AF50-4W5

5.1. STANDARD MAINTENANCE

Perform maintenance in 6 to 12 monthly intervals, depending on the

environmental dirt and operation of the unit.

The points to be followed are:

1.- Set the AF50-4W5 in STOP mode and turn off the main switch
(OFF position).
2.- Wait 5 minutes for the capacitors to discharge.
3.- Clean the ventilation grilles, the inside of the unit and fans.
4.- Check the state and tightness of the electrical connections.
5.- Replace the display battery if necessary.
The display uses a CR2032 3V battery. The LED in the bottom left corner of the
display indicates the state of the battery.
9 Green: the battery is correct.
9 Red: low battery level.
Display battery

Figure 64: Rear of the display.

The battery display is in its rear, as indicated in Figure 64.

It is best to note the configuration of the AF50-4W5, refer to 4.3.-

CONFIGURATION

When the panel battery is changed, the language, date and time of the unit have
to be reconfigured. ( refer to 4.3.5.- SCREEN CONFIGURATION.)

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5.2. COOLING TURBINES AND FANS

The cooling fans and turbines must work properly to avoid

overheating in the active filter components.

Table 11 gives the number of fans and/or turbines required to cool the inductors
and the semiconductors according to the active filter model.

Inductor IGBT cooling

AF50 model IGBT cooling fans
cooling fans turbines

AF50-4W5-25 A 3 2 -
AF50-4W5-50 A 3 4 -
AF50-4W5-100 A 3 - 1
AF50-4W5-150 A 6 - 2
AF50-4W5-200 A 6 - 2
Table 11 : Cooling components depending on the active filter model.

The following symptoms in the behaviour of the filter can indicate wear in the
fans or turbines:

9 Increased noise in the fan / turbine.

9 Increased temperature in the unit under the same environmental
conditions and load.
9 The AF50-4W5 periodically indicates the temperature alarm.

If any sign of wear is detected, the affected fan/turbine should be replaced.

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5.2.1. INDUCTOR COOLING FANS

5.2.1.1. AF50-4W5-25 A / 50 A / 100 A MODELS
Follow these instructions to replace the inductor cooling fans in the AF50-4W5-
25A, AF50-4W5-50A and AF50-4W5-100A models:

Figure 65: Position of the inductor fans in the AF50-4W5-25, AF50-4W5-50 and

AF50-4W5-100.

1.- Set the AF50-4W5 to STOP mode and turn off the main switch
(OFF position).
2.- Wait 5 minutes for the energy accumulated in the capacitors to discharge.
3.- Open the AF50-4W5 cabinet and disconnect the fan's power supply. (Figure
66)
The power supply terminals are located in the lower left corner of the fan. Grasp
the terminal firmly and pull to disconnect it.

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Figure 66: Disconnection of the fan power supply.

4.- Use a 3 mm Allen key to unscrew the 4 screws fixing the fan to the front
panel. (Figure 67)

Figure 67: Unscrew the 4 screws from the fan

5.- Replace the damaged fan, connecting the power supply terminals in the
bottom left corner.

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6.- Use the 3 mm Allen key to fix the fan to the front panel. (Figure 68)

Figure 68: Fix the fan to the front panel.

7.-Connect the power supply terminals.

5.2.1.2. AF50-4W5-150 A / 200 A MODELS

Follow these instructions to replace the inductor cooling fans in the AF50-4W5-
150A, and AF50-4W5-200A models:

Figure 69: Position of the inductor fans in the AF50-4W5-150 and AF50-4W5-200 filters.

1.- Set the AF50-4W5 to STOP mode and turn off the main switch
(OFF position).

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2.- Wait 5 minutes for the energy accumulated in the capacitors to discharge.
3.- Remove the protection board from the inductor compartment.
(Figure 70)

Figure 70: Remove the protection board from the inductor compartment.

4.- Take off the inductor busbars and cables. (Figure 71)
9 Use a 10 mm socket spanner and 5 mm Allen key to take off the cables
from the inductors' side.
9 Use a 13 mm socket spanner and 13 mm open-end spanner to
disconnect the cable from the mains side.

Figure 71: Take off the inductor busbars and cables.

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5.- Unscrew the compartment cover fasteners with a no. 20 Torx key and remove
the cover. (Figure 72).

Figure 72: Unscrew the cover fasteners

6.- Disconnect the power supply fans by firmly grasping the terminal and pulling
to disconnect it. (Figure 73)

Figure 73: Disconnect the power supply from the fans.

7.-Take out the fan being changed using a socket spanner or 7 mm spanner to
hold the rear nut and a flat or Phillips screwdriver to loosen the screw. (Figure
74)

Figure 74: Remove the fan.

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8.- Fix and connect the replacement fan.

9.- Fix the inductor compartment cover.
10.- Fasten the inductor cables and busbars.
11.- Fit the protection board.

5.2.2. COOLING FANS/TURBINES OF THE IGBTs

5.2.2.1. AF50-4W5-25 A / 50 A MODELS
The AF50-4W5-25 and AF50-4W5-50 active filters cool the IGBTs using fans.
The fans are fixed to the IGBT heatsink. Each unit has four fans: two on the top
and two on the bottom.
(Figure 75).

Figure 75: Position of the IGBT upper and lower fans (AF50-4W5-25 and AF50-4W5-50).

