Bender iso1685 Series User manual

Manual
iso1685…
Insulation monitoring device for unearthed
AC, AC/DC and DC power supplies (IT systems)
up to AC 1000 V / DC 1500 V
Software version D408 v1.0x
iso1685P_D00003_00_M_XXEN / 04.2014

©Bender GmbH & Co. KG
All rights reserved.
Reprinting only with permission
of the publisher.
Subject to change!
Bender GmbH & Co. KG
Londorfer Str. 65 • 35305 Gruenberg • Germany
P.O. Box 1161 • 35301 Gruenberg • Germany
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
Web: http://www.bender.de

3
Table of Contents
iso1685P_D00003_00_M_XXEN / 04.2014
1. Making effective use of this document ............................................................... 5
1.1 How to use this manual ......................................................................................................... 5
1.2 Device-specific safety instructions .................................................................................... 5
1.3 General safety instructions ................................................................................................... 5
1.4 Work activities on electrical installations ........................................................................ 6
1.5 Address setting and termination ....................................................................................... 6
2. Function ....................................................................................................................7
2.1 Device features ......................................................................................................................... 7
2.2 Intended use .............................................................................................................................. 7
2.3 Function ...................................................................................................................................... 7
2.3.1 Insulation monitoring ............................................................................................................ 8
2.3.2 Insulation fault location ......................................................................................................... 8
2.3.3 Self test after connection to the supply voltage .......................................................... 9
2.3.4 Automatic self test ................................................................................................................... 9
2.3.5 Manual self test ......................................................................................................................... 9
2.3.6 Assignment of the alarm relays K1, K2, K3 ................................................................... 10
2.3.7 Standby mode ........................................................................................................................ 10
2.3.8 Measured value transmission to the control inputs of the inverter ................... 10
2.3.9 BMS bus .................................................................................................................................... 10
2.3.9.1 RS-485 interface with BMS protocol ........................................................................ 10
2.3.9.2 Topology RS-485 network .......................................................................................... 11
2.3.9.3 BMS protocol ................................................................................................................... 11
2.3.9.4 Commissioning of an RS-485 network with BMS protocol ............................. 12
2.3.10 Alarm and operating messages via the BMS bus ...................................................... 13
2.3.10.1 Alarm messages .............................................................................................................. 13
2.3.10.2 Operating messages ..................................................................................................... 13
2.4 Display and operating controls ....................................................................................... 14
2.4.1 Alarm LEDs on the top of the enclosure ....................................................................... 14
2.4.2 Display and operating elements on the pcb .............................................................. 15
2.4.3 Alarm LEDs on the pcb ........................................................................................................ 16
2.4.4 DIP switch and µSD card on the pcb .............................................................................. 17
2.4.4.1 Setting the BMS address .............................................................................................. 17
2.4.4.2 Setting the permissible system leakage capacitance
or measurement speed ................................................................................................ 18

Table of Contents
4iso1685P_D00003_00_M_XXEN / 04.2014
2.4.5 Starting the firmware update via the BMS bus ........................................................... 18
2.4.6 History memory ...................................................................................................................... 18
2.4.7 Resetting error messages ...................................................................................................18
3. Installation, connection and commissioning ................................................. 19
3.1 Installation ................................................................................................................................ 19
3.2 Connection ............................................................................................................................... 20
3.3 Commissioning ....................................................................................................................... 22
3.3.1 Factory settings ...................................................................................................................... 22
3.3.2 Commissioning flow chart insulation fault monitoring .......................................... 23
3.3.3 Commissioning flow chart insulation fault location ................................................. 24
3.3.4 Error codes ............................................................................................................................... 25
4. Technical data ....................................................................................................... 27
4.1 Data for iso1685P in tabular form .................................................................................... 27
4.2 Standards and certifications .............................................................................................. 29
4.3 Characteristic curves ............................................................................................................ 30
4.3.1 The measurable leakage capacitance depends on the insulation resistance 30
4.3.2 Response time for insulation measurement ................................................................ 31
4.4 PCB component layout and terminal plugs ................................................................. 32
4.5 Example of alarms stored in the history memory ...................................................... 33
4.6 Ordering data .......................................................................................................................... 34
5. Service .................................................................................................................... 35
INDEX ...........................................................................................................................37

