ISOMETER® IR155-3203/IR155-3204

Insulation monitoring device (IMD) for unearthed DC drive systems

(IT systems) in electric vehicles
Version V004

IR155-32xx-V004_D00115_05_D_XXEN/06.2024
ISOMETER® IR155-3203/IR155-3204 Insulation monitoring device (IMD) for unearthed
DC drive systems (IT systems) in electric vehicles

Product description
The ISOMETER® IR155-3203/-3204 monitors the insulation resistance between the insulated
and active HV-conductors of an electrical drive system (Un = DC 0 V…1000 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…).
Device features The fault messages (insulation fault at the HV-system, connection or device error of the
• Suitable for 12 V and 24 V systems IMD) will be provided at the integrated and galvanic isolated interface (high- or low-side
driver). The interface consists of a status output (OKHS output) and a measurement output
• Automatic device self test (MHS/MLS output). The status output signalises errors or that the system is error free, i.e
• C
 ontinuous measurement of the insulation the "good" condition as shown by the "Operating principle PWM driver" diagram on page 5.
resistance 0…10 MΩ The measurement output signalises the actual insulation resistance. Furthermore, it is
– Response time for the first measurement possible to distinguish between different fault messages and device conditions, which
of the system state (SST) is < 2 s after are base frequency encoded.
switching the supply voltage on
Function
– Response time < 20 s for insulation
The ISOMETER® IR155-3203/-3204 generates a pulsed measuring voltage, which is super­
resistance measurement (DCP)
imposed on the IT system via terminals L+/L- and E/KE. The latest measured insulation
• A
 utomatic adaptation to the existing condition is available as a pulse-width-modulated (PWM) signal at terminals MHS (for
system leakage capacitance (≤ 1 μF) IRI55-3204) or MLS (for IR155-3203). The connection between the terminals E/KE and the
• D
 etection of earth faults and interruption chassis ground (Kl.31) is continuously monitored. Therefore it is necessary to install two
of the earth connection separated conductors from the terminals E or KE to chassis ground.

I
• Insulation monitoring of AC and DC Connection monitoring of the earth terminals E/KE is specified for RF ≤ 4 MΩ if the
insulation faults for unearthed systems (IT ISOMETER® is connected as shown in the application diagram on page 3.
systems) 0…1000 V
Once power is switched on, the device performs an initialisation and starts the system
• U
 ndervoltage detection for voltages below state (SST) measurement. The ISOMETER® provides the first estimated insulation resistance
500 V (adjustable at factory by Bender) during a maximum time of 2 seconds. The DCP measurement (continuous measurement
• Short-circuit proof outputs for: method) starts subsequently. Faults in the connecting wires or functional faults will be
– Fault detection (high-side output) automatically recognised and signalled.
– Measured value (PWM 5…95 %) and During operation, a self test is carried out automatically every five minutes. The interfaces
status (f = 10…50 Hz) at high or inverted will not be influenced by these self tests.

I
low-side driver (MHS/MLS output) Connection monitoring of the earth terminals E/KE may not work as intended when RF
• Protective coating (SL 1307 FLZ) > 4 MΩ if the supply terminals (Kl.15/Kl.31) are not galvanically isolated from the
chassis earth (Kl.31).
Approvals
Standards
Corresponding standards and regulations* * Normative exclusion
IEC 61557-8 2014-12 The device went through an automotive
IEC 61010-1 2010-06 test procedure in combination with multi
IEC 60664-1 2004-04 customer requirements reg. ISO16750-x.
ATTENTION ISO 6469-3 2011-12 The standard IEC61557-8 will be fulfilled by
Observe precautions for handling electrostatic ISO 23273-3 2006-11 creating the function for LED warning and
sensitive devices. ISO 16750-1 2006-08 test button at the customer site if necessary.
Handle only at safe work stations. ISO 16750-2 2010-03
The device includes no surge and load
ISO 16750-4 2010-04
dump protection above 50 V. An additional
E1 (ECE regulation No. 10 revision 5)
ATTENTION central protection is necessary.
acc. 72/245/EWG/EEC 2009/19/EG/EC
The device is monitoring HIGH VOLTAGE. DIN EN 60068-2-38 Z/AD:2010
Be aware of HIGH VOLTAGE near to the device. DIN EN 60068-2-30 Db:2006
DIN EN 60068-2-14 Nb:2010
DIN EN 60068-2-64 Fh:2009
DIN EN 60068-2-27 Ea:2010
Abbreviations
DCP Direct Current Pulse
SST Speed Start Measuring

