NuWave SSRMAN-1BFS Series User manual

Rev.1.5 06/18
COPYRIGHT 2013 NUWAVE TECHNOLOGIES,INC.
SSRMAN-1BFS SERIES USERS MANUAL
FAST SYNCHRONOUS BURST FIRING MODULE

SSRMAN-1BFS Users Manual Page 2
Copyright 2013 NUWAVE TECHNOLOGIES,INC.
TABLE OF CONTENTS
1. Ordering Codes .................................................................................................................................................2
2. Description.........................................................................................................................................................2
2.1 Features....................................................................................................................................................3
3. Installation / Safety Information .........................................................................................................................3
3.1 Solid State Relay Installation ....................................................................................................................3
3.2 Mounting Instructions................................................................................................................................ 4
3.3 Electrical Connections ..............................................................................................................................4
3.3.1 Internal Diagram...............................................................................................................................4
3.4 Limited Warranty.......................................................................................................................................4
4. Operation...........................................................................................................................................................5
4.1 Power Supply............................................................................................................................................5
4.2 24V Power Fusing.....................................................................................................................................5
4.3 Command Input........................................................................................................................................5
4.3.1 Input Fail-safe Protection.................................................................................................................5
4.4 Cycle Times..............................................................................................................................................5
4.5 Cycle Times –266mS Selection (Fast Synchronous Burst Firing)...........................................................7
4.5.1 Fast Synchronous Burst Firing Mode...............................................................................................7
4.5.2 Fast Synchronous Burst Firing Advantages.....................................................................................8
4.6 Line Voltage Compensation (-LVC Option)...............................................................................................8
4.7 Power Limit...............................................................................................................................................9
4.7.1 Power Limit Adjustment Procedure..................................................................................................9
4.8 Configuration Dipswitch............................................................................................................................9
4.9 Control Output.........................................................................................................................................10
4.10 Output LED.............................................................................................................................................10
4.11 Three Phase Operation...........................................................................................................................11
4.11.1 Three Phase Special Wiring Considerations .................................................................................11
4.12 Wiring Multiple Units...............................................................................................................................11
4.12.1 Connecting Power & Commands in Parallel..................................................................................11
5. Electrical Specifications................................................................................................................................... 12
6. Mechanical Dimensions...................................................................................................................................12
7. Contact Information.........................................................................................................................................12
8. WIRING DIAGRAM (4-20mA, 0-5V, 0-10V Inputs).........................................................................................13
9. WIRING DIAGRAM (Potentiometer Input) ...................................................................................................... 13
10. WIRING DIAGRAM (0-135 Ohm Input) ......................................................................................................14
11. WIRING DIAGRAM 3 PHASE DELTA –Zero Crossing .............................................................................14
12. WIRING DIAGRAM 3 PHASE 4 WIRE Y –Zero Crossing.........................................................................15
1. Ordering Codes
Ordering Codes SSRMAN-1BFS-___
SSR Control Module
Single Pole
Fast Synchronous Burst Firing
-PL (Power Limit)
-135 (135 Ohm Input)
-LVC (can be used w/-PL
2. Description
The SSRMAN-1BFS is a zero cross burst firing control module designed for use with
standard footprint random fire SSRs (Solid State Relays). The module mounts directly on
the SSR’s input screws. The module operates by varying duty cycle of SSR’s control input
synchronous to the AC line. The power delivered to the load is proportional to the
command input signal. The SSRMAN-1BFS is factory programmed for the desired cycle
time. The cycle time is specified in the ordering code as the number of cycles, since it is
synchronous to the AC power line.

