rotork AD-8240 User manual

Digital Servo
Amplifiers
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Redefining Flow Control
AD-8140 & AD-8240
Instruction Manual

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Instruction Manual IM-0665
IM-0665
AD-8140 & AD-8240
Digital Servo Amplifiers
Table of Contents
General Information .............................................. 2-3
Installation Wiring .................................................... 3
Specifications ........................................................... 4
Troubleshooting Guide ............................................. 4
Start-up ..................................................................... 5
Major Dimensions .................................................... 6
DIP Switch Charts .................................................... 6
Typical Wiring Diagrams .......................................... 7
Parts Identification .................................................... 8
Due to wide variations in the terminal numbering
of actuator products, actual wiring of this device
should follow the print supplied with the unit.
Instruction Manual
IM-0665
AD-8140 & AD-8240
Digital Servo Amplifiers
Table of Contents
General Information .............................................. 2-3
Installation Wiring .................................................... 3
Specifications ........................................................... 4
Troubleshooting Guide ............................................. 4
Start-up ..................................................................... 5
Major Dimensions .................................................... 6
DIP Switch Charts .................................................... 6
Typical Wiring Diagrams .......................................... 7
Parts Identification .................................................... 8
Due to wide variations in the terminal numbering
of actuator products, actual wiring of this device
should follow the print supplied with the unit.
Instruction Manual
Section Page
General Information 3-4
Installation Wiring 4
Specifications 5
Troubleshooting Guide 5
Start-Up 6
Major Dimensiopns 7
DIP Switch Charts 7
Typical Wiring Diagrams 8
Parts Indentification 9