5
iso1685P_D00003_00_M_XXEN / 04.2014
1. Making effective use of this document
1. 1 How to use this manual
This operating manual is designed for electrically skilled persons working in electrical
engineering and electronics!
To make it easier for you to understand and revisit certain sections of text and instructions in the
manual, we have used symbols to identify important instructions and information. The meaning of
these symbols is explained below:
1. 2 Device-specific safety instructions
1. 3 General safety instructions
In addition to these operating instructions, the "Important safety instructions for Bender products“,
which are also included in the scope of supply, are an integral part of the device documentation.
Information calling attention to hazards is marked with this warning symbol
Information which is designed to help you make the best use of the product is
highlighted with the information symbol
Hazard due to excessively high locating current or excessively
high locating voltage!
An excessively high locating currentmay damage sensitive loads (e.g. in
control circuits) or trigger unintended switching processes. For this rea-
son select a lower locating current for these systems. In case of doubt,
please contact our service department (see "chapter 5. Service").
Danger of electric shock!
When opening the device there is the danger of touching live parts.
Switch off the mains voltage before opening the device!

Making effective use of this document
6iso1685P_D00003_00_M_XXEN / 04.2014
1. 4 Work activities on electrical installations
Only skilled persons are permitted to carry out the work necessary to install, commission and
run a device or system.
Follow the relevant provisions which apply to working governing on electrical installations par-
ticularly EN 50110 or the regulations which take its place.
If the device is being used in a location outside the Federal Republic of Germany, the applicable
local standards and regulations must be complied with. European standard EN 50110 can be
used as a guide.
1. 5 Address setting and termination
Correct address setting and termination of the iso1685… series insulation monitoring device is es-
sential for correct functioning.
Ensure correct address setting and termination of the device!
Risk of electric shock!
Touching uninsulated live conductors can result in death or serious in-
jury. Therefore avoid any physical contact with active conductors and
ensure compliance with the regulations for working on electrical instal-
lations.
Risk of bus errors!
Double assignment of addresses on the respective BMS busses can cause
serious malfunctions.

7
iso1685P_D00003_00_M_XXEN / 04.2014
2. Function
2. 1 Device features
Insulation monitoring in extensive unearthed power supply systems up to
AC 1000 V / DC 1500 V
Measurement of low-resistance insulation faults
Separately adjustable response values Ran1 (Alarm 1) and Ran2 (Alarm 2) (both 200 …1 M)
for prewarning and alarm
Automatic adaptation to high system leakage capacitances up to 2000 µF, selectable range
Integrated locating current injector up to 50 mA
Device self test with automatic fault message in the event of a fault
Alarm relays separately adjustable for insulation fault 1, insulation fault 2 and device error
RS-485 interface (BMS bus), e.g. to control insulation fault location
µSD card with data logger and history memory for alarms
2. 2 Intended use
The device is used for monitoring the insulation resistance of extensive systems which are designed
as IT systems. The specific measurement technique monitors the insulation resistance also in exten-
sive installations where extremely high system leakage capacitances against earth exist due to inter-
ference suppression methods. Also, the adaptation to high system leakage capacitances occurs
automatically.
The device generates locating current pulses required for insulation fault location. That allows the
detection of the insulation fault using permanently installed or mobile insulation fault locators.
2. 3 Function
Insulation monitoring is carried out using an active measuring pulse which is superimposed onto the
IT system to earth via the integrated coupling.
When the insulation resistance between the IT system and earth falls below the set prewarning re-
sponse value Ran1 the LED "Alarm 1” lights and the alarm relay K1 switches. When the values fall be-
low the alarm response value Ran2 , also LED "Alarm 2” lights and the alarm relay K2 switches.
The locating current injector integrated in the device for insulation fault location is externally acti-
vated via the BMS interface. When starting insulation fault location, the LED "PGH on" signals the
locating current pulse.
The integrated µSD card is used as data logger for storing all relevant events.
The following measured values, statuses and alarms are stored during operation:
– Insulation resistances and leakage capacitances
– System voltages, partial voltages to earth, supply voltages
– Temperatures: current controller of the locating current injector, coupling L1/+, L2/–
– Insulation fault
– Connection fault
– Device error

