ISOMETER Headline IR /IR

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1 ISOMETER Headline IR /IR Insulation Sub-Headline monitoring device (IMD) for unearthed DC drive systems (IT systems) in electric vehicles Version V4 Vorläufiges Datenblatt IR155-32xx-V4_D115_2_D_XXEN/9.216

ISOMETER IR155-323/IR155-324 Insulation monitoring device (IMD) for unearthed DC drive systems (IT systems) in electric vehicles ISOMETER IR155-324 Device features Suitable for 12 V and 24 V systems

2 ISOMETER IR /IR Insulation monitoring device (IMD) for unearthed DC drive systems (IT systems) in electric vehicles ISOMETER IR Device features Suitable for 12 V and 24 V systems Automatic device self test Continuous measurement of the insulation resistance 1 MΩ Response time for the first measurement of the system state (SST) is < 2 s after switching the supply voltage on Response time < 2 s for insulation resistance measurement (DCP) Automatic adaptation to the existing system leakage capacitance ( 1 μf) Detection of earth faults and interruption of the earth connection Insulation monitoring of AC and DC insulation faults for unearthed systems (IT systems) 1 V Undervoltage detection for voltages below 5 V (adjustable at factory by Bender) Short-circuit proof outputs for: Fault detection (high-side output) Measured value (PWM 5 95 %) and status (f = 1 5 Hz) at high or inverted low-side driver (M HS /M LS output) Protective coating (SL 131ECO-FLZ) Approvals ATTENTION Observe precautions for handling electrostatic sensitive devices. Handle only at safe work stations. ATTENTION The device is monitoring HIGH VOLTAGE. Be aware of HIGH VOLTAGE near to the device. Product description The ISOMETER IR /-324 monitors the insulation resistance between the insulated and active HV-conductors of an electrical drive system (U n = DC V 1 V) and the reference earth (chassis ground Kl.31). The patented measurement technology is used to monitor the condition of the insulation on the DC side as well as on the AC motor side of the electrical drive system. Existing insulation faults will be signalled reliably, even under high system interferences, which can be caused by motor control processes, accelerating, energy recovering etc. Due to its space-saving design and optimised measurement technology, the device is optimised for use in hybrid or fully electric vehicles. The device meets the increased automotive requirements with regard to the environmental conditions (e.g. temperatures and vibration, EMC ). The fault messages (insulation fault at the HV-system, connection or device error of the IMD) will be provided at the integrated and galvanic isolated interface (high- or low-side driver). The interface consists of a status output (OK HS output) and a measurement output (M HS /M LS output). The status output signalises errors or that the system is error free, i.e the "good" condition as shown by the "Operating principle PWM driver" diagram on page 5. The measurement output signalises the actual insulation resistance. Furthermore, it is possible to distinguish between different fault messages and device conditions, which are base frequency encoded. Function The ISOMETER iso-f1 IR /-324 generates a pulsed measuring voltage, which is superimposed on the IT system via terminals L+/L- and E/KE. The latest measured insulation condition is available as a pulse-width-modulated (PWM) signal at terminals M HS (for IRI55-324) or M LS (for IR ). The connection between the terminals E/KE and the chassis ground ( Kl.31) is continuously monitored. Therefore it is necessary to install two separated conductors from the terminals E or KE to chassis ground. Connection monitoring of the earth terminals E/KE is specified for R F 4 MΩ if the ISOMETER is connected as shown in the application diagram on page 3. Once power is switched on, the device performs an initialisation and starts the system state (SST) measurement. The ISOMETER provides the first estimated insulation resistance during a maximum time of 2 seconds. The DCP measurement ( continuous measurement method) starts subsequently. Faults in the connecting wires or functional faults will be automatically recognised and signalled. During operation, a self test is carried out automatically every five minutes. The interfaces will not be influenced by these self tests. Connection monitoring of the earth terminals E/KE may not work as intended when R F > 4 MΩ if the supply terminals (Kl.15/Kl.31) are not galvanically isolated from the chassis earth (Kl.31). Standards Corresponding standards and regulations* IEC IEC IEC ISO ISO ISO ISO ISO E1 (ECE regulation No. 1) acc. 72/245/EWG/EEC 29/19/EG/EC DIN EN Z/AD:21 DIN EN Db:26 DIN EN Nb:21 DIN EN Fh:29 DIN EN Ea:21 Abbreviations DCP Direct Current Pulse SST Speed Start Measuring * Normative exclusion The device went through an automotive test procedure in combination with multi customer requirements reg. ISO1675-x. The standard IEC will be fulfilled by creating the function for LED warning and test button at the customer site if necessary. The device includes no surge and load dump protection above 6 V. An additional central protection is necessary. 2 IR155-32xx-V4_D115_2_D_XXEN/9.216

