DRS Overview 07

Installation & Start-up Manual MD500
MD500 Drive System
070-904698 Rev 2
EFFECTIVE 10/17/07
SUPERCEDES 8/12/03
This page has been intentionally left blank.
MD500 Modular Drive System
Installation & Start-up Manual
070-904698
EFFECTIVE 10/17/07
SUPERCEDES 8/12/03
© 2007 DRS Electric Power Technologies, Inc.

All Rights Reserved
Safety Instructions
General Safety Warnings in this manual appear in two ways:

Instructions • Dangerous voltage warnings, preceded by a Dangerous Voltage symbol,
indicate the presence of voltages which may cause death or serious injury.
These warnings describe procedures to avoid death or serious injury.
• General warnings, preceded by a General Warning symbol, indicate situa-

tions or conditions which may cause death or serious injury. These warn-
ings describe procedures to avoid death or serious injury.
CAUTIONS inform you of situations or conditions which will damage or cause

additional motor-operation down-time if you do not take suggested steps to
correct or address such situations or conditions.
Note: Notes provide you with additional and useful information. Although less
urgent than cautions and warnings, notes are important and should not be
ignored.
Warning Symbols For your own safety please pay special attention to instructions containing these
symbols:
This warning symbol indicates the presence of dangerous
voltage. This symbol informs you of high voltage conditions,
situations, and locations that may cause death or serious in-
jury if you do not follow precautions and proper steps.
This warning symbol indicates a general warning.
This warning symbol indicates an electrostatic discharge

hazard.
iv MD500 Installation & Start-up Manual

Safety Instructions
Warnings, Cautions,
and Notes
Warning! Your drive contains dangerous voltages. Always check that the
MD500 is safe, after disconnecting the power, by measuring the DC bus volt-
age and line input voltage. Failure to check voltages could cause death or seri-
ous injury. Only a qualified electrician should carry out the electrical installa-
tion.
The DC bus capacitors contain dangerous DC voltage levels. After discon-

necting the supply, wait at least 10 minutes before taking any measurements.
DRS EPT recommends that after the waiting period a shorting stick be used
across the DC bus to insure complete discharge of the capacitor bank.
CAUTION: Electrostatic discharge (ESD) can damage electronic cir-

cuits. Do not handle any components without following the proper ESD pre-
cautions.
MD500 Installation & Start-up Manual v

Table of Contents
Chapter 1 – Introduction ......................................................................................... 1-1

How To Use This Manual ........................................................................................................... 1-1
Intended Audience ....................................................................................................................... 1-2
Warranty and Liability Information ............................................................................................. 1-2
Related Publications.................................................................................................................... 1-2
Chapter 2 – System Overview ................................................................................2-1

System Description ....................................................................................................................... 2-1
Product Highlights ......................................................................................................................... 2-1
Component Descriptions ............................................................................................................... 2-2
Chapter 3 – Installation Instructions .....................................................................3-1

Unpacking and Handling................................................................................................................ 3-1
Inspection of Received Equipment ................................................................................................. 3-1
Environmental Considerations ........................................................................................................ 3-3
Space Requirements ...................................................................................................................... 3-3
Mounting ...................................................................................................................................... 3-3
Cooling System Requirements ....................................................................................................... 3-7
System Wiring ............................................................................................................................... 3-9
On-Site Power Installation........................................................................................................... 3-10
Grounding ................................................................................................................................... 3-10
Power Wiring .............................................................................................................................. 3-11
Control Wiring ............................................................................................................................ 3-13
Cable Routing ............................................................................................................................. 3-13
Motor Timing .............................................................................................................................. 3-16
Multiple Drive Configuration ........................................................................................................ 3-16
MD500 Installation with DRS EPT Motors.................................................................................. 3-22
Chapter 4 – Start-up and Normal Operation .......................................................4-1

Safety Precautions......................................................................................................................... 4-1
Installation Inspection .................................................................................................................... 4-1
Status and Fault Indicators ............................................................................................................ 4-2
Power Up and Enabling the System ............................................................................................... 4-3
Disabling and Power Down of the System...................................................................................... 4-5
Normal Operation ......................................................................................................................... 4-6
System Reset ................................................................................................................................ 4-8
If The System Does Not Operate .................................................................................................. 4-9
vi MD500 Installation & Start-up Manual

Table of Contents
Appendix A – MD500 Technical Specifications ................................................... A-1

Appendix B – Control Cable Signal Details ......................................................... B-1
Appendix C – User Supplied Cables ..................................................................... C-1
Appendix D – PA44 Installation Requirements ................................................... D-1
Appendix E – CE Compliant Information ............................................................ E-1
Glossary................................................................................................................... G-1
Index........................................................................................................................... I-1
MD500 Installation & Start-up Manual vii

Table of Revisions
Date Revision Description of Revisions

11/1/1999 1.00 Formal Release
11/15/1999 1.10 Updated and corrected information on page C-4
11/24/1999 1.11 Added full-size installation drawings to Appendix D
8/12/2003 1.12 Changed company name throughout to DRS or DRS EPT
10/17/2007 2.00 Re-released added Appendix F
viii MD500 Installation & Start-up Manual

Chapter 1 – Introduction
This chapter describes the purpose and contents of this manual, describes the
intended audience, provides warranty information, and lists related publica-
tions.
How To Use This The purpose of this manual is to provide you with the information necessary to
install, start-up, and operate a MD500 Drive System. This manual also de-
Manual scribes features and functions of the drive and requirements such as external
drive control connections, wiring, and cable sizes and routing.
Chapter 1 – Introduction, the chapter you are reading now, introduces you to
the MD500 Drive System Installation & Start-up Manual and conventions used
throughout the manual.
Chapter 2 – System Overview provides a brief system description, lists prod-

uct highlights and describes drive components.
Chapter 3 – Installation Instructions describes planning for drive installation,

unpacking, new drive inspection, and drive mounting. This chapter also in-
cludes requirements for the cooling system , connections for input and output
wiring and external control wiring.
Chapter 4 – Start-up and Normal Operation describes safety, installation in-

spection, how to set start-up parameters, and how to operate the drive system.
Appendix A – MD500 Technical Specifications lists input and output voltages,

amperage, and other useful data.
Appendix B – Control Cable Signal Details includes pinout details for all
DRS EPT supplied cables and a detailed description with pinouts of all signals
for the user supplied cables that interface to the MD500 Drive.
Appendix C – User Supplied Cables provides details on wire specification and

cable construction for all user supplied cables.
Appendix D – Intentionally left blank.
Appendix E – PA44 Installation Details provides information on installation,

cooling, and wiring requirements for DRS PTI’s PA44 motor.
Appendix F – Intentionally left blank.
Glossary lists and defines terms common to all MD500 Drive Systems.
Index helps you locate the page number of topics contained in this manual.
MD500 Installation & Start-up Manual 1-1

Chapter 1 – Introduction
Intended Audience The audience for this manual has:
• Knowledge of standard electrical wiring practices, electronic

components, and electrical schematic symbols.
• Thorough understanding of safe operating practice when installing

and working with electrical power systems.
• Minimal knowledge of DRS PTI product names and terminology.
• No experience or training in installing or operating an MD500.
The audience for this manual will install, start-up and operate the MD500
Modular Drive System.
Warranty and The terms of any warranty for your DRS PTI Modular Drive System are
defined in the original purchase order for the equipment.
Liability
Information In addition to any warranty terms, in no event and under no circumstances shall
the manufacturer be liable for damages and failures due to misuse, abuse, im-
proper installation, or abnormal conditions of temperature, dust, corrosives, or
failures due to operation above rated capacities. Nor shall the manufacturer
ever be liable for consequential or incidental damages.
If you have any questions concerning your DRS PTI Drive System, contact
our support team.
Phone: (978) 353-5500
Fax: (978) 353-5501
The technical data and specifications are valid at the time of printing.
DRS PTI reserves the right to make subsequent alterations.
1-2 MD500 Installation & Start-up Manual

Chapter 2 – System Overview
This chapter describes the features and functions of the MD500 Modular Drive
System, and includes illustrations and block diagrams. It also describes the
MD500 modular components and a general principle of system operation.
System The MD500 is an AC/AC motor drive system designed to operate brushless,
permanent magnet motors. Figure 2.1 shows an overall block diagram of the
Description MD500 Drive System. The drive is a PWM type converter utilizing the latest
in IGBT (Insulated Gate Bipolar Transistor) technology.
Product The MD500 Drive System offers a variety of benefits to the user:
Highlights · Cost effective, 53 in3/kW

· High efficiency - 97% at rated conditions
· Up to four drives can be operated in a Master/Slave configuration
· Low maintenance
· Field programmable flash memory
MD500 POWER MODULE
Input INPUT MODULE BUCK MODULE CHOKE MODULE INVERTER MODULE

Output
3O DIODE RECTIFIER
3O 3O 3O
PM
3
MOTOR
INPUT
DISCONNECT CURRENT CURRENT
SWITCH FEEDBACK FEEDBACK
GATE GATE
DRIVERS DRIVERS
PRECHARGE
CIRCUIT
BRAKE BRAKE
RESISTOR CIRCUIT
MODULE
MEASUREMENT
(HI-VOLTAGE CONTROL BOARD)
MD500 SYSTEM CONTROL MODULE
MOTOR I/O
SYSTEM STATUS MONITOR CUSTOMER I/O

ISOLATED POWER BUCK CPU/MOTOR
1 SUPPLY AND CONTROLLER CONTROLLER
POWER DISTRIBUTION RS232 RS485
NETWORK
Figure 2.1 MD500 Drive System — Block Diagram

Component The major components of the MD500 system are (reference Figure 2.1):
Descriptions · Power Module

· System Control Module
· Brake Resistor Module
The Power Module is the power stage of the drive system and consists of four
separate modules, each module mounted on its own cold plate. They are the
Input Module, the Buck Module, the Choke Module, and the Inverter Module.
Figure 2.2 depicts the basic system topology of the MD500 Power Module.
The three phase diode bridge (located on the Input Module) rectifies the input
AC voltage to DC. The rectified DC voltage is regulated in the Buck Module
by means of a switching regulator which is of a buck topology. The buck con-
verter outputs variable DC voltage based on motor speed. The Choke Module
(located under the Input Module) together with the capacitor bank located on
the Inverter Module, forms an LC filter. Regulated DC voltage is fed into the
Inverter Module which outputs PWM regulated variable frequency current.
In addition to the diode rectifier, the Input Module consists of:
· A circuit for precharging the input rectifier capacitor bank prior to the
closure of the AC mains input disconnect. Precharging prevents large
inrush currents into the capacitors.
· A brake circuit that prevents excessive voltage on the DC bus by dump-
ing energy into the Brake Resistor.
· DC voltage control circuits for protection and regulation.
The System Control Module is the “brains” of the MD500 Drive System (ref-
erence Figure 2.1). It operates from 120V, single phase, 50/60 Hz AC. It con-
tains the controllers for both the Buck Module and the Inverter Module. It also
interfaces with external controls and motor sensors. Also provided are commu-
nication interfaces for RS232, RS485, and LONworks. Resident in the control-
ler is a Motorola 68332 microprocessor and flash memory with download ca-
pability for upgrading DRS EPT’s control software. The controller requires a
resolver output to sense motor position.
The MD500 Drive may be operated as a closed loop velocity control system or
a torque control system depending on specific application requirements.
Refer to Appendix A for Technical Specifications on the MD500 Drive Sys-

tem.

INPUT MODULE BUCK MODULE CHOKE MODULE
600 VAC
3
INPUT
VARIABLE VOLTAGE
0 - 700 VDC
BRAKE
INVERTER MODULE CIRCUIT
TO
BRAKE
RESISTOR
TO MOTOR
Figure 2.2 MD500 Power Module — System Topology


Chapter 3 – Installation Instructions
This section provides information on the installation requirements for the MD500
Drive System. It includes mounting and cooling requirements, wiring details,
and information on configuring multiple systems if more than one drive is used.
If any questions arise during installation, the user is urged to contact DRS PTI
before proceeding with the installation.
Unpacking and The MD500 Drive and associated equipment is shipped in a secure wooden
Handling crate. Table 3.1 is a list of DRS PTI supplied equipment. When unpacking the
equipment, keep the crate upright and follow the directions depicted in Figure
3.1. Once the equipment has been unpacked, save the shipping crate in case the
equipment has to be transported.
Inspection of Your MD500 Drive System was inspected and carefully packed before leaving
the factory. Upon receipt, visually inspect the equipment. Table 3.2 provides a
Received checklist for this inspection. In the event that damage may have occurred dur-
Equipment ing transportation, notify the shipper immediately.
Assembly Name Assembly Number

Modules
MD500 Power Module 765-904710
MD500 System Control Module 765-904705
Brake Resistor Module 760-904675
Auxiliary Equipment
MD500 Connector Mate Kit 755-904695
AC Interlock Controls Cable 681-904741
HVCB Controls Cable 681-904742
Buck Driver Controls Cable 681-904743
Buck Current Controls Cable 681-904744
Inverter Driver Controls Cable 681-904745
Inverter Current Controls Cable 681-904746
Table 3.1 DRS PTI Supplied Equipment

1 TOP VIEW 2 SIDE VIEW

Foam insert
2x4 supports
(Qty.2)
SYSTEM CONTROL MODULE

BRAKE RESISTOR MODULE
SYSTEM CONTROL MODULE
+ + + +
POWER MODULE
BRAKE RESISTOR
MODULE
7/16th Speed Screws

Remove the Brake Resistor Module by
Crate outer on corners (Qty. 4) of
Power Module panel
removing four 7/16th hex screws.
2x4 supports
Unscrew all Philips speed screws from the Remove the System Control Module by
lid and remove the lid. removing four 7/16th hex screws.
3 4 Spreader bar
(Qty.3)
Eyebolts
(Qty.4)
POWER MODULE
+ + + +
POWER MODULE
Remove four 7/16th hex screws from the four

corners of the Power Module.
Remove the 2x4 supports by removing the
Note: The plastic bag covering the Power
speed screws from the outside of the
Module cannot be removed until the module
shipping container. is lifted from the container.
Remove the six coiled cables and the Locate four eyebolts, attach lifting straps and
Connector Mate Kit. spreader bars and lift the module from
container.
Figure 3.1 Unpacking Instructions

Inspection Checklist
Verify the part numbers with the purchase order and/or packing slip.
Check for physical damage.
Check for loose hardware (screws, etc.).
Check for broken and/or loose wire connections.
Table 3.2 Visual Inspection Checklist
Environmental Location of the equipment is important to maintain proper operation and normal
operating life. The Drive System should be installed with the following consider-
Considerations ations:
· Operating Ambient (-20 0C to +50 0C)

· Protected from moisture
· Protected from corrosive gases or liquids
· Protected from airborne dirt or metallic particles
· Protected from excessive vibration
· Storage Temperature (-20 0C to +70 0C)
The electronics should be located inside a suitable enclosure conforming to

recognized codes such as UL, NEC, CSA, IEC, etc.
Space The overall dimensions and weight of the three major components, the Power
Module, the System Control Module, and the Brake Resistor Module, are shown
Requirements in Figures 3.2, 3.3, and 3.4 respectively. Because of the high voltages that the
equipment is operated at, it is important that a space barrier be left around the
Power Module and the Brake Resistor. The “voltage barrier” space require-
ments should be in accordance with recognized codes such as UL, NEC, CSA,
etc. There also needs to be sufficient space around the equipment for air circu-
lation since air is a form of cooling (reference Cooling System Requirements
section for more details).
Mounting The electronics may be mounted in any orientation. However, consideration

should be given for the filling and draining of the cooling liquid and sufficient
access to the equipment in the event service is required. If space is an issue,
consider a mounting arrangement that is secure but will allow removal of the
complete unit to facilitate service.
The DRS PTI supplied control cables that interconnect the System Control
Module and the Power Module are 12.5 ft. (3.8 meters) in length. Keep this
cable length in mind when selecting the mounting locations for these modules.
Reference Figures 3.2, 3.3, and 3.4 for details on mounting hole placement for
the Power Module, System Control Module, and Brake Resistor Module re-
spectively.

