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
www.westcar.it - [e-mail]
3
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
www.westcar.it - [e-mail]
4
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
www.westcar.it - [e-mail]
5
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
www.westcar.it - [e-mail]
6
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
www.westcar.it - [e-mail]
7
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
www.westcar.it - [e-mail]
8
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
www.westcar.it - [e-mail]
9
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
www.westcar.it - [e-mail]
10
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

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
www.westcar.it - [e-mail]
11
3.5 Typical installation schematics
MFC VERSION
Fig. 3.5.1 - MFC base circuit
Fig. 3.5.2 - MFC Reverse direction

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
www.westcar.it - [e-mail]
12
Fig. 3.5.3 - MFC Star-delta starting
MFD VERSION
Fig. 3.5.4 - MFD Base circuit

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
www.westcar.it - [e-mail]
13
Fig. 3.5.5 - MFD Reverse direction
Fig. 3.5.6 - MFD Star-delta starting

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
www.westcar.it - [e-mail]
14
P2 - P1
4 Start-up
4.1 Working mode
Braking mode selection
It’s possible to set 4 different braking modes:
Constant Torque Fig. 1
DIP switch SW3 (C0) OFF SW4 (C1) OFF
Linearbraking torque set by “Torque” (P2)
Constant output current
Coppia
Velocità
Torque
P2
Figura 1
Coppia frenante
Giri motore
Tempo
P3 Braking time
Decreasing Torque Fig. 2
DIP switch SW3 (C0) OFF SW4 (C1) ON
The braking torque set by “Torque”(P2) is constant until 50% of the cycle time,
then it decreases. The decreased amount is set by “Compensation” (P1)
Increasing Torque Fig. 3
DIP switch SW3 (C0) ON SW4 (C1) OFF
Coppia
Velocità
Torque
P2
Figura 2
Coppia frenante
Giri motore
P1 Compensation
Tempo
P3 Braking time
The braking torque starts from the value set by “Torque” (P2), it increases
until 50% of the cycle time, then it stays constant until the end of the braking
cycle. The increased amount is set by “Compensation” (P1)
Variable Torque Fig. 4
DIP switch SW3 (C0) ON SW4 (C1) ON
The braking torque starts from the value set by “Torque”(P2), it increases
Coppia
Ve locità
P2
Torque
Coppia frenante
Giri motore
Figura 3
P2+ P1
P1 Compensation
Tempo
until 50% of the cycle time where it reaches the values set by “Compensation”(P1) P3 Braking time
Then it decreases until it reaches the value set by “Torque”(P2)
Braking time selection
Two time ranges can be set by DIP Switch SW1 (FS-T)
Position OFF With “Braking time” (P3) the range is between 1 and 20 sec
Position ON With “Braking time”(P3) the range is between 10 and 100 sec
Braking mode selection
Coppia
Ve locità
P2
Torque
Giri motore
Figura 4
Coppia frenante
P1 Compensation
P2
Tempo
P3 Braking time
Two cut-off modes can be set from DIP Switch SW2 (A/M)
Position OFF Automatic Current / torque profiles
Braking ends when the motor becomes still, but the cycle is reset only at the end of the set time
Position ON Manual
Braking is active until the end of the set time
4.2 First start procedure
First start
•Check that the module size fulfils the grid voltage specifications and is adequate for the installed motor
•Set the configuration switches for the desired functionality, leaving SW2 in manual ON position
•Set the “Compensation”(P1) and “Torque”(P2) to zero (anticlockwise)
•Open the motor fuses and test the Working and Braking cycle
•Regulate the desired braking time (in the phase following the cut-off) by acting on “Braking time”(P3) (during the
cut-off cycle it will be visualized by LED Cycle ON). The cycle time can only be regulated when the cycle is not
active, and is proportional to the potentiometer rotation angle. It’s necessary to set a time, check it and correct it
before starting a new cycle. Corrections made during the cycle are active only for that cycle
•Verify that the start command is inactive during the braking time
•Set “Torque”(P2) until it has a braking effect (20 - 30% of the trimmer’s rotation). If a DC ammeter is available,
measure the current on the T1 wire and regulate the torque based on the measured current and the detected
braking behavior
•Restore the motor fuses and execute the working cycle
•Readjust if necessary “Torque”(P2) and “Braking time”(P3) in order to have the desired cut-off time
•The braking time is intended as cycle time. If the motor stops before the end of the set time it’s possible to
activate the auto off function, which stops the braking current when the motor stops.
In any case, even if the braking current is not active the cycle will end when the set time ends. The restart will
only be possible at the end of the braking cycle (cycle time finished)
•To activate the automatic cut-off function set SW2 to Auto (OFF)
•Repeat the working cycle if needed to further optimize the system’s functionality

