Instruction Manual

IM-0607

AD-8100 & AD-8200 Servo Amplifiers

Table of Contents
General Information ................................................. 2
Basic Models ............................................................ 3
Specifications ........................................................... 3
Installation Wiring .................................................... 3
Setup & Calibration ............................................... 4-6
Troubleshooting Guide ............................................. 7
Typical Wiring Diagrams ..................................... 8-12
AD-8130/EC-10835 Physical Layout ....................... 13
AD-8230/EC-10836 Physical Layout ....................... 14
Major Dimensions .................................................. 15

WARNING
Failure to properly wire torque/thrust
switches will result in actuator damage.
Refer to the specific wiring diagram supplied
with your actuator for correct wiring.

Due to wide variations in the terminal numbering

of actuator products, actual wiring of this device
should follow the print supplied with the unit.

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 GENERAL INFORMATION
INTRODUCTION RECEIVING/INSPECTION
Jordan Controls, Inc., designs, manufactures, and tests its Carefully inspect for shipping damage. Damage to the
products to meet many national and international shipping carton is usually a good indication that it has
standards. For these products to operate within their received rough handling. Report all damage immediately
normal specifications, they must be properly installed and to the freight carrier and Jordan Controls, Inc.
maintained. The following instructions must be followed
and integrated with your safety program when installing, Unpack the product and information packet—taking care
using, and maintaining Jordan Controls products: to save the shipping carton and any packing material
should return be necessary. Verify that the items on the
• Read and save all instructions prior to installing, packing list or bill of lading agree with your own.
operating, and servicing this product.
STORAGE
• If you do not understand any of the instructions, contact
your Jordan Controls representative for clarification. If the product will not be installed immediately, it should
be stored in a clean, dry area where the ambient
• Follow all warnings, cautions, and instructions marked temperature is not less than -20° F, and is a non-corrosive
on, and supplied with, the product. environment.

• Inform and educate personnel in the proper installation, EQUIPMENT RETURN

operation, and maintenance of the product.
A Returned Goods authorization (RG) number is required
• Install equipment as specified in Jordan Controls to return any equipment for repair. This must be obtained
installation instructions and per applicable local and from the Jordan Controls Service Department. (Telephone:
national codes. Connect all products to the proper 414/461-9200) The equipment must be shipped, freight
electrical sources. prepaid, to the following address after the RG number is
issued:
• To ensure proper performance, use qualified personnel
Jordan Controls, Inc.
to install, operate, update, tune, and maintain the
5607 West Douglas Avenue
product.
Milwaukee, Wisconsin 53218
Attn: Service Department
• When replacement parts are required, ensure that the
qualified service technician uses replacement parts To facilitate quick return and handling of your equipment,
specified by Jordan Controls. Substitutions may result in include:
fire, electrical shock, other hazards, or improper RG Number on outside of box
equipment operation, and will void product warranty. Your Company Name, Contact Person, Phone/Fax number
Address
• Keep all product protective covers in place (except Repair Purchase Order Number
when installing, or when maintenance is being Brief description of the problem
performed by qualified personnel), to prevent electrical
shock, personal injury, or damage to the actuator. ABBREVIATIONS USED IN THIS MANUAL
WARNING - SHOCK HAZARD AC Alternating Current
DC Direct Current
Installation and servicing must be performed only by DIP Dual Inline Package (switch)
qualified personnel. Hz Hertz
LED Light Emitting Diode
WARNING - ELECTROSTATIC DISCHARGE LOS Loss of Signal
mA Milliamp
This electronic control is static-sensitive. To protect the NC No Connection
internal components from damage, never touch the RG Return of Goods
printed circuit cards without using electrostatic discharge Vac Volts ac
(ESD) control procedures. Vdc Volts dc