Mounting Hole
8 places
38.0”
(965mm)
.56”
(14mm)
35.0”
(889mm)
35.4”
(899mm)
36.0”
(914mm)
.6” 1.0”
(15mm) (25mm)
.6”
(15mm)
10.6”
(269mm)
24.4”
(614mm)
37.4”
(950mm)
1.0” minimum
(25mm)
air circulation space
12.0”
(304mm)
1.0” minimum 1.0” minimum 1.0”

(25mm) (25mm) (25mm)
air circulation space air circulation space
Approximate Weight 385 lbs (174.6 kg)
Figure 3.2 Power Module - Mounting Dimensions

+ +
4.2”
(106mm)
+ +
13.2”
(335mm)
2X .56”
6.0” minimum Cooling Air (14.2mm)
(152mm) Outlet
25.15”
(638.8mm)
26.0”
(660mm)
6.0” minimum
(152mm)
Cooling Air Cooling Air .31”
Inlet Inlet (7.8mm)
Mounting Hole
10.0”
4 places
(254mm)
Approximate Weight = 20 lbs (9.0 kg) 11.0”
(279mm)
Radius
12.24”
(310.9mm)
15.8”
(401mm)
3.6”
(91mm)
Figure 3.3 System Control Module - Mounting Dimensions

WARNING!
Un-grounded, non-conducting, metal components must be shielded from
human contact.
.56”
(14mm)
Mounting Hole
4 places 25.9”
(657mm)
Approximate Weight 45 lbs (20.4 kg)

8.1”
(205mm)
6.0” Min
(152mm)
22.6”
2.4”
(574mm)
(61mm)
6.0” Min Air Flow

(152mm
Air Flow
Ungrounded,
non-conducting,
metal
components
15.1”
(385mm)
Air Flow
6.0” Min
(152mm Air Flow
Figure 3.4 Brake Resistor Module - Mounting Dimensions

Cooling System The Power Module requires both liquid and air cooling. The dominant method is
liquid cooling through the use of internal cold plates. DRS PTI requires the use
Requirements of a 50/50 mixture of water and ethylene glycol for this cooling liquid. The
ethylene glycol should contain corrosion protection additives for aluminum.
Heat dissipated varies with the power demand on the system. Table 3.3 shows
a chart of the heat dissipation and liquid cooling requirements under maximum
load conditions. Reference Figure 3.5 for details on the cooling system con-
figuration. In addition to liquid cooling, it is recommended that a minimum of
1” of space be provided around the Power Module to provide air circulation
(reference Figure 3.2).
The System Control Module has a built in fan that provides cooling for the
components internal to the module. It is recommended that a minimum of 6”
of space be provided at the fan end and the vent end of the System Control
Module to allow proper airflow (reference Figure 3.3). Similarly, there should
be a minimum of 6” of space around the Brake Resistor Module to provide air
circulation (reference Figure 3.4).
Required Coolant Flow 15 GPM 57 LPM

Coolant Heat Load 34,130 BTU/hr 10 kW
Delta Pressure 11 psi 75 kPa
Maximum Coolant Inlet Temperature 122 Deg. F 50 Deg. C
Table 3.3 Power Module Cooling System Requirements
Notes:
1. Cooling system requirements shown are for maximum load conditions.

2. Significant variations occur when using motors that require less than
maximum power and an estimate should be made for each application prior
to selection of cooling equipment.
3. When sizing the heat exchanger unit DRS PTI recommends a capacity of
at least 50% or greater than the known heat load.

Choke Module Buck Module Inverter Module

Cold Plate Cold plate Cold Plate
Input Module Inverter Buck

Cold Plate Module Module
(chassis not
shown)
In In
In
Out Out
Out
Min 5 GPM
Min 5 GPM
Min 5 GPM
Heat
Exchanger
(15 kW)
Pump
o
Min 15 GPM Max 50 C inlet Flow Switch
15 GPM
Notes:
1. All cooling fittings on all coldplates are the same size: 8X SAE straight thread port for 1/2” OD tube fitting
- IAW SAE J1926 or MS16142.
2. Wire the flow switch to the AC mains disconnect remote trip so if the coolant flow stops, main power is
disconnected (refer to table B.1).
Figure 3.5 Power Module Cooling System Schematic

System Wiring Figure 3.6 is a reference diagram for ground, power, and control wiring. The
diagram is for reference only and should not be used as a specification for
cable ratings and shielding requirements. For specific requirements, refer to
the individual sections on grounding, power, and control wiring.
SYSTEM CONTROL MODULE (A5)

AC INVERTER MODULE BUCK INPUT BUCK SYSTEM INTERFACE
ON MODULE MODULE MODULE
J1 OUT
J8 RS232 COMPUTER
J3 J4 J5 J6 J7
J9 RS485 MASTER/SLAVE COMMUNICATION
FUSE
J2 IN CURRENT GATE HVCB CURRENT
J10 CUSTOMER I/O CUSTOMER CONTROL
GATE
CONTROLS SENSE J11
SENSE DRIVE DRIVE MOTOR I/O MOTOR SENSORS
NOTE:
W4
120VAC CONTROL NETWORK CONNECTORS J12 & J13
POWER AND (RESERVED FOR FUTURE EXPANSION)
AC INTERLOCKS W3
ARE NOT SHOWN.
W5
W6
W1 W2
1
INPUT
DISCONNECT &
POWER MODULE (A1)
PROTECTION J2 J1 J1 J2 J1 J2
INPUT BUCK INVERTER

L1 MODULE MODULE MODULE
(A1) (A2) (A4)
A1- MOTOR PH_A RTN

CHOKE
600 VAC MODULE
MOTOR PH_A
3φ L2 A1+
(A3)
UNDER
INPUT MODULE
B1- MOTOR PH_B RTN
L3 B1+ MOTOR PH_B
BRAKE
C1- MOTOR PH_C RTN
RESISTOR (A6)
NEG (-) C1+ MOTOR PH_C
DB- MOTOR HOUSING
POS (+) DB+
Control Cables Power Cables Ground Cables
1 Reference Figure 3.7 for details.
Figure 3.6 Ground, Power, and Control Cables Interconnection Diagram

On-Site Power The MD500 Drive is designed for use on a three-phase input power system.
Four wires (three phase plus a ground wire) are required for the input wiring.
Installation Input conductors must be sized to local code.
WARNING:
Do not connect or disconnect input or output power wiring, control power
wiring, or control wires, when power is applied
Grounding Refer to Figure 3.6 for ground connections. The MD500 Power Module is
equipped with a terminal block that serves as a single point ground to the entire
system which includes the Power Module, the System Control Module, the
Brake Resistor Module, and the motor. Refer to Table 3.4 for ground cable
size. Local code will always supercede DRS PTI’s sizing recommendations.
WARNING:
It is critical for safety reasons as well as proper system operation that the ground-
ing scheme depicted in Figure 3.6 be strictly adhered to.
Ground Cable Wiring

From Power Module To
Recommended
Maximum
Maximum Cable Size
Nut
Terminal Tightening (AWG) Assembly Terminal Stud Size
Tightening
Torque (Nm)
Torque (Nm)
Control
Ground 40 6 Ground M6x1 X 13 5.9
Module
Brake
Ground 40 2 Ground M6x1 X 20 10
Resistor
Ground 40 2 Motor Housing 9
Ground 40 2 AC Mains Ground
Note: The hex key size for the ground terminals on the Power Module is 5/16” or M8.
Table 3.4 Recommended Ground Cable Sizes

Power Wiring Refer to Figure 3.6 for power cable interconnects and Table 3.5 for power
cables specifications. Figure 3.7 depicts the input disconnect and protection
circuit in greater detail.
Power Cable Wiring

From Power Module
Required
Maximum Cable
To Notes
Stud Size Nut Ampacitie
Terminal
Size x Pitch X mmL Tightening s or size
Torque (Nm)
*L1 (2x) M8x1.25 X 23.5 14.3 450Arms AC Mains PH 1 Via Input Disconnect
DB- M6x1 X 16.8 10 2 AWG Brake Resistor NEG.
DB+ M6x1 X 16.8 10 2 AWG Brake Resistor POS.
A1- M8x1.25 X 13.6 14.3 300Arms Motor Ph_A RTN
A1+ M8x1.25 X 13.6 14.3 300Arms Motor Ph_A
B1- M8x1.25 X 13.6 14.3 300Arms Motor Ph_B RTN
B1+ M8x1.25 X 13.6 14.3 300Arms Motor Ph_B
C1- M8x1.25 X 13.6 14.3 300Arms Motor Ph_C RTN
C1+ M8x1.25 X 13.6 14.3 300Arms Motor Ph_C
*Note: There are two studs available for each input connection (L1, L2, and L3). This provides the user with
the option to install two smaller capacity cables rather than one large cable.
Table 3.5 Power Cable Specifications

INPUT DISCONNECT AND PROTECTION (USER SUPPLIED)
ABB 500HP, 3 POLE, A.C. OPERATED
CONTACTOR (P/N: EH550C-1)
OR EQUIVALENT
GE 3 POLE, 800A, 600V
BREAKER (P/N: SKHA36AT0800) WITH MTE CORPORATION
600A TRIP COIL (P/N: SRPK800A600) 3 PHASE, 600V, 50/60HZ, 500HP, 3%
OR EQUIVALENT REACTOR (P/N: RL-50002)
BUSSMAN 660V, 630A OR EQUIVALENT
FUSE (P/N: 170M6460)
OR EQUIVALENT
CIRCUIT LINE
BREAKER CONTACTOR FUSES REACTOR
L1
600VAC MAINS
L2
L3
COIL DATA: MD500

120VAC
2900VA INRUSH POWER
105VA HOLDING MODULE
MOV
GE 3 PHASE, 3 WIRE
MOV (P/N: 9L10MAM333)
OR EQUIVALENT
CURRENT STEP-UP RELAY

DICTATED BY CONTACTOR COIL
REQUIREMENTS
120VAC COIL (16VA MAX.),

30AMP AC CONTACT N.O. RELAY
VA RATING DICTATED (MAGNECRAFT P/N: W91S1A32-120
BY CONTACTOR COIL
REQUIREMENTS
OR EQUIVALENT)
TO MD500 SYSTEM
CONTROL MODULE
(REFER TO FIGURE 3.8)
600VAC TO 120VAC, 50/60HZ
INDUSTRIAL CONTROL TRANSFORMER
(ACME TRANSFORMERS P/N: TA-2-81002
OR EQUIVALENT)
Notes:
1. The circuit breaker and contactor are required components. These two components may be replaced by a
motor driven circuit breaker. It is the responsibility of the user to ensure that the referenced circuit breaker
conforms to local code. Local code will always supercede DRS PTI's recommendation.
2. The fuses, MOV, and line reactor are recommended components. Fuses will not protect semiconductors
but will prevent collateral damage in case a semiconductor fails or a short circuit occurs. MOV's are typically
used for clamping high voltage surges while line reactors are used for supressing transients.
3. The manufacturers referenced in this diagram is meant as a reference to the user to aid in component
selection and is not a solicitation.
Figure 3.7 Typical AC Mains Input Disconnect and Protection Scheme

Control Wiring There are a total of thirteen connection ports on the MD500 System Control
Module numbered J1 through J13 (reference Figure 3.6). Two out of the thir-
teen, J12 and J13, are currently not used and are reserved for future expansion.
Of the remaining eleven ports, six connect to the MD500 Power Module, one
to the motor, one to a computer for diagnostics, one to another System Control
Module (if using more than one MD500 System), one is for 120VAC power/
interlocks, and one is reserved for customer digital/analog inputs and outputs.
Table 3.6 details the cables required for these connections.
Of the eleven control cables required, six cables are supplied by DRS PTI.
Refer to Appendix B for the pinouts of these cables. The other five cables are
fabricated by the end user using connectors supplied by DRS PTI. Appendix B
provides pinouts and a detailed description of the external control signals re-
quired for drive operation. Refer to Figure 3.8 for an overview of the user
controls portion of these external control signals. The five cables that are end
user specific may be obtained from DRS PTI at an additional cost. Refer to
Appendix C for information on procurement and fabrication.
DRS PTI recommends the use of an Uninterruptable Power Supply (UPS) for
the 120VAC control power (reference Figure 3.8). A UPS equivalent to Ameri-
can Power Conversion’s Model 600 rated at 400VA, with a run time of 13
minutes, can be used. This enables the user to power down the system in a
normal fashion in case of loss of the 120VAC control power.
Cable Routing Routing of cables is important for proper operation of any drive system. The
power and control cables shall not be routed in one bundle. Although all con-
trol cables are properly shielded, to prevent electromagnetic interference, route
power and control cables as far away from each other as possible.

Control Cable Wiring

Cable From To
Name Destination
Reference System Control Module
and and Port No.
Designator Port No.
DRS EPT Assembly No.
KAC-EDC DRS EPT Assembly No.
KAC-EDC
AC Interlock Controls Input Module (A1)
W1 J1 J2
681-904741 760-904715
HVCB Controls Input Module (A1)
W2 J6 J1
681-904742 760-904715
Buck Driver Controls Buck Module (A2)
W3 J5 J1
681-904743 760-904720
Buck Current Controls Buck Module (A2)
W4 J7 J2
681-904744 760-904720
Inverter Driver Controls Inverter Module (A4)
W5 J4 J1
681-904745 760-904730
Inverter Current Controls Inverter Module (A4)
W6 J3 J2
681-904746 760-904730
AC Input * W12 J2 Customer AC Interlocks
Motor Interface* W13 J11 Motor
Customer Interface* W14 J10 Customer Controls
RS232* W15 J8 Computer/Serial Comm Port RS232
Control Module (A5)

RS485* W16 J9 J9
765-904705
Network Input/Output W17 J12 N/A
Network Input/Output W18 J13 N/A
* Customer Supplied
Table 3.6 Control Cable Wiring

AC INTERLOCKS CABLE
USER CONTROLS (USER SUPPLIED) KAC-EDC (CABLE W12 IN APPENDIX C)
DRS EPT
REFERENCE
REFERENCE
CONTROL POWER SWITCH
120VAC, 1PH, 120V_LINE 1
50/60HZ, 3A RMS 120V_NEUT 2
120V, 2.5A PRECHG 3
PRECHARGE PRECHG+
RECOMMENDED UPS 4
PUSHBUTTON
SWITCH CB_INT 5
A CURRENT STEP-UP RELAY MAY CB_INT_RTN 6
BE NECESSARY DEPENDING ON THE
TYPE OF INPUT DISCONNECT USED
7
INPUT
(REFER TO FIGURE 3.7). DISCONNECT FLOW
SWITCH J2
SWITCH 120V_LINE
MD500 SYSTEM CONTROL MODULE

200 mA CONTINUOUS
AC MAINS (PUSH TO STOP
INPUT EMERGENCY) (400 mA for 100 mS)
DISCONNECT
120V_NEUT
24VDC
AC/DC
REGULATED
CONVERTER
2.5WATTS
24VDC
24V_RETURN
ENABLE ON/OFF SWITCH ENABLE 1

(CLOSED=ENABLE, OPEN=DISABLE) ENABLE_RET 20
MOTOR SPEED REFERENCE SPDCTL 2
SPDCTL POT SPDCTL_RET
0-10K 21
MOTOR TORQUE REFERENCE TRQLIMIT 3
14K CW TRQLIMIT_RET 22
10V BRKTRQ 4
BRKTRQ_RET 23
SYSTEM RESET RESET
TRQLIMIT POT 5
0-10K RESET_RET 24
14K MOTSPEED 6
CW
10V MOTSPEED_RET 25
MTRTRQ 7
MTRTRQ_RET 26
RESET ON/OFF SWITCH
MOTTEMP 8
(PUSH TO RESET)
MOTTEMP_RET 27
5.1K DRVTEMP 9
SYSTEM TEMPERATURE WARNING
DRVTEMP_RET 28
(ON IF OVER TEMPERATURE)
DRVZSPD 10
5.1K SYSTEM READY (NO FAULTS) DRVZSPD_RET 29
(ON IF READY) READY 11
READY_RET 30
DIRECTION ON/OFF SWITCH DIRECTION 12
(USER DEFINED FORWARD/REVERSE) DIRECTION_RET 31
mA METER
MOTOR SPEED (4-20mA) J10
KAC-EDC
DRS EPT
REFERENCE
REFERENCE
mA METER
MOTOR TORQUE (4-20mA) CUSTOMER I/O CABLE
(CABLE W14 IN APPENDIX C)
24V_RETURN
Figure 3.8 User Control Signals