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
www.westcar.it - [e-mail]
15
Compensation settings
To optimize the braking function in can be useful to compensate the braking action either in the first half of the braking
phase when the motor’s speed is highest to avoid abrupt braking, or in the second half when the speeds are low to avoid
mechanical resonance.
To activate the compensation function, refer to the information in page 14 to determine the required braking behavior.
•Decreasing torque
Set the programming switches as explained in page 14
Set “Torque”(P2) to have the desired initial braking torque, leaving “Compensation”(P1) at 20%
Increase “Compensation” (P1) to soften the braking at the end of the cycle
Compensation potentiometer at 0% = No braking compensation
Compensation potentiometer at 100% = Braking reduction equal to 50% of the maximum torque
•Increasing torque
Set the programming switches as explained in page 14
Set “Torque”(P2) to have the desired initial braking torque, leaving “Compensation”(P1) at 20%
Increase “Compensation” (P1) to increase the braking at the end of the cycle
Compensation potentiometer at 0% = No braking compensation
Compensation potentiometer at 100% = Braking increase equal to 50% of the maximum torque

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
www.westcar.it - [e-mail]
16
5 Dimensions and weight
Suggested
MF size
Dimensions [mm]
Weight
[kg]
W
H
D
W1
H1
MFC
20
106
170
95
50
160
0,8
MFC
30
106
170
95
50
160
0,8
MFC
50
106
170
160
75
160
1,9
MFC
75
106
170
160
75
160
1,9
MFC
100
106
170
160
75
160
1,9
MFD
50
106
170
120
75
160
1,3
MFD
75
106
170
120
75
160
1,3
MFD
100
106
170
120
75
160
1,3
MFD
150
166
240
190
100
220
4
MFD
200
166
240
190
100
220
4
MFD
300
166
240
190
100
220
4
MFD
400
206
280
210
120
260
6
MFD
500
216
300
350
120
280
16

WESTCAR S.r.l. - Via Monte Rosa, 14 - 21058 Milano (MI), Italia
www.westcar.it - [e-mail]
17
6 Troubleshooting
PROBLEM
CONDITION
SUGGESTED SOLUTION
The motor doesn’t run and it doesn’t
accept the working command
LED Cycle ONis lit
Cycle time too long
The module is executing a braking cycle
Wait the end of the braking time and if
necessary reduce it from “Time” (P3)
The motor doesn’t run and it doesn’t
accept the working command
LED Cycle ON is off
Check that the motor start contact between
terminals 1 - 3 is closed
The motor runs but doesn’t brake at
the cut-off command
LED Cycle ON doesn’t turn on at the
cut-off
Check that the braking command contact
4 - 5 is closed
The brakingcycle stops just after the
cut-off command
LED Cycle ONis lit
Low braking torque
Set SW2 to OFF to turn off the automatic
brake cut-off
Increase“Torque”(P2)
The brakingcycle doesn’t stop when
the motor is still and continues until
the end of the braking time
LED Cycle ON is lit
Set SW2 to ON to turn on the automatic
brake cut-off
Increase“Torque”(P2)
The braking cycle is executed but the
cut-off time is not enough
LED Cycle ON is lit
Increase “Torque” (P2)
Increase“Braking time”(P3)
Make sure that SW3 and SW4 are positioned
correctly
During braking there areunwanted
vibrations at low speeds
Light load with a lot of inertia from
big flywheels
Select the Decreasing Torque working
mode and regulate “Compensation”(P1) to
reduce the braking action at the end of the
cycle
At the beginning of the braking cycle
there are unwanted vibrations and
knocks
Load with significant play in the
transmission
Choose the Increasing Torque working
mode and regulate “Compensation”(P1) to
increase the braking action at the end of the
cycle