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 GENERAL DESCRIPTION
The AD-8000 series of servo amplifiers are on/off triac SPECIFICATIONS
output AC servo amplifiers suitable for operating a variety
of Jordan Controls actuators. Standard features include on- POWER:
board switch selectable command input for 0-5 Vdc, 0-10 Voltage Input: 120 or 240 Vac, 50 or 60 Hz, single phase
Vdc, or 4-20mA; selectable loss of command signal (Voltage input must match actuator motor voltage
operation; 4-20mA isolated output transmitter tracking rating)
actuator shaft position; dynamic motor braking; 120 or 240 Power Consumption: less than 20 watts for amplifier
Vac, 50/60 Hz. input power depending on actuator motor functions only
being used; and on-board LED's and adjustment pots for Voltage Output: identical to voltage input
ease of set-up. The customer's command signal is isolated Current output: 10 amps maximum at 120 or 240 Vac
from both the ac line and the electric motor in the Fuse protection: customer supplied. Size based on
actuator. actuator controlled, and local codes
Null output (AD-8230): rated 2 amperes @ 120 or
In addition, the AD-8230 servo amplifiers features an 240 Vac, 50 or 60 Hz
isolated, “null” output for customer use. The amplifier will
output line voltage AC, or half wave DC, when the COMMAND SIGNAL INPUTS, FIELD SELECTABLE:
actuator is stopped, or when running - selectable by the 4-20mA current command into a 200 ohm impedance
customer. 0 to 5 or 0 to10 vdc voltage command into a
100,000 ohm impedance
BASIC MODELS 1000 ohm potentiometer command is an option on the
AD-8230/EC-10836 model only
AD-8130: For integral installation on all Jordan AC
powered 1100, 1700, 2400 and 5100 Series actuators POSITION FEEDBACK SIGNAL:
1000 ohm potentiometer
AD-8130/EC-10835: For direct replacement of AD-8850 4 to 20mA (optional on AD-8230/EC-10836
and AD-8860 models only)

AD-8230: For integral installation on all Jordan AC POSITION SIGNAL OUTPUT: Isolated, 2 wire,
powered 1500, 1600 and 3330 Series actuators 4 to 20mA signal

AD-8230/EC-10836: For new installations requiring remote APPROXIMATE WEIGHTS:

servo amplifier installation or for direct replacement of AD-8130, AD-8230 & AD-8230/EC-10842 - 2 lbs. (0.9
existing AD-8813, AD-8823, AD-8833 and AD-8843 series kg)
amplifiers. Also used as an integral amplifier with Jordan AD-8130/EC-10835 & AD-8230/EC-10836 - 4 lbs. (2 kg)
SM-5220 actuator. with enclosure “E” - 25 lbs. (11 kg)
with enclosure “X” - 40 lbs. (18 kg)
AD-8230/EC-10842: For replacement of all AD-8210 and
AD-8220 Series amplifiers. (Same as AD-8230, except with
a wire harness and molex connectors)

INSTALLATION WIRING
Most installations locate the servo amplifier inside a Jordan • Typical wiring diagrams are shown on pages 8 thru 12.
actuator, for ease of mounting and to protect the amplifier.
This is the preferred mounting arrangement. For remote Actual wiring should follow the print supplied with the
mounting, the servo amplifier and actuator should be as actuator.
close to each other as possible.
• Fusing must be installed in line power, and should be of
Ensure all connections are correct and tight before the slow blow type.
applying power. Power, command signal, feedback signal,
and motor output are the minimum required connections. • After installation, it is recommended that all conduits be
To connect optional features for electromagnetic brake sealed to prevent water damage.
control or optional indicator lights, refer to the wiring
diagram for the specific amplifier and actuator. • All low level signal wiring should be a shielded type
with the shield grounded at source common.
• All wiring should be done in accordance with
prevailing codes by qualified personnel.