Motor Timing The MD500 Drive System is designed to operate brushless, permanent magnet,
motors. The system requires that a resolver be mounted on the rotor shaft for
position sensing. The controller provides a reference sine wave to the resolver
and uses the resolver feedback signals (modulated sine and cosine) to deter-
mine the exact position of the rotor. The controller then uses this information
to apply current to the stator windings at the proper time with respect to the
back-emf voltage generated by the rotating magnets. For this reason, the re-
solver outputs must be in sync (timed) with the motor. The controller uses a
resolver/digital chip that converts the resolver feedback signals to a 12 bit digi-
tal address. This address can be offset, to time the motor. A 9 bit dip switch is
used to offset the address. This is in turn used by an EPROM programmed to
provide properly phased winding currents to the motor. The EPROM program
is matched to the number of poles of the motor.
Multiple Drive The MD500 Drive System may be operated as a stand alone drive with one
motor or together with other MD500 Drives for multiple motor operation. The
Configuration system supports 1, 2, 3, or 4 motor configurations. Each MD500 System Con-
troller requires its own resolver feedback signals from its motor. The multiple
drive configuration assumes that the coupling between the motor shafts is pro-
vided mechanically through user supplied gearboxes. The operation of mul-
tiple drives is in the form of a Master/Slave configuration where one drive
serves as the Master and the rest serve as Slave(s). The communication link
between Master and Slave(s) is RS485.
A cable connection diagram for multiple drive configuration is depicted in

Figure 3.9. Each Power Module is connected to the AC mains via a dedicated
input disconnect per Figure 3.7. The earth ground to the Power Modules should
be star connected. The wiring (power, ground, and control cables) of a Power
Module to its respective System Control Module, Brake Resistor, and motor
should be done as depicted in Figure 3.6.
An AC Interlocks wiring scheme for multiple drive operation is depicted in

Figure 3.10 while a typical wiring scheme for customer digital/analog interface
is depicted in Figure 3.11. The user has the option of choosing any MD500
Drive as a Master. A System Control Module recognizes itself as the Master
when it receives the control signals from J10, the Customer I/O port. A System
Control Module recognizes itself as a Slave when it receives commands from
J9, the RS485 port.
When using more than one drive, the RS485 network needs to be properly
terminated. Located inside the System Control Module is a three position header
and a movable shunting jumper that is used for RS485 termination. Your MD500
Drive is shipped from the factory in the single drive configuration - the termi-
nating resistor is in. In a multiple drive configuration, only the end modules
require the terminating resistor. Reference Figure 3.12 for details.

RESOLVER
CUSTOMER CONTROLS MASTER

CUSTOMER CONTROL MODULE 1 POWER MODULE
DIGITAL/ANALOG I/O J2, J10 J11 1
& AC INTERLOCKS
2
J9 J1,J3-J7
6
INPUT MOTOR
6 1
DISCONNECT &
3
PROTECTION 1
BRAKE
RESISTOR 2 RESOLVER
CONTROL MODULE 2 POWER MODULE

J2, J10 J11 2
2
J9 J1,J3-J7
6
MECHANICAL COUPLING THROUGH GEARBOXES

INPUT
MOTOR
6 2
DISCONNECT &
PROTECTION 2 3
BRAKE
RESISTOR 2 RESOLVER
SLAVE 2
J2, J10 J11 3
2
J9 J1,J3-J7
6
MOTOR
INPUT
6 3
DISCONNECT &
3
PROTECTION 3
BRAKE
RESISTOR 2 RESOLVER
SLAVE 3
J2, J10 J11 4
2
J9 J1,J3-J7
6
INPUT MOTOR
DISCONNECT & 6 4
PROTECTION 4 3
3
600VAC BRAKE
3O RESISTOR 2
Notes: 1. Customer can select any System Control Module as the master (reference Figure 3.11).
2. The earth ground to the modules should be star connected.
3. 1,2,3 or 4 motor configurations are supported.
4. Insure that grounding to individual components is maintained according to a single drive configu-
ration (reference Figure 3.6).
Figure 3.9 Typical Multiple Drive Configuration

Customer AC Interlocks
*CONTROL
POWER
SWITCH
LINE
120VAC
NEUTRAL
PRECHARGE
PUSHBUTTON
SWITCH
INPUT DISCONNECT
EMERGENCY SWITCH
120V_LINE
1
120V_NEUT CONTROL MODULE
2 1
PRECHG
INPUT DISCONNECT 3
1 FLOW PRECHG+
4 J2
SWITCH 1
CB_INT
5
CB_INT_RTN
6
120V_LINE
1
2 2
PRECHG
INPUT DISCONNECT 3
2 FLOW PRECHG+
4 J2
SWITCH 2
CB_INT
5
CB_INT_RTN
6
120V_LINE
1
2 3
PRECHG
INPUT DISCONNECT 3
3 FLOW PRECHG+
SWITCH 3 4 J2
CB_INT
5
CB_INT_RTN
6
120V_LINE
1
2 4
INPUT DISCONNECT PRECHG
3
4 FLOW PRECHG+
4 J2
SWITCH 4
CB_INT
5
CB_INT_RTN
6
7
*Note:
The Control Power Switch may be one switch for all modules (as shown), or one switch per module.
Figure 3.10 Typical Multiple Drive AC Interlocks Connection
MASTER
24VDC KAC-EDC
DRS EPT
REFERENCE
REFERENCE
ENABLE ON/OFF SWITCH ENABLE 1
(CLOSED=ENABLE, OPEN=DISABLE) ENABLE_RET 20
MOTOR SPEED REFERENCE SPDCTL 2
SPDCTL POT SPDCTL_RET
0-10K 21
MOTOR TORQUE REFERENCE TRQLIMIT 3
14K CW TRQLIMIT_RET 22
10V BRKTRQ 4
SYSTEM CONTROL MODULE 1

BRKTRQ_RET 23
SYSTEM RESET RESET
TRQLIMIT POT 5
0-10K RESET_RET 24
14K MOTSPEED 6
CW
10V MOTSPEED_RET 25
MTRTRQ 7
MTRTRQ_RET 26
RESET ON/OFF SWITCH
MOTTEMP 8
(PUSH TO RESET)
MOTTEMP_RET 27
5.1K DRVTEMP 9
MD1 TEMPERATURE WARNING
DRVTEMP_RET 28
(ON IF OVER TEMPERATURE)
DRVZSPD 10
5.1K MD1 READY (NO FAULTS) DRVZSPD_RET 29
(ON IF READY) READY 11
READY_RET 30
DIRECTION ON/OFF SWITCH DIRECTION 12
(USER DEFINED FORWARD/REVERSE) DIRECTION_RET 31
mA METER
MD1 MOTOR SPEED (4-20mA) 24V_RETURN J10
mA METER
MD1 MOTOR TORQUE (4-20mA) CUSTOMER I/O
CABLE (CABLE W14
IN APPENDIX C)
REPEAT 3 TIMES
NOT CONNECTED NOT CONNECTED NOT CONNECTED

WHEN USED AS WHEN USED AS WHEN USED AS
SLAVE SLAVE SLAVE
SLAVE 1 SLAVE 2 SLAVE 3
24VDC
1 1 1
20 20 20
120VAC, AC/DC
1PH, REGULATED 2 2 2
50/60HZ CONVERTER 21 21 21
5.0WATTS 3 3 3
22 22 22
24V_RETURN 4 4 4
23 23 23
5 5 5
24 24 24
6 6 6
25 25 25
7 7 7
24VDC 26 26 26
8 8 8
5.1K MD2 TEMP WARNING
27 27 27
(ON IF OVER TEMP)
9 9 9
5.1K MD2 READY 28 28 28
(ON IF READY) 10 10 10
29 29 29
5.1K MD3 TEMP WARNING
11 11 11
(ON IF OVER TEMP)
30 30 30
5.1K MD3 READY 12 12 12
(ON IF READY) 31 31 31
5.1K MD4 TEMP WARNING J10 J10 J10

(ON IF OVER TEMP)
CUSTOMER I/O CUSTOMER I/O CUSTOMER I/O
5.1K MD4 READY CABLE (CABLE W14 CABLE (CABLE W14 CABLE (CABLE W14
(ON IF READY) IN APPENDIX C) IN APPENDIX C) IN APPENDIX C)
24V_RETURN
Figure 3.11 Typical Multiple Drive Digital/Analog I/O Connection

End Module Middle Module Middle Module End Module
Control Control Control Control

Module Module Module Module
1 2 3 4
A J9 B J9 B J9 A J9
RS485 Cable (Cable W16 in Appendix C)
View Inside Control Module
Shunting
Jumper
3 Position
Header
Terminating Resistor In Terminating Resistor Out

(Factory default) (Multiple Drive Position
(Multiple Drive Position Middle Control Modules only)
End Control Modules only)
A B
Figure 3.12 Multiple Drive RS485 Network Jumper Configuration
Cooling may be done either with one heat exchanger/pump unit per MD500
Drive as shown in Figure 3.5 (multiplied by the number of MD500 Drives) or
a single heat exchanger/pump unit feeding multiple drives as shown in Figure
POWER
MODULE 3.13. This is up to the user. Regardless of what method is used, DRS PTI
1 recommends one flow switch per MD500 Drive with each flow switch wired to
its respective input disconnect remote trip.
FLOW
o
MIN. 15 GPM MAX. 50 C INLET SWITCH HEAT
1 EXCHANGER
15 GPM (60 kW)
POWER
MODULE PUMP
2
FLOW
o
MIN. 15 GPM MAX. 50 C INLET SWITCH
2
15 GPM
POWER
MODULE
3
FLOW
MIN. 15 GPM MAX. 50o C INLET SWITCH
3
15 GPM
POWER
MODULE
4
FLOW
MIN. 15 GPM MAX. 50o C INLET SWITCH
4
15 GPM
Note:
Each flow switch should be independently wired to its respective AC mains input disconnect remote
trip (reference Figure 3.10).
Figure 3.13 Typical Multiple Drive Cooling Schematic

MD500 DRS PTI’s PA44 series motor is a 450 HP motor ideal for operation with the
MD500 Drive System.
Installation with
DRS PTI Appendix E provides information on the installation requirements for the PA44
motor including cooling, wiring, and its interconnection with the MD500 Drive.
Motors For more information on DRS PTI’s motors, contact the factory.

Chapter 4 – Start-up and Normal Operation
This section provides general information on the operation of the MD500 Drive
System. It includes a description on how to enable/disable the drive and what
the normal operating modes and conditions are. It also provides information on
what to do if the drive does not operate as expected.
Safety Danger! To avoid serious personal injury, do not operate the drive system until
all interlocks are properly installed and operational. Never approach the drive
Precautions system or attempt to touch it with power on. If diagnostic probes have to be
hooked up, always do so with no power applied. If the drive has been subjected
to power, do not approach it until both the AC mains and control power have
been removed and a 10 minute minimum discharge time has elapsed. DRS PTI
also recommends a shorting stick be used to insure discharge.
Installation Warning! This equipment is subjected to high voltages and high currents. If
the installation of the system is not done properly, a potential for equipment
Inspection damage and/or personal injury is present. In addition to following requirements
in accordance with recognized codes such as UL, NEC, CSA, it is necessary to
inspect and verify that the equipment has been installed and wired correctly.
Table 4.1 provides a checklist which should be followed prior to providing
control and main power to the equipment.
Installation Inspection Checklist

Verify equipment mounting hardware is secure and tight.
Verify correct wiring of the AC mains input disconnect and its energizer coil which is
fed by KAC-EDC's
DRS PTI System Control Module.
Verify power cables (AC mains, motor, and brake resistor) are secure and tightened to
the listed torque specification.
Verify ground cables (Power, System Control and Brake Resistor Modules, and
motor) installed, secure, and tightened to the listed torque specification.
Verify Control cables (KAC-EDC

DRS PTI supplied and customer supplied) in place and no
loose connections (at System Control and Power Modules).
Verify cooling hoses are properly installed - no loose fittings and no leaks.
Verify sufficient free space around the equipment (Power, System Control, and Brake
Resistor Modules) to allow air circulation and provide a "voltage barrier".
Table 4.1 Installation Inspection Checklist

Status and Fault Before start-up of the MD500 it is recommended that you review the function
and purpose of the LED status and fault indicators located on the System Con-
Indicators trol Module. These indicators can verify proper operation and identify various
faults that would prevent normal operation.
Indicator Function
System Control Module - Status and Fault Indicators
This status indicator will turn on when there is 120VAC control power present in the
AC On
System Control Module.
This status indicator will turn on when the precharge circuit has charged the capacitor
Precharge OK
bank to 800 volts. This is a visible indication that enabling of the system can proceed.
This status indicator will turn on when the Brake circuit has been activated due to the
Brake Enable
DC link voltage exceeding 760V.
This fault indicator will turn on when the Brake IPM module has detected a brake
Brake Fault
circuit fault or the IPM module cable is disconnected.
This fault indicator will turn on when the motor is not correctly grounded causing the
Motor Ground
motor ground sense line to rise above 30VAC. If this indicator is on, the Buck
Fault
regulator is disabled to prevent drive operation.
Buck Controller Board - Status and Fault Indicators
This status indicator will turn on when there is +5VDC power present on the Buck
D15
Controller PCB.
This fault indicator will turn on when a buck module IGBT fault has occurred or the
D16
DC bus has exceeded the upper threshold.
D19 This status indicator will turn on when the enable signal from the CCB is present.
High Voltage Control Board - Status Indicator
This status indicator will turn on when there is +15VDC power present and the
D1
precharge function is enabled.
Commercial Controller Board - Status Indicators
D1 - +5V This status indicator will turn on when there is +5VDC power present on the CCB.
This status indicator will be on as long as the microprocessor is correctly executing its
D2 - Run
program instructions.
D3 - Reset This status indicator will turn on when the reset function is activated.
D40 - +15V This status indicator will turn on when there is +15VDC power present on the CCB.
D41 - -15V This status indicator will turn on when there is -15VDC power present on the CCB.
Table 4.2 Status And Fault Indicators

Power Up and The drive shall not be operated before the installation checklist (Table 4.1) has
been completed. A normal start-up checklist for the drive is provided in Table
Enabling the 4.3. A normal start-up flow chart is shown in Figure 4.1.
System
Normal Start-up Checklist

Verify AC mains input disconnect switch is "OFF".
Verify 120VAC control power is "OFF".
Verify the following user input status:
ENABLE "OFF"
SPDCTL at zero setting
TRQLIMIT at zero setting
RESET "OFF"
DIRECTION set to desired rotation (forward or reverse)
Turn on cooling system and verify flow meets minimum requirements.
Turn 120VAC control power on. The system is now ready for pre-charge.
Turn the input disconnect emergency switch "ON" (closed position).
Hold the pre-charge push button down for 12 seconds. This precharges the DC bus
to 800-850V which in turn closes the input disconnect coil.
Turn ENABLE "ON" and verify that the controller responds with READY.
If operating under Speed control:
Set TRQLIMIT to maximum desired torque.
Turn SPDCTL knob to desired speed. The motor will rotate up to the speed
setting as long as the torque load does not exceed the TRQLIMIT setting.
If operating under Torque control:

Set SPDCTL to maximum desired speed.
Set TRQLIMIT to desired torque. The motor will rotate up and settle at a
speed that produces the torque as dictated by the TRQLIMIT setting
provided the speed does not exceed the SPDCTL setting.
Table 4.3 Normal Start-up Checklist

MD500 Power-Up
and Enabling Turn 120VAC Control
Power ON.
Verify
Input Disconnect
Emergency Switch Check 120VAC Control Module
OFF. No
Source. AC ON Light
ON?
Verify 120VAC Yes

Control Power
OFF. Fix 120VAC 120VAC
No System
Source Source OK?
Temperature OK
No
(MOTTEMP LED
Verify ENABLE OFF)?
Yes
OFF.
Check
Yes
AC Fuse
Verify SPDCTL at
ZERO setting. Turn Input Disconnect
Emergency Switch ON.
Replace Fuse No Fuse OK?