3 ISOMETER IR /IR Wiring diagrams HV system DC V 1V (-32x only) HV system DC V 8V (-321 only) L XLA- 1 XLA+ Version V4 L+ 3 XK1A M HS M LS NC OK HS Kl.31 Kl.15 E KE Notice: Kl.31 M HS only on variants -324 and -321 M LS only on variant Connector XLA+ Pin 1+2 L+ Line Voltage 2 - Connector XLA- Pin 1+2 L- Line Voltage 3 - Connector XK1A Pin 1 Kl. 31 Chassis ground/ electronic ground Pin 2 Kl. 15 Supply voltage Pin 3 Pin 4 Kl. 31 Chassis ground Kl. 31 Chassis ground (separate line) Pin 5 M HS Data Out, PWM (high side) Pin 6 M LS Data Out, PWM (low side) Pin 7 Pin 8 n.c. OK HS Status Output (high side) Typical application Charger AC Vehicle coupler iso-f1 HV DC Circuit Load enable relay Drive enable relay IMD vehicle IR155-32xx-V4_D115_2_D_XXEN/

4 ISOMETER IR /IR Technical data Insulation coordination acc. to IEC Protective separation (reinforced insulation) between (L+/L-) (Kl. 31, Kl. 15, E, KE, M HS, M LS, OK HS ) Voltage test AC 35 V/1 min Supply/IT system being monitored Supply voltage U S Max. operating current I S Max. current I k HV voltage range (L+/L-) U n Power consumption DC 1 36 V 15 ma 2 A 6 A/2 ms inrush current AC 1 V (peak value) 66 V r.m.s. (1 Hz 1 khz) DC 1 V < 2 W Response values Response value hysteresis (DCP) 25 % Response value R an 1 kω 1 MΩ Undervoltage detection 5 V Measuring range Measuring range 1 MΩ Undervoltage detection 5 V default setting: V (inactive) Relative uncertainty SST ( 2 s) good > 2* R an ; bad <.5* R an Relative uncertainty DCP 85 kω ±2 kω (default setting 1 kω) 1 kω 1 MΩ ±15% Relative uncertainty output M (fundamental frequency) ±5 % at each frequency (1 Hz; 2 Hz; 3 Hz; 4 Hz; 5 Hz) Relative uncertainty undervoltage detection U n 1 V ±1 %; at U n 3 V ±5 % Relative uncertainty (SST) Good condition 2* R an Bad condition.5* R an No Insulation fault (high) Insulation fault (low) Response value = 5kΩ 1kΩ 2kΩ 1MΩ Relative uncertainty DCP 1 kω 1 MΩ ±15 % 1 kω 1.2 MΩ ±15 % to ±7 % 1.2 MΩ ±7 % MΩ ±7 % to ±15 % 1 MΩ ±15 % Time response Response time t an (OK HS ; SST) t an 2 s (typ. < 1 s at U n > 1 V) Response time t an (OK HS ; DCP) (when changing over from R F = 1 MΩ to R an /2; at C e = 1 µf; U n = DC 1 V) t an 2 s (at F ave = 1*) t an 17.5 s (at F ave = 9) t an 17.5 s (at F ave = 8) t an 15 s (at F ave = 7) t an 12.5 s (at F ave = 6) t an 12.5 s (at F ave = 5) t an 1 s (at F ave = 4) t an 7.5 s (at F ave = 3) t an 7.5 s (at F ave = 2) t an 5 s (at F ave = 1) during the self test t an + 1 s Switch-off time t ab (OK HS ; DCP) (when changing over from R F = 1 MΩ to R an /2; at C e = 1 µf; U n = DC 1 V t ab 4 s (at F ave = 1) t ab 4 s (at F ave = 9) t ab 33 s (at F ave = 8) t ab 33 s (at F ave = 7) t ab 33 s (at F ave = 6) t ab 26 s (at F ave = 5) t ab 26 s (at F ave = 4) t ab 26 s (at F ave = 3) t ab 2 s (at F ave = 2) t ab 2 s (at F ave = 1) during a self test t ab + 1 s Duration of the self test 1 s (every five minutes; should be added to t an /t ab ) Measuring circuit System leakage capacitance C e 1 µf Smaller measurement range and increased measuring time at C e > 1 µf (e.g. max. range 1 3 µf, t an = 68 s when changing over from R F 1 MΩ to R an /2) Measuring voltage U M ±4 V Measuring current I M at R F = ±33 µa Impedance Z i at 5 Hz 1.2 MΩ Internal DC resistance R i 1.2 MΩ * F ave = 1 is recommended for electric and hybrid vehicles +15% +7% -7% -15% Absolute uncertainty 1kΩ 1.2MΩ 1MΩ 85 kω ±2 kω +1.5MΩ +84kΩ +2kΩ +15kΩ -15kΩ -2kΩ -84kΩ -1.5MΩ kω 85kΩ1kΩ 1.2MΩ 1MΩ 4 IR155-32xx-V4_D115_2_D_XXEN/9.216