3
SET-UP & CALIBRATION sealed at the factory at 0.1% of the control signal span,
and this setting will normally be satisfactory. Should
When placing the amplifier and actuator into service, the the deadband need to be increased, counterclockwise
amplifier must be calibrated for the application. The servo rotation of the DEADBAND pot will increase the
amplifier is supplied factory calibrated when ordered with deadband, preventing “hunting”. Clockwise rotation of
a Jordan Actuator and should require only minor the pot will decrease the deadband. The correct
adjustment. setting is the point where no “hunting” is observed
AND when both the green and yellow LED's go out
Read and follow the instructions carefully before when the actuator stops.
attempting to make adjustments to the servo amplifier. CAUTION: The deadband must NEVER be adjusted
to allow both the yellow and green LED's to be on at
1. First, be sure that the line power to the actuator the same time. This will result in dangerous
matches the actuator nameplate. Improper input overheating and burnout.
voltage will cause the actuator to misperform. The
amplifier voltage selector switch must be in the correct 7. Loss of signal. In the event of a loss of command
position for the motor voltage being used. Refer to the signal (“LOS”), the servo amplifier can be programmed
actuator nameplate for correct voltage to apply. to either lock in place or go to a customer adjusted
Operating voltage changes cannot be made simply by preset position. Loss of signal feature is only available
changing the position of the amplifier voltage switch. when using 4-20mA command signal. This feature is
normally factory supplied in the lock-in-place
2. Check connections. POWER SHOULD BE OFF. Check selection. A signal level below 3mA results in a loss of
that the amplifier is properly mounted, that all signal detection by the servo-amplifier. Refer to the
connections to the actuator are in accordance with the DIP SWITCH chart on pages 5 and 6 to select desired
correct Jordan Controls wiring diagram, and that the operation. Then, with the servo amplifier in normal
unit is properly grounded in accordance with all operation, apply a command signal below the
prevailing Electric Codes. Incorrect wiring may cause minimum 3 mA position. If lock-in-place is selected
permanent damage to the servo amplifier and actuator. the actuator should stop and the red LOS LED should
Verify that the command signal is connected to the light. If “move to preset” is selected, rotate the LOS
proper terminals. Using a voltmeter, confirm that the pot until the actuator moves to the desired position
command signal is present and properly polarized. and stops. Reapply and then remove the command
Dynamic braking is standard on this amplifier and, signal several times to verify correct operation.
when used, reduces coasting and improves positioning 8. Loop powered 4-20mA transmitter. This amplifier is
accuracy by applying a braking action to the motor equipped with an on-board two wire transmitter that
during stopping. Dynamic braking must be selected transmits the true actuator output shaft position and
“on” or “off” prior to making any amplifier requires an external 12 to 36 Vdc power supply.
adjustments. The dynamic brake functions by Adjustment is as follows: Apply a command signal to
energizing both motor windings for a fraction of a the actuator at the minimum value. For 4-20mA
second. Select either “on” or “off” using the systems this would normally be 4mA. After the
appropriate DIP switches. actuator moves to position and stops, adjust the pot
3. Verify DIP switch settings. Refer to the DIP switch labeled 4mA until the indicator displays 4mA. Then
location and table on pages 5 and 6 for the specific apply a 20mA command signal and wait for the
amplifier being adjusted. Confirm that the switches are actuator to move and stop. Then adjust the pot labeled
properly set for the intended application. For special 20mA until the indicator displays 20mA. Repeat this
applications not listed, consult factory. Incorrect DIP procedure until the desired accuracy is achieved.
SWITCH settings will prevent proper operation. Check 9. Switched null output:The AD-8230 is equipped with a
position of the null output jumper P1 and verify that it TRIAC that will switch line voltage to a customer
is in the correct position. available connection. This feature may be used to
4. NOW APPLY POWER. operate a brake in the actuator or to light remote
indicating lights. If used for an internal
5. Set HI TRIM and LO TRIM. Apply command signal at electromagnetic brake, proper adjustment and set-up
minimum input value. For 4-20mA systems this would was performed at the factory. For remote indicating
normally be 4mA. Adjust pot labeled LO TRIM to lights, this feature can be configured for either AC or
move actuator position to correspond with minimum DC output, and to be ON when either the motor is
desired position without actuating the end-of-travel running or when it is idle. A jumper on the printed
limit switch. Next apply command signal at maximum circuit board indicates the output as AC or DC. Refer
input value. For 4-20mA systems this would normally to the DIP SWITCH chart to select the output as either
be 20mA. Adjust pot labeled HI TRIM to move ON when the actuator is running, or ON when it is
actuator position to correspond with maximum idle.
desired position without actuating the end-of-travel
limit switch. Some interaction of the above pot settings
will require repeating this procedure until proper
accuracy is achieved.

