JORDAN CONTROLS AD-7830 Manual

-1-
Instruction Manual
AD-7830 Servo Amplifier
Table of Contents
General Information ................................................. 2
Introduction ....................................................... 2
Receiving/Inspection .......................................... 2
Storage ............................................................... 2
Equipment Return .............................................. 2
Abbreviations Used in This Manual .................... 2
General Description ................................................. 3
Actuator Compatability ....................................... 3
Basic Models ...................................................... 3
Specifications ..................................................... 3
Installation Wiring .................................................... 3
Set-up and Calibration .......................................... 4-5
Component Location ............................................... 6
Troubleshooting Guide ............................................. 7
Typical Wiring Diagrams .......................................... 8
Major Dimensions ............................................... 9-10
IM-0606
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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INTRODUCTION
Jordan Controls, Inc., designs, manufactures, and tests
its products to meet many national and international
standards. For these products to operate within their
normal specifications, they must be properly installed
and maintained. The following instructions must be
followed and integrated with your safety program when
installing, using, and maintaining Jordan Controls
products:
Read and save all instructions prior to installing, operat-
ing, and servicing this product.
If you do not understand any of the instructions,
contact your Jordan Controls representative for clarifi-
cation.
Follow all warnings, cautions, and instructions marked
on, and supplied with, the product.
Inform and educate personnel in the proper installa-
tion, operation, and maintenance of the product.
Install equipment as specified in Jordan Controls
installation instructions and per applicable local and
national codes. Connect all products to the proper
electrical sources.
To ensure proper performance, use qualified personnel
to install, operate, update, tune, and maintain the
product.
When replacement parts are required, ensure that the
qualified service technician uses replacement parts
specified by Jordan Controls. Substitutions may result in
fire, electrical shock, other hazards, or improper
equipment operation, and will void product warranty.
Keep all product protective covers in place (except
when installing, or when maintenance is being per-
formed by qualified personnel), to prevent electrical
shock, personal injury, or damage to the actuator.
WARNING - SHOCK HAZARD
Installation and servicing must be performed only by
qualified personnel.
WARNING - ELECTROSTATIC DISCHARGE
This electronic control is static-sensitive. To protect the
internal components from damage, never touch the
printed circuit cards without using electrostatic dis-
charge (ESD) control procedures.
RECEIVING/INSPECTION
Carefully inspect for shipping damage. Damage to the
shipping carton is usually a good indication that it has
received rough handling. Report all damage immedi-
ately to the freight carrier and Jordan Controls, Inc.
Unpack the product and information packettaking
care to save the shipping carton and any packing
material should return be necessary. Verify that the
items on the packing list or bill of lading agree with
your own.
STORAGE
If the product is not installed immediately, it should be
stored in a clean, dry, non-corrosive environment.
EQUIPMENT RETURN
A Returned Goods authorization (RG) number is
required to return any equipment for repair. This must
be obtained from Jordan Controls (414/461-9200).
The equipment must be shipped, freight prepaid, to
the following address after the RG number is issued:
Jordan Controls, Inc.
5607 West Douglas Avenue
Milwaukee, Wisconsin 53218
Attn: Service Department
To facilitate quick return and handling of your
equipment, include:
RG Number on outside of box
Your Company Name, Contact Person, Phone, Fax
Address
Repair Purchase Order Number
Brief description of the problem
ABBREVIATIONS USED IN THIS MANUAL
AC Alternating Current
DC Direct Current
DIP Dual Inline Package (switch)
Hz Hertz
LED Light Emitting Diode
LOS Loss of Signal
mA Milliamp
NC No Connection
RG Return of Goods
Vac Volts ac
Vdc Volts dc
AD-7830 Servo Amplifier