Function
8iso1685P_D00003_00_M_XXEN / 04.2014
Following each device start-up, a new file is generated. If the current file size exceeds 10 MByte dur-
ing operation, a new file is generated. The file name contains the time and date of the creation time.
Usually, it takes two days until the maximum file size is reached. Hence, a SD card with a memory
space of 2 GByte can record data for approx. 400 days. When the card has reached the maximum data
volume, always the oldest file will be overwritten. The history memory on the µSD card contains all
saved alarms in csv. format.
2.3.1 Insulation monitoring
For insulation monitoring, a pulsating AC measuring voltage is superimposed on the IT system. The
measuring pulse consists of positive and negative rectangular impulses of the same amplitude. The
period depends on the system leakage capacitances in each case and the insulation resistance of the
system to be monitored.
Fig. 2.1: Pulse sequence of the measuring voltage for insulation fault monitoring
An insulation fault between system and earth closes the measuring circuit. When the insulation re-
sistance between the IT system and earth falls below the set response values Ran1 and Ran2 (response
value Ran1 musst be set higher than Ran2), the associated alarm relay switches K1 (11, 12, 14).
Detected insulation faults are signalled to other bus devices via the BMS bus. In addition, the alarm
LEDs Alarm 1 and Alarm 2 will light up.
2.3.2 Insulation fault location
For insulation fault location, a suitable locating current is superimposed onto the faulty IT system
with which EDS… insulation fault locators can locate insulation faults. iso1685P utilises an internal
locating current injector with IL≤50 mA DC.
Fig. 2.2: Pulse sequence of the internal locating current injector for insulation fault location
When permanently installed insulation fault locators (with master capability) are used, such as
EDS460-D or EDS490-D, control and synchronisation of the locating current injector is carried out by
one of the insulation fault locators in BMS master mode. For this purpose, the iso1685P has to com-
municate with the insulation fault locator via the BMS bus.
Um
t
2 s 4 s 2 s 4 s
I
L
t

Function
9
iso1685P_D00003_00_M_XXEN / 04.2014
Parameterisation of insulation fault location
By means of the BMS gateway, e.g. the COM460IP or terminal program, different modes can be
selected via the BMS bus:
off:
to switch off insulation fault location.
auto (automatic):
Factory setting = Insulation fault location and pause, alternately 5 minutes each. During each
pause, the device automatically switches to insulation fault measurement.
on (permanent):
the locating current required for insulation fault location is permanently supplied to the device.
In addition, the value of the locating current required for insulation fault location has to be set to
1…50 mA.
2.3.3 Self test after connection to the supply voltage
Once connected to the supply voltage, all internal measurement functions, the components of the
process control such as data and parameter memory as well as the connections to earth are checked.
Once the self test is finished, after approx. 5 s the normal measurement mode begins.
If a device or connection error is detected, the corresponding alarm will be signalled via the BMS bus
as well as via the alarm relay K3 (31-32-34). This relay is continuously operating in N/C operation, i.e.
it de-energises even in case of a complete device failure.
During this self test, when the device is being started, the alarm relays K1 and K2 are not switched.
2.3.4 Automatic self test
All supply voltages are continuously monitored. The following tests are continuously carried out in
the background:
- Connection E-KE
- Temperature measurement of coupling device and locating current injector
A self test is automatically carried out at 24 hour intervals.
During the automatic self test, the alarm relays K1 (11-12-14) and K2 (21-22-24) are not switched. K3
won't be switched either.
2.3.5 Manual self test
The self test is started via the BMS interface by a BMS master with test button.
Only in the manual self test mode, the following tests are carried out:
- internal Flash
- CPU register
- Watchdogs
- Oscillator
- Restart of the device including re-initialising and recalibration
During the automatic self test via the BMS bus, the alarm relays K1 (11-12-14) and K2 (21-22-24) are
not switched. K3 would only be switched at a reboot of the device.
During the insulation fault location process, the function of insulation resistance
measurement is deactivated.