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Copyright 2013 NUWAVE TECHNOLOGIES,INC.
2.1 Features
•Command input accepts 4-20mA, 0-10V, 0-5V, 0-135 , Potentiometer
•Fast Sychronous Burst Algorithm provides true linear power at fast cycle times
•Drives multiple solid state relays (SSRs)
•Small (1.75x1.40”) module mounts on the input terminals of an inexpensive SSR
•Fits under finger-safe covers
•LED output indicator
•Adjustable Power Limit (-PL) Option
•Single phase and three phase control
3. Installation / Safety Information
Responsibility for determining suitability for use in any application / equipment lies solely on
the purchaser, OEM and end user. Suitability for use in your application is determined by
applicable standards such as UL, cUL and CE and the completed system involving this
component should be tested to those standards.
WARNING: FIRE HAZARD!! Even quality electronic components
CAN FAIL KEEPING FULL POWER ON! Provide a SEPARATE (redundant) OVER
TEMPERATURE SHUTDOWN DEVICE to switch the power off if safe temperatures are
exceeded.
WARNING: HIGH VOLTAGE!! This control is installed on a Solid State
Relay with high voltage on it. This control must be installed in a GROUNDED enclosure by
a qualified electrician in accordance with applicable local and national codes including NEC
and other applicable codes. Provide a safety interlock on the door to remove power before
gaining access to the device.
3.1 Solid State Relay Installation
Make sure that the voltage and current ratings of the Solid State Relay
(SSR) are sized correctly for the load, otherwise a hazardous condition such as
over-heating, failure of the SSR, fire or explosion may result. Contact the SSR
manufacturer for more details.
The SSR must be mounted to a heat sink as per the SSR
manufacturers requirements otherwise a hazardous condition such as over-
heating, failure of the SSR, fire or explosion may result. Contact the SSR
manufacturer for more details.

SSRMAN-1BFS Users Manual Page 4
Copyright 2013 NUWAVE TECHNOLOGIES,INC.
3.2 Mounting Instructions
The SSRMAN mounts directly to the control input terminals of an
SSR using two #6-32 screws. Some relays have short input
screws and longer screws will required to reach through the
contacts on the SSRMAN.
Be sure to observe the correct polarity when mounting the module
(module should be positioned over the SSR). The module should
sit firmly on top of the SSR when the screws are tightened.
3.3 Electrical Connections
See the WIRING DIAGRAMS at the end of this
document. Make sure the module ordered is
the correct module for the application before
wiring.
Before wiring the module all Dip Switch
settings for the command input and special
features should be setup properly per the
Dipswitch Configuration Section.
The terminal blocks on the sides of the
SSRMAN for connecting 24V Power and the
command signal can accept 16-30 AWG wire.
3.3.1 Internal Diagram
Please reference the internal diagram below to be absolutely sure that the system wiring
will be compatible with the control module.
3.4 Limited Warranty

SSRMAN-1BFS Users Manual Page 5
Copyright 2013 NUWAVE TECHNOLOGIES,INC.
NuWave Technologies, Inc. warrant this product to be free from defect in workmanship and
materials for a period of two (2) years from the date of purchase.
1. Should unit malfunction, return it to the factory. If defective it will be repaired or
replaced at no charge.
2. There are no user serviceable parts on this unit. This warranty is void if the unit shows
evidence of being tampered with or subjected to excessive heat, moisture, corrosion or
other misuse / misapplication.
3. Components which wear or damage with misuse are excluded, e.g. relays.
4. NuWave Technologies, Inc. shall not be responsible for any damage or losses however
caused, which may be experienced as a result of the installation or use of this product.
NuWave Technologies, Inc. liability for any breach of this agreement shall not exceed
the purchase price paid E. & O.E.
4. Operation
4.1 Power Supply
The SSRMAN-1BFS power requirement is 24V AC +/-15% 47-63Hz
4.2 24V Power Fusing
Fusing may be accomplished by fusing each module separately or fusing groups of the
modules with either primary or secondary fusing. The current draw of each SSRMAN-
1BFS is 65mA max.
4.3 Command Input
The SSRMAN-1BFS can accept 4-20mA, 0-10V, 0-5V, and Potentiometer. The
SSRMAN-1BFS-135 can only accept a 0-135 Input. All command inputs are not
isolated from the 24V power input; they share a common ground. The type of command
input can be configured via the dipswitch. The default setting is 0-5V/potentiometer.
When wiring multiple SSRMAN-1BFS units together, follow the guidelines in the Wiring
Multiple SSRMAN-1BFS section.
Any leg of the command input can tolerate shorts to the (0V) input. Connecting the 24V
power to the command input will cause damage to the unit.
When 4-20mA is selected via the dipswitch, a 249 Ohm shunt resistor is present at the
command input between the 0V and IN terminals. Be sure not to exceed 20mA DC on
the input as damage to the unit may result. If the command input is wired to a 0-20mA or
4-20mA output of another device, the 0V terminal must remain at the same potential as
the negative lead of the current output from the other device, otherwise damage to the
SSRMAN may result.
4.3.1 Input Fail-safe Protection
If the signal sent to the SSRMAN-1BFS’ command input should become electrically open
the control output will be forced to an off or less than 5% output power state.
4.4 Cycle Times
The cycle time refers to the total time between an on and off cycle.