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GENERAL DESCRIPTION
The AD-7830 servo amplifier is a full-featured device
that provides high performance actuator operation
when matched with a Jordan Controls dc actuator.
Standard features include: selectable command signal
inputs, speed control, over current protection,
undervoltage protection, short circuit protection,
overtemperature protection, a 2 wire, loop powered,
4 - 20mA actuator position output signal, and loss of
current command signal features. The amplifier is
powered from 120/240 Vac, 50/60 Hz, single phase
power supply.
ACTUATOR COMPATABILITY
The AD-7830 servo amplifier can be mounted integral
to all jordan Controls SM/LA-5000 Series 90 and 180
Vdc motor power actuators, or installed remotely for all
other 90 and 180 Vdc motor power actuators.
BASIC MODELS
AD-7830: 120/240 Vac, single phase, 50/60 Hz input
power for integral actuator mounting.
AD-7830-P: Same as above, designed for remote
mounting.
AD-7830-R73: Same as AD-7830, but designed for
remote mounting as a retrofit to the obsolete AD-7300
servo amplifier.
SPECIFICATIONS
Voltage Input: 120 or 240 Vac +/- 10% (switch
selectable), 50/60 Hz, 1-phase. Note: Voltage must be
240 Vac when controlling actuators with 180 Vdc
nameplates.
Current Input: 15 amps maximum continuous; up to
20 amps for brief periods during actuator movement.
Voltage output: Up to 180 Vdc. Factory set (jumper)
for the specific actuator to be controlled. This setting is
either for 90 or 180 Vdc model actuators.
Current ouput: Up to 20 amps for brief periods
during actuator movement.
Command signal input: Field selectable 4 - 20mA
current command into a 200 ohm impedance. 0 to 5,
0 to 10 Vdc or optionally using EC-10844 for -10 to
+10 Vdc command into a 100k ohm impedance.
Position feedback signal: 1000 ohm potentiometer
or 4 - 20 mA, switch selectable. 4 to 20 mA feedback
is normally used for remote amplifier installations.
Other inputs: Position limit switches (2) and torque or
thrust limit switches (2) from actuator. Auto/Manual
switch with increase and decrease capabiity.
Note: When using external Auto/Manual switch, DIP
SWITCH SW1-4 must be set for manual operation on
amplifier.
Position output signal: Loop powered, 2 wire, 4 - 20
mA signal.
Other visual outputs: LEDs for loss of current com-
mand signal (1), actuator driving direction (2) and
null (1).
Approximate Weights: AD-7830-P or R73P: 10 lbs.
AD-7830-E or R73E: 35 lbs.
INSTALLATION WIRING
Most installations locate the servo amplifier inside a
Jordan Controls actuator, for ease of mounting and to
protect the amplifier. This is the preferred mounting
arrangement. For remote mounting, the servo ampli-
fier and actuator should be as close to each other as
possible. For distances exceeding 50 feet, consult
Jordan Controls.
Ensure all connections are correct and tight before
applying power. Power, command signal, feedback
signal and motor output are the minimum required
connections.
 All wiring should be done in accordance with prevail-
ing codes by qualified personnel.
 A typical wiring diagram is shown on page 8 .
Due to wide variations in terminal numbering of
various actuator products, actual wiring should
follow the print supplied with the actuator.
 Fusing must be installed in line power, and should be
of the slow blow type.
 After installation, all conduits must be sealed to
prevent water damage and to maintain enclosure
integrity.
 All low level signal wiring must be shielded type with
the shield grounded at source common.

