WESTCAR MFC User manual

INSTRUCTION MANUAL
MFC –MFD
COD 22421-EN-2022/10
DC current injection
electronic braking group
The solution to brake an AC motor while
preventing mechanical stress
Integrated connection contactor MFC
External connection contactor MFD
WESTCAR S.r.l.
Via MONTE ROSA,14
20149 Milano (MI)
www.westcar.it

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
www.westcar.it - [e-mail]
2
INDEX
1 Overview .....................................................................3
1.1 Safety..........................................................................3
1.2 Warnings.....................................................................3
1.3 Warranty......................................................................3
1.4 General description.....................................................4
1.5 Features......................................................................4
1.6 I/O connections ...........................................................6
2 Controls and settings ................................................7
2.1 Operator panel ............................................................7
2.2 Settings.......................................................................7
2.3 Signaling .....................................................................8
2.4 DIP switch settings......................................................8
3 Installation ..................................................................9
3.1 Connections................................................................9
3.2 General notes..............................................................9
3.3 Protection fuses ..........................................................10
3.4 Supply voltage.............................................................10
3.5 Typical installation schematics....................................10
4 Start-up........................................................................14
4.1 Working mode.............................................................14
4.2 First start procedure....................................................14
5 Dimensions and weight.............................................16
6 Troubleshooting.........................................................17

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
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1 Overview
1.1 Safety
The following instructions imply that this product has to be set up by a technician aware of the installation,
working and servicing procedures ofelectric machines ingeneral. Knowledge of the laws inforce about security
and of all the good senses to avoid accidents is mandatory to operate on the machines.
The following instructions are only referred to the use and servicing of the braking modules with MFC - MFD
microprocessor control.
1.2 Warnings
Electrical equipment can be a source of security risk. It is therefore necessary to know deeply the regulations
and the control and working devices of the installation before operating on the machine.
The setting of the braking module must be made by a qualified technician, who must know the installation rules
to follow in compliance with safety and protection standards necessary.
➢Some unforeseeable stops and reboots could occur in case of a parameter variation during the
setting phase with working machine
➢The MFC - MFD module is not provided with fuses for short circuit protection. These have to be
assembled by the installer following the instructions on the chart on page 10
Emissions
The MF series is compliant with EMC regulation, CE mark.
During the current injection cycle, being a power control with phase control regulation, interferences are given
out at radio frequency level due to the quick thyristors’ commutation, that usually are not relevant as
interferences.
However, if electrical measurement devices or low frequency receivers are placed near the MF module, it is
necessary to include line filters or shielded wiring in the installation.
In case of need, please contact our offices.
1.3 Warranty
The only valid warranty conditions are those stipulated at the purchase.
➢The device has been designed to control the braking and cut-off cycle of an asynchronous three-phase
motor and as such must be used
➢Possible re-phasing groups have to be installed upstream of the starter system and never on the
motor side
We do not take responsibility for damage due to use, installation or working conditions not conforming to what
advised in this handbook.
The braking module dimensioning must be given based on the real needs of the motor braking torque (and
consequently on the current) necessary for the device cut-off.
No responsibility due to the wrong dimensioning can be attributed us.
Possible tampering will definitely cause the decay of every guarantee and can cause great damage and/or
accidents.
For all possible applications it's necessary to consider that the motor braking is made by injecting a current on
the stator and therefore is of a dissipative kind.
We disclaim all responsibility concerning accidental and consequential damages.
➢The information contained in this handbook are correct at the moment of printing. We reserve
ourselves the right to modify the content and the product’s technical data without notice
No part of this handbook can be copied without written authorization from Westcar S.r.l.
WARNING: The working cycle of the device provides for the braking and slow down, not the
control of the still motor.
For security applications combine the braking module circuit with a device for still motor control
suited to the required class of security.