Verify TRQLIMIT
at ZERO setting. Hold Precharge Push
Button Switch Down for
12 seconds.
Verify RESET
OFF. Yes
Control Module
Verify DIRECTION No PRECHARGE OK
set to desired LED ON?
rotation
(FORWARD or
REVERSE) Yes
No
Toggle RESET Turn ENABLE
switch ON/OFF, then switch ON.
toggle ENABLE
switch OFF/ON.
READY
LED ON?
Consult MD500 Operation and
READY
Troubleshooting Manual or No
LED ON?
contact KEC Technical Support.
Yes
Yes
No
Operating Under
No
Speed Control?
Motor operating
Operation Under
at desired speed
Torque Control
and torque? Yes
Set SPDCTL to Set TRQLIMIT to

maximum desired speed. maximum desired torque.
Yes
Set TRQLIMIT Set SPDCTL

to desired torque. to desired speed.
MD500 Power-Up and
Enabling Complete.
Figure 4.1 Normal Start-up Flow Chart

Table 4.2 is a typical start-up procedure. It may vary from user to user depend-
ing on user specific I/O’s. As a minimum, the MD500 Drive requires the fol-
lowing five standard digital and analog inputs from the user (refer to Appendix
B for details):
· ENABLE (Digital)
· SPDCTL - Speed Control (Analog)
· TRQLIMIT - Torque Limit (Analog)
· RESET (Digital)
· DIRECTION (Digital)
Additionally, the system requires the following user provided 120VAC inter-
locks (refer to Appendix B for details):
· Precharge Enable (Push button)

· Input Disconnect Enable (“Push-to-stop” Emergency button)
In turn, the MD500 Drive provides the user with four standard analog/digital
outputs (refer to Appendix B for details):
· MOTSPEED - Motor Speed (Analog)

· MTRTRQ - Motor Torque (Analog)
· MOTTEMP - System Temperature (Digital)
· READY - Ready (Digital)
The user has the option of requesting additional or non standard I/O’s at an
extra cost. If your application requires more or nonstandard I/O’s, contact the
factory.
Disabling and The drive is disabled by turning the ENABLE switch “OFF”. The system can
then be powered down by opening the input disconnect switch.
Power Down of
the System
Danger! If the drive is disabled by turning the ENABLE switch “OFF”, re-
member that the drive is still on line with the AC mains and will remain on line
(therefore, high voltages are present on the unit) until the input disconnect
switch has been opened. It is also extremely important that the AC mains input
disconnect be opened prior to switching off of the 120VAC control power.
Failure to follow this sequence may result in damage to the equipment.
Warning! Do not approach the Power Module or the Brake Resistor until the
main and control power have been removed and 10 minutes of discharge time
has elapsed.

Normal When the precharge push button switch is held down, a circuit (located on the
Input Module) is enabled that provides a trickle charge to the capacitor bank on
Operation the output of the diode rectifier. In 12 seconds, the capacitor bank is charged to
800-850 volts. This precharge cycle prevents the occurrence of large inrush
currents that can potentially damage the capacitors.
After the closure of the input disconnect switch, all other input control signals
(DIRECTION, SPDCTL, and TRQLIMIT) will be ignored until the ENABLE
signal is made “true” by the user. However, the SPDCTL input must be set to
zero before the ENABLE signal is made “true”. Any setting other than zero
will prevent the drive from operating. This is true any time the ENABLE signal
transitions from “false” to “true”.
Once an ENABLE “true” signal is applied to the drive, it responds with a

READY “true” signal as long as all conditions in the system are acceptable.
The following conditions must exist for a READY “true” signal to be received
from the drive after the ENABLE signal has been applied to it:
1. 120VAC control power to the Control Module must be connected and

“ON”.
2. The SPDCTL input signal must be at zero setting.
3. The RESET signal must be “false”.
4. The ENABLE signal must remain “true” following the initial “false” to
“true” transition.
5. No temperatures in excess of the internally set maximum limits exist
anywhere in the system including the motor, the Power Module, and the
System Control Module.
6. There are no fault conditions.
7. If a fault condition has caused a shutdown, the RESET signal must have
been applied to clear the fault (see section on System Reset for details on
resetting the system following a shutdown).
If these conditions are all satisfied, the READY signal will become “true” within
one second after the ENABLE “true” signal has been applied. Certain fault
conditions are not recognized by the system until the system tries to operate. In
these cases, the system will shut itself down after the occurrence of a fault and
the READY signal will become “false”.

Assuming that the READY signal has become “true” following an ENABLE
“true” signal, the drive will now operate based on the other input control sig-
nals. The DIRECTION signal allows the operation of a motor either in forward
or reverse. What constitutes forward or reverse rotation for the motor is left to
the user to define. The SPDCTL signal has an input range of 0 to 10V and
governs the operating speed of the motor. The TRQLIMIT signal has an input
range of 0 to 10V and sets the maximum operating torque for the motor. Refer
to Appendix B for details.
The motor can be operated either under speed control (governed by the SPDCTL
signal) or under torque control (governed by the TRQLIMIT signal). If operat-
ing under speed control, the TRQLIMIT would first be set to some desired
value. The SPDCTL signal would then be set according to what the desired
operating speed for the motor is. The motor will rotate up to the SPDCTL
setting and operate at that speed as long as the torque load does not exceed the
TRQLIMIT setting. If operating under torque control, the SPDCTL would first
be set to some desired value. The TRQLIMIT signal would then be set accord-
ing to what the desired torque is. The motor will rotate up and settle at a speed
that produces the torque as dictated by the TRQLIMIT signal as long as the
speed does not exceed the SPDCTL setting. In either case, the operating speed
and torque of the motor are limited by the setting of the SPDCTL and TRQLIMIT
signals respectively.
The DRS PTI controller uses a proportional plus integral (PI) algorithm imple-
mented in software to maintain speed. If the motor is rotating in one direction
and the state of the DIRECTION signal is changed, the PI loop will ask for
torque to reverse the rotation of the motor. The torque command (which is
internal to the speed loop) will be limited to zero until the motor stops. Once
the motor has stopped, the internal torque command will be allowed to reverse
polarity, and the motor will then start spinning in the opposite direction. Note
that there is an internal torque ramp rate limit that prevents sudden application
of high torque.
The MOTSPEED and MTRTRQ signals are 4-20mA signals which are pro-
vided as outputs to the user. They respectively reflect the speed and torque that
the motor is operating at. MOTSPEED is calculated from the resolver feed-
back while MTRTRQ is calculated from a measure of the commanded motor
phase current. Refer to Appendix B for details.

Under all conditions, the MOTTEMP signal will go “true” if the temperature of
the motor, the Power Module, or the System Control Module exceeds internally
(software) set warning limits. The signal is intended to serve as a warning to the
operator that temperatures are exceeding their normal operating limits. The
system will continue to operate normally unless any of the temperatures exceed
their upper safe limit. In this case, the system will shut down and the READY
signal will become “false”. The system will also shut down and the READY
signal will become “false” if other system faults (such as short circuit, over
voltage, IGBT gate drive, etc.) occur. Note that the system will remain non-
operational until a system reset is applied (refer to System Reset section for
details on resetting the system following a shutdown).
The Brake Resistor / Brake Circuit is provided as a protection feature to pre-

vent the DC link voltage from exceeding limits that could potentially damage
the equipment. The Brake Circuit (which is located on the Input Module) will
not activate under normal operating conditions. If for some reason the DC link
voltage rises above a certain limit (specifically 760 V), the Brake Circuit will
enable and dump the excess capacitive energy into the Brake Resistor. The
brake will stay enabled until the voltage drops to an acceptable level (specifi-
cally 730 V).
Danger: The Brake Circuit is only intended for small duty cycles - a continu-
ous over voltage condition will damage the circuit.
System Reset In the event that the MD500 Drive shuts itself down due to a fault condition,
the following steps must be taken in sequence for the system to run again (as-
suming that the conditions which caused the shutdown have cleared):
1. The RESET signal must be toggled “true” and then back to “false”.
2. The SPDCTL input signal must be at a zero setting.
3. The ENABLE signal must transition from “false” to “true”.
Note that some of the shutdown conditions become apparent only when the
system tries to operate. Thus, following the RESET/ENABLE sequence, the
system may respond with a READY “true” signal until it tries to operate. If the
drive does not resume normal operation following the RESET/ENABLE se-
quence even after the shutdown condition has cleared, there are probably hard-
ware problems in the system. In this event, please refer to the next section.

If The System If your MD500 Drive System will not operate, take the steps listed in Table 4.3.
If the drive still does not operate then there are probably hardware problems
Does Not Operate which are not obvious or visible. In this case, the customer has the option
of troubleshooting the system themselves or contacting DRS PTI’s Customer
Service.
Danger! Proper safety procedures must be followed to prevent personal injury

while performing the following checklist.
Drive Not Operational Checklist

Verify cables (Power, Ground, and Control) are properly wired and no loose connections.
Verify proper coolant flow and that the flow switch has not opened.
Verify control power on (check Control Module AC ON light). If the Control Module AC
ON light is off, there is no supplied AC power, or either the bulb or the fuse is open.
Verify the input disconnect switch has closed after the pre-charge sequence is completed.
Verify READY "true" (READY indicator on) signal following an ENABLE "true" command
If READY indicator does not turn on:
Toggle the RESET switch to "ON" and then back to "OFF".
Verify that the SPDCTL signal is set to zero.
Toggle the ENABLE switch to "OFF" and then back to "ON".
If the motor does not rotate:
Verify the TRQLIMIT setting is adequate for present motor loading.
Verify proper motor timing.
Verify DC link voltage is greater than 100 VDC after the system has been enabled
and TRQLIMIT and SPDCTL signals have been set at the desired settings.
Table 4.3 Drive Not Operational Checklist


Glossary
AC Mains AC mains in this manual refers to the 3-phase input voltage that provides power
to the MD500. The line voltage is connected to the MD500 Power Module on
terminals L1, L2, and L3.
Analog Input An Analog Input is a 0-10V DC, or 4-20 mA DC input to the MD500 from the
user.
Analog Output An Analog Output is a 0-10VDC, or 4-20 mA DC output from the MD500 for
use in external control and indicator circuits.
Brake Circuit The Brake Circuit is a protection feature for preventing excessive voltages on
the DC link.
Buck Module The Buck Module is a DC-DC converter which outputs variable DC voltage
based on motor speed. Its input is the rectified voltage from the AC mains.
Choke Module The Choke Module holds the inductors that form an LC filter with the capaci-
tors on the Inverter Module.
Control Power Control Power refers to the input voltage to the System Control Module. It
requires 120V, 50/60 Hz, single phase AC power.
Converter A Converter is a device that converts electrical power from either AC to DC,
DC to AC, AC to AC, or DC to DC.
CSA CSA is an acronym for Canadian Standards Association.
DC Link The DC Link in this manual refers to the DC bus between the Buck Module
and the Inverter Module.
Digital Input A Digital Input is a two-state (Off -On) input to the MD500 from the user.
0 volts = Off, 24 volts = On.
A Digital Output is a two-state (Off -On) output from the MD500 for use in
Digital Output
external control and indicator circuits.
EPROM EPROM is an acronym for Erasable Programmable Read Only Memory. The
EPROM is the non-volatile memory that stores motor waveform data.
ESD ESD is an acronym for ElectroStatic Discharge. ESD cautions indicate situa-
tions in which static electricity can damage circuit boards in the MD500 Drive
System. Follow the precautions listed in the Safety section at the beginning of
this manual when installing or removing circuit boards.
MD500 Installation & Start-up Manual G-1

Glossary
Heat Exchanger A Heat Exchanger is a device used to transfer thermal energy from one me-
dium to another.
HVCB HVCB is an acronym for High Voltage Control Board. The HVCB contains
isolation circuits for sensing high voltages.
IEC IEC is an acronym for International Electrotechnical Commission.
IGBT IGBT is an acronym for Insulated Gate Bipolar Transistor. An IGBT is a fast
switching power transistor.
Input Disconnect Input Disconnect in this manual refers to the switch that is required to connect/
disconnect the AC mains from the Power Module.
Input Module The Input Module contains a 3-phase diode bridge which converts the AC line
voltage to rectified DC. It also contains the precharge circuitry, the brake cir-
cuitry, and the HVCB.
Inverter Module The Inverter Module is a DC-AC converter which outputs PWM regulated
variable frequency current. Its input is the DC Link voltage.
NEC NEC is an acronym for National Electrical Code.
Precharge Precharge is a term used to describe the controlled charging of a rectifier ca-
pacitor bank before applying the AC input power.
Power Module The Power Module is the power stage of the MD500 system. It is an AC-AC
converter that takes single frequency/voltage power and outputs a variable fre-
quency current.
PWM PWM is an acronym for Pulse Width Modulation. The MD500 is a PWM type
converter.
Resolver A Resolver is a position sensing device. The MD500 requires the use of a
resolver for motor position sensing.
RS232 RS232 is a single-ended serial communications standard. The MD500 uses

RS232 to communicate diagnostic information to a personal computer.
RS485 RS485 is a bi-directional serial communication standard. RS485 uses differen-

tial transmitters and receivers sharing a common two-pair cable. Devices can
talk or listen according to network protocol.
G-2 MD500 Installation & Start-up Manual

Glossary
Shorting Stick A Shorting Stick is a safety device used to insure complete discharge of stored
energy. After input power is disconnected, wait ten minutes and then connect
the shorting stick across the DC bus.
Star Connected The term Star Connected refers to a wiring scheme where all connections origi-
nate from a single point.
System Control The System Control Module controls the Buck and Inverter Modules, inter-
Module faces with external controls and motor sensors, and provides communication
interfaces.
Toggle Toggle is a term usually used when describing a switch function. A switch is
toggled when it is moved from one position to another and then returned to its
original position.
UL UL is an acronym for Underwriters Laboratory.
Voltage Barrier Voltage Barrier in this manual refers to the space required around equipment
that insures sufficient distance, for a given voltage,to prevent arcing and/or
personal injury.
MD500 Installation & Start-up Manual G-3

Glossary
G-4 MD500 Installation & Start-up Manual

Index
A M
Analog Inputs 4-5 Master/Slave 3-16
Analog Outputs 4-5 MD500 Drive
Block Diagram 2-1
B description 2-1
Brake Circuit 4-8 DRS supplied equipment checklist 3-1
Brake Resistor Module Not Operational Checklist 4-9
mounting dimensions 3-6 unpacking and handling 3-1
Buck Module 2-2 inspection checklist3-3
inspection prior to installation 3-1
C instructions3-2
Cables MD500/PA44
interconnection length 3-3 cooling system schematic E-7
routing 3-13 interconnection diagram E-3
user supplied C-1 Motor Timing 3-16
Choke Module 2-2 Mounting the MD500 3-3
Control Wiring 3-13 Multiple Drive Configuration 3-16
Cooling System AC interlocks connection 3-18
requirements 3-7 cooling schematic 3-21
schematic 3-8 digital/analog I/O connection 3-19
RS485 network jumper configuration 3-20
D
O
Digital Inputs 4-5
Digital Outputs 4-5 On-Site Power Installation 3-10
grounding
E recommended cable sizes 3-10
power wiring
Environmental Considerations 3-3
cable specifications 3-11
ESD warning v
P
I
PA44 Motor 3-22
IGBT 2-1
cooling system schematic E-6
Input Module 2-2
installation requirements E-1
Installation
Ports 3-13
inspection 4-1
Power Module
inspection checklist 4-1
description 2-2
Inverter Module2-2
mounting dimensions 3-4
System Topology 2-3
Precharging 2-2
MD500 Installation & Start-up Manual I-1

Index
R T
Resolver 2-2, 3-16 Technical specifications A-1
RS485 Torque Control 2-2, 4-7
Network 3-16 Troubleshooting 4-9
termination 3-16
U
S
User Control Signals 3-15
Safety
precautions 4-1 V
Safety instructions Velocity Control 2-2
general iv Voltage Barrier 3-3
warning symbols iv
Space Requirements 3-3 W
Speed Control 4-7 Warning symbols iv
Star connected 3-16 Warranty information 1-2
Start-up4-5
checklist 4-3
flow chart 4-4
procedure 4-5
Sync 3-16
System Control Module
description 2-2
mounting dimensions 3-5
System Wiring 3-9
interconnection diagram 3-9
I-2 MD500 Installation & Start-up Manual

