Ir155-4210-V004 D00377 D Xxen PDF
Ir155-4210-V004 D00377 D Xxen PDF
Ir155-4210-V004 D00377 D Xxen PDF
ISOMETER®
Sub-Headline
Insulation monitoring device (IMD) for unearthed charging systems
(IT systems), for e.g. electric vehicles
Version V004
Vorläufiges Datenblatt
IR155-4210-V004_D00377_02_D_XXEN/02.2022
ISOMETER® IR155-4210 Insulation monitoring device (IMD)
for unearthed charging systems (IT systems),
for e.g. electric vehicles
Product description
The ISOMETER® IR155-4210 monitors the insulation resistance between the insulated and
active HV-conductors of an electrical drive/charger system (Un = DC 0…800 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/charger system. Existing insulations faults will be signalised
reliably even under high system interferences which can be caused by motor/charger
control processes, etc.
Due to its space saving design and optimised measurement technology, the device is op-
timised for use in chargers for hybrid or fully electric vehicles. The device meets the increased
automotive requirements in regard of the environmental conditions (e.g. temperatures
ISOMETER® IR155-4210 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-side driver). The
Device features interface consists of a status output (OKHS output) and a measurement output (MHS output).
• Suitable for 12 V and 24 V systems The status output signalises errors resp. the “good” condition. The measurement output
signalises the actual insulation resistance. Furthermore it’s possible to distinguish between
• Automatic device self test
different fault messages and device conditions, which are base frequency encoded.
• Continous measurement of insulation
resistance 0…10 MΩ Function
– Response time < 2 s after power on for The ISOMETER® IR155-4210 generates a pulsed measuring voltage, which is superimposed
first estimated insulation resistance (SST) on the IT system by the terminals L+/L- and E/KE. The currently measured insulation con-
– Response time < 10 s for measured dition is available as a pulse-width-modulated signal at the terminal MHS.
insulation resistance (AMP) The connection between the terminals E/KE and the chassis ground ( Kl.31) is continu-
ously monitored. Therefore it’s necessary to install two separated conductors from the
• Automatic adaptation to the existing
terminals E resp. KE to chassis ground.
system leakage capacitance (≤1 μF)
Once power is switched on, the device performs an initialisation and starts the SST
• Detection of ground faults and lost
measurement. The device provides the first estimated insulation resistance during a
ground line
maximum time of 2 sec. The AMP measurement ( continuous measurement method)
• Isolation monitoring of AC and DC starts subsequently. The AMP measurement provides the first successful value at 10 sec
insulation faults for unearthed systems after power on. Faults in the connecting wires or functional faults will be automatically
(IT systems) 0…800 V peak recognised and signalled.
• Low voltage detection for voltages below
500 V (value configurable EOL Bender) Standards
• Short protected outputs for: Corresponding norms and regulations*
– Fault detection (high side output) IEC 61557-8 2007-01 * Normative exclusion
IEC 61010-1 2010-06 The device went through an automotive
– Measurement value (PWM 5… 95 %) &
IEC 60664-1 2004-04 test procedure in combination of multi
status (f = 10…50 Hz) at high side driver
IEC 61326-2-4 2010-05 customer requirements reg. ISO16750-x.
(MHS output)
ISO 6469-3 2001-11 The norm IEC61557-8 will be fulfilled by
• Conformal coating (SL1301ECO-FLZ)
ISO 23273-3 2006-11 creating the function for LED warning and
• UL 2231 compliant test button at the customer site if necessary.
ISO 16750-1 2006-08
Approvals ISO 16750-2 2010-03 The device includes no surge and load
dump protection above 40V. An additional
ISO 16750-4 2010-04
central protection is necessary.
e1 acc. 72/245/EWG/EEC 2009/19/EG/EC
DIN EN 60068-2-38 Z/AD:2010
DIN EN 60068-2-30 Db:2006
DIN EN 60068-2-14 Nb:2010
ATTENTION DIN EN 60068-2-64 Fh:2009
Observe precautions for handling DIN EN 60068-2-27 Ea:2010
electrostatic sensitive devices. UL2231-1 2002
Handle only at safe work stations. UL2231-2 2002
ATTENTION Abbreviations
The device is monitoring HIGH AMP Adaptive Measuring Pulse
VOLTAGE. SST Speed Start Measuring
Be aware of HIGH VOLTAGE near
to the device.