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
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1.4 General description
The MFC - MFD braking control group is a DC converter for the control of an asynchronous three-phase
motor’s braking cycle. The circuits to manage the working / cut-off cycle with the interlocks necessary to a
correct running are integrated in the product.
The MFC model offers a complete version, which includes the on-board power insertion contactor, the
concerning control circuits, and the cycle interlock relay.
The MFD expects the assembly of the power contactor externally, although it provides for the control and
auxiliary supply circuits of the contactor on board.
The working parameters can be set by the front control trimmers with analogical regulation; this allows to adjust
immediately and intuitively both the starting functions and the different parameters of the working conditions.
The diagnostics and the monitoring of the working status are made by led display.
Two relay outputs are included to manage the working cycle and the interface towards the system.
1.5 Features
1.5.1 Electrical
Supply voltage Single phase 230 - 400 V -15% / +10% (optional 440V - 500V)
Service voltage Derived from supply voltage (separated on request)
Frequency 50 / 60 Hz +/- 2 Hz
Nominal current 20 - 500 A in 10 sizes
Output voltage DC with supply shuttering phase regulation
Braking control Voltage program with max value limit Imax
Cut-off control Automatic or non-stop (time-limited)
Protections Thermal pad on the heat sink set on 85 °C for all sizes
RC and VDR suppressors on the thyristors
Motor
power
400V
[kW]
Motor
nominal
current
[A]
Motor
power
230V
[kW]
Motor
nominal
current
[A]
Suggested
MF size
7,5
14,8
4
14,5
MF
20
15
28,5
7,5
28
MF
30
22
42
11
42
MF
50
37
69
18,5
68
MF
75
55
100
22
80
MF
100
75
131
37
130
MF
150
110
195
55
192
MF
200
160
285
75
248
MF
300
200
370
100
356
MF
400
250
460
132
425
MF
500
NB: Sizes MF20 and MF30 have been discontinued
1.5.2 General
Protection degree IP20
Electrostatic discharges IEC 1000-4-2 /3
Noise IEC 1000-4-3 /3
Bursts IEC 1000-4-4 /4
Stocking temperature -10 / +70°C
Working temperature +5 / +40°C*
Relative humidity 90% without condensation
Altitude 1000 m above sea level
Installation position Vertical +/- 15°
*The MFC - MFD module can supply nominal values of braking current up to 50 °C inside the panel; above
this temperature performance degrades by 2% for every 1 °C rise. Maximum temperature of 55 °C.

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
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Dissipation
- In the power circuit: P = I(1) * ΔV(2) * Duty cycle(3)
- In the control circuit: Pmax = 7,5 VA
- In the contactor circuit: Pmax = 15 VA
(1) I = Phase current (starting effective value about 4 x In)
(2) ΔV = Equivalent voltage drop (typically 1,5V)
(3) Consider the braking phase only because at full speed it is not active
Maximum allowed cycles:
120 per hour with 1/3 intermittence between braking cycle and the next one (=0,025)

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
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6
7
8
9
/
1
2
3
4
5
T3
A1
A2
1.6 I/O Connections
1.6.1 Power terminal blocks
The power supply and services inputs are in the lower part.
The power supply connection is on the L1 and L2 lugs for the supply, the power output connection towards the
motor is on the T1 and T2 lugs while T3 is a signal only connection.
The Pe earth connection is on the side.
To guarantee the certified protection, the cables have to be made passed through the proper pre-cut holes.
Alimentazione MFC / MFD
L1 L2 T3 T2 T1 3AC Motor
M
1.6.2 Control terminal blocks
The control terminal board is made to be wire connected (max. section 1,5 mm2).
Here's the analysis of the function of every single connection:
1
2
3
4
5
Modello MFC
Modello MFD
Fig 1.6.2 Auxiliary terminal blocks
Control terminal
lug
FUNCTION
MFD
MFC
1
RL1
Internal contact for motor
restart management after
braking cycle
2
RL2
3
RLC
4
WORK
Braking module enable
(clean contact)
5
WORK
6
DIAG
Contactor diagnostics
(clean contact)
7
DIAG
8
CONT
External contactor control
9
CONT
T3
Motor signal return
A1
Auxiliary supply (on request)
A2