Index
MD500 Installation & Start-up Manual I-3

EFFECTIVE 10/17/07
070-904698 Rev 2.00
SUPERCEDES 8/03
166 Boulder Drive, Suite 201E

Fitchburg, MA 01420
Telephone: (978) 353-5500

Fax: (978) 353-5501
E-mail: info@drs-pt.com
Printed in USA
Appendix A – MD500 Technical Specifications
Input Power
Voltage: 600VAC, 3 Phase, +10%, -15%
Frequency: 50/60Hz, +/- 10%
Phase Sequencing: Non Sensitive
Displacement Power Factor: 1 for > 40% Rated Load (Figure A-1)
Output Power
Rated Load: 450 HP (Figure A-5)
Drive Capacity: 400 kVA
Configuration: 3 Phases, 6 Wire (H-Bridge)
Rated Output Current: 240A RMS per Phase (Figure A-2)
Output Voltage: 0 to Applied Input Voltage
Output Frequency: 0 to 850Hz, Fundamental
Cooling
Coolant: 50/50 Ethylene Glycol/Water Mixture
Maximum Inlet Temperature: +50 oC (+122 oF)
Minimum Flow Rate: 57 lpm (15 gpm)
Pressure Drop: 75 kPa (11 psi)
Maximum Pressure: 138 kPa (20 psi)
Characteristics
Losses: 10 kW (34,130 Btu/hr) Maximum (Figure A-3)
Efficiency: 97% and Higher for > 60% Rated Load (Figure A-4)
Switching Device: Insulated Gate Bipolar Transistor (IGBT)
Operating PWM Frequency: 10 kHZ
Protective Features
Load Short Circuit: Limits Cycle by Cycle Current to 400A Peak per Phase.
Overcurrent: Monitors Drive Output Phase Overcurrent.
Overvoltage: Monitors Bus Overvoltage.
Enables Brake Circuit.
Undervoltage: Monitors Bus Undervoltage.
Temperature: Monitors Drive and Motor Overtemperature.
Motor Ground Fault: Monitors Motor Housing Voltage.
Control Power
Voltage: 100VAC to 130VAC, Single Phase
Frequency: 47Hz to 63Hz
Maximum Current: 3A RMS
Interlocks
Precharge: Enables Precharge Sequence (120VAC Circuit)
Input Disconnect: Energizes Input Disconnect Coil Following Completion
of Precharge Sequence (120VAC Circuit).
MD500 Installation & Start-up Manual A-1

Appendix A - MD500 Technical Specifications
Control Characteristics
Two Operating Modes: 1. Speed Control
2. Torque Control
Multiple Drives: Up to 4 can be Operated in Master/Slave Configuration.
Control Signals
Two Programmable Analog Inputs: 1. Motor Speed Reference (0-10V)
2. Motor Torque Reference (0-10V)
Four Programmable Digital Inputs: 1. Enable (0-24V)
2. Direction (0-24V)
3. System Reset (0-24V)
4. Spare (0-24V)
Two Programmable Analog Outputs: 1. Motor Speed (4-20mA)
2. Motor Torque (4-20mA)
Four Programmable Digital Outputs: 1. System Ready (Open Collector +/-)
2. System Temperature Warning (Open Collector +/-)
3. Spare 1 (Open Collector +/-)
4. Spare 2 (Open Collector +/-)
Communication
TM
Diagnostics: RS232 (Interfaces with LabVIEW )
Multiple Drive Master/Slave: RS485
Motor Interface
One Thermocouple Input: For use with Infrared Thermocouple Transmitter to
Measure Temperature of a Rotating Part (ex. Rotor).
Two Thermistor Inputs: 1 megohm (For Measurement of Temperature on Parts
that are Not Electrically Live ex. Stator Core).
Resolver: Reference Sine (+/-), Feedback Sine (+/-) & Cosine (+/-)
for Motor Position Sense.
Brake Circuit
Resistor Value: 5 ohms
Rated Continuous Current: 41A DC
Surge Current Capacity: 160A for 4 seconds every 2.5 minutes.
Environment
Enclosure: Open Chassis
Location: Indoor (Protected from Corrosive Gas and Dust)
o o o o
Ambient Operating Temperature: -20 C to +50 C (-68 F to +122 F)
o o o o
Storage Temperature: -20 C to +70 C (-68 F to +158 F)
Relative Humidity: < 95%, non-condensing
Vibration: < 0.5G
Shock: 5G Peak for 11 ms
Altitude: 3,300 ft (1,000 meters) without Derating.
A-2 MD500 Installation & Start-up Manual

Figure A-1 Input Power Factor vs. Load Figure A-2 Typical Output Phase Current
1.2
Displacement Power Factor

1.0
Power Factor
200 A/div
0.8
Overall Power Factor

0.6
0.4
10 20 30 40 50 60 70 80 90 100
Load (% of Rated Output Power) 0.5 ms/div
Figure A-3 MD500 Losses vs. Load Figure A-4 MD500 Efficiency vs. Load
10.0 100
8.0 98
Efficiency (%)
Losses (kW)
6.0 96
4.0 94
2.0 92
0.0 90
10 20 30 40 50 60 70 80 90 100 10 20 30 40 50 60 70 80 90 100
Load (% of Rated Output Power) Load (% of Rated Output Power)
Figure A-5 MD500/PA44 Operating Characteristics

1400 1033 373 500
298 400
1300 959
Torque (ft-lbs)
Torque (Nm)
Power (kW)
Power (HP)
224 300
1200 885
149 200
1100 811
75 100
1000 737 0 0
1200
1600
2000
2400
2800
400
800
0
1200
1600
2000
2400
2800
400
800
0
Speed (RPM) Speed (RPM)
MD500 Installation & Start-up Manual A-3

A-4 MD500 Installation & Start-up Manual

Appendix B – Control Cable Signal Details
The MD500 System Control Module has thirteen connection ports numbered
J1 through J13. This section provides a description of all the signals that flow
in and out of the System Control Module through these ports. Signals that are
user provided are described in greater detail than signals that are internal to the
MD500 Drive. A signal is defined as an input if it is an input to the MD500,
and an output if it is an output from the MD500. All pins that are referenced as
shields are internally connected to the chassis of the System Control Module
which in turn is grounded to earth ground via the GROUND stud.
Input Module (A1) Control Module (A5)

Port # J2
Port # J1 (P/N: AMP 206061-1)
(P/N: AMP 206061-1) Port Name: AC Out
Mate P/N: AMP 206060-1
Pin No. Pin No. Ref. Function
1 1 CB_INT_IN 120VAC Line
2 2 CB_INT 120VAC to 600VAC Input Disconnect Coil
3 3 PRECHG+ Precharge enable (120VAC Line)
4 4 PRECHG- Precharge enable return (120VAC Neutral)
AC Interlock Controls Cable - W1

P/N 681-904741 (DRS PTI supplied)
Table B.1 AC Interlock Signals

MD500 Installation & Start-up Manual B-1
Input Module (A1) Control Module (A5)

Port # J1
Port Name: Port # J6 (P/N: AMP 208224-1)
(P/N: AMP 206306-1)
HVCB, Input Module Mate P/N: AMP 206305-1
Pin No. Pin No. Ref Function
1 1 SHIELD Cable shield termination (chassis ground)
2 2 +15V +15V power
3 3 GND +15V return
5 5 N.C. No Connection
6 6 BUSMON+ Modulated DC link voltage
7 7 BUSMON- Modulated DC link voltage return
8 8 +CPTEMP_RECT Cold plate temperature (not used)
9 9 -CPTEMP_RECT Cold plate temperature return (not used)
10 10 +15V_CCB +15V power
11 11 AGND_CCB +15V return
14 14 MOTOR_GND Motor chassis ground
17 17 VBUS+ DC link voltage
18 18 VBUS- DC link voltage return
23 23 GND +15V return
24 24 GND +15V return
25 25 VIN_OV_FAULT Input rectifier output overvoltage fault
27 27 +MOD Input rectifier output voltage AC ripple
28 28 -MOD Input rectifier output voltage AC ripple return
29 29 GFI_FAULT Motor ground fault
30 30 BRAKE_FAULT Brake IGBT fault
31 31 BRAKE_ENABLED Brake circuit ON
33 33 SHIELD Cable shield (chassis ground)
34 34 PRECHARGE_OK Precharge complete
HVCB Controls Cable - W2

Table B.2 High Voltage Control Board Signals

B-2 MD500 Installation & Start-up Manual
Buck Module (A2) Control Module (A5)

Port # J1
Port Name: Gate Drive, Port # J5 (P/N: AMP 206934-5)
(P/N: AMP 206151-1)
Buck Module Mate P/N: AMP 206150-1
2 2 +5V +5V supply for fault opto-coupler
3 3 +5V +5V supply for fault opto coupler
6 6 /BUCKD PWM signal, Phase 1 IGBT
7 7 GND Fault signal return
11 11 /FAULTD Fault signal, Phase 1 IGBT
12 12 +15V +15V supply for PWM opto-coupler
13 13 +15V +15V supply for PWM opto-coupler
14 14 /BUCKE PWM signal, Phase 2 IGBT
15 15 /FAULTE Fault signal, Phase 2 IGBT
20 20 /BUCKA PWM signal, Phase 3 IGBT
21 21 /FAULTA Fault signal, Phase 3 IGBT
23 23 FPS+15V +15V power for floating power supply
24 24 FPS+15V +15V power for floating power supply
29 29 FPS_GND Ground (+/- 15V return) floating power supply
30 30 FPS_GND Ground (+/- 15V return) floating power supply
32 32 +CPTEMP_BUCK Cold plate temperature
33 33 -CPTEMP_BUCK Cold plate temperature return
34 34 FPS-15V -15V power for floating power supply
35 35 FPS-15V -15V power for floating power supply
Buck Driver Controls Cable - W3

Table B.3 Buck Gate Drive Signals
Buck Module (A2) Control Module (A5)

Port # J2
Port Name: Current Port # J7 (P/N: AMP 207369-1)
(P/N: AMP 205840-3)
Sense, Buck Module Mate P/N: AMP 205839-3
1 1 SHIELD Overall shield termination, Phase 1 (chassis gnd)
4 4 +15V_I +15V power to hall current sensor, Phase 1
5 5 -15V_I -15 V power to hall current sensor, Phase 1
6 6 GND_I Individual shield termination, Phase 1
9 9 ISENSE_D Hall current sensor output (1V/100A), Phase 1
10 10 GND_I Hall current sensor output return, Phase 1
11 11 GND_I Individual shield termaination, Phase 1
15 15 SHIELD Overall shield termination, Phase 2 (chassis gnd)
17 17 -15V_I -15V power to hall current sensor, Phase 2
19 19 -15V_I -15V power to hall current sensor, Phase 3
20 20 SHIELD Overall shield termination Phase 3 (chassis gnd)
21 21 ISENSE_E Hall current sensor output (1V/100A), Phase 2
24 24 ISENSE_A Hall current sensor output(1V/100A), Phase 3
Buck Current Controls Cable - W4

Table B.4 Buck Current Feedback Signals

Inverter Module (A4) Control Module (A5)

Port # J1
(P/N: AMP 205843-1)
Inverter Module Mate P/N: AMP 205842-1
2 2 GATE1 PMW signal, Phase A+ top
3 3 GATE8 PMW signal, Phase B- bottom
5 5 GATE4 PMW signal, Phase A- bottom
8 8 GATE7 PMW signal, Phase B- top
9 9 IGBT_ F1 Fault signal, Phase A+ IGBT
12 12 GATE3 PMW signal, Phase A- top
13 13 GATE2 PMW signal, Phase A+ bottom
14 14 IGBT_F2 Fault signal, Phase A- IGBT
15 15 +15V +15V supply for PMW opto-coupler
17 17 IGBT_F4 Fault signal, Phase B- IGBT
24 24 IGBT_F5 Fault signal, Phase C+ IGBT
28 28 GATE6 PWM signal, Phase B+ bottom
30 30 IGBT_F3 Fault signal, Pahse B+ IGBT
31 31 GATE11 PWM Signal, Phase C- top
32 32 IGBT_F6 Fault signal, Phase C- IGBT
J4 continued on next page
Inverter Driver Controls Cable - W5

Table B.5 Inverter Gate Drive Signals


Port # J1
(P/N: AMP 205843-1)
Inverter Module Mate P/N: AMP 205842-1
35 35 +CPTEMP_INV Cold plate temperature
36 36 -CPTEMP_INV Cold plate temperature return
37 37 GATE5 PWM signal, Phase B+ top
38 38 GATE12 PWM signal, Phase C- bottom
39 39 GATE10 PWM signal, Phase C+ bottom
40 40 GATE9 PWM signal, Phase C+ top
46 46 +15V_F +15V power for floating power supply
53 53 GND_F Ground (+/- 15V return) floating power supply
60 60 -15V_F -15V power for floating power supply
J4 continued from previous page
Inverter Driver Controls Cable - W5

Table B.5 Inverter Gate Drive Signals (cont.)


Port # J2
Port Name: Current Port # J3 (P/N: AMP 207216-8)
(P/N: AMP 206038-1)
Sense, Inverter Module Mate P/N: AMP 206039-1
1 1 SHIELD Overall shield termination, Phase A (chassis gnd)
4 4 +15_I +15V power to hall current sensor, Phase A
5 5 -15V_I -15 V power to hall current sensor, Phase A
6 6 GND_I Individual shield termination, Phase A
9 9 +I_FB1 Hall current sensor output (1V/100A), Phase A
10 10 -I_FB1 Hall current sensor output return, Phase A
11 11 GND_I Individual shield termaination, Phase A
15 15 SHIELD Overall shield termination, Phase B (chassis gnd)
16 16 +15V_I +15V power to hall current sensor, Phase B
17 17 -15V_I -15V power to hall current sensor, Phase B
18 18 +15V_I +15V power to hall current sensor, Phase C
19 19 -15V_I -15V power to hall current sensor, Phase C
20 20 SHIELD Overall shield termination Phase C (chassis gnd)
21 21 +I_FB2 Hall current sensor output (1V/100A), Phase B
22 22 -I_FB2 Hall current sensor output return, Phase B
23 23 GND_I Individual shield termination, Phase C
24 24 +I_FB3 Hall current sensor output (1V/100A), Phase C
25 25 -I_FB3 Hall current sensor return, Phase C
26 26 GND_I Individual shield termination, Phase B
27 27 GND_I Individual shield termination, Phase B
28 28 GND_I Individual shield termination, Phase C
Inverter Current Controls Cable - W6

Table B.6 Inverter Current Feedback Signals

Control Module (A5)

Port # J2 (P/N: AMP 211401-1)
Port Name: AC In
Customer AC Interlocks Mate P/N: AMP 211399-1
Control
Power Pin No. Ref Function
Switch
1 120V_Line Line side 120VAC control power
120VAC
2 120V_NEUT Neutral side 120VAC control power
Precharge
Pushbutton 3 PRECHG Precharge enable (120VAC Line)
Switch
Input Disconnect 4 PRECHG+ Precharge enable (120VAC Line)

Emergency Switch
Flow
5 CB_INT Input disconnect enable (120VAC Line)
Switch
6 CB_INT_RTN Input disconnect enable return (120VAC Neutral)
7 N.C. No Connection
AC Interlocks Cable - W12
(Appendix C, User supplied)
Table B.7 AC Interlock Signals
120VAC Type Range Function

J2 pins 1 & 2 Input 120VAC, 50/60 Hz Control power
The MD500 Drive System requires 120V, single phase, 50/60Hz AC power for its controls. The current
draw on the 120V line varies depending on the load but will not exceed an rms value of 3A. The System
Control Module is equipped with a 3A fuse that will prevent excessive current draw in the event of an
internal short circuit or any other abnormal conditions. DRS PTI recommends the use of a standard
ON/OFF switch for this power.
PRECHG Type Range Function