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Copyright 2013 NUWAVE TECHNOLOGIES,INC.
The SSRMAN-1BFS has 4 available cycle times settable via the dipswitches.
The cycle times are specified below in # of cycles and can be correlated to their
respective times using the table below for both 50 and 60 Hz Line frequencies (note that
the –LVC option only has the fast burst firing cycle time and the dipswitch is disabled):
Dip
Switch
6
Dip
Switch
4
#of
cycles
Cycle
Time
(60Hz)
Cycle
Time
(50Hz)
Resolution
( % of FS)
*OFF
*OFF
~16
266mS
320mS
~1%
ON
OFF
60
1S
1.2S
1.66%
OFF
ON
600
10S
12S
0.166%
ON
ON
6000
100S
120S
0.0166%

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Copyright 2013 NUWAVE TECHNOLOGIES,INC.
*Synchronous Firing Method
When burst firing AC with conventional PWM, there is a tradeoff between resolution and
cycle time. Generally the cycle time should be chosen based on the mass of the load to
be controlled; the larger the load mass, the longer the cycle time can be. For the best
possible resolution, its standard practice to choose the longest cycle time that can be
used without causing process ripple. Longer cycle times generally provide greater control
resolution, but the Fast Synchronous Burst setting provides excellent resolution at a fast
cycle time.
4.5 Cycle Times –266mS Selection (Fast Synchronous Burst Firing)
When the SSRMAN-1BFS cycle time is set to 266mS (320mS @ 50Hz) the Fast
Synchronous Burst Firing mode is turned on. The cycle time becomes longer near zero
and full power levels to provide improved control resolution. For Example, since the
SSRMAN-1BFS generally modulates 16 AC cycles, the lower limit in power that will
maintain the cycle time is 1/16 or 6.25%. The SSRMAN-1BFS will use increased off
periods below 6.25% power and above 94.75% power.
4.5.1 Fast Synchronous Burst Firing Mode
As shown below, the SSRMAN-1BFS Fast Synchronous Burst Firing mode selectively
fires fractional numbers of cycles. Since pulse width modulation alone would limit the
resolution to 16 steps or 6.25% when modulating 16 AC cycles, a proprietary algorithm is
employed to provide improved resolution of 0.5-1%. In this firing mode, the cycle time is
varied as well as the on time. To select the Fast Synchronous Burst Firing Mode set
Diswitches 1 and 3 to the off position.

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Copyright 2013 NUWAVE TECHNOLOGIES,INC.
4.5.2 Fast Synchronous Burst Firing Advantages
The two plots below are actual data for a 425 degF capable 10KW resistive heater
ramped from 0-100% power over two hours. The first plot shows straight 16 cycle,
266mS cycle time PWM. Note the nonlinearity humps due to poor resolution. The
second plot shows the linearity improvement with the Fast Synchronous Burst. Any
visible overall curvature is a normal heater characteristic.
h:min:s 17:30:0017:55:0018:20:0018:45:0019:10:00
450
400
350
300
250
200
150
100
50
Fast PWM of zero cross fired loads can result in poor linearity / resolution (above)
h:min:s 15:00:0015:25:0015:50:0016:15:0016:40:00
450
400
350
300
250
200
150
100
50
NuWave Fast Synchronous Burst algorithm results in excellent linearity / resolution (above)
4.6 Line Voltage Compensation (-LVC Option)
The SSRMAN-1BFS’ line voltage compensation keeps the power constant on the load as
the line voltage changes. The line voltage is measured via the 24VAC power applied to
the SSRMAN-1BFS’ module. To use the Line Voltage Compensation feature properly, a
24VAC power transformer should be fed from the same mains as the load circuit to be
controlled as per the wiring diagrams at the end of this document. On the SSRMAN-
1BFS, Line Voltage compensation can be ordered by adding –LVC to the suffix of the
part #. When line voltage compensation is specified, only the fast synchronous burst
cycle time is available (the dipswitch setting of cycle times is disabled).