Function
10 iso1685P_D00003_00_M_XXEN / 04.2014
2.3.6 Assignment of the alarm relays K1, K2, K3
K1 switches when the value falls below the prewarning response value Ran1 (insulation resistance).
K2 switches when the value falls below the alarm response value Ran2 (insulation resistance).
K3 switches in the event of a device or connection error.
2.3.7 Standby mode
During the standby mode, the coupling unit of the device is galvanically isolated from the system
being monitored. The standby mode can be activated resp. deactivated via the BMS channel 10:
Activate the standby mode using the BMS command STDBY 1
Deactivate the standby mode using the BMS command STDBY 0
Query the current state using the BMS command TRSH? 10
The standby mode of the ISOMETER®, for example, allows team operation of inverters, since in inter-
connected systems only one insulation monitoring device is allowed to be connected
in each system.
2.3.8 Measured value transmission to the control inputs of the inverter
All recorded measured values, operating messages and alarms are made available via the BMS bus.
2.3.9 BMS bus
2.3.9.1 RS-485 interface with BMS protocol
The RS-485 interface, galvanically isolated from the device electronics, serves as a physical transmis-
sion medium for the BMS protocol. When an iso1685P or other bus-capable devices are intercon-
nected via the BMS bus in a network, the BMS bus must be terminated at both ends with a 120 
resistor. For this purpose, the device is equipped with the terminating switch RS-485 (ON/OFF).
An RS-485 network that is not terminated, is likely to get instable and may result in malfunctions.
Only the first and the last device in one line may be terminated. Hence, stub feeders in the network
must not be terminated. The length of the stub feeders is restricted to 1 meter.
Fig. 2.3: Wiring and termination of the BMS bus with SS8100
on the pcb or at the enclosure
maximumlength of the RS-485 network: 1200 m
1. device … device last device
stub feeder
max. 1 m
2))21
56
ON
OFF
RS-485
SS8103
ST6101
LEDs

Function
11
iso1685P_D00003_00_M_XXEN / 04.2014
2.3.9.2 Topology RS-485 network
The optimum topology for the RS-485 network is a daisy-chain connection. In this connection,
device 1 is connected to device 2, device 2 to device 3, device 3 to device n etc. The RS-485 network
represents a continuous path without branches.
Correct arrangement
Three examples for correct arrangement:
Wrong arrangement
Three examples for wrong arrangement:
Wiring
The suitable type of wiring for the RS-485 network is:
shielded cable, core diameter ≥0.8 mm
(z.B. J-Y(St)Y2x0.8), shield connected to earth (PE) on one end.
Connection to the terminals A and B.
The number of bus nodes is restricted to 32 devices. When more devices are to be connected,
Bender recommends to use a DI1 repeater.
2.3.9.3 BMS protocol
This protocol is an essential part of the Bender measuring device interface (BMS bus protocol). Data
transmission generally makes use of ASCII characters.
Interface data are:
Baud rate: 9600 baud
Transmission: 1 start bit, 7 data bits, 1 parity bit, 1 stop bit (1, 7, E, 1)
Parity: even
Checksum: Sum of all transmitted bytes = 0 (without CR and LF)
The BMS bus protocol works according to the Master-Slave principle. Only one master may exist in
each network. All bus devices are identified by a unique BMS address. The master cyclically scans all
other slaves on the bus, listens to their signals and then carries out the corresponding commands.
DI1
132
33 64