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 ISOMETER® IR155-3203/IR155-3204

Wiring diagrams
HV system DC 0…1000 V (-320x only)
HV system DC 0…800 V (-3210 only) 1 Connector XLA+
L-
Pin 1+2 L+ Line Voltage
L+ 2 Connector XLA-
Pin 1+2 L- Line Voltage

2 1 2 1
3 Connector XK1A
Pin 1 Kl. 31 Chassis ground/electronic ground
Pin 2 Kl. 15 Supply voltage
2 1 Kl.31
Pin 3 Kl. 31 Chassis ground

8 7 6 5 4 3 2 1
XLA- XLA+
E
Kl.15 Pin 4 Kl. 31 Chassis ground (separate line)
KE
Pin 5 MHS Data Out, PWM (high side)
Version V004
MHS
Pin 6 MLS Data Out, PWM (low side)
3 MLS
NC
XK1A
Pin 7 n.c.
OKHS
Pin 8 OKHS Status Output (high side)
Notice: Kl.31
MHS only on variants -3204 and -3210
MLS only on variant -3203

Typical application
Vehicle
Charger
coupler iso-F1
HV DC Circuit
AC

Load enable Drive enable

relay relay

IMD

vehicle

IR155-32xx-V004_D00115_05_D_XXEN/06.20243
ISOMETER® IR155-3203/IR155-3204

Technical data
Insulation coordination acc. to IEC 60664-1 Time response
Protective separation (reinforced insulation) Response time tan (OKHS; SST) tan ≤ 2 s (typ. < 1 s at Un > 100 V)
 between (L+/L-) – (Kl. 31, Kl. 15, E, KE, MHS, MLS, OKHS) Response time tan (OKHS; DCP)
Voltage test AC 3500 V/1 min (when changing over from RF = 10 MΩ to Ran/2; at Ce = 1 µF; Un = DC 1000 V)
Supply/IT system being monitored  tan ≤ 20 s (at Fave = 10*)
Supply voltage US  DC 10…36 V  tan ≤ 17.5 s (at Fave = 9)
Max. operating current IS 150 mA  tan ≤ 17.5 s (at Fave = 8)
Max. current Ik 2A  tan ≤ 15 s (at Fave = 7)
 6 A/2 ms inrush current  tan ≤ 12.5 s (at Fave = 6)
HV voltage range (L+/L-) Un AC 0…1000 V (peak value)  tan ≤ 12.5 s (at Fave = 5)
 0…660 V RMS (10 Hz…1 kHz)  tan ≤ 10 s (at Fave = 4)
 DC 0…1000 V  tan ≤ 7.5 s (at Fave = 3)
Power consumption <2W  tan ≤ 7.5 s (at Fave = 2)
Response values  tan ≤ 5 s (at Fave = 1)
 during the self test tan + 10 s
Response value hysteresis (DCP) 25 % Switch-off time tab (OKHS; DCP)
Response value Ran 100 kΩ…1 MΩ (when changing over from Ran/2 to RF = 10 MΩ; at Ce = 1 µF; Un = DC 1000 V
Undervoltage detection  0…500 V  tab ≤ 40 s (at Fave = 10)
Measuring range  tab ≤ 40 s (at Fave = 9)
Measuring range  0…10 MΩ  tab ≤ 33 s (at Fave = 8)
Undervoltage detection  0…500 V default setting: 0 V (inactive)  tab ≤ 33 s (at Fave = 7)
Relative uncertainty  tab ≤ 33 s (at Fave = 6)
SST (≤ 2 s) good > 2* Ran; bad < 0.5* Ran  tab ≤ 26 s (at Fave = 5)
Relative uncertainty DCP 0…85 kΩ  ±20 kΩ  tab ≤ 26 s (at Fave = 4)
(default setting 100 kΩ) 100 kΩ…10 MΩ  ±15%  tab ≤ 26 s (at Fave = 3)
Relative uncertainty output M (fundamental frequency) ±5 % at each frequency  tab ≤ 20 s (at Fave = 2)
 (10 Hz; 20 Hz; 30 Hz; 40 Hz; 50 Hz)  tab ≤ 20 s (at Fave = 1)
Relative uncertainty  during a self test tab + 10 s
undervoltage detection  Un ≥ 100 V  ±10 %; at Un ≥300 V  ±5 % Duration of the self test  10 s
Relative uncertainty (SST) “Good condition” ≥ 2* Ran  (every five minutes; should be added to tan/tab)
 “Bad condition” ≤ 0.5* Ran Measuring circuit
System leakage capacitance Ce ≤ 1 µF
No Insulation fault
(high)
Smaller measurement range and increased measuring time at Ce  > 1 µF
 (e.g. max. range 1 MΩ @ 3 µF,
 tan = 68 s when changing over from RF 1 MΩ to Ran/2)
Insulation fault
(low) Measuring voltage UM ±40 V
50kΩ
Response value =
200kΩ 10MΩ Measuring current IM at RF = 0 ±33 µA
 100kΩ
Impedance Zi at 50 Hz ≥ 1.2 MΩ
Relative uncertainty DCP 100 kΩ…10 MΩ ±15 % Internal DC resistance Ri ≥ 1.2 MΩ
 100 kΩ…1.2 MΩ  ±15 % to ±7 %
 1.2 MΩ  ±7 % * Fave = 10 is recommended for electric and hybrid vehicles
 1.2…10 MΩ  ±7 % to ±15 %
 10 MΩ  ±15 %
+15%
+7%
0
-7%
-15%