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
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Supply
Fault
Brak e Cycle
active ON
Electronic Brake MFD
Compensation
Torque
Braking
Time
P1
P2
P3
2 Controls and settings
2.1 Operator panel
The setting panel shown in figure 2.1.1 is how it appears to the operator.
There are two different sections concerning the setting of the braking module and its signaling.
2.2 Settings
Fig. 2.1.1 - Operator panel
In the lower part there are the P1, P2, P3 parameter regulation potentiometers, with the functions:
P1 =
Compensation
Allows to set the correction or compensation of the torque during the braking time according to
the selected torque function
Turned clockwise increases the correction amount
Default pre adjustment at 25%
Regulate on the field 0 ÷ 50%
P2 =
Torque
Allows to set the base torque amount that will be applied during the braking phase
Turned clockwise increases the torque
Default pre adjustment at 50%
Regulate on the field 0 ÷ 100%
P3 =
Time
Fix the length of cut-off cycle
Turned clockwise increases the slope time
Default pre adjustment at 50%
Regulates on the field 1 ÷ 20” when SW1 OFF
Regulates on the field 10 ÷ 100” when SW1 ON

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
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2.3 Signaling
For signaling, the DL1, DL2, DL3, DL4 LEDs visible on the operator panel have the following functions:
DL1 =
Supply Green Front
Signals the presence of the auxiliary supply and of the relative internal service voltages
DL2 =
Fault Red Front
Signals a function block due to:
Overtemperature
Signals the exceeding of the maximum temperature
Active = Fixed red
Event memorization = Slow blinking led
Overcurrent
Signals the intervention of max current protection
Active = Quick blinking led
Cycle fault
Signals a fault in the activation / interlocks sequence
Active = blinks every 2 seconds
The recovery after the fault takes place only with a reset order or resetting the power
supply.
DL3 = Current injection Red Front
Signals the condition of the braking current
The brightness is proportional to the motor braking current
DL4 = Braking required Yellow Front
Signals the condition of active cut-off cycle
2.4 DIP switch settings
SW1 (FS-T) OFF= Full scale cycle time = 20 sec
ON = Full scale cycle time = 100 sec
SW2 (A/M) OFF= Current injection automatically stops when the motor stops
ON = Current injection stops at the end of the set time
SW3 (C0) OFF SW4 (C1) OFF Function: Constant Torque
SW3 (C0) OFF SW4 (C1) ON Function: Decreasing Torque
SW3 (C0) ON SW4 (C1) OFF Function: Increasing Torque
SW3 (C0) ON SW4 (C1) ON Function: Variable Torque
The starting braking torque is set by the frontal potentiometer “Torque” (P2) in the range 0-100%, increases
by the value set by “Compensation”(P1) for half of the set braking time (“Time”P3), then decreases until the
end of braking time, returning to the starting value (Fig. 4 page 13)
The starting braking torque is set by the frontal potentiometer “Torque”(P2) in the range 0-100% and
remains as such for half of the set braking time (“Time” P3).
After half time begins the function Increasing torque. The increased amount is set by “Compensation”(P1),
which adjusts in the rage 0-50%, that will be applied gradually till the end of braking time (Fig. 3 page 13)
The starting braking torque is set by the frontal potentiometer “Torque”(P2) on the range 0-100% and remains
as such for half of the set braking time (“Time” P3).
After half time begins the function Decreasing torque. The decreased amount is setby “Compensation”(P1),
which adjusts in the range 0-50%, that will be applied gradually till the end of braking time(Fig. 2 page 13)
The braking torque is set by the frontal potentiometer “Torque”(P2) on the filed 0-100%.
The “Compensation”(P1) adjustment is not active (Fig. 1 page 13)

