NuWave SSRMAN-1BFS Series Bedienungsanleitung

Rev.1.5 06/18

SSRMAN-1BFS SERIES USERS MANUAL

FAST SYNCHRONOUS BURST FIRING MODULE

SSRMAN-1BFS Users Manual Page 2

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.

SSRMAN-1BFS Users Manual Page 3

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

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

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.

SSRMAN-1BFS Users Manual Page 6

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

Dip

Switch

#of

cycles

Cycle

Time

(60Hz)

Cycle

Time

(50Hz)

Resolution

( % of FS)

*OFF

~16

266mS

320mS

~1%

OFF

1.2S

1.66%

OFF

600

10S

12S

0.166%

6000

100S

120S

0.0166%

SSRMAN-1BFS Users Manual Page 7

*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.

SSRMAN-1BFS Users Manual Page 8

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

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

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).

SSRMAN-1BFS Users Manual Page 9

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 )

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.

SSRMAN-1BFS Users Manual Page 10

0-135R

4-20mA

0-10V

CYTA

4-20mA

CYTB

Command Input

0-5V (Default)

OFF

Potentiometer

OFF

0-10V

OFF

4-20mA

OFF

1-5V

OFF

2-10V

OFF

0-135*

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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