5 ISOMETER IR /IR Output Measurement output (M) M HS switches to U S 2 V (324) (external pull-down resistor to Kl. 31 necessary 2.2 kω) M LS switches to Kl V (323) (external pull-up resistor to Kl. 15 reqired 2.2 kω Hz Hi > short-circuit to U b + (Kl. 15); Low > IMD off or short-circuit to Kl Hz Normal condition Insulation measurement DCP; starts two seconds after power on; First successful insulation measurement at 17.5 s PWM active 5 95 % 2 Hz undervoltage condition Insulation measurement DCP (continuous measurement); starts two seconds after power on; PWM active 5 95 % First successful insulation measurement at 17.5 s Undervoltage detection 5 V (Bender configurable) 3 Hz Speed start measurement Insulation measurement (only good/bad evaluation) starts directly after power on 2 s; PWM 5 1 % (good) and 9 95 % (bad) 4 Hz Device error Device error detected; PWM % 5 Hz Connection fault earth Fault detected on the earth connection (Kl. 31) PWM % Status output (OK HS ) OK HS switches to U S 2 V (external pull-down resistor to Kl. 31 required 2.2 kω) High No fault; R F > response value Low Insulation resistance response value detected; Device error; Fault in the earth connection Undervoltage detected or device switched off Operating principle PWM driver Condition Normal and Undervoltage detected (1 Hz; 2 Hz) Duty cycle 5 % = > 5 MΩ ( ) Duty cycle 5 % = 12 kω Duty cycle 95 % = kω (M HS ; M LS )/V U high R F = 9 % x 12 kω dc meas - 5% - 12 kω dc meas = measured duty cycle (5 % 95 %) Grey invalid Working range PWM 5% 95% PWM/% Operating principle PWM driver Condition SST (3 Hz) (M HS ; M LS )/V U high Good Grey invalid Operating principle PWM driver Condition Device error and Kl.31 fault (4 Hz; 5 Hz;) (M HS ; M LS )/V U high Duty cycle 5 1 % ( good ) 9 95 % ( bad ) Bad PWM/% Grey invalid Device fault or Kl.31 Fault Duty cycle % PWM/% Load current I L 8 ma Turn-on time to 9 % V out max. 125 µs Turn-off time to 1 % V out max. 175 µs Slew rate on 1 3 % V out max. 6 V/µs Slew rate off 7 4 % V out max. 8 V/µs Timing 324 (inverse to 323) V OUT 9% 1% t on dv/dt on t off dv/dt off EMC Load dump protection < 6 V Measurement method Bender-DCP technology Factor averaging F ave (output M) 1 1 (factory set: 1) ESD protection Contact discharge directly to terminals Contact discharge indirectly to environment Air discharge handling of the PCB 1 kv 25 kv 6 kv Connection On-board connectors TYCO-MICRO MATE-N-LOK 1 x (Kl. 31, Kl.15, E, KE, M HS, M LS, OK HS 2 x (L+, L-); The connection between the respective connecting pins at L+ or L- may only be used as redundancy. Cannot be used for looping through! Crimp contacts TYCO-MICRO MATE-N-LOK Gold 14 x Conductor cross section: AWG 2 24 Enclosure for crimp contacts TYCO-MICRO MATE-N-LOK receptor HSG single R TYCO-MICRO MATE-N-LOK receptor HSG single R IR155-32xx-V4_D115_2_D_XXEN/