Function
12 iso1685P_D00003_00_M_XXEN / 04.2014
A device receives the MASTER function by assigning Bus address 1 to it.
BMS master
A master can query all warning and operating messages from a slave.
If bus address 1 is assigned to a device, this device automatically represents the master, that means
that all addresses between 1 and 150 are cyclically scanned via the BMS bus for alarm and operating
messages. If the master receives no answer from five subsequent addresses, the scanning cycle will
be started again. If the master recognises incorrect answers from a slave, the fault message "Fault RS-
485" will be output via the BMS bus.
Fault causes may be:
Addresses are assigned twice
A second master exists on the BMS bus
Interference signals occur on the bus lines
A defective device is connected to the bus
Terminating resistors are not activated resp. not connected
2.3.9.4 Commissioning of an RS-485 network with BMS protocol
Connect the terminals A and B of all bus devices in one line.
Switch the terminating resistors on at the start and the end of the RS-485 network. If a device at
the end of the bus is not terminated, connect a 120  resistor to the terminals A and B.
Switch the supply voltage on.
Assign the master function and address 1 to a bus-capable device.
Assign addresses (2…33) to all other bus devices in consecutive order.
The iso1685P can only be operated as BMS SLAVE!

Function
13
iso1685P_D00003_00_M_XXEN / 04.2014
2.3.10 Alarm and operating messages via the BMS bus
Messages are transmitted to a maximum of 12 BMS channels. All alarm and operating messages
which may occur are described below.
2.3.10.1 Alarm messages
2.3.10.2 Operating messages
Alarm Channel Meaning
Alarm 1 (insulation fault) 1 Insulation resistance < response value Ran1
Alarm 2 (insulation fault) 2 Insulation resistance < response value Ran2
Connection system 4 Connection error (available from software version 2.x)
Connection PE 5 Connection error: E/KE not connected to PE
Device error 7 Internal device error with error code
Overtemperature
coupling 10 Overtemperature coupling L1/+
Overtemperature
coupling 11 Overtemperature coupling L2/–
Overtemperature PGH 12 Overtemperature of the locating current injector
Alarm Channel Meaning
Insulation resistance 1 Insulation resistance ≥response value Ran1
Insulation resistance 2 Insulation resistance ≥response value Ran2
Leakage capacitance 4 Leakage capacitance Ceto earth
System voltage 5 Voltage between L1/+ and L2/–
Partial voltage U+/PE 6 Voltage between L1/+ and PE
Partial voltage U-/PE 7 Voltage between L2/– and PE
PGH current 8 Current locating current of the locating current injector
(PGH)
Temperature coupling 10 Current temperature of the coupling L1/+
Temperature coupling 11 Current temperature of the coupling L2/–
Temperature PGH 12 Current temperature of the locating current injector

Function
14 iso1685P_D00003_00_M_XXEN / 04.2014
2. 4 Display and operating controls
2.4.1 Alarm LEDs on the top of the enclosure
LED Description
ON
(green)
Power On indicator
Flashes with a pulse duty factor of
approx. 80 % and 1 Hz.
Device error:
Lights continuously, when the device stops
functioning (device stopped).
Software update:
Flashes approx. three times faster during firmware
update. Update time < 4 minutes
PGH ON
(green)
Insulation fault location:
Flashes with the cycle of the locating current.
Service
(yellow)
Internal device and connection error (system,
earth):
Lights continuously.
Also refer to the list of error codes page 25.
A L A R M
1
(yellow)
Insulation fault 1 (prewarning):
Lights continuously, when the insulation resistance
falls below response value 1, RF < Ran1.
Flashes:
Connection fault earth.
ALARM 2
(yellow)
Insulation fault 2 (Alarm):
Lights continuously, when the insulation resistance
value falls below response value 2, RF < Ran2.
Flashes:
Connection fault earth.
SERVICE
ALARM 2
ISOMETER
®
iso1685
ON
ALARM 1
PGH ON

Function
15
iso1685P_D00003_00_M_XXEN / 04.2014
2.4.2 Display and operating elements on the pcb
I2 I1 A B S 31 32 34 21 22 24 11 12 14 E KE A1 A2
L1/+ L2/-
SS8100: Termin RS485
µSD-Card
DIP switch
Alarm LEDs
I2: I2+, I2- I1: I1+, I1-