 100kΩ 1.2MΩ 10MΩ

Absolute uncertainty 0…85 kΩ  ±20 kΩ

+1.5MΩ

+84kΩ

+20kΩ
+15kΩ

-15kΩ
-20kΩ

-84kΩ

-1.5MΩ

 0kΩ 85kΩ100kΩ 1.2MΩ 10MΩ

4 IR155-32xx-V004_D00115_05_D_XXEN/06.2024
 ISOMETER® IR155-3203/IR155-3204

Output Operating principle PWM driver

Measurement output (M) • Condition “SST” (30 Hz)
MHS switches to US – 2 V (3204)  Duty cycle 5…10 % (“good”)
(external pull-down resistor to Kl. 31 necessary 2.2 kΩ)  (MHS ; MLS)/V 90…95 % (“bad”)
Grey → invalid
MLS switches to Kl. 31 + 2 V (3203)
Uhigh
(external pull-up resistor to Kl. 15 reqired 2.2 kΩ
 0 Hz  Hi > short-circuit to
 Ub + (Kl. 15); Low > IMD off or short-circuit to Kl. 31

„Good“

„Bad“
 10 Hz  Normal condition
 Insulation measurement DCP;
 starts two seconds after power on; PWM/%
 First successful insulation measurement at ≤ 17.5 s 0
5 10 90 95 100
 PWM active 5…95 % 
 20 Hz  undervoltage condition Operating principle PWM driver
 Insulation measurement DCP (continuous measurement); • Condition “Device error” and “Kl.31 fault” (40 Hz; 50 Hz;)
 starts two seconds after power on;  Duty cycle  47.5…52.5 %
 PWM active 5…95 % (MHS ; MLS)/V
 First successful insulation measurement at ≤ 17.5 s Grey → invalid

 Undervoltage detection 0…500 V Uhigh

 (Bender configurable)

„Device fault“ or
„Kl.31 Fault“
 30 Hz  Speed start measurement
 Insulation measurement (only good/bad evaluation)
 starts directly after power on ≤ 2 s;
 PWM 5…10 % (good) and 90…95 % (bad)
PWM/%
0
 40 Hz  Device error 47.5 52.5 100
 Device error detected; PWM 47.5…52.5 % 
Load current IL 80 mA
 50 Hz  Connection fault earth Turn-on time  to 90 % Vout max. 125 µs
 Fault detected on the earth connection (Kl. 31) Turn-off time  to 10 % Vout max. 175 µs
 PWM 47.5…52.5 % Slew rate on  10…30 % Vout max. 6 V/µs
Status output (OKHS) Slew rate off  70…40 % Vout max. 8 V/µs
OKHS switches to US – 2 V Timing 3204 (inverse to 3203)
(external pull-down resistor to Kl. 31 required 2.2 kΩ) VOUT
High  No fault; RF > response value
Low  Insulation resistance ≤ response value detected; 90%
 Device error; Fault in the earth connection ton
 Undervoltage detected or device switched off dV/dtoff

