a pure inductor and load current builds up linearly
in it. When Q1 is off, the primary stored energy is delivered to the secondary to supply load
current and replenish the charge on output capacitors that they had lost when Q1 was on.
This circuit has some output voltages as follows: ±15V, +12V, +5V, nicoal+12V（Fan）,
HFPW±. The power of ±15V, +12V, +5V supply steady voltage for all kinds of IC and other
device. The +12V（Fan）is supplied for fans and relays. The HFPW± supply a high
frequency power for the switch(SCR/IGBT) driver and some other drive board.

9 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 1. Introduction
1.5.2 PFC/Boost circuit

Figure 1-3 PFC/Boost Circuit

As shown in the Figure 4.2, when Q1/Q2 is on, and D1/D2 is off, the choke(L1/L2) will
store energy and the current crossing the choke will increase by degrees with time pass.
When the Q1/Q2 is off, the choke releases energy and the D1/D2 is on, the current of the
choke will be descending with time pass. Therefore, we can control the current waveform
of chokes (input current) by regulating the time of Q1/Q2 on and off.

1.5.3 Inverter circuit

The input of the half-bridge inverter topology is DC voltage, and the output is AC voltage.
Half-bridge topology major advantage is that it subjects their transistors on the off state to
a voltage stress equal to the DC input voltage and not twice that as do the push-pull and
singled forward converter. An additional valuable feature of the half-bridge topology is that
leakage inductance spikes are easily clamped to the DC supply bus and any energy stored
in the leakage inductance is returned to the input bus instead of having to be dissipated in
some resistive element.

Figure 1-4 Half Bridge inverter topology

The topology works as follows. Q1 and Q2 are switched on at alternate half cycles. The
junction voltage of Q1 and Q2 is a high frequency rectangular waveform. This rectangular
wave through the LC filter will become a standard sine wave.

10 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 1. Introduction
1.5.4 Charger
The utility of charger is to recharge and maintain the batteries at fully charged condition.
The charger charges the batteries with a constant current at initial stage and as the battery
voltage keep increasing, the charge current decreases accordingly until the batteries come
to the constant charge voltage point, the charge voltage will change to the floating charge
voltage point after 30min. In general, the charger will control the output voltage at a
constant level (273V±1%), in this way, to make the battery full recharged but not over
recharged, protects and prolongs the lifetime of charged batteries.

As shown in the figure below the buck-boost topology of the charger

Figure 1-5 Topology of the charger

The charger is not only for the standard model but also for the long run model, and the
charge current is can be changed from 0.5A~2A for B model and 0.5A~ 6A for LB model.

1.5.5 EMI Board

Input EMI board is connected between utility and the input of rectifier.

Output EMI board is connected between the output of inverter and output terminal block.

Figure 1-6 Topology of the EMI

The EMI board can prevent the UPS being interference by external electronic/magnetic
noise which generated by the other electronic system, and prevent the noise generated
inside the UPS system interference other system.

11 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 1. Introduction
1.6 Wiring diagram
Wiring diagram of ITYS-E 6kVA

12 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 1. Introduction
Wiring Diagram of ITYS-E 10kVA

13 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 1. Introduction
1.7 Internal view.

PCB’s location
Charger PCB

PFC PCB

Communication
PCB

Control PCB

Input EMI Filter PCB

Inverter PCB

Output EMI Filter PCB Bypass Switch

14 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 2. Hardware replace

2. Hardware replace
The operation allowed on site are:
-electronic cabinet swap
-battery cabinet swap

2.1 Electronic cabinet and battery cabinet swap.

In case of failure in the electronic cabinet or battery cabinet, follow the instructions below.

-Remove the battery cable and after the earth cable.

-Remove the five screw shows in the picture

-Slide the upper part from the front to the rear.

-Replace the cabinet fault and mount the metal plate with the five screws

15 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 3. Communication

3. Communication
3.1 RS232 Port.

The UPS provided RS232 port in one D-sub 9 female connector.

The USB port has only the function to connect via Local View.

The pin assignment of the RS232 port D-sub 9 female connector is defined as follows:

Figure 3-1 RS232 Pin Assignment

Pin 2: PC receives line RS-232 data from UPS.

Pin 3: PC transmits line RS-232 data to UPS.
Pin 5: Signal ground.

Attention: cable is different than Masterys or Delphys that adopt null-modem

(cross) cables.
It’s possible to connect in serial 2 null-modem cables to have a straight
cable.

16 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 3. Communication

3.2 USB port.

The UPS provided USB port in one B female connector.

The USB port has only the function to connect via Local View.

3.3 Emergency Power Off (EPO).

The Emergency Power Off (EPO) input connection allows you to connect the UPS
system to your facility’s EPO circuit.
Connecting the UPS system to the EPO circuit enables remote emergency shutdown
of the UPS system’s output.
This contact is normally close.

17 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 4. Battery
4. Battery

4.1 Battery cabinet

The DC system is one string batteries.

The Battery power is a series of 16 pcs batteries (12Vdc VRLA) for the ITYS-E 6kVA.

The Battery power is a series of 20 pcs batteries (12Vdc VRLA) for the ITYS-E
10kVA.

In the B model the battery cabinet is in a unique solution with the UPS.

In the LB model the battery cabinet is separated from the UPS cabinet.