2 IR155-4210-V004_D00377_02_D_XXEN/02.2022
ISOMETER® IR155-4210
Wiring diagrams
1
XLB- XLB+
Kl.15 Pin 6 n.c.
2
E
Pin 7 n.c.
3
KE
4
Version V004 MHS Pin 8 OKHS Status Output (high side)
5
MLS
6
NC
7
XK1B
8
OKHS
Notice:
Kl.31
MHS only at -4204 and -4210
MLS only at -4203
Typical application
Supply Vehicle
coupler coupler
Charger
Charger to vehicle diagnostic (load enable)
F1
L+
L-
PEN
Charger IMD Load enable Drive enable IMD
relay PE relay relay
IR155 IR155
RAE
IR155-4210-V004_D00377_02_D_XXEN/02.2022 3
ISOMETER® IR155-4210
Technical data
Supply voltage Us DC 10…36 V Absolute error (AMP) 0…85 kΩ ±20 kΩ
Nominal supply voltage DC 12/24 V
Voltage range 10…36 V
Max. operational current Is 150 mA
Max. current Ik 2A
6 A/2 ms Rush-In current
Power dissipation Ps <2 W
Line L+/L- Voltage Un AC 0…800 V peak;
0…560 V rms (10…1 kHz)
DC 0…1000 V
UL 2231 DC 0…800 V
Protective separation (reinforced insulation) between
(L+/L-) – (Kl.31, Kl.15, E, KE, MHS, OKHS)
Voltage test AC 3500 V/1 min
Load dump protection < 40 V
Under voltage detection 0…500 V; Default: 0 V (inactive)
System leakage capacity Ce ≤ 1 µF
Reduced measuring range and increased measuring time at Ce > 1µF Measurement Output (M)
(E.g. max. range 1 MΩ @ 3 µF, tan = 16 s @ change over RF 1MΩ > Ran/2) MHS switches to Us – 2V (4210)
Measuring voltage Um ±40 V (external load to ground necessary Þ 2.2 kΩ) 0 Hz Hi > short to
Measuring current Im at RF = 0 ±33 µA Ub+ (Kl.15); Low > IMD off or short to Kl.31
Impedance Zi at 50 Hz ≥ 1.2 MΩ
Internal resistance Ri ≥ 1.2 MΩ 10 Hz Normal Condition
Measurement range 0…10 MΩ Insulation measuring AMP; starts 10 s after
Measurement method Bender AMP Technologie Power-On; PWM active 5…95 %
Relative error at SST (≤ 2 s) Good > 2 * Ran; Bad < 0.5 * Ran 20 Hz Under voltage condition
Relative error at AMP 0…85 kΩ±20 kΩ Insulation measuring AMP (correct measurement)
100 kΩ…10 MΩ±15 % starts 10 s after Power-On;
Relative error Output – M (base frequencies) ±5 % at each frequency PWM active 5…95 %
(10 Hz; 20 Hz; 30 Hz; 40 Hz; 50 Hz) Under voltage detection 0…500 V
Relative error under voltage detection Un ≥ 100 V±10 %; (EOL Bender configurable).