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Copyright 2013 NUWAVE TECHNOLOGIES,INC.
Without Lin e Voltage Compen sation
120VAC
108VAC
(-10%)
MAINS VOLTAGE
1KW
0.81KW
(~-20%)
LOAD POWER
SSR MAN -1BFS Line Voltage Compensation
120VAC
108VAC
(-10%)
MAINS VOLTAGE
LOAD POWER
With a 10% drop in line voltage, SSRMAN load power drops less th an 2%
(120V, 1KW, 14.4 O hm Load )
E
R
P=
1KW
4.7 Power Limit
The Power Limit feature is used in conjunction with the Line Voltage Compensation
feature to limit the power delivered to the load. The Power Limit is adjustable via a
potentiometer located just below the input terminal block. For this feature to work
properly Line Voltage Compensation (-LVC) must be ordered and the power transformer
for the SSRMAN-1BFS must be connected to the same mains as the load power is
connected to. This feature can be used without Line Voltage Compensation and will
simply clip the command signal to a set level.
4.7.1 Power Limit Adjustment Procedure
The Power Limit is adjustable from 10% to 100% of the max power. Setting the Power
Limit potentiometer half way corresponds to a Power limit of approximately 55%. With
the command input set to approximately 100% (on startup) turn the pot fully CCW. Then
just turn the pot CW until the desired maximum output power is achieved. For this
feature to work as a true max limit, it is important that the Line Voltage Compensation
version be ordered.
If the line voltage compensation is not present in the ordering code (-LVC), the max limit
will act as a percentage of output limit and the absolute max limit will change with line
voltage.
4.8 Configuration Dipswitch
The configuration dipswitch is used for setting up the command input and cycle times.
Using a pen point gently push the switch up for on and down for off according to the
setup outlined in the table below.

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Copyright 2013 NUWAVE TECHNOLOGIES,INC.
0-135R 4-20mA 0-10V CYTA 4-20mA CYTB
Command Input
1
2
3
5
0-5V (Default)
OFF
OFF
OFF
OFF
Potentiometer
OFF
OFF
OFF
OFF
0-10V
OFF
OFF
ON
OFF
4-20mA
OFF
ON
OFF
ON
1-5V
OFF
OFF
OFF
ON
2-10V
OFF
OFF
ON
ON
0-135*
ON
OFF
OFF
OFF
*Module must be ordered as SSRMAN-1BFS-135 for 0-135input support.
4.9 Control Output
The SSRMAN-1BFS SSR output drive is a DC pulsed current limited drive signal of
10V/15mA (24VAC power). This is more than enough current for driving most 3-32V
standard SSRs, however it is still important to review the data sheet for the SSR you
would like to use for compatibility with the SSRMAN-1BFS’s output drive. The control
output can tolerate a momentary direct short. The following graph will allow you to verify
the SSR’s compatibility with the SSRMAN-1BFS over wide input voltage variations.
SSRMAN-1BFS Output Drive Current vs. SSR Input Voltage Drop
4.10 Output LED

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Copyright 2013 NUWAVE TECHNOLOGIES,INC.
The SSRMAN-1BFS’ RED output LED will turn on when the output is on. The output
LED is wired in series with the SSR’s input. If there is a poor connection on the SSR
input terminals or a problem with the SSR’s input, the output LED will not become
energized.
4.11 Three Phase Operation
Three SSRMAN-1BFSs can be used to control three poles of a three phase load for
inside delta or grounded wye configurations. The Module should be wired as shown in
the wiring diagrams, using one transformer for each leg to be controlled.
4.11.1 Three Phase Special Wiring Considerations
The SSRMAN-1BFS derives its AC synchronization from the applied 24VAC power.
Each 24VAC transformer’s primary must be connected to the corresponding leg power to
be controlled by each SSRMAN-1BFS. See the wiring diagrams at the end of this
document.
4.12 Wiring Multiple Units
If more than one SSRMAN-1BFS is to be used from a non-isolated or common command
signals:
1. A common power transformer can be shared. If the input selected is 0-10V or 0-
5V, the inputs should be wired in parallel.
2. If multiple units must be powered from one power transformer and 4-20mA input is
selected, one module should be set for 4-20mA and the remaining modules should
be set for 1-5V.
3. If the command is 4-20mA, and the command inputs are to be wired in series, a
separate power transformer for each module is required to isolate the inputs.
4.12.1 Connecting Power & Commands in Parallel
When multiple SSRMAN-1BFS power inputs and commands are wired in parallel, all of
the 0V terminals must be connected together follows:
Power: Command:
0V-----0V-----0V-----> 0V-----0V-----0V----->
24V---24V---24V----> IN------IN-----IN------>
No crossing of the power input feed or command signal is permitted. If for some reason
the power should become crossed, it will cause a direct short in the system. If properly
fused, the fuse will blow and the SSRMAN-1BFS will not be damaged. If the command
inputs are wired improperly, damage to SSRMAN-1BFS can result.
We do not guarantee operation of the SSRMAN-1BFS with any other manufacturer's
SSR control module. Using them in the same circuit may cause either module to be
damaged.