Operating principle PWM driver dV/dton

• Condition “Normal” and “Undervoltage detected” (10 Hz; 20 Hz) toff
 Duty cycle 5 % = > 50 MΩ (∞) 10%
 Duty cycle 50 % = 1200 kΩ 
 Duty cycle 95 % = 0 kΩ EMC
90 % x 1200 kΩ Load dump protection < 50 V
RF = - 1200 kΩ Measurement method  Bender-DCP technology
dcmeas - 5% Factor averaging

 dcmeas = measured duty cycle (5 %…95 %) Fave (output M) 1…10 (factory set: 10)
ESD protection
Contact discharge – directly to terminals  ≤ 10 kV
(MHS ; MLS)/V
Grey → invalid
Contact discharge – indirectly to environment  ≤ 25 kV
Uhigh
Air discharge – handling of the PCB ≤ 6 kV
„Working range PWM“

Connection
On-board connectors  TYCO-MICRO MATE-N-LOK
5%…95%

 1 x 2-1445088-8
 (Kl. 31, Kl.15, E, KE, MHS, MLS, OKHS
2 x 2-1445088-2 (L+, L-); The connection between the respective connecting pins at L+
PWM/% or L- may only be used as redundancy. Cannot be used for looping through!
0
5 95 100
 Crimp contacts  TYCO-MICRO MATE-N-LOK Gold
 14 x 1-794606-1
 Conductor cross section: AWG 20…24
Enclosure for crimp contacts TYCO-MICRO MATE-N-LOK receptor HSG single R -1445022-8
 TYCO-MICRO MATE-N-LOK receptor HSG single R -1445022-2

IR155-32xx-V004_D00115_05_D_XXEN/06.20245
General data Dimension diagram
Necessary crimp tongs (TYCO) 91501-1 Dimensions in mm
Operating mode/mounting continuous operation/any position
PCB dimensions (L x W x H) 140 mm x 60 mm x 15 mm
Temperature range  -40…+105 °C
Voltage failure  ≤ 2 ms
Flammability class acc. to UL 94 V-0 15 0 5 78.25 135 140
Mounting
M4 metal screws with locking washers between screw head and PCB. Torx, T20 with a 60
55
maximum tightening torque of 4 Nm for the screws. Furthermore, a maximum of 10 Nm
XLA- XLA+
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 10 mm.
Before mounting the device, ensure sufficient insulation between the device and the vehicle
XK1A
or the mounting points (min. 11.4 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). 5
0
Deflection  max. 1 % of the length or width of the PCB The connector XK1A is 1mm ø 4.2 10mm copper circumferential on the rear
longer than the PCB dimensions side and 8.4mm on the front side
Coating  thick-film lacquer
Weight 52 g ±2 g

Ordering information

Parameters Response value Ran Fave Undervoltage detection Measured value output Type Art. No.

300 V Low side IR155-3203 B91068138V4

Continuously set value 100 kΩ 10
0 V (inactive) High side IR155-3204 B91068139V4
Low side IR155-3203 B91068138CV4
Customer-specific setting 100 kΩ…1 MΩ 1…10 0…500 V
High side IR155-3204 B91068139CV4

Accessories Example for ordering

IR155-3204-100kΩ-0V + B 9106 8139V4
Type designation Art. No. IR155-3204-200kΩ-100V + B 9106 8139CV4
Fastening set B91068500 The parameters, i.e. the response value and undervoltage
protection value must be included in the order.
Connector set IR155-32xx B91068501

Bender GmbH & Co. KG

Londorfer Straße 65
35305 Grünberg
Germany © Bender GmbH & Co. KG, Germany
Subject to change!
Tel.: +49 6401 807-0 The specified standards take into account the
info@bender.de edition valid until 06.2024 unless otherwise
www.bender.de indicated.