J2 pins 3 & 4 Input 120VAC, 50/60 Hz Precharge Enable
The MD500 Drive System utilizes 120V, single phase, 50/60Hz AC power for precharge of the capacitor
bank on the output side of the 3 phase diode rectifier. The precharge circuit consists of a step-up
transformer, a rectifier bridge, and resistors. The 120VAC circuit to the transformer is completed via these
pins when the user commands it. The recommended switch for the circuit on the user end is a
momentary push-button. Note that the user needs to hold the push-button switch for 12 seconds to allow
the voltage to build up to 660V.
CB_INT Type Range Function

J2 pins 5 & 6 Output 120VAC, 50/60 Hz AC Mains Input Disconnect Enable
The MD500 provides 120V, single phase, 50/60Hz AC power that is used for energizing the AC mains
input disconnect coil. Note that this 120V will not be available until the precharge sequence has been
completed. The MD500 waits for the voltage on the input diode rectifier output to reach 660V before
providing 120V on these pins. (Note also that if the diode rectifier output drops below 566V, this 120V
power is removed to prevent operation of the system if an under voltage condition occurs on the AC
mains). Because precharge of the capacitor on the diode rectifier output is crucial for the prevention of
large inrush currents, DRS PTI requires that this 120VAC be used to control the AC mains input
disconnect. This also prevents high voltages from appearing on the IGBT power terminals before the IGBT
gates have been energized. DRS PTI recommends the use of a push-to-stop emergency switch in line
with this signal.
Table B.8 AC Interlock Signal Details

Control Module (A5)

Port # J8 (DB9 Male)
Port Name: RS232
Mate: DB9 Female
PC RS232 Port
Pin No. Ref Function
PC Receive 6 N.C. No Connection
2 TX Controller RS232 Transmit (TX)
3 RX Controller RS232 Receive (RX)
PC Transmit 8 N.C. No Connection
5 COM Controller digital ground (RS232 gnd)
RS232
Ground 4 SHIELD Cable shield termination (chassis gnd)
RS232 Communications Cable - W15

Table B.9 Communication Signals (RS232) for Diagnostics

Control Module (A5)

Port Name: Customer I/O
User
Mate: DB37 Female
Supplied
24VDC Pin No. Ref Function
1 ENABLE System enable, digital input, 0-24V
20 ENABLE_RET System enable return
10V
REF 2 SPDCTL Motor speed reference, analog input, 0-10V
21 SPDCTL_RET Motor speed reference return
10V
REF 3 TRQLIMIT Motor torque reference, analog input, 0-10V
22 TRQLIMIT_RET Motor torque reference return
4 BRKTRQ Digital input spare, 0-24V
23 BRKTRQ_RET Digital input spare return
5 RESET System reset (after shutdown), digital input, 0-24V
24 RESET_RET System reset return
mA
6 MOTSPEED Motor speed, analog output, 4-20mA
Meter
25 MOTSPEED_RET Motor speed return
mA 7 MTRTRQ Motor torque, analog output, 4-20mA
Meter
26 MTRTRQ_RET Motor torque return
8 MOTEMP System temperature warning
27 MOTEMP_RET System temperature warning return
9 DRVTEMP Digital output spare 1 (No connection)
28 DRVTEMP_RET Digital output spare 1 return (No connection)
10 DRVZSPD Digital output spare 2 (No connection)
29 DRVZSPD_RET Digital output spare 2 return (No connection)
11 READY System ready for operation, digital output
30 READY_RET System ready for operation return
12 DIRECTION Dir. of motor rotation cmd, digital input, 0-24V
31 DIRECTION_RET Dir. of motor rotation command return
24VDC_RTN
SHIELD
13 SHIELD Cable shield termination (chassis ground)
32 SHIELD Cable shield termination (chassis ground - N.C.)
14 SHIELD Cable shield termination (chassis ground - N.C.)
15, 16 N.C. No connection
Customer I/O Cable -W14 33, 34 N.C. No connection
(Appendix C, User supplied) 17, 18 N.C. No connection
Table B.10 Customer I/O Signals

ENABLE Type Range Description

J10 pins 1 & 20 Digital Input 0 - 24V 0V = "false", 24V = "true"
The ENABLE signal enables the MD500 to operate when “true” and disables the MD500 when “false”. Note
that the ENABLE signal “handshakes” with the READY signal. All excitation to the motor windings is
terminated when the ENABLE line is “false”.
SPDCTL Type Range Description

J10 pins 2 & 21 Analog Input 0 - 10V 0V = 0 RPM, 10V = set in software
The speed of the motor under operation with the MD500 is a function of the SPDCTL signal. The sensitivity of
the SPDCTL signal can be set in software depending on any particular motor maximum speed specification.
Note, however, that the maximum allowed speed is a function of the internal voltage limit of the MD500
Drive.Also, the speed allowed for a motor at a pre-determined torque output is a function of the power limit of
the MD500 Drive. At any given speed, the product of the SPDCTL signal and the TRQLIMIT signal cannot
exceed the power limit of the MD500 Drive.
TRQLIMIT Type Range Description

J10 pins 3 & 22 Analog Input 0 - 10V 0V = 0 Nm, 10V = set in software
The torque produced by the motor under operation with the MD500 is a function of the TRQLIMIT signal. The
sensitivity of the TRQLIMIT signal can be set in software depending on any particular motor maximum torque
specification. Note, however, that the maximum allowed torque is a function of the internal current limit of the
MD500 Drive. Also, the torque output of a motor at a pre-determined speed is a function of the power limit of
the MD500 Drive. At any given speed, the product of the SPDCTL signal and the TRQLIMIT signal cannot
exceed the power limit of the MD500 Drive.
BRKTRQ Type Range Description

J10 pins 4 & 23 Digital Input 0 - 24V Spare
This is a digital spare input to the MD500 Drive and can be set according to a specific application need. Note
that this is a non-standard input and requires software modifications that will be user specific. If you would like
to use this input for your application, consult the factory.
RESET Type Range Description

J10 pins 5 & 24 Digital Input 0 - 24V 0V = "false", 24V = "true"
The RESET signal is a means of resetting the system following a fault, which in turn causes a shutdown,
provided that the conditions which caused the fault have cleared. The RESET signal must be toggled “true”
and then back to “false” to reset the system after a shutdown has occurred. Shutdown conditions which
require a reset to restore normal operation include, but are not limited to:
1. A temperature in the motor (refer to signal definitions for Motor I/O - J11) exceeds an internally set
temperature limit. The temperature limits are set in software according to the specifications of the motor
under operation.
2. A temperature of a coldplate (on either the Buck Module or the Inverter Module) exceeds an internally set
temperature limit.
3. A fault indicated by an IGBT or the corresponding IGBT gate drive circuit.
4. The voltage on the dc link (between the Buck Module and the Inverter Module) exceeds 800V.
5. Motor speed exceeds internally set speed limit. The speed limit is set in software according to the
specifications of the motor under operation.
Table B.11 Customer I/O Signal Details

MOTSPEED Type Range Description

J10 pins 6 & 25 Analog Output 4 - 20mA 4mA = 0RPM, 20mA = set in software
The MOTSPEED is a signal proportional to motor shaft speed as determined from the resolver feedback
signal (refer to signal definitions for Motor I/O - J11). The sensitivity of the MOTSPEED signal can be set
in software according to a given application requirement.
MTRTRQ Type Range Description

J10 pins 7 & 26 Analog Output 4 - 20mA 4mA = 0RPM, 20mA = set in software
The MTRTRQ is a signal proportional to motor torque as calculated from the commanded motor phase
current. Consequently, the equation for MTRTRQ is a function of the type of motor under operation. Also,
its sensitivity can be set in software according to a given application requirement.
MOTTEMP Type Range Description

J10 pins 8 & 27 Digital Output see note 1 On = Sys_Temp_W arning = "false"
Off = Sys_Temp_W arning = "true"
The MOTTEMP signal is provided as a warning to the user that one or more temperatures have exceeded
internally set warning limits. The MOTTEMP signal will go “true” if the temperature of the motor (refer to
signal definitions for Motor I/O - J11), or the Power Module coldplates, or the Control Module exceeds an
internally set warning limit. Note that there is a 10 degree C hysteresis such that once MOTTEMP has
become "true", the temperature which exceeded the warning limit must fall 10 degerees C below this limit
for the signal to go false. Note also that no control action is taken since this signal is intended as a
warning only unless if any of the temperatures reach internally set shutdown lmimits. In this case, the
system will shut itself off and a RESET would have to be applied.
Note 1: The MOTTEMP signal is provided to the user through an optical isolator and both the collector
and emitter of the optically isolated transistor are available on pins 8 and 27 respectively
DRVTEMP Type Range Description

J10 pins 9 & 28 Digital Output see note 1 Spare
This is a digital spare output and can be set according to a specific application need. Note that this is a
non-standard output and requires software modifications that will be user specific.
Note 1: The DRVTEMP signal is provided to the user through an optical isolator and both the collector and
emitter of the optically isolated transistor are available on pin 9 and pin 28 respectively. If the user decides
to use this output, DRS PTI recommends that the transistor collector be tied to a 24VDC supply with a
current limiting resistor and the emitter to a LED.
Table B.11 Customer I/O Signal Details (cont.)

DRVZSPD Type Range Description

J10 pins 10 & 29 Digital Output see note 1 Spare
This is a digital spare output and can be set according to a specific application need. Note that this is a
non-standard output and requires software modifications that will be user specific.
Note 1: The DRVZSPD signal is provided to the user through an optical isolator and both the collector and
emitter of the optically isolated transistor are available on pin 10 and pin 29 respectively. If the user
decides to use this output, DRS PTI recommends that the transistor collector be tied to a 24VDC supply
with a current limiting resistor and the emitter to a LED.
READY Type Range Description

J10 pins 11 & 30 Digital Output see note 1 On = Sys_Ready = "false"
Off = Sys_Ready = "true"
The READY signal is provided as an output from the MD500. W hen the ENABLE signal is “true”, if the
conditions in the motor and drive are normal and the system is ready to operate, the READY signal
becomes “true”. Conditions under which the READY signal may remian "false" include, but are not limited
to:
1. ENABLE is "true" and RESET is also "true"

2. System over temperature
3. Control cables that interconnect the Power Module and the Control Module are not connected
4. Hardware failures (such as IGBT's, IGBT gate drivers, broken wires, etc.)
5. Excessive voltage on the link dc voltage
6. Motor over speed
7. The ENABLE signal makes the "false" to "true" transistion with the SPDCTL and TRQLIMIT signals set
to some level other than 0V.
Note1: The READY signal is provided to the user through an optical isolator and both the collector and
emitter of the optically isolated transistor are available on pins 11 and 30 respectively.
DIRECTION Type Range Description

J10 pins 12 & 31 Digital Input 0 - 24V 0V = Reverse, 24V = Forward
The motor can rotate either clockwise (CW ) or counterclockwise (CCW ) depending on the state of the
DIRECTION signal. The CW or CCW direction of rotation depends on which side the motor is being
viewed from. Consequently, what constitutes FORW ARD vs. REVERSE direction of rotation for the motor
is left up to the user to define. The controller "thinks" the rotation is REVERSE if the DIRECTION
command is 0V and FORW ARD if it is 24V.
Table B.11 Customer I/O Signal Details (cont.)

Control Module (A5)

Motor End
Port Name: Motor I/O
Mate: DB25 Female
1 +ROT +15V Power to Infrared transmitter
Transmitter
Infrared
Thermocouple 4-20
IR
mA
t
O
14 -ROT Temp. sensor, Infrared Thermocouple
2 SHIELD_ROT Chassis ground for shield termination
15 +ST1 Temp. sensor, Thermistor 1
Thermistor
t
O
3 -ST1 Temp. sensor, Thermistor 1 return
16 SHIELD_ST1 Chassis ground for shield termination
4 +ST2 Temp. sensor, Thermistor 2
Thermistor
t
O
17 -ST2 Temp. sensor, Thermistor 2 return
18 +COS Resolver cosine wave output
6 -COS Resolver cosine wave output return
S2 S4
19 SHIELD_COS Chassis ground for shield termination
R- S3 7 +SIN Resolver sine wave output
R+ S1
Resolver
20 -SIN Resolver sine wave output return
8 SHIELD_SIN Chassis ground for shield termination
21 +REF Resolver reference signal
9 -REF Resolver reference signal return
22 SHIELD_REF Chassis ground for shield termination
10 SHIELD_RESOLVER Chassis ground for shield termination
23 CFG0_IN Reserved for future expansion (N.C.)
12 +5V Reserved for future expansion (N.C.)
25 MOTOR_GND_HV Motor Housing Voltage Sensing
Motor
Housing 13 SHIELD_MOTOR_GND Chassis ground for shield termination
Motor I/O Cable - W13

Table B.12 Motor I/O Signals

+ROT, -ROT Type Range Description

J11 pin 1 Output +15VDC 15V to Infrared Thermocouple Transmitter
J11 pin 14 Input 4 - 20 mA 4mA = 0 deg C., 20mA = set in software
The ROT signal is intended for temperature measurement of a rotating part, i.e. the rotor. An infrared
thermocouple would be mounted on the motor and fed by a transmitter that is powered by the +ROT
signal. The transmitter would then feed the -ROT signal back to the controller as a measure of
temperature. The sensitivity of the signal can be set in software according to a given application
requirement.
ST1 Type Range Description

J11 pins 15 & 3 Input 1Meg Thermistor 1
The ST1 signal is intended for measurement of a temperature using a thermistor. A thermistor is a
temperature measuring device that has a well defined temperature vs. resistance curve. This curve is built
into DRS PTI’s software. Note that this signal is not isolated from the control power. It cannot be used for
temperature measurement of anything that is subjected to live volatages and currents (for example, the
winding of a motor).
ST2 Type Range Description

J11 pins 4 & 17 Input 1Meg Thermistor 2
The ST2 signal is intended for measurement of a temperature using a thermistor. A thermistor is a
temperature measuring device that has a well defined temperature vs. resistance curve. This curve is built
into DRS PTI’s software. Note that this signal is not isolated from the control power. It cannot be used for
temperature measurement of anything that is subjected to live volatages and currents (for example, the
winding of a motor).
COS Type Range Description

J11 pins 18 (+) & 6 (-) Input 0 - 5V Resolver Cosine
SIN
J11 pins 7(+) & 20 (-) Input 0 - 5V Resolver Sine
REF
J11 pins 21(+) & 9 (-) Output 0 - 5V Resolver Reference
The MD500 controller requires that a resolver be mounted on the motor shaft for position sensing. A
resolver is a position sensing device that requires an AC reference signal (+/- REF) as input and in turn
provides two complimentary AC waves as outputs (+/- COS & +/- SIN) whose implitutued are proportional
to position and frequencies are proportional to RPM. This information is then processed by the controller
whereby it "knows" the exact position of the rotor (with respect to the stator) as well as the speed the
motor is operating at. The controller then uses this information to excite the stator windings at the
appropriate time. For this reason, the resolver outputs must be in sync or timed with the motor.
MOTOR_GND Type Range Description

J11 pin 25 Input NA Motor Housing Voltage Sense
This signal is a provision for sensing a difference in voltage between the motor chassis and the drive
chassis which are both connected to earth ground. Under normal conditions, the motor chassis and the
drive chassis are at the same potential (i.e. earth ground). If for some reason (for example, borken or
disconnected ground cable) the motor chassis potential starts floating away from earth ground potential
(=>30V), the controller will stop operation (not a shutdown) until the potential difference becomes less
than 30V.
Table B.13 Motor I/O Signal Details

Control Module (A5)

Port# J9 (DB15 Male)
Port Name: RS485
Mate: DB15 Female
1 RS485+ RS485 Transmit + (TX+) & Receive + (RX+)
9 RS485- RS485 Transmit - (TX-) & Receive - (RX-)
2 SHIELD_IN Cable shield terminated at RS485 isolated ground
10 N.C. No connection
3 RS485- RS485 Transmit - (TX-) & Receive - (RX-)
11 RS485+ RS485 Transmit + (TX+) & Receive + (RX+)
4 SHIELD_OUT Cable shield terminated at RS485 isolated ground
5,6,7,8 N.C. No connection
12,13,14,15 N.C. No connection
Note: This port is used for Multiple Drive Operation only (see the Multiple Drive Configuration section in
Chapter 3 for details). Therefore, when using only one MD500, disregard this connection.
Control Module 1 Control Module 2 Control Module 3 Control Module 4