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Redefining Flow Control
General Information
INTRODUCTION
Rotork Controls, 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 in-stalled
and maintained. The following instructions must be
followed and integrated with your safety program when
installing, using, and maintaining Rotork Controls
products:
•Read and save all instructions prior to installing,
operating, and servicing this product.
•If you do notunderstand any of the instructions,
contact your Rotork Controls representative for
clarification.
•Follow all warnings, cautions, and instructions
marked on, and supplied with, the product.
•Inform and educate personnel in the proper
installation, operation, and maintenance of the
product.
•Install equipment as specified in Rotork 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 Rotork 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
performed 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 discharge (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
immediately to the freight carrier and Rotork Controls,
Inc. Unpack the product and information packet—taking
care to save the shipping carton and packing material
should returnbe 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 (RG) authorization number is
required to return any equipment for repair. This
must be obtained from Rotork Controls
(414/461-9200).
The equipment must be shipped, freight prepaid, to
the following address after the RG number is issued:
Rotork Controls,
5607 West Douglas Avenue
Milwaukee, Wisconsin 53218
Attn: Service Department
To facilitate quick return and handling, include:
RG Number on outside of box
Your Company Name, Contact Person, Phone, Fax
Address
Repair Purchase Order Number
Brief description of the problem
GENERAL INFORMATION
2
INTRODUCTION
Rotork Controls, 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 in-stalled
and maintained. The following instructions must be
followed and integrated with your safety program when
installing, using, and maintaining Rotork Controls
products:
•Read and save all instructions prior to installing,
operating, and servicing this product.
•If you do notunderstand any of the instructions,
contact your Rotork Controls representative for
clarification.
•Follow all warnings, cautions, and instructions
marked on, and supplied with, the product.
•Inform and educate personnel in the proper
installation, operation, and maintenance of the
product.
•Install equipment as specified in Rotork 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 Rotork 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
performed 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 discharge (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
immediately to the freight carrier and Rotork Controls,
Inc. Unpack the product and information packet—taking
care to save the shipping carton and packing material
should returnbe 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 (RG) authorization number is
required to return any equipment for repair. This
must be obtained from Rotork Controls
(414/461-9200).
The equipment must be shipped, freight prepaid, to
the following address after the RG number is issued:
Rotork Controls,
5607 West Douglas Avenue
Milwaukee, Wisconsin 53218
Attn: Service Department
To facilitate quick return and handling, include:
RG Number on outside of box
Your Company Name, Contact Person, Phone, Fax
Address
Repair Purchase Order Number
Brief description of the problem
GENERAL INFORMATION
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General Information
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GENERAL ACTUATOR DESCRIPTION
The AD-8000 series of digital servo amplifiers are
on/off triac output AC servo amplifiers suitable for
operating a variety of Rotork Controls actuators.
Standard features include: onboard switch selectable
command input for 0-5Vdc, 0-10Vdc, or 4-20mA;
selectable loss of command signal operation; 4-20mA
isolated output transmitter tracking actuator shaft
position; dynamic motor braking; 120 to 240Vac, 50/
60Hz input power depending on actuator motor being
used; and on-board LED’s and encoder adjusting knob
for ease of set-up.
The customer’s command signal is isolated from both
the ac line and the electric motor in the actuator. In
addition, the AD-8240 servo amplifiers feature an
isolated, “null” output for customer use.
WARRANTY INFORMATION
Warranty: Subject to the following, Jordan expressly warrants the
products manufactured by it as meeting the applicable Rotork
product specifications and that such products are free from defects
in material and workmanship for a period of one (1) year from the
date of delivery.
The foregoing is the sole and exclusive warranty made by Jordan
with respect to the products. Rotork makes no other warranties,
either express or implied (including, without limitation, warranties
as to merchantability or fitness for a particular purpose).
The purchaser retains responsibility for the application and
functional adequacy of the offering. See Rotork's General
Conditions of Sale - Product,for complete warranty information.
ABBREVIATIONS USED IN THIS MANUAL
A or Amps ........................................................Ampere
ac ................................................... Alternating Current
° C ......................................................Degrees Celsius
CW .............................................................. Clockwise
CCW ...............................................Counterclockwise
dc .........................................................Direct Current
° F ................................................. Degrees Fahrenheit
G ............................................................ Earth Ground
Hz ....................................................................... Hertz
kg ................................................................... Kilogram
L ................................................... Line (power supply)
lbs ..................................................................... Pounds
lbf. ................................................................ Lbs. Force
LVDT .............. Linear Variable Differential Transformer
mA ................................................................. Milliamp
mfd .............................................................Microfarad
mm ............................................................ Millimeters
N ......................................................... Newton (force)
NEMA ........... National Electrical Manufacturing Assoc.
Nm .......................................................Newton Meter
NPT ........................................... National Pipe Thread
Ph .......................................................................Phase
PL ............................................... Position Limit Switch
P/N .......................................................... Part Number
RPM ........................................ Revolutions per Minute
SEC .................................................................. Second
TL .................................................. Thrust Limit Switch
Vac ................................................................... Volts ac
Vdc .................................................................. Volts dc
VR .................................................. Variable Resistance
W ........................................................................ Watt
General Information
Most installations locate the servo amplifier inside a
Rotork Controls actuator, for ease of mounting and to
protect the amplifier. This is the preferred mounting
arrangement. For remote mounting, the servo
amplifier and actuator should be as close to each other
as possible.
Ensure all connections are correct and tight before
applying power. Power, command signal, feedback
signal, and motor output are the minimum required
connections.
To connect optional features refer to wiring diagram
for the specific amplifier and actuator.
Installation Wiring
All wiring should be done in accordance with
prevailing codes by qualified personnel.
Typical wiring diagrams are shown on page 7. Actual
wiring should follow the print supplied with the
actuator.
Fusing must be installed in line with input power, and
should be of the slow blow type. After installation, it is
recommended that all conduits be sealed to prevent
water damage. All low level signal wiring should be a
shielded type with the shield grounded at source
common.
Installation Wiring