4.2 Battery Voltage regulation:

It’s possible to modify the floating voltage of battery charger via LCD.
The rated charged voltage refer to one battery is 13,65V
Range of settings show in the table below:

UPS SIZE NOMINAL MIN SETTABLE STANDARD MAX SETTABLE

VOLTAGE VOLTAGE VOLTAGE VOLTAGE
6 (16 batt) 192V 212V 218,4V 224,8V
10 (20 batt) 240V 266,6V 273V 279,4V

The total gap of the settings is ± 6,4V, minimum calibration step is 0,1V settable via
LCD.
Refer to User Manual for the procedure to change the parameter.

18 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 5. Troubleshooting
5. Troubleshooting
The UPS display give some indication about the failure that can happen in the UPS.

Below there is a display picture

5.1 Trouble shooting according to warning indication

The following tables show the description of the LCD display string:

19 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 5. Troubleshooting
5.2 Trouble shooting according to fault indication

CODE FAULT DESCRIPTION ACTION

When the bus voltage can’t reach the set value in 30s, the fault
signal will be sent.
01 BUS soft start failure Mainly check that the IGBT and SCR power components for the
PFC and the utility power SCR are well. Meanwhile check that
the components on the drive circuit are well.

When one of the follow conditions have been meet, the fault
signal will be sent.
1. The time that the +Bus voltage keeps higher than 450V or
the –BUS voltage keeps lower than –450V is more than 50 ms.
2. The time that the +Bus voltage keeps higher than 400V or
02 BUS voltage high
the –BUS voltage keeps lower than –400V is more than 1.5s.
The PSDR board could be damaged;
Mainly check that the IGBT and SCR power components for the
PFC and the utility power SCR are well. Meanwhile check that
the components on the drive circuit are well.

When the time that the +Bus voltage keeps lower than 230V or
the –BUS voltage keeps higher than –230V is more than
200ms, the fault signal will be sent. The PSDR board could be
03 BUS voltage low damaged.
Mainly check that the IGBT and SCR etc power components for
the PFC and the utility power SCR are well. Meanwhile check
that the components on the drive circuit are well.

When the difference between the ±Bus voltage absolute value

keeps more than 40V for 2 minutes, the fault signal will be
BUS voltage sent. The PSDR board could be damaged.
04
unbalance Mainly check that the IGBT and SCR etc power components for
the PFC and the utility power SCR are well. Meanwhile check
that the components on the drive circuit are well.

When the difference between the ±Bus voltage absolute value

keeps more than 40V for 2 minutes, the fault signal will be
sent. The PSDR board could be damaged.
11 INV soft start failure
Mainly check that the IGBT and SCR etc power components for
the PFC and the utility power SCR are well. Meanwhile check
that the components on the drive circuit are well.

When the INV voltage keeps higher than 276V for 128 ms, the
fault signal will be sent. The PSDR boardcould be damaged;
12 INV voltage high Mainly check that the power components for power INV and
on the drive circuit are normal. Check that the IGBT protective
circuit and some PFC components are normal.

20 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 5. Troubleshooting

When the INV voltage keeps lower than 140V for 128 ms, the
fault signal will be sent. The PSDR board could be damaged;
13 INV voltage low Mainly check that the power components for power INV and
on the drive circuit are normal. Check that the IGBT protective
circuit and some PFC components are normal.

When the time that the INV output voltage keeps less than
50V and the output current keeps more than 20A is over 3
periods, the fault signal will be sent.
14 Output short circuit Remove all the loads. Turn off the UPS. Check whether the
output of UPS and loads is short circuit. Make sure the short
circuit is removed, and the UPS has no internal faults before
turning on again.

When the output power on the INV terminal is over -800W,

the fault signal will be sent.
1A Negative power fault Check that the input and output connections are correct, and
then check that the INV relays RY5 is OK, or the STS(Q13, Q14,
Q20,Q25 and their driver circuit) are OK.

When the battery voltage is more than 310V, the fault signal
will be sent.
It is probably the charger or PSDR board damaged.
Check that the battery SCR（Q21）or the battery relay (RY3,
Battery SCR short
21 RY4) on the PSDR board are well.
circuit
Check that the components for the battery drive signals are
normal. Check the circuit of the utility power SCR part.
If the PSDR board is ensured normal by check, it may indicate
that the output of the charger is abnormal.

After the Bus soft start has finished, the INV PWM is off and
24 INV relay short circuit detect more than 50V INV voltage, the fault signal will be sent.
Check that the INV relay RY5 on the PSDR board is OK.

Check the battery. If the battery is damaged, replace the

battery immediately,
28 Battery loss
if the battery is OK, make sure that the battery breaker is in
“ON” position.
Check whether the UPS is overloaded, the air vents are
blocked, and the ambient temperature is over 40℃.
If the overload or block is removed, please make the UPS cool
41 Over temperature
down for 10 minutes before turning on again.
It is not recommended the UPS is operated at the ambient
temperature of over 40℃.

The CPU can not build communication and the control board
42 Internal fault
is damaged.

Check the loads and remove some non-critical loads.

43 Overload
Check whether some loads are failed.

21 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 NOTES:

22 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.
 NOTES:
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................
................................................................................................................................................

23 MSMITYTWXX31-GB_00– ITYS-E 6-10kVA - Service Manual

This document is the property Socomec - Copying and distribution without specific written authorization strictly forbidden.