General data Necessary crimp tongs (TYCO) 9151-1 Operating mode/mounting continuous operation/any position Temperature range -4 +15 C Voltage failure 2 ms Flammability class acc.

6 General data Necessary crimp tongs (TYCO) Operating mode/mounting continuous operation/any position Temperature range C Voltage failure 2 ms Flammability class acc. to UL 94 V- Mounting M4 metal screws with locking washers between screw head and PCB. Torx, T2 with a maximum tightening torque of 4 Nm for the screws. Furthermore, a maximum of 1 Nm tightening torque to the PCB at the mounting points. Mounting and connector kits are not included in delivery, but are available as accessories. The maximum diameter of the mounting points is 1 mm. Before mounting the device, ensure sufficient insulation between the device and the vehicle or the mounting points (min mm to other parts). If the device is mounted on a metal or conductive subsurface, this subsurface has to be at earth potential (Kl.31; vehicle mass). Deflection max. 1 % of the length or width of the PCB Coating thick-film lacquer Weight 52 g ±2 g Ordering information Dimension diagram Dimensions in mm PCB dimensions (L x W x H) 14 mm x 6 mm x 15 mm XLA- XLA+ The connector XK1A is 1mm longer than the PCB dimensions ø 4.2 Example for ordering IR kΩ-V + B V4 IR kΩ-1V + B CV4 1mm copper circumferential on the rear side and 8.4mm on the front side Measured value Parameters Response value R an F ave Undervoltage detection Type Art. No. output 3 V Low side IR B V4 Continuously set value 1 kω 1 V (inactive) High side IR B V4 Low side IR B CV4 Customer-specific setting 1 kω 1 MΩ 1 1 V 5 V High side IR B CV4 Accessories Type designation Art. No. Fastening set B Connector set IR155-32xx B Bender GmbH & Co. KG P.O. Box Gruenberg Germany Londorfer Strasse Gruenberg Germany Tel.: Fax: info@bender.de The parameters, i.e. the response value and undervoltage protection value must be included in the order. XK1A BENDER Group IR155-32xx-V4_D115_2_D_XXEN / / pdf / Bender GmbH & Co. KG, Germany Subject to change! The specified standards take into account the version that was valid at the time of printing.

ISOMETER IR Headline. Version V004. Vorläufiges Datenblatt

ISOMETER IR Headline. Version V004. Vorläufiges Datenblatt Headline ISOMETER IR155-4210 Sub-Headline Insulation monitoring device (IMD) for unearthed charging systems (IT systems), for e.g. electric vehicles Version V004 Vorläufiges Datenblatt TDB106035en / 06.2012