The instructions that follow must be observed in replacing the fans:

1.- Place the AF50-4W5 in STOP mode and turn off the main switch
(OFF position).
2.- Wait 5 minutes for the energy accumulated in the capacitors to discharge.
3.-Remove the protection board and unfasten the front panel holding the
electronic boards. (Figure 76)

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Figure 76: Position of the protection board ( AF50-4W5-25 and AF50-4W5-50)

4.- Remove the right side cabinet cover.

UPPER FANS
5.- Remove the extractor hood fasteners to be able to reach the top fans.
(Figure 77)

Figure 77: Remove the fasteners from the extractor hood.

6.- Lift the extractor hood, disconnect the power supply from the fans and
remove the hood. (Figure 78)

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Figure 78: Disconnect the power supply from the fans and remove the hood.

7.-Remove the four fan screws to extract them.(Figure 79)

Figure 79: Remove the fan screws.

8.- Replace the damaged fans. Fit the fan, leaving the power supply pins on the
side of the IGBTs
9.- Pass the power supply cable through the drill hole on the hood.
10.- Connect the power supply of the two fans.
11.- Screw back on the extractor hood fasteners.
LOWER FANS
12.- Remove the power supply cable from the bottom heatsink fans. (Figure 80)

Figure 80: Remove the power supply cable

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13.- Reach into the fans from the side and remove the right fan fasteners. It is
best to follow the order of the steps shown in Figure 81.

1 2 5

3
4

Figure 81: Remove the fan fasteners on the right.

14.- Remove the left fan by unscrewing the four fasteners.

15.- Replace the left fan with a new one.
16.- Replace the fan on the right.
17.- Connect the fan power supply cables.
18.- Lift up and attach the front panel metal plate.
19.- Fit the protection board.
20.- Fit the side cover.
21.- Start up the unit and check that the fans operate correctly.

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5.2.2.2. AF50-4W5-100 A / 150 A / 200 A MODELS

The AF50-4W5-100A, AF50-4W5-150A and AF50-4W5-200A active filters
cool the IGBTs using turbines.

Figure 82: Position of the cooling turbine in the AF50-4W5-100.

Figure 83: Position of the cooling turbines in the AF50-4W5-150 and AF50-4W5-200 filters.

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The instructions that follow must be observed:

1.- Place the AF50-4W5 in STOP mode and turn off the main switch
(OFF position).
2.- Wait 5 minutes for the energy accumulated in the capacitors to discharge.
3.- Remove the front panel protection board.
4.- Drop the front panel metal plate. (Figure 84)
5.- Remove the DC bus busbar. (Figure 84)
6.- Disconnect the earth wire from the front panel metal plate. (Figure 84)
7.- Remove the top crossbar. (Figure 84)

5 5

4 6

Figure 84: Steps 4, 5, 6 and 7

8- Remove the back cabinet cover. The side cabinet covers can be removed if
more space or light is needed during these procedures.
9.- Disconnect the inverter bridge R-S-T phases. (Figure 85)

Figure 85: Disconnect the inverter bridge R-S-T phases.

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10.- Disconnect the IGBT connectors from the gate board. The top board must
first be removed to be able to disconnect the IGBTs from the bottom board.
11.- Disconnect the NTC connectors from the controller board
12.- Take the NTC probe cabling out of the channel.
13.-. Disconnect the turbine power supply.
The location of the power supply depends on the turbine model.
9 If the turbine is black, the power supply is on the front part (Figure 86).

Figure 86: Disconnect the turbine power supply (black turbine).

9 If the turbine has a steel finish, the power supply is on the rear part
(Figure 87).

Figure 87: Disconnect the turbine power supply (steel turbine).

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14.- Unscrew the extractor hood fasteners on the back metal plate (Figure 88).

Figure 88: Unscrew the fasteners from the extractor hood.

15.- Remove the screws fastening the heatsink to the hood. (Figure 89)

Figure 89: Remove the screws fastening the heatsink to the hood.

16.- Unscrew the bottom fasteners from the pack formed by the heatsink body,
the turbine and the IGBT bridge while the whole pack is held.

It is best to have two people do this task. (Figure 90)

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Figure 90: Unscrew the bottom fasteners.

17.- Move the pack towards the bottom until the heatsink comes out of the
extractor hood. (Figure 91)
18.- Tilt the pack towards the outside of the cabinet and remove it. (Figure 91)

Figure 91: Remove the pack from the cabinet.

19.- Place the pack on a flat, stable surface to unscrew the turbine fasteners.
(Figure 92)

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Figure 92: Unscrew the turbine fasteners

20.- Replace the turbine with the spare.

21.- Reinsert the pack into the cabinet.
22.- Fix the extractor hood.
23.- Connect the turbine power supply.
24.- Connect the R-S-T phases to the inverter bridge.
25.- Put the NTC probe cable back in the channel.
26.- Connect the NTC probe.
27.- Connect the IGBTs to the driver board and reinstall the driver board if
necessary.

Respect the R-S-T order of the connectors.

28.- Connect the DC bus busbar.

29.- Insert the top crossbar of the AF50-4W5 cabinet.
30.- Connect the earth wire to the front panel metal plate of the AF50-4W5.
31.- Fit the protection board.
32.- Check that the turbine operates correctly.

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