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SET-UP & CALIBRATION
(See Dip Switch Table on page 5 and component
locations on page 6 for reference)
When placing the amplifier and actuator into
service, the amplifier must be calibrated for the appli-
cation. The servo amplifier is supplied factory cali-
brated when ordered with a Jordan Controls actuator
and should require only minor adjustment.
Read and follow the instructions carefully before
attempting to make adjustments to the servo amplifier.
1. Make sure that the 120 or 240 Vac, single phase,
line power selector switch is in its proper position
(corresponds to the incoming power supply).
Improper selection will cause product failure.
(Located in blue box labled SW1)
2. Check connections. Power should be off and
actuator load disconnected for initial set-up.
Check that the amplifier is properly mounted, that
all connections to the actuator are in accordance
with the correct Jordan Controls wiring diagram,
and that the unit is properly grounded in accor-
dance with all prevailing electric codes. Incorrect
wiring may cause permanent damage to the servo
amplifier and actuator. Verify that the command
signal is connected to the proper terminals. Using
a voltmeter, confirm that the command signal is
present and properly polarized.
3. Verify settings. The DIP SWITCH is located on the
servo amplifier. Refer to the dip switch table on
page 5. Confirm that the switches are properly set
for the intended application. For special applica-
tions not listed, consult factory. Incorrect DIP
SWITCH settings will prevent proper operation.
Again, refer to the wiring diagram supplied with
the actuator for correct switch configuration.
4. Insure that the output voltage jumper on TB1 pins
is in the correct position to correspond with the
actuator nameplate voltage (90 or 180 Vdc). See
page 6 for the location of this jumper.
5. Apply input power.
6. Set ZERO and SPAN. Apply command signal at
minimum input value. For 4-20mA systems this
would normally be 4mA. Adjust potentiometer
(pot) labeled ZERO to move actuator position to
correspond with minimum desired position,
without actuating the end of travel limit switch.
Next apply command signal at maximum input
value. For 4-20mA systems this would normally be
20mA. Adjust pot labeled SPAN to move actuator
position to correspond with maximum 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.
7.SPEED adjust pot must be set to limit the output
voltage to a maximum of either 90 or 180 Vdc to
match actuator nameplate voltage. It may also be
adjusted to reduce this voltage output, slowing
actuator speed to match system dynamics.
WARNING: Do not exceed catalog speed rating.
8. The BALANCE pot is to adjust speed bi-directionally
to compensate for driven load dynamics such as
overhung and backdriving type applications. The
adjustment allows for matching actuator speed in
both directions of travel. To adjust, turn the balance
pot in one direction or the other until the actuator
speed is identical in both directions when under
load.
9. Set DEADBAND pot. Deadband prevents unstable
operation, or hunting. Counterclockwise rotation
of the DEADBAND pot will increase the deadband,
preventing hunting. Clockwise rotation of the pot
will decrease the deadband, improving accuracy.
The correct setting is the point where no hunting
is observed AND when both the green and yellow
LED's go out when the actuator stops.
CAUTION: The deadband must NEVER be ad-
justed to allow both the yellow and green LED's to
be on at the same time. This would result in danger-
ous motor and amplifier overheating and burnout.
10. Set loop GAIN pot. Loop gain is the response and
stability of the actuator/amplifier combination. A
higher GAIN setting will result in better positioning
accuracy, but may cause the actuator to hunt or
oscillate when in NULL, overheating the amplifier
and shortening the actuator life. Clockwise rotation
of the GAIN pot increases the loop gain. With the
amplifier in null (red null LED on and actuator
stopped moving after responding to a command
signal) adjusts the GAIN pot until the actuator JUST
BEGINS to become unstable, or hunts. Then
rotate the pot ONE TURN COUNTERCLOCKWISE.
After setting loop gain, reset the DEADBAND as
described above. It may be necessary to reset the
GAIN and DEADBAND until proper loop response is
achieved.

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11. Loop powered 4-20mA transmitter. This amplifier is
equipped with an on-board loop powered transmit-
ter that can transmit the true actuator output shaft
position in 4-20mA units. The transmitter requires
an external 12-36 Vdc regulated power supply, load
resistor, and indicator; available from Jordan
Controls at extra charge. After wiring is completed
per the wiring diagram shipped with the actuator,
adjustment is as follows: Apply a command signal to
the actuator at the minimum value. For 4-20mA
systems this would normally be 4 mA. After the
actuator moves to position and stops, adjust the pot
labeled 4mA until the indicator displays 4mA. Then
apply a 20mA command signal and wait for the
actuator to move and stop. Then adjust the pot
labeled 20mA until the indicator displays 20mA.
Some interaction of the above pot settings will
require repeating this procedure until proper
accuracy is achieved. Adjustment is complete.
12. Loss of 4-20mA signal. In the event of a loss of
current command signal (LOS), the servo ampli-
fier can be programmed to either lock in place or
go to a preset position. Referring to the DIP
SWITCH TABLE, select one option and position the
DIP SWITCH accordingly. If move to preset
option is selected, the preset position must be
adjusted now.
With the servo amplifier in normal operation,
remove the positive command signal wire from the
amplifier. The LED labled LOS lights, indicating a
loss of command signal, and the actuator will move
to the preset LOS pot setting. Slowly adjust the
LOS pot until the actuator shaft is in the position
desired when loss of command signal occurs.
Reconnect the command signal. Adjustment is
complete.
Note: With Dip Switch 4 in its manual position,
momentary switches S1, S2 and S3 can be used to
manually stroke the actuator. Depressing S1 will cause
the actuator to move in one direction, and depressing
S2 will cause the actuator to move in the opposite
direction. The end of travel limit switches in the
actuator will protect against overtravel in either
direction.
With Dip Switch 4 in its manual or automatic
position, depressing S3 will immediately stop actuator
travel.
Switch Position Function
On 4-20mA Command Signal
Off Not Using 4-20mA Command
On Voltage Command Signal
Off Current Command Signal
On Loss of Signal - Park in Place
Off Loss of Signal - Go to Set Point
On Auto Operation
Off Manual Operation
On 0-5 Vdc Command Signal
Off 0-10 Vdc Command Signal
On 4-20mA Remote Feedback
Off Pot Feedback
On Not Used
Off Not Used
On Not Used
Off Not Used
AD-7830 DIP SWITCH TABLE
1
2
3
8
4
5
6
7