6. Set DEADBAND. Deadband prevents unstable

operation, or “hunting”. The deadband pot is torque

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 AD-8130
SET-UP AND CALIBRATION
SW2 DIP SWITCH TABLE COMPONENT SIDE

SWITCH POSITION FUNCTION

0-5 VDC OR 4-20mA

ON
COMMAND INPUT
1
0-10 VDC VOLTAGE
OFF
COMMAND INPUT

0-10 VDC OR
ON
2 4-20mA COMMAND INPUT

OFF 0-5 VDC VOLTAGE COMMAND INPUT

ON LOSS OF SIGNAL - OFF

3
OFF LOSS OF SIGNAL - ON

MOVE TO PRESET POSITION

ON
ON LOSS OF SIGNAL
4
DO NOT MOVE TO PRESET
OFF
ON LOSS OF SIGNAL NOTE: When retrofitting the AD-8130 to replace models
ON LOCK IN PLACE ON LOSS OF SIGNAL AD-8110 or AD-8120, note that the actuator mating
5 connector for TB1 is a 6 pin connector that should
DO NOT LOCK IN PLACE
OFF
ON LOSS OF SIGNAL
engage pins 1 through 6 only. Pins 7 and 8 are 4-20mA
outputs for new installations and are not used for
ON DYNAMIC BRAKE ON replacements. (Note location of pin 1 on above drawing;
6
OFF DYNAMIC BRAKE OFF
pins are numbered left to right.) Contact factory if your
connectors are located on the component side of the
0-5 OR 0-10 VOLTAGE board.
ON
7 COMMAND INPUT

OFF 4-20mA COMMAND INPUT

NOTE: When using loss of signal, if DIP switches 4 and 5 are in their on
position, the loss of signal action will be lock in place.

COMPONENT LOCATION
(Looking at component side of board)

5
 AD-8230
SET-UP AND CALIBRATION
SW1 DIP SWITCH TABLE ON-BOARD JUMPER SETTING
CONTROLS NULL OUTPUT ONLY
SWITCH POSITION FUNCTION
ON 0-5 VDC OR 4-20mA COMMAND INPUT JUMPER
1 NULL OUTPUT RESULT
OFF 0-10 VDC VOLTAGE COMMAND INPUT POSITION
0-10 VDC OR 4-20mA AC* LINE VOLTAGE
ON
2 COMMAND INPUT DC HALF WAVE dc
OFF 0-5 VDC VOLTAGE COMMAND INPUT *Must be in ac position when used with 3330 model series actuator
ON LOSS OF SIGNAL - OFF equipped with EC-10678 Brake Module.
3
OFF LOSS OF SIGNAL - ON
ON MOVE TO PRESET ON LOSS OF SIGNAL
4 DO NOT MOVE TO PRESET
OFF
ON LOSS OF SIGNAL
ON LOCK IN PLACE ON LOSS OF SIGNAL
5 DO NOT LOCK IN PLACE
OFF
ON LOSS OF SIGNAL
ON DYNAMIC BRAKE ON
6
OFF DYNAMIC BRAKE OFF
0-5 OR 0-10 VOLTAGE
ON
7 COMMAND INPUT
OFF 4-20mA COMMAND INPUT

8
ON
NULL OUTPUT IS ON WHEN
MOTOR IS RUNNING
NULL OUTPUT IS ON WHEN
Caution
OFF*
MOTOR IS IDLE Dip Switch 8 & 9 must be off when no
NULL OUTPUT IS ON WHEN
ON*
MOTOR IS IDLE connections are made to TB2-7 and TB2-8.
9
NULL OUTPUT IS ON WHEN
OFF
MOTOR IS RUNNING
*Must be in these positions when used with 3330 model actuators.