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Redefining Flow Control
Specifications
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Specifications
Standard Line Voltage: 120/240Vac, ±10%,
50/60 Hz (Slide switch select)
(Voltage input MUST match
the actuator motor voltage
rating).
Power Consumption: Less than 20 watts for amplifier
functions only.
Voltage Output: Identical to voltage input.
Current Output: 10 amps max. at 120 or 240 Vac.
Fuse protection: Customer supplied. Size based on
actuator controlled and local codes.
Null output (AD-8240): Rated 2 ampers
@120/240Vac, 50/60Hz.
Command Signal Inputs:
• 4-20mA, 4-12mA, 12-20mA into a 200Ωshunt
resistor
• 0-5Vdc into 100,000Ωimpedance
• 0-10Vdc into 100,000Ωimpedance
Position Feedback Signal: 1000Ωpotentiometer
4-20mA (optional on
AD-8240 models only).
Position Output Signal: Isolated 4-20mA, loop
powered with 12-36Vdc
external power supply.
Field Wiring Terminations: Plugable terminal block,
wire size range 26-14
AWG.
Command Signal Monitor: The 8000 series loss-of-
signal circuitry monitors
the command signal
input. If the command
signal drops below or
above the rating, the
actuator will either lock
in place or run to a
preset position (user
selectable).
Limit Signals: Internal: Part of servo control.
Output Shaft Motion: All models can go either
direction on an increasing
command signal. This is
determined by the ZERO and
SPAN settings.
Temperature Limits: -40° to 150° F (-40° to 65° C).
Duty Cycle: Unrestricted modulating duty.
(Cont. duty).
Position Accuracy: 1% of full range.
Deadband: Factory preset to 1%. Field adjustable.
Troubleshooting
For visual troubleshooting, LEDs are provided to display the status of the actuator.
These are located on the same side of the lower board as SW1. The identification of
these LEDs are shown in the table below.
LED Function
MICRO OK This LED flashes when the microprocessor is running. If this is not on, verify
power to the board.
INC This LED is on when the actuator is extending the ouput shaft for linear
actuators, or rotating the output shaft CW for rotary actuators.
DEC This LED is on when the actuator is retracting the ouput shaft for linear
actuators, or rotating the output shaft CCW for rotary actuators
1 Flash - Indicates loss of 4-20 mA signal (LOS).
2 Flashes - Indicates loss of the feedback signal.
3 Flashes - Indicates a stall condition.
L.O.S.
Troubleshooting

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Start-up
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1) Power. Before applying AC power to TB2 set slide
switch to the correct voltage (120/240Vac)
2) Command Calibration. This procedure calibrates the
minimum and maximum command to the unit.
A) Set command signal to low level, normally 4 mA.
B) For AD-8140 amplifiers, depress ZERO
pushbutton (S1) and LOS pushbutton (S4) until
the SPARE LED illuminates. For AD-8240 amplifi-
ers, depress ZERO pushbutton (S1) and LOS
pushbutton (S4) until the LOS LED flashes.
C) Set command signal to high level, normally 20 mA.
D) For AD-8140 amplifiers, depress SPAN
pushbutton (S2) and LOS pushbutton (S4) until
the SPARE LED illuminates. For AD-8240 amplifi-
ers, depress SPAN pushbutton (S2) and LOS
pushbutton (S4) until the LOS LED flashes.
3) Auto/Manual (Option). If the unit has the Auto/
Manual switch option, place it in the auto position.
4) Setpoints. These are the end of travel extremes
corresponding to the actuator output shaft positions
for low (4mA) and high (20mA) command signal
levels. They are set by the ZERO and SPAN
pushbuttons and adjusting knob. All settings require
the holding of a push button and the turning of the
adjusting knob.
A) Set the command signal to lowest level,
normally 4mA.
B) Adjust LO setpoint (ZERO) by holding ZERO push
button (S1) and turning adjusting knob to move
actuator output shaft to desired position. Turn
the adjusting knob CW to extend the ouput shaft
for linear actuators, or rotate the output shaft
CW for rotary actuators. Turn the adjusting knob
CCW to retract the ouput shaft for linear actua-
tors, or rotate the output shaft CCW for rotary
actuators. Release button.
C) Set the command signal to highest level,
normally 20mA.
D) Adjust HI setpoint (SPAN) by holding SPAN push
button (S2) and turning adjusting knob to move
actuator output shaft to desired position. Turn the
adjusting knob CW to extend the ouput shaft for
linear actuators, or rotate the output shaft CW
for rotary actuators. Turn the adjusting knob
CCW to retract the ouput shaft for linear actua-
tors, or rotate the output shaft CCW for rotary
actuators. Release button.
Start-Up
5) Transmitter. This adjustment sets the endpoints of
the 4-20 mA transmitter to account for variations in
accuracy of the input command.
A) Set command signal to low level, normally 4 mA.
B) For AD-8140 amplifiers, depress ZERO
pushbutton (S1) and LOS pushbutton (S4) until
the SPARE LED illuminates. For AD-8240
amplifiers, depress ZERO pushbutton (S1) and
LOS pushbutton (S4) until the LOS LED flashes.
While depressing pushbuttons, turn adjusting
knob CW to increase the 4 mA point, or CCW to
decrease the 4 mA point.
C) Set command signal to high level, normally
20 mA.
D) For AD-8140 amplifiers, depress SPAN
pushbutton (S2) and LOS pushbutton (S4) until
the SPARE LED illuminates. For AD-8240
amplifiers, depress SPAN pushbutton (S2) and
LOS pushbutton (S4) until the LOS LED flashes.
While depressing pushbuttons, turn adjusting
knob CW to increase the 20 mA point, or CCW
to decrease the 20 mA point.
6) Deadband. This adjustment establishes the actuator
servo sensitivity. It is factory set at 1% and should not
be field adjusted. If the actuator begins to oscillate
(Green and Yellow LEDs turn on and off rapidly),
decrease the sensitivity by holding deadband push
button (S3) and turning adjusting knob CW until
oscillation stops. Release button.
Oscillations will result in decreased life of the
unit. Consult Factory.
7) Loss of Signal Preset. This adjustment establishes
the position to which the actuator will travel upon a
loss of command signal condition. To activate this
setting, SW3 must be OFF. Adjust the setting by
holding the LOS push button (S4) and turning the
adjusting knob to set the preset position. Turn the
adjusting knob CW to extend the ouput shaft for
linear actuators, or rotate the output shaft CW for
rotary actuators. Turn the adjusting knob CCW to
retract the ouput shaft for linear actuators, or rotate
the output shaft CCW for rotary actuators.
8) Verify all settings by running the actuator through its
travel range several times.