at Un ≥ 300 V±5 %
30 Hz Speed Start
Response value hysteresis (AMP) 25 %
Insulation measuring (only good/bad estimation);
Response value Ran 100…200 kΩ
Starts directly after Power-On; response time ≤ 2 s;
higher tolerances at Ran < 85 kΩ; (Default: 100 kΩ)
PWM 5…10 % (good) and 90…95 % (bad)
Response time tan (OKHS; SST) tan ≤ 2 s (typ. < 1 s at Un > 100 V)
Response time tan (OKHS; AMP) tan ≤ 10 s 40 Hz IMD Error
Switch-off time tab (OKHS; AMP) tab ≤ 26 s IMD error detected; PWM 47.5…52.5 %
Self test time 10 s
(only at power on) 50 Hz Ground error
Relative error (SST) “Good-Value” ≥ 2 * Ran Error on measurement ground line (Kl. 31) detected
“Bad-Value” ≤ 0.5 * Ran PWM 47.5…52.5 %
Status Output (OKHS)
OKHS switches to Us – 2 V
(external load to ground necessary Þ 2.2 kΩ)
High No fault; RF > response value
Low Insulation resistance ≤ response value
detected; IMD error; ground error,
Relative error (AMP) 100 kΩ ±15 % under voltage detected or IMD off
100 kΩ…1.2 MΩ ±15 % to ±7 % (ext. pull-down resistor required)
1.2 MΩ ±7 %
1.2…10 MΩ ±7 % to ±15 %
10 MΩ ±15 %
4 IR155-4210-V004_D00377_02_D_XXEN/02.2022
ISOMETER® IR155-4210
Connectors Samtec Mini Mate Housing, IPD1-08-S-K
(Kl. 31B, Kl.15, KE, E, MHS, MLS, OKHS)
Molex Mini Fit Jr. Housing, 39-01-2025, (L+, L-)
Crimp contacts Samtec Mini Mate Gold, CC79R2024-01-L, AWG 20…24
Molex Mini Fit Jr. Gold, 39-00-0089, AWG 16
Operating mode/mounting Continuous operation/any position
Temperature range -40…+105 °C
Operating principle PWM- driver Voltage dropout ≤ 2 ms
• Condition “SST” (30 Hz) Fire protection class acc. UL94 V0
Duty cycle 5…10 % (“Good”)
ESD protection:
90 … 95 % (“Bad”)
Contact discharge – directly to terminals ≤ 10 kV
Contact discharge – indirectly to environment ≤ 25 kV
Air discharge – handling of the PCB ≤ 6 kV
Mounting
Screw mounting: M4 metal screws with locking washers between screw head and PCB.
Torx, T20 with a max. tightening torque of 4 Nm for the screws. Furthermore max. 10 Nm
pressure to the PCB at the mounting points.
Mounting and connector kits are not included in delivery, but are available
as accessories. The max. diameter of the mounting points is 10 mm.
Before mounting the device, ensure sufficient insulation between the device and the vehicle
resp. the mounting points (min. 11.4 mm to other parts). If the IMD is mounted on a metal
Operating principle PWM- driver
or conductive subsurface, this subsurface has to get ground potential (Kl.31; vehicle mass).
• Condition “Device error” and “Kl.31 fault” (40 Hz; 50 Hz) Deflection max. 1 % of the length resp. width of the PCB
Duty cycle 47.5…52.5 % Conformal coating Thick-Film-Lacquer
Weight 52 g ±2 g
IR155-4210-V004_D00377_02_D_XXEN/02.2022 5
Ordering information
Parameters Response value Ran Undervoltage detection Measured value output Type Art. No.
Continuously set value 100 kΩ 0 V (inactive) high-side IR155-4210 B91068143
Customer-specific setting 100…200 kΩ 0…500 V high-side IR155-4210 B91068143C
Dimension diagram
IR155-4210-V004_D00377_02_D_XXEN / 02.2022 / © Bender GmbH & Co. KG, Germany – Subject to change! The specified standards take into account the edition valid until 02.2022 unless otherwise indicated.
Dimensions in mm
PCB dimensions (L x W x H) 140 x 60 x 17 mm
60
55
XLB- XLB+
XK1B
5
0
ø 4.2 10mm copper circumferential on the rear
side and 8.4mm on the front side
BENDER Group