COMPONENT LOCATION
(Looking at component side of board)

6
 TROUBLESHOOTING GUIDE

TROUBLE POSSIBLE CAUSE REMEDY

1. Motor does not operate a) No power to amplifier a) Restore power

b) Amplifier is in Loss-of-Signal b) Check command signal
(LED3 is on)
c) Amplifier deadband is too wide c) Reduce deadband setting
d) Actuator is wired incorrectly d) Correct per wiring diagram
e) Amplifier is defective e) Replace with new amplifier

2. Motor moves in only one direction a) Motor and feedback potentiometer a) For AD-8130, reverse potentiometer
are out of phase or no control leads at TB1-4 & 6 molex connector
(see illustration below); for AD-8230
reverse potentiometer leads at
TB1-4 & 6 terminal strip
b) Amplifier is defective b) Replace with new amplifier

3. LED’s stay on around null or at null a) Deadband is too narrow a) Increase deadband settings
b) Command signal is too noisy b) Shield command signal wires

AD-8130 MOLEX CONNECTOR

(Shown larger than actual)

Procedure to change leads in molex connectors (AD-8130 only).

1. With a small screwdriver, depress tang in the small 2. Gently bend the tangs outward with a small
rectangular opening on the connector, and gently screwdriver or knife blade to ensure they will lock
remove wires corresponding to pins 4 and 6. Note tightly when reinserted into the connector block.
wire colors so they can be reversed in step 3. 3. Reverse lead wire color from original location and
reinsert back into the connector block.

7
TYPICAL WIRING DIAGRAMS
AD-8130 INTERCONNECT WIRING

8
TYPICAL WIRING DIAGRAM
AD-8130/EC-10835 INTERCONNECT WIRING
(REPLACEMENT FOR AD-8850 AND AD-8860)

9
TYPICAL WIRING DIAGRAM
AD-8230 INTERCONNECT WIRING

10
 TYPICAL WIRING DIAGRAM
AD-8230/EC-10842
(REPLACEMENT FOR AD-8210, AD-8220 AND AD-8210-1001)

NOTE: When replacing AD-8210 or AD-8220 with this amplifier,

remove and relocate field wiring as follows:

*These terminals will only have field wiring when 4 to 20mA position
AD-8210/AD-8220 TERMINAL AD-8230 TERMINAL feedback signal transmitter (ST-4130) is used.
1* Move to TB1-8 **Command signal ground shield should be grounded at source common
and left “floating” at AD-8230.
3* Move to TB1-7

4 Move to TB1-2

5 Move to TB1-1

6 None**

7 Move to TB2-3

8 Move to TB2-2

9 Move to TB2-1

11
 TYPICAL WIRING DIAGRAMS
AD-8230/EC-10836
(REPLACEMENT FOR AD-8813, AD-8823, AD-8833 AND AD-8843)
(Also used as an integral amplifier in Jordan model SM-5220 actuators)

4 to 20mA POSITION FEEDBACK SIGNAL

NOTE: The above diagram illustrates 4 to 20mA position feedback signal with customer supplied loop power. An optional
24 Vdc loop power supply is also available from Jordan. Refer to the wiring diagram furnished with the actuator for special
calibration instructions when 4 to 20mA feedback is furnished.

12
AD-8130/EC-10835 PHYSICAL LAYOUT

13
AD-8230/EC-10836 PHYSICAL LAYOUT

14
 MAJOR DIMENSIONS
AD-8230/EC-10836 INSTALLED IN REMOTE ENCLOSURE

NEMA 7 & 9

15
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 The dimensions in this manual are subject to change without notice and should
not be used for preparation of drawings or fabrication of installation mounting.
Current installation dimension drawings are available upon request.

JORDAN CONTROLS, INC.

5607 West Douglas Avenue
Milwaukee, Wisconsin 53218
Phone: (414) 461-9200
FAX: (414) 461-1024
E-Mail: jordan@jordancontrols.com
www.jordancontrols.com
IM-0607 5/00

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