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Redefining Flow Control
Major Dimensions
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DIP Switch Charts
AD-8240
Major Dimensions
For Remote Mounted AD-8240 Amplifiers
AD-8140
Switch Switch Position Function
ON (Up) Current Command
OFF (Down) 0-5V / 0-10V Voltage Command
ON (Up) 0-5V Voltage Command
OFF (Down) Current / 0-10V Command
ON (Up) LOS Lock-in-Place
OFF (Down) LOS Preset Position
ON (Up) Dynamic Brake On
OFF (Down) Dynamic Brake Off
4
DIP Switch Configurations SW2
1*
2*
3
Switch Switch Position Function
ON (Up) Current Command
OFF (Down) 0-5V / 0-10V Voltage Command
ON (Up) 0-5V Voltage Command
OFF (Down) Current / 0-10V Command
ON (Up) LOS Lock-in-Place
OFF (Down) LOS Preset Position
ON (Up) Dynamic Brake On
OFF (Down) Dynamic Brake Off
ON (Up) Null Output is On When Motor is at Idle
OFF (Down) Null Output is On When Motor is Running
ON (Up) 4-20 mA Feedback (not transmitter output)
OFF (Down) Voltage Feedback
4
5
6
DIP Switch Configurations SW2
1*
2
3
* NOTE:When selecting a current command configuration, Jumper on J4 is between pins 3 and 4. When selecting
a voltage command configuration, Jumper on J4 is between pins 5 and 6, prior to unit power-up.
DIP Switch Charts

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Typical Wiring Diagrams
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Typical Wiring Diagrams
Due to wide variations
in terminal numbering
of actuator products, actual
wiring should follow the print
supplied with the unit.
AD-8140
AD-8240

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Redefining Flow Control
Parts Indentification
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.
ROTORK CONTROLS,
5607 West Douglas Avenue
Milwaukee, Wisconsin 53218
Phone: [phone] FAX:
[phone]
www.rotork.com
IM-0665 04/15
AD-8240
AD-8140
(Location of J1)
With power applied short pins
3, 4 on J1. If done correctly all
l.e.d.s will turn off. This will
restore to factory defaults.
With power applied
short pins 3, 4 on J1.
If done correctly all
l.e.d.s will turn off.
This will restore to
factory defaults.

Rotork plc
Brassmill Lane, Bath, UK
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email [email protected]
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Redefining Flow Control
PUB53-002-00
Issue 04/15
As part of a process of on-going product development, Rotork reserves the right to amend and change
specifications without prior notice. Published data may be subject to change. For the very latest version
release, visit our website at www.rotork.com
The name Rotork is a registered trademark. Rotork recognises all registered trademarks. Published and
produced in the UK by Rotork Controls Limited. POWTG0415
www.rotork.com
A full listing of our worldwide sales and
service network is available on our website.
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