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
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WARNING: The working cycle of the device provides for the braking and slow down, not the
control of the still motor.
For security applications combine the braking module circuit with a device for still motor control
suited to the required class of security.
Power ON cycle setting
JP2 OFF= When power is supplied the cycle starts with the braking
command ON
ON = When power is supplied the MF waits for a normal braking cycle
to start the braking
Default: at shipment the cycle is active after the first normal cycle
3 Installation
3.1 Connections
In the installation schematics on pages 11, 12, 13 are indicated the connection schematics for typical
applications of the MFC / MFD braking system
The following considerations for general connection apply:
Power supply mains 380/400V 2 phases
Connect to L1, L2 on the power terminal block
Power supply mains 220/230V 1 phase + earth
Connect to A1, A2 on the control terminal block (in models with separated auxiliary power supply)
Braking cycle control
It can be done by closing a clean contact on terminals 4, 5
It can be obtained by NC contact of the K1 power contactor or by a net potential signal
For PLC control use a return to obtain a clean contact
Protection conductor ( ) Pe
The module is provided with anchorage for the Pe protection conductor connection
Make sure to make the connection properly
Shielding
Usually it’s not necessary
Cycle agreements
On the terminal board are available some relay contacts, that run the agreement of the motor restart
after a braking cycle on terminals 1, 2, 3
3.2 General notes
The braking module fastening is foreseen with the proper stock brackets. These must be put on the lower part
in the specific slots.
To enter the terminal boards, please refer to the following instructions.
To maintain the advised protection level, please use the specific pre-cut slit for the wires.
Install the device in vertical position. Avoid assembly near heat sources.
Leave around the device minimum 10 mm free area to the sides and below, to guarantee the necessary air
circulation. Natural or forced ventilation is from the bottom to the top.
In case of box or cabinet assembly, please foresee a good air circulation with mouths or supported ventilation,
that could guarantee the necessary change of air.
Arrange the air change so that an internal board temperature lower than 40°C or consider the derating values
at page 4.
Connect the auxiliary circuit according to how indicated on the installation schematic, having care to keep the
control wires path as separated as possible from the power ones.

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
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3.3 Protection fuses
The MFC / MFD module isn’t supplied with fuses on board for the protection of power circuit.
Extra-rapid fuses or magneto-thermic switches can be used based on the expected protection coordination.
Please contact our office for any further information.
The size of the advised fuses for the 400Vac application is on the following chart:
MF size
Motor
power
[kW]
Nominal
current
[A]
Current
max 10”
[A]
aM fuse
size
[A]
MF 20
7,5
15
30
15
MF 30
15
30
60
30
MF 50
22
50
100
50
MF 75
37
75
150
75
MF 100
55
100
200
100
MF 150
75
150
300
150
MF 200
110
200
400
200
MF 300
160
300
600
300
MF 400
200
370
740
370
MF 500
250
460
920
460
NB: Sizes MF20 and MF30 have been discontinued
Fig. 3.3.1 –Protection fuses size
Note: The needs of security exercise require that the installation should be made by qualified workers,
as foreseen by the laws in force.
Do not insert the re phasing group on the motor side output. If the re phasing group would be necessary,
please always insert it upstream the main working contactor.
The re phasing group must be of fixed / without automatic regulation type.
3.4 Supply voltage
MFC Versions 15 - 150
In the standard version the module is designed for 230 / 400 Vac, different values on request
The auxiliary voltage is derived internally and is 230 / 400 Vac settable with internal jumpers
MFD Versions 200 - 500 A
In the standard version the module is designed for 230 / 400 Vac, different values on request
An auxiliary voltage of 220 Vac must be supplied for the services (Ventilation 20VA)
At the moment of shipping the standard version is designed for 400 Vac supply
PLEASE INDICATE THE REQUIRED VOLTAGE IN THE ORDER OR CONTACT OUR OFFICE FOR THE
NECESSARY INSTRUCTIONS TO MAKE THE 230 / 400 / 440 V VARIATION