11 11 11 11
*Terminating *Terminating
Resistor 3 3 3 Resistor 3
4 4 4 4
1 1 1 1
+ + + +
9 - 9 - 9 - 9 -
- - - -
+ + + +
2 2 2 2
ISO_COM ISO_COM ISO_COM ISO_COM
RS485
Communication Cable - W16
* Only the first and last modules have the terminating resistor installed. This is accomplished by repositioning
a jumper inside the System Control Module. For details see the Multiple Drive Configuration section in
Chapter 3.
Table B.14 Communication Signals (RS485) for Master/Slave Operation

Control Module (A5)

Port # J12
Port Name: Network In (P/N Conxall 17281-3SG-300)
Mate P/N: Conxall 16282-3PG-311
1 NET_A Reserved for future expansion
2 NET_B Reserved for future expansion
3 JP2_NI_JP Reserved for future expansion
Control Module (A5)

Port # J13
Port Name: Network Out (P/N: Conxall 17281-3PG-300)
Mate P/N: Conxall 16282-3SG-311
1 NET_A Reserved for future expansion
2 NET_B Reserved for future expansion
3 JP3_NI_JP Reserved for future expansion
Table B.15 Network Input/Output Signals (reserved for future expansion)


Appendix C – User Supplied Cables
There are currently a total of eleven control cables on the MD500 system, of which six are supplied by DRS
PTI and five are user provided. Each of the cables described here are referenced in Appendix B. Proper
construction and shielding is essential so that noise does not effect system performance. The following provides
the user with recommendations on wire type and cable construction and details on required connectors for the
five cables. All connectors that are referenced here are supplied to the user in the MD500 Connector Mate Kit
(P/N: 755-904695). The user may request DRS PTI to construct these cables at an additional cost. Contact the
factory for details.
Cable # Mates to: Function

W12 J2 of System Control Module Provides to the Control Module 120VAC power from the user as
well as AC interlocks for precharge and AC mains input
disconnect.
CONTROL MODULE END
120V_LINE
USER END
1 120V_NEUT
2 PRECHG
3 PRECHG_RTN
4 CB_INT
5 CB_INT_RTN
6
7
7 PIN CIRCULAR CONNECT OR
P/N: AM P 211399-1
SOCKET P/N: AM P 66101-3 16 AWG, 300V
BACKSHELL P/N: 206966-1 (6X)
This cable is used to interface with the customer for AC interlocks. Refer to Appendix B for a detailed
description on these signals.
MD500 Installation & Set-up Manual C-1

Appendix C - User Supplied Cables

W13 J11 of System Control Module Provides position and temperature information from the motor.
P
+PS T O INFRARED
-PS T HERM OCUPLE
T RANSM IT T ER
TO
P1 T HERM IST OR
1 +ROT
14 -ROT
2 SHIELD_ROT P
15 +ST1
3 -ST1 TO
MOTOR END
16 SHIELD_ST1 T HERM IST OR
4 +ST2
CONTROL MODULE END
17 -ST2
5 SHIELD_ST2 P
18 +COS
6 -COS
19 SHIELD_COS P
7 +SIN
20 -SIN TO
8 SHIELD_SIN P RESOLVER
21 +REF
9 -REF
22 SHIELD_REF
10 SHIELD_RESOLVER
23 CFG0_IN
11 CFG1_IN RESERVED
24 CFG2_IN FOR FUT URE
12 +5V 3 T WIST ED PAIRS WIT H
EXPANSION
25 MOTOR_GND_HV INDIVIDUAL AND OVERALL
13 SHIELD_MOTOR_GND P
SHIELDS, 22AWG
TO
DB25 CONNECT OR - M ALE M OT OR
P/N: AM P 747912-2 HOUSING
BACKSHELL KIT P/N: AM P 748676-3
1 T WIST ED SHIELDED PAIR, 22AWG

(4X) DO NOT T ERM INAT E
SHIELDS AT T HIS
END
This cable is used to interface with the motor. Refer to Appendix B for a detailed description on these
signals.
C-2 MD500 Installation & Set-up Manual

Appendix C -User Supplied Cables

W14 J10 of System Control Module Provides and receives digital/analog signals to/from the user.
1 ENABLE P
20 ENABLE_RET
2 SPDCTL
21 SPDCTL_RET P
3 TRQLIMIT
22 TRQLIMIT_RET
4 BRKTRQ P
23 BRKTRQ_RET
5 RESET
24 RESET_RET P
USER END
6 MOTSPEED
25 MOTSPEED_RET
CONTROL MODULE END
7 MTRTRQ P
26 MTRTRQ_RET
8 MOTEMP
27 MOTEMP_RET P
9 DRVTEMP
28 DRVTEMP_RET
10 DRVZSPD P
29 DRVZSPD_RET
11 READY
30 READY _RET P
12 DIRECTION
31 DIRECTION_RET
13 SHIELD P
32
14
33 P
15
34
16
35
17 DO NOT
36 T ERM INAT E
18 12 T WIST ED PAIRS WIT H OVERALL SHIELD,
37 SHIELD AT
22AWG
19 T HIS END
DB37 CONNECT OR - M ALE

P/N: AM P 747916-2
BACKSHELL KIT P/N: AM P 748676-4
This cable is used to interface with the customer for digital/analog signals. Refer to Appendix B for a
detailed description on these signals.


W15 J8 of System Control Module Provides RS232 communication with a PC for diagnostics.
Option 1
CONTROL MODULE END
RS232
OPT O-ISOLAT ION
M ODULE
PC END
T ELEBYT E M odel 768
DRS EPT PN:
KEC-EDC
750-105326
DB9 DB25 DB25 DB9
M ALE M ALE FEM ALE FEM ALE
BLACK BOX CORPORAT ION BLACK BOX CORPORAT ION
SHIELDED & GROUNDED SHIELDED & GROUNDED
RS232 CABLE RS232 CABLE
PN: CBPS118536 (20ft) PN: CBPS118535 (20ft)
KEC-EDC
DRS EPT PN: 681-105307
681-105307 KEC-EDC
DRS EPT PN:
PN: 681-105306
681-105306
1
Option 2
CONTROL MODULE END
6 P
2
7 CM TX PC RX
PC END
3 CM RX PC TX
8 CM GND PC COM
4 SHIELD
9
5
1 T RIAD WIT H OV ERALL SHIELD, DO NOT
DB9 CONNECT OR - M A LE 22AWG T ERM INAT E
P/N: AM P 747904-2
BACKSHELL KIT P/N: 748676-1 AM P SHIELD AT
T HIS END
This cable is used to interface with a PC for diagnostic purposes. DRS PTI provides the user with a
LabVIEW host that communicates with the controller through this port and receives information from
the controller on voltages, currents, speed, torque, temperatures, faults, etc. This information is
particularly helpful, if the system has a problem, to help isolate the source of the problem. DRS PTI
recommends that the communication line between the System Control Module and the computer be
optically isplated. An RS232 opto-isolation module such as that manufactured by Telebyte Technology,
Inc. (Model 768) or equivalent can be used to achieve this (see Option 1). If optical isolation is not
used, it is recommended that a PC (laptop) with a two wire power cord be used to that potential ground
loops are avoided. The RS232 cable depicted as Option 2 may be replaced with a standard off-the-
shelf shielded cable such as that manufactured by Black Box Corporation (PN: EDN12H-0020-MF).

Appendix C -User Supplied Cables

W16 J9 of System Control Module Provides RS485 communication between System Control
Modules for multiple drive operation.
NOT E: T HIS CHASSIS GROUND WIRE

P1 P P2
SHOULD CONNECT T O CONNECT OR
1 RS485+ 1
9 P1 BACKSHELL WHICH T HEN PICKS RS485- 9
2 UP CHASSIS GROUND FROM T HE 2
CONTROL MODULE 1
CONTROL MODULE 2
10 CONT ROL M ODULE. P 10
3 RS485- RS485- 3
11 RS485+ RS485+ 11
4 SHIELD1 SHIELD2 4
12 12
5 5
13 13
6 6
14 14
7 7
15 15
8 8
1 T WIST ED SHIELDED PAIR, 22AWG (4X)

P P3
RS485+ 1
RS485- 9
2
CONTROL MODULE 3
P 10
RS485- 3
RS485+ 11
SHIELD3 4
12
5
13
6
14
7
15
8
P1, P2, P3, P4: DB15 CONNECT OR - M ALE

P/N: AM P 747908-2 P P4
BACKSHELL KIT P/N: AM P 748676-2 RS485+ 1
RS485+
RS485- 9
SHIELD3 2
CONTROL MODULE 4
NOT E: EACH M D500 CONNECT OR M AT E KIT ( 755-904695) 10
CONT AINS ONE CONNECT OR AND BACKSHELL KIT . 3
11
4
12
5
13
6
14
7
15
8
This cable is used for communication between MD500 System Control Modules if more than one
MD500 Drive System is operated in a Master/Slave configuration. The Master receives user
commands from the Customer I/O port (J10) and transmits them to the Slave(s) via this communication
link. The diagnostic information from the Slave(s) can also be obtained by using LabVIEW through the
RS232 port (J8) or from the analog/digital outputs through the Customer I/O port (J10).


Appendix D – PA44 Installation Requirements
This section provides general installation requirements for DRS PTI’s PA44
series motor including cooling and its interconnection with the MD500 Drive.
The PA44 series motors are axial field, permanent magnet, brushless motors
and consist of a single rotor located between two, three phase stators. Both the
positive and negative terminals of all stator phases are brought out into the
motor junction box where the corresponding phases of each stator is wired in
series. Power connections to the stators are made via screw type terminals
located inside this junction box. A ground stud is also provided for grounding the
motor housing to earth ground. Mounted on the rotor shaft is a resolver for
motor position sensing. Impregnated in each stator core are two thermistors for
stator temperature sensing. The motor is also equipped with an infrared thermo-
couple and transmitter for rotor temperature sensing. The motor has four
control connectors (J1 through J4) where J1 is for resolver signals, J2 is for
rotor temperature signals, and J3 and J4 are for stator temperature signals.
Figure D.1 provides information on how the ground, power, and control cables
are connected between the MD500 Drive and the PA44 motor. Table D.1
details pinouts for the MD500 System Control Module Motor I/O port (J11) as
it connects to the PA44 sensors. Figure D.2 provides details on wire specifica-
tion, cable construction, and connector termination information for the control
cable from the motor to the drive. Note that this cable is to be provided by the
user.
As with the MD500, the PA44 motor requires both liquid cooling and air cool-
ing and the dominant method is liquid cooling. The required coolant is a 50/50
mixture of water and ethylene glycol and, as with the drive, heat dissipated
varies with power demand. Table D.2 shows a chart of the heat dissipation and
cooling requirements under maximum load conditions for the PA44 motor. Ref-
erence Figure D.3 for details on cooling system configuration for the PA44
motor. The user has the option of using separate heat exchanger/pump units for
the motor and drive (as depicted in Figures D.3 and 3.5 respectively) or one
heat exchanger/pump unit for the motor/drive system as depicted in Figure D.4.
In either case, DRS PTI recommends separate flow switches for the motor
and drive with each flow switch wired to the ‘input disconnect remote trip’.
Figure D.5 shows a typical cooling system schematic for a multiple MD500/
PA44 configuration.
MD500 Installation & Start-up Manual D-1

An MD500 Drive and PA44 motor shipped from the factory as a system will
have the motor properly timed before shipment. Recall from Appendix B that
the DIRECTION signal defines the direction of motor rotation and what con-
stitutes FORWARD vs. REVERSE is left up to the user to define. For the PA44
series motor, DIRECTION=0V=REVERSE is defined as clockwise shaft rota-
tion, viewing the shaft from the output shaft side of the motor. And
DIRECTION=24V=FORWARD is defined as counterclockwise shaft rotation,
again viewing the shaft from the output shaft side of the motor.
D-2 MD500 Installation & Start-up Manual

SYSTEM CONTROL MODULE (A5)
AC INVERTER MODULE BUCK INPUT BUCK SYSTEM INTERFACE

ON MODULE MODULE MODULE
J1 OUT
J8 RS232 COMPUTER
J3 J4 J5 J6 J7
J9 RS485 MASTER/SLAVE COMMUNICATION
FUSE
J2 IN CURRENT GATE HVCB CURRENT
J10 CUSTOMER I/O CUSTOMER CONTROL
GATE
SENSE DRIVE DRIVE CONTROLS SENSE J11 MOTOR I/O
A-A
W2 W4
120VAC CONTROL
POWER AND
AC INTERLOCKS W3 MOTOR
JUNCTION BOX
W5 ROTOR
TEMP
J2
W6
RESOLVER
J1 J3
W1 STATOR STATOR
TEMP TEMP
2 J4 1
INPUT
DISCONNECT &
PROTECTION J2 J1 J1 J2 J1 J2
SHAFT ON OPPOSITE SIDE

INPUT BUCK INVERTER
L1 MODULE MODULE MODULE
(A1) (A2) (A4)
A1-
2C+ 1A-
DETAIL A-A
600 VAC CHOKE
JUNCTION BOX
3φ
L2 MODULE
A1+
(A3) 2B- 1C+ TOP VIEW
UNDER
INPUT MODULE
MOTOR
CONNECTIONS
B1- 2A+ 1B-
L3 B1+ 2C- 1A+

SHAFT
SIDE
2B+ 1C-
C1-
BRAKE
RESISTOR (A6) 2A- 1B+
NEG (-) C1+
DB-
POS (+) DB+
POWER MODULE (A1)
CONTROL CABLES POWER CABLES GROUND CABLES
Figure D.1 MD500/PA44 Interconnection Diagram

MD500 Control Module (A5)

PA44 End Port Name: Motor I/O
Mate: DB25 Female
Transmitter
Infrared 1 +ROT +15V Power to Infrared transmitter

Thermocouple
IR
4-20mA
t
O
14 -ROT Rotor temperature sensor
2 SHIELD_ROT Chassis ground for shield termination
15 +ST1 Stator 1 temperature sensor
Thermistor
t
O
3 -ST1 Stator 1 temperature sensor return
4 +ST2 Stator 2 temperature sensor
Thermistor
t
O
17 -ST2 Stator 2 temperature sensor return
18 +COS Resolver cosine wave output
6 -COS Resolver cosine wave output return
S2 S4
19 SHIELD_COS Chassis ground for shield termination
R- S3
7 +SIN Resolver sine wave output
R+ S1
Resolver 20 -SIN Resolver sine wave output return
8 SHIELD_SIN Chassis ground for shield termination
21 +REF Resolver reference signal
9 -REF Resolver reference signal return
22 SHIELD_REF Chassis ground for shield termination
10 SHIELD_RESOLVER Chassis ground for shield termination
23 CFG0_IN Reserved for future expansion
12 +5V Reserved for future expansion
Motor 25 MOTOR_GND_HV Motor Housing Voltage Sensing

Housing
13 SHIELD_MOTOR_GND Chassis ground for shield termination
Table D.1 PA44 Motor Control Signals

P
+ROT +PS INFRARED
-ROT T HERM OCOUPLE
-PS T RANSM IT T ER
TO PA44 J2
DO NOT T ERM INAT E
SHIELD
P P2
+ST1
-ST1 1
2
ST AT OR 1
+ST1 3
4 T HERM IST ORS
SHIELD_ST1 P
+ST1 -ST1 5
*SPARE TO PA44 J3
-ST1 6
TO MD500
CONTROL MODULE
P P3
J11 +ST2
P1 -ST2 1
1 +ROT 2
ST AT OR 2
14 -ROT +ST2 3
4 T HERM IST ORS
2 SHIELD_ROT SHIELD_ST2 P
15 +ST1 +ST2 -ST2 5
*SPARE TO PA44 J4
3 -ST1 -ST2 6
16 SHIELD_ST1
4 +ST2
17 -ST2
5 SHIELD_ST2 P
18 +COS
6 -COS
19 SHIELD_COS P
7 +SIN
20 -SIN
8 SHIELD_SIN P P4
21 +REF +REF
9 -REF -REF 1
22 SHIELD_REF +COS 2
RESOLVER
10 SHIELD_RESOLVER -COS 3
23 CFG0_IN +SIN 4
11 CFG1_IN -SIN 5 TO PA44 J1
RESERVED 3 T WIST ED PAIRS WIT H
24 CFG2_IN 6
FOR FUT URE INDIVIDUAL AND OVERALL
12 +5V DO NOT T ERM INAT E
EXPANSION SHIELDS, 22AWG
25 MOTOR_GND_HV SHIELDS
13 SHIELD_MOTOR_GND
DB25 CONNECT OR - M ALE P T1