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Component Location
Amplifier Power Board
(Enclosed in Metal Case)
Customer Interface Board
50PinRibbon
Input Voltage
1(Blue Box) Driver Board 68C-038504-001
2Interface Board 68C-035606-001
3Ribbon Cable 25A-035285-002
Spare Parts List

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Troubleshooting Guide
Trouble Possible Cause Remedy
a. No power to amplifier a. Restore power
b. Amplifier is defective b. Replace amplifier
c. Amplifier is in Loss of Signal mode
(Red LOS LED is on) c. Restore command signal
d. Actuator/amplifier is wired
incorrectly
d. Correct per wiring diagram furnished
with unit
e. Amplifier deadband is too wide e. Reduce deadband setting
f. Dip Switches not properly set f. Set Dip Switches per Dip Switch table
a. Zero and span pots not properly adjusted a. Adjust per set-up and calibration
instructions
b. Actuator position limit switch activated b. Limit switches must be set to trip just
outside of zero and span set points
c. Dip Switches not properly set c. Set Dip Switches per Dip Switch Table
d. Actuator torque or thrust limit switch
activated d. Determine cause for overload and correct
a. Deadband is too narrow a. Increase deadband setting
b. Command signal is too noisy b. Command signal wiring must be shielded
with shield grounded at source common only
a. Speed pot not properly adjusted a. Adjust speed pot as required but not faster
than catalog ratings
b. Bal pot needs adjustment b. Adjust Bal pot as required
a. Input voltage selector switch not in
correct position a. Correct position as required
b. 180 Vdc actuators must have 240 Vac
input to amplifier b. Insure proper power supply is available
c. Amplifier output voltage jumper selector
in wrong position c. Correct jumper position
a. Mechanical binding in actuator or driven
load a. Repair/replace as needed
b. Inadequate voltage to actuator b. Refer to installation wiring and set-up &
calibration procedures in this manual
Amplifier burned up at power-up a. Power connected to wrong terminals a. Replace amplifier and wire per wiring diagram
furnished with equipment.
a. Incorrect external wiring. a. Make sure power supply is in sequence with
transmitter.
b. Incorrect external power supply. b. Measure power supply output volatage.
No 4- 20 mA output
Amplifier output voltage does not match
actuator nameplate voltage
Actuator does not pull load
Motor does not operate
Actuator does not go full stroke
Yellow and Green LEDs stay on around
null or at null
Actuator stroking speed is too fast or too
slow for application in one or both
directions

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Wiring Diagrams
With AD-7830 Integral to Actuator
With AD-7830 Remote from Actuator
Notes:
1. 240 Vac input is required where actuator nameplate voltage
is 180 Vdc.
2. 24 Vdc power supply is required.
3. VRI potentiometer signal requires conversion to 4-20mA
signal at actuator with 24 Vdc loop power when amplifier
distance from actuator exceeds 50 feet of wiring.
Notes:
1. 240 Vac input is required where
actuator nameplate voltage is 180 Vdc.
2. 24 Vdc power supply is required.
3. When using external Auto/Manual
switch, DIP SWITCH SW1-4 must be
set for manual operation on amplifier.
Due to wide variations
in terminal numbering
of actuator products, actual
wiring should follow the print
supplied with the actuator.
Note 1
Note 2
Note 3

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AD-7830-P - Amplifier Mounted on a Panel
Major Dimensions
AD-7830-R73P
Retro-fit for AD-7300 Series

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NOTES:
1. When the AD-7830 series amplifier is remotely located, consult factory when distance to
actuator exceeds 50 feet of wire run distance.
2. Shielded wiring is required with the shield grounded at source common for all low level circuits.
This includes command & feedback signals and position torque limit switches.
Major Dimensions (Remote Mount)
AD-7830-E Installed in remote enclosure
NEMA 4
These dimensions 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: [phone]
FAX: [phone]
E-Mail: [email protected]
IM-0606 2/00