Vehicle sensors –

Insulation monitoring
ISOMETER® iso175​
ISOMETER® IR155

Design the future

of energy
 Insulation monitoring for Possible causes of insulation faults in vehicles
electric and hybrid vehicles

Our innovative insulation monitoring devices protect The solution: Insulation faults in DC vehicle charging applications It is also possible that insulation material is worn down
the entire electric drive system and minimise the risk Continuous monitoring of the insulation resistance can lead to safety hazards and system malfunction. by mechanical stress such as vibration, shear forces
of an electric shock. The power supply system in with an insulation monitoring device. The following examples are typical causes for or abrasion by wrong installation or drive over at edges
electric vehicles must be regarded as an isolated insulation faults: nearby the DC charger.
power supply system while driving. A major challenge Active measurement: Furthermore, vandalism or stealing of cables can
here is to detect insulation faults at an early stage. The active measurement method increases Overload of the used insulation by applying excessive be a root cause for risk of electric shock as well.
Causes of insulation faults during normal operation electrical safety in electromobility by detecting faults voltage to insulation materials, mechanical stress
can be, for example: dirt, salt, moisture, defective not only during vehicle operation, but before the vehicle of cables (e.g., during installation). This can lead to
plug connections, mechanical influences, etc. is started. Even when the battery is not connected. material failure or flashover, whereby especially
arcs in DC systems can lead to a fire.

High currents or voltage spikes can stress the

insulation, leading to insulation failure. Contamination
with dust, moisture, or other pollutants can weaken
insulation materials as well. Contaminated insulation
becomes more susceptible to breakdown. Over time,
insulation materials may degrade due to ageing,
IMD especially when the material is subject to rapid and
IMD
frequent temperature changes or loss of insulation
material flexibility.

DC contactor RESS
DC + F Inverter
DC - F V =
L1 F

In DC ≥ 6mA (Option)

= Air conditioning
PFC

N Other loads
=
CP
Control pilot AC on-board
PP
function charger
PE with galvanic
IMD
14 V on-board
insulation (Option) power supply
= (galvanically
isolated)

© www.bender.de Electr. chassis / protective equipotential bonding

RTyre

2 3
 ISOMETER® iso175

The ISOMETER® iso175 is an insulation monitoring device for

unearthed drive systems in hybrid and electric vehicles.

It has a patented, active measuring method for continuous moni-

toring of the insulation resistance in a high-voltage system.
Depending on the variant, the device communicates with its
system environment using different CAN protocols
(standard Bender, SAE J1939).r,

Features:EJ1939).
ƒ Insulation measurement also when
the vehicle's HV electric system is not energised
ƒ Suitable for 12 V to 24 V DC power supply
ƒ Detection of symmetrical and asymmetrical faults
ƒ CAN bus interface
ƒ Automatic adaptation to the system leakage capacitance
(up to 10 µF depending on profile)
ƒ Integrated self-diagnosis (online self test)
ƒ HV connection monitoring (offline self test)
ƒ Continuous monitoring of the earth connection
ƒ Undervoltage detection

ISOMETER® IR155

The ISOMETER® IR155 monitors the insulation resistance between

the insulated and active HV conductors of an electrical drive
system and the reference earth.

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.

Features:
ƒ Insulation monitoring device (IMD) for unearthed DC drive
systems (IT systems) in electric vehicles
ƒ Continuous measurement of the insulation resistance 0…10 MΩ
ƒ Insulation monitoring of AC and DC insulation faults
for unearthed systems (IT systems) 0…1000 V
ƒ Short-circuit proof outputs for fault detection
and measured value
ƒ Suitable for 12 V to 24 V power supply

4 5
 Comparison of products

IR155-4203/
IMD features ISOMETER® iso175​
IR155-4204
System voltage range DC 0…1000 V​ DC 0…1000 V​

Max. leakage capacitance Ce 5 (10) µF 1 µF

Error signal output 1 (Error) 1 (Error)

Detection of symmetrical/asymmetrical faults

Self diagnosis

Undervoltage detection

Decoupling of HV connection

Interface: PWM

Interface: CAN

CAN protocols SAE J1939, Bender

Art. No. B91068201 - 206 B91068138(C)V4 – 143(C)

IEC 61010-1
IEC 60664-1
IEC 60068-2-6 IEC 61557-8
IEC 60068-2-14 IEC 61010-1
IEC 60068-2-27 IEC 60664-1
IEC 60068-2-64 ISO 6469-3
Standards
ISO 6469-3 ISO 23273-3
ISO 16750-2 ISO 16750-1
ISO 16750-3 ISO 16750-2
ISO 16750-4 ISO 16750-4
(UN)ECE R10 Rev.6
SAE J1939-82

6 7
bender.de

Bender GmbH & Co. KG

Londorfer Straße 65
35305 Grünberg
Germany
Tel.: +49 6401 807-707
emobility@bender.de
www.bender.de/en

Photos: AdobeStock (© SappiStudio, © Superingo)

and Bender Archive.

2246de / 01.2024 / © Bender GmbH & Co. KG, Germany –

Subject to change! The specified standards take into
account the version valid at the time of printing.