P/N: AM P 747912-2 M OT OR
BACKSHELL KIT HOUSING
P/N: AM P 748676-3
TO PA44 GROUND STUD
1 T WISTED SHIELDED PAIR, 22AWG (6X)
DO NOT T ERM INAT E
SHIELD
NOT ES:
P1 IS SUPPLIED WIT H M D500 M AT E-KIT
P2, P3, P4, & T 1 ARE SUPPLIED WIT H PA44 M AT E-KIT
P2, P3, P4 P/N: CANNON M S27473E8A35S
BACKSHELL FOR P2, P3, P4 P/N: GLENAIR M 85049/49-2-8N
* INDICAT ES INTERNAL BACKUP T HERM IST OR.
Figure D.2 MD500/PA44 Control Signal Interface Cable

Required Coolant Flow 7 GPM 26.4 LPM

Coolant Heat Load 61,420 BTU/hr 18kW
Delta Pressure 50 psi 345 kPa
Maximum Coolant Inlet Temperature 120 Deg F 49 Deg C
Table D.2 PA44 Cooling System Requirements
Notes:
1. Cooling system requirements shown are for maximum load conditions.
2. Significant variations occur when using motors in applications that require
less than maximum power and an estimate should be made for each applica-
tion prior to selection of cooling equipment.
3. When sizing the heat exchanger unit DRS PTI recommends a capacity of
at least 50% or greater than the known heat load.
HEAT
EXCHANGER
(27 kW)
STATOR 1
STATOR 2
PA PUMP
SERIES
MOTOR
MIN. 3.5 GPM
MIN. 3.5 GPM
FLOW SWITCH
7 GPM
Note:
1. Wire the flow switch to the AC mains input disconnect remote trip so if the coolant flow
stops, main power is disconnected.
Figure D.3 PA44 Cooling System Schematic

HEAT
EXCHANGER
(42 kW)
MD500 PUMP
POWER
MODULE
MIN. 15 GPM
STATOR 1
STATOR 2
PA
SERIES
MOTOR
MIN. 3.5 GPM
MIN. 3.5 GPM
FLOW SWITCH
7 GPM
Figure D.4 MD500/PA44 Cooling System Schematic

MD500
1 HEAT
EXCHANGER
(168 kW)
FLOW
MIN. 15 GPM
SWITCH
15 GPM PUMP
MD500
2
MIN. 15 GPM
MD500
3
MIN. 15 GPM
MD500
4
MIN. 15 GPM
PA44
1
MIN. 7 GPM
PA44
2
MIN. 7 GPM
PA44
3
MIN. 7 GPM
PA44
4
MIN. 7 GPM
Figure D.5 Typical Multiple MD500/PA44 Cooling System Schematic

Appendix E – CE Compliant Information
The following section describes the requirements of this motor drive when its
intended use requires compliance with CE with the following directives EMC
per EN 61800-3:2004 (Clauses 6.3 -6.5 only) and Low Voltage per EN
60204-1: 1997.
The MD500 Drive is an AC/AC variable speed motor drive system designed to
operate DRS PA Series brushless, permanent magnet motors (PA44 & PA57).
The drive is a PWM type converter utilizing the latest IGBT (Integrated Gate
Bipolar Transistor) technology. The major components of the MD500 system
are:
· Power Module
· System Control Module
· Brake Resistor Module
Test configuration for both EMC per EN 61800-3:2004 (Clauses 6.3 -6.5 only)
and Low Voltage per EN 60204-1: 1997 was comprised of the following.
1. MD500 Drive (part number 805-904700)
a. MD500 Drive Power Module (part number 760-904710)
b. MD500 System Control Module (part number 760-904705)
2. Input Line Filter (not provided by DRS, is the responsibility of the
integrator).
a. Schaffner FN 3359-400 rated 690V or equivalent.
3. Cable Shielding, required for EMC compliance (not provided by
DRS, is the responsibility of the integrator).
a. Flexible metal conduit (4" conduit used on all AC, Motor and
I/O cables)
4. Drive Shielding, required for EMC compliance (not provided by
DRS, is the responsibility of the integrator).
a. Steel electrical cabinet (IP 22 minimum rating, or equivalent
steel enclosure.
The MD500 Drive Power Module, System Control Module and Input Line
Filter must be properly and securely mounted inside an electrical enclosure
with enclosure doors can be securely closed (tool secured) during operation to
prevent accidental contact with live parts. The doors on the electrical enclo-
sure do not require EMI gasketing; standard rubber or foam gaskets are ad-
equate. The drive power module must be mounted or positioned within the
steel enclosure so that all liquid fittings are located at the bottom of the drive/
enclosure so that any coolant leaks will not contact other electrical components
resulting electrical damage and/or creating a shock hazard.
MD500 Installation & Start-up Manual E-1

Good design practices call for the input line filter to be placed in close proximity
to the entry of the AC input power lines and the distance between the filters
output and the drives AC input connections should also be kept to a reasonable
minimum. EMC rated conduit must be used and properly installed to shield all
AC, motor and I/O control cables that exit the electrical enclosure.
All external/user grounds must be clearly marked, identified and properly con-
nected prior to operating this drive.
Entry into the steel electrical enclosure housing the MD500 drive shall not be
attempted for a period of 10 minutes after all power has been removed from
the system. This is to allow for the dissipation of dangerous if not lethal levels
stored electrical energy. Safe entry into the electrical enclosure can be made
by trained technicians after the 10 minute dissipation period. MD500 Drive is
equipped with bleed resistors that completely remove all electrical voltages
from the drive within 5 minutes from the time input power is removed.
E-2 MD500 Installation & Start-up Manual

Additional protections should be considered by the integrator/user to prevent

accidental contact when the doors to the cabinet are open.
Warning: Operation of the MD500 Drive System may produce sound pres-
sures in excess of 85dB. Therefore; is recommended integrators/users of this
equipment consider the use of proper hearing protection when in close proxim-
ity to the equipment during operation of the MD500 Drive System.
Figure E.1 Typical MD500 Drive & Enclosure Configuration

The following information has been included in this section as required by CE

– EN 60204-1; 1997

• MD500 drive system must be placed in a steel “IP 22” minimum or

equivalent enclosure.
• All power and control cables must be properly shielded (grounded

metal conduit) or contained inside the enclosure.
• MD500 drive system must be sufficiently and properly grounded via

marked protective earting terminals.
• A properly rated 3 phase input line filter (i.e., Schaffner #FN

3359HV-600-99) must be installed as a component of the input
power cabling and the line filter must be installed inside the enclosure
housing the MD500 drive system.
• A protective earthing terminal marked “PE” is located near the

phase connections. This marking also applies for the control cabinet.
Additional ground terminals have been marked with the symbol to the
left.
• Main Disconnect, Overcurrent and Ground Fault Protection :
Since this system has no Main Disconnect or Overcurrent Protec-

tion, an IEC compliant disconnecting device and overcurrent
protection must be provided by the OEM or user in the end installa-
tion. It is recommended a main disconnect rated at 500A per
MD500 Drive, plus 100kA fused with an AIC rating of 65,000A. It
is also recommended a properly rated ground fault interrupter be
included as part of the AC input protection.
• Fuse holder on the MD500 System Controller Enclosure:
The MD500 System Controller Enclosure has been marked with the
fuse symbol(to the left) to show the rating and fuse location.
Warning: Only the line side of the control input voltage is fused.
Therefore, if a neutral is not used and the fuse opens, the other line
can still be energized.

• Protect the user/maintenance against accidental contact with

live parts:
The MD500 system must be installed in a proper enclosure (IP22 mini-

mum) which is tool secured. If enclosure is opened and live parts are
exposed during servicing while the disconnect is in the on position, those
parts must be fully guarded to prevent accidental contact. The barriers
also need to be marked with the hazardous voltage warning mark. This
requirement of EN 60204-1; 1997 must be observed and complied with
by the OEM or user of the MD500 Drive.
• The MD500 Drive is provided with the following Protective Features

in the form of error codes.
• Overvoltage Monitors bus Overvoltage;

enables brake circuit
• Undervoltage Monitors bus undervoltage
• Temperature Monitors drive & motor temperature
• Motor ground interlock Monitors motor housing ground
Errors are assigned one of three levels of severity. They are:
1) warnings – the motor is not in imminent danger but the operator

should be made aware of the issue
2) alarms – the motor is in imminent danger and overrides the operator’s

commands by setting a the velocity target to zero to stop the motor in
an orderly manner; once the
3) shutdown – the motor has a failure and/or is about to suffer a failure

so all active controls are immediately halted (drive IGBTs are turned
off, pre-regulator is turned off)
The following is a list of all assigned MD500 errors codes:


• Transformer (#T1 located in the Input Module) requires 120VAC

over current protection.
Transformer T1 is protected by line fuse F1 (3 amps). This line fuse is

located on the side of the System Controller Enclosure.
• Safety Related Circuits (control / operation of MD500 System).
It is the responsibility of the integrator to make sure that all safety related
circuits must be wired using “pull-up” vs. “pull-down” technology to
prevent an accident should a ground fault occur.
• Control Circuits:
The integrator of MD500 system must provide 120 volts to the control
system. This may be accomplished through the use of a ‘CE” approved
transformer outside the MD500 system when working with voltages
greater than 120 volts.
• Start, Stop and Emergency Stop Functions
Approved start, stop, and emergency stop functions must be provided by

the integrator in the end installation in agreement with EN 60204-1; 1997.
• Control circuits in the event of a failure; need to provide protec-

tion to reduce risk as below.
- Protective devices: Reference embedded error codes page 4 of

Appendix F.
- Proven Circuitry: Circuitry has been proven (fielded units).
- Partial or complete redundancy: Shut-Down Controls in the event
of system fault.
- Earth faults: MD500 contains ground fault sensing (re: High
Voltage PCB, #904771)
The MD500 circuitry is proven since this product has been shipped since
1998 (247 units in the field) without incident.
LED’s comply with the following table (not all colors in table may
be used in the MD500).

• Noise Reduction Protection is Required
While operating the MD500 Drive System the emitted audible noise may
exceed 85 db, therefore personal noise reduction protection should be
used.
• Translation of Safety Sections relative to the MD500 Drive

System.
DRS, the manufacturer of the MD500 Drive System will provide all
documentation (including Safety Sections) in the English language, and it
will be the responsibility of the integrator to translate and provide the
Safety Sections into the language of the host country
• Orientation of the MD500 Drive System relative to coolant/fluid

fittings and flexible coolant/fluid hoses.
The MD500 Drive can be installed and operated in any orientation as

stated in the MD500 Installation & Start-up Manual (page 3-3, Mount-
ing), however; if the unit is installed in compliance with CE - Low
Voltage Directive it is the responsibility of the integrator to make sure all
coolant/fluid fittings and flexible coolant/fluid hoses, etc. are installed
such that liquids drain away from fittings and the MD500 drive system.

• Troubleshooting the MD500 Drive.
Chapter 4, Sections 3 & 9 of the MS500 Installation & Start-up Manual

addresses several high level operational faults that may occur at start-up
or during normal operation. If the integrator or user is unable to resolve
the problem it is recommended DRS PTI be contacted for factory
support.
• MD500 Drive System (p/n 805-904700) Nameplate
It is the responsibility of the integrator to make sure an approved name-

plate (copy of approved nameplate is shown below) is attached and
visible on the MD500 Drive.

• Community Languages
The integrator/user (not the manufacturer) has agreed to translate

and provide the documentation in languages other than English as
prescribed by the machinery directive. The manufacturer (DRS
Power Technology, Inc.) will provide all documentation in the English
language.
The machinery directive requires the following:
“The instructions must be drawn up in one of the Community lan-

guages by the manufacturer or his authorized representative estab-
lished in the Community. On being put into service, all machinery
must be accompanied by a translation of the instructions in the
language or languages of the country in which the machinery is to
be used any by the instructions in the original language.
This translation must be done either by the manufacturer or his
authorized representative established in the Community or by the
person introducing the machinery into the language area in question.
By way of derogation from this requirement, the maintenance
instructions for use by specialized personnel employed by the
manufacturer or his authorized representative established in the
Community may be drawn up in only one of the Community
languages understood by those personnel.”

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Installation & Start-up Manual MD500

MD500 Drive System

© 2007 DRS Electric Power Technologies, Inc.

General Safety Warnings in this manual appear in two ways:

• General warnings, preceded by a General Warning symbol, indicate situa-

CAUTIONS inform you of situations or conditions which will damage or cause

This warning symbol indicates a general warning.

This warning symbol indicates an electrostatic discharge

iv MD500 Installation & Start-up Manual

The DC bus capacitors contain dangerous DC voltage levels. After discon-

CAUTION: Electrostatic discharge (ESD) can damage electronic cir-

MD500 Installation & Start-up Manual v

Chapter 1 – Introduction ......................................................................................... 1-1

Chapter 2 – System Overview ................................................................................2-1

Chapter 3 – Installation Instructions .....................................................................3-1

Chapter 4 – Start-up and Normal Operation .......................................................4-1

vi MD500 Installation & Start-up Manual

Appendix A – MD500 Technical Specifications ................................................... A-1

MD500 Installation & Start-up Manual vii

Date Revision Description of Revisions

viii MD500 Installation & Start-up Manual

Chapter 2 – System Overview provides a brief system description, lists prod-

Chapter 3 – Installation Instructions describes planning for drive installation,

Chapter 4 – Start-up and Normal Operation describes safety, installation in-

Appendix A – MD500 Technical Specifications lists input and output voltages,

Appendix C – User Supplied Cables provides details on wire specification and

Appendix D – Intentionally left blank.

Appendix E – PA44 Installation Details provides information on installation,

Appendix F – Intentionally left blank.

MD500 Installation & Start-up Manual 1-1

Intended Audience The audience for this manual has:

• Knowledge of standard electrical wiring practices, electronic

• Thorough understanding of safe operating practice when installing

• Minimal knowledge of DRS PTI product names and terminology.

• No experience or training in installing or operating an MD500.

1-2 MD500 Installation & Start-up Manual

Highlights · Cost effective, 53 in3/kW

MD500 POWER MODULE

Input INPUT MODULE BUCK MODULE CHOKE MODULE INVERTER MODULE

MD500 SYSTEM CONTROL MODULE

SYSTEM STATUS MONITOR CUSTOMER I/O

Figure 2.1 MD500 Drive System — Block Diagram

Descriptions · Power Module

In addition to the diode rectifier, the Input Module consists of:

Refer to Appendix A for Technical Specifications on the MD500 Drive Sys-

2-2 MD500 Installation & Start-up Manual

INPUT MODULE BUCK MODULE CHOKE MODULE

Figure 2.2 MD500 Power Module — System Topology

MD500 Installation & Start-up Manual 2-3

This page has been intentionally left blank.

2-4 MD500 Installation & Start-up Manual

Assembly Name Assembly Number

Table 3.1 DRS PTI Supplied Equipment

MD500 Installation & Start-up Manual 3-1

1 TOP VIEW 2 SIDE VIEW

SYSTEM CONTROL MODULE

SYSTEM CONTROL MODULE

7/16th Speed Screws

Remove four 7/16th hex screws from the four

Figure 3.1 Unpacking Instructions

Table 3.2 Visual Inspection Checklist

· Operating Ambient (-20 0C to +50 0C)

The electronics should be located inside a suitable enclosure conforming to

Mounting The electronics may be mounted in any orientation. However, consideration