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Copyright 2013 NUWAVE TECHNOLOGIES,INC.
5. Electrical Specifications
Command Inputs 4-20mA, 0-10V, 0-5V, 0-135 , Pot, 0-135 
Input Impedance 10K (0-10V), 250(4-20mA), 100K(0-5V)
0-135 Excitation Current 13mA max
Control Output SSR Drive, nominally 10V at 15mA (24VAC)
Output Resolution 0.5% for 4-20mA, 0-5V, pot and 0-10V; 1% for 0-135 
Output Linearity 1.5% for 4-20mA, 0-5V, pot and 0-10V; 5% for 0-135 
Power Limit Range 10-100% of max load power
External Potentiometer Res. 1K-25K
Ambient Temperature Range 0 to 60 °C
Power Supply Voltage 24VAC +15/-15%.
Power Consumption 65mA (Power consumption 1.6W MAX).
Line Frequency Range 47-63 Hz.
Terminal Block wire Gauge 16-30 AWG
Terminal Block Material Polyamide 6.6 UL 94 V-0, Black
6. Mechanical Dimensions
0-135R 4-20mA 0-10V CYTA 4-20mA CYTB
1.40"
1.75"
Max Height is 0.6”
7. Contact Information
NuWave Technologies, Inc
866-379-3597
www.nuwaveproducts.com

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Copyright 2013 NUWAVE TECHNOLOGIES,INC.
8. WIRING DIAGRAM (4-20mA, 0-5V, 0-10V Inputs)
FUSE
AC POWER
SOURCE
PROCESS
CONTROLLER
FUSE
24VAC
HEATER
CONTROL
TRANSFORMER
4-20mA,
0-5V,OR
0-10V
+
-
SSRMAN-1BFS WIRING DIAGRAM (4-20mA, 0-5V, 0-10V INPUT)
L
N
SSR
0-135R 4-20mA 0-10V CYT A 4-20mA CYT B
9. WIRING DIAGRAM (Potentiometer Input)
FUSE
AC POWER
SOURCE
FUSE
24VAC
SSR
HEATER
CONTROL
TRANSFORMER
SSRMAN-1BFS WIRING DIAGRAM (POTENTIOMETER INPUT)
L
N
POTENTIOMETER
CW
CCW
W
SSR
0-135R 4-20mA 0-10V 4-20mA CYT A CYT B

SSRMAN-1BFS Users Manual Page 14
Copyright 2013 NUWAVE TECHNOLOGIES,INC.
10. WIRING DIAGRAM (0-135 Ohm Input)
FUSE
AC POWER
SOURCE
FUSE
24VAC
SSR
HEATER
CONTROL
TRANSFORMER
SSRMAN-1BFS WIRING DIAGRAM (0-135 Ohm)
L
N
SSR
0-135R 4-20mA 0-1 0V 4-20mA CYT A CYT B
0-135R
11. WIRING DIAGRAM 3 PHASE DELTA –Zero Crossing
FUSE
24VAC
SSRMAN-1BFS WIRING DIAGRAM
FUSE
FUSE
FUSE
FUSE
FUSE
3 PHASE INSIDE DELTA CONNECTION
SSR
SSR
SSR
L1
L2
L3
HEATER2
HEATER1
HEATER3
24VAC
24VAC
COMMAND INPUTS:
WIRED IN PARALLEL FOR 0-10V
WIRED IN SERIES FOR 4-20MA

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Copyright 2013 NUWAVE TECHNOLOGIES,INC.
12. WIRING DIAGRAM 3 PHASE 4 WIRE Y –Zero Crossing
FUSE
24VAC
SSRMAN-1BFS WIRING DIAGRAM
SSR
SSR
CONTROL
TRA NSFORMER
FUSE
FUSE
CONTROL
TRA NSFORMER
FUSE
SSR
FUSE
CONTROL
TRA NSFORMER
FUSE
L1
L2
L3
N
3 PHASE 4 WIRE Y CONNECTION
24VAC
24VAC
HEATERS
0-10V
COMMAND
+
-