Function
16 iso1685P_D00003_00_M_XXEN / 04.2014
2.4.3 Alarm LEDs on the pcb
LED Description
ON
(green)
Power On indicator
Flashes with a pulse duty factor of approx. 80 %.
Device error:
Lights continuously, when the device stops
functioning (device stopped).
Software update:
Flashes faster during the firmware update approx.
three times faster than in the standard mode,
update time < 4 minutes.
PGH On
(green)
Insulation fault location:
Flashes with the cycle of the locating current.
Service
(yellow)
Internal device and connection error (system,
earth):
Lights continuously.
Also refer to the list of error codes page 25.
Alarm 1
(yellow)
Insulation fault 1:
Lights continuously, when the insulation resistance
falls below response value 1, RF < Ran1.
Flashes:
Connection fault earth.
Alarm 2
(yellow)
Insulation fault 2:
Lights continuously, when the insulation resistance
value falls below response value 2, RF < Ran2.
Flashes:
Connection fault earth.
SDCARD-
LED
- Lights:
a compatible µSD card was inserted.
- Flashes/flickers:
the device is getting access to the µSD card.
- Flashes slowly (1 Hz):
an incompatible µSD card has been inserted.

Function
17
iso1685P_D00003_00_M_XXEN / 04.2014
2.4.4 DIP switch and μSD card on the pcb
The relative position of the operating elements is shown in the presentation below.
2.4.4.1 Setting the BMS address
The factory setting of the BMS address can be changed using the DIP switch SS8103.
Factory setting BMS address = 2
DIP switch,
SD card Function
SS8100 Termination BMS RS-485
SS8103
BMS address setting A0
Setting, leakage capacitance
Setting, measurement speed
ST6101 Alarm resetting
Firmware update
XST8000 Memory for firmware and log files
(µSD card)
SS8103
BMS
address A4 A3 A2 A1 A0
2 00000
3 00001
4 00010
5 00011
6 00100
7 00101
8 00110
9 00111
10 01000
.. .. .. .. .. ..
... ... ... ... ... ...
33 11111
XST8000
SS8103
ST6101
LEDs
SS8100 ON
OFF
RS-485
OFF ON

Function
18 iso1685P_D00003_00_M_XXEN / 04.2014
2.4.4.2 Setting the permissible system leakage capacitance
or measurement speed
Segments 6 and 7 of the DIP switch SS8103 are used to select the maximum system leakage capaci-
tance Ce max and to set the measurement speed. The measurement speed, for example,
can be set to "Slow" in the event of frequently occurring false alarms caused by transients in the sys-
tem. In the Slow mode, the measuring time doubles. Segment 8 is reserved.
2.4.5 Starting the firmware update via the BMS bus
The firmware can be updated via the BMS bus using the BMS update manager which
can be obtained from Bender.
2.4.6 History memory
All warnings, alarms and device errors are stored in the internal history memory with date and time.
The time the event started, the time of acknowledgement and end of the event are recorded.
The history data is copied from the internal EEPROM to the History.csv file on the µSD card under the
following conditions:
– following device start-up
– during operation once an hour
– when a compatible µSD card has been inserted
For the evaluation of the history memory, the Excel tool "iso1685 History.xlsx" can be made available.
By way of example, history memory entries are shown on page 33.
2.4.7 Resetting error messages
Recorded errors are provided as alarm messages on the BMS bus.
Pressing the reset button ST6101 will reset these error messages. If the error continues to exist, the
message will be generated again.
Before changing the settings on the DIP switch make sure that the supply voltage
is switched off.
DIP switch SS8103, segment 6:
OFF = 150 µF = Ce max
ON = 500 µF = Ce max
DIP switch SS8103, segment 7:
OFF = Fast
ON = Slow
When the maximum system leakage capacity Cemax is set to 500 μF the upper
limit of measuring range for the insulation resistance decreases from 1 MΩ
to 200 kΩ. Therefore, check the setting of the response values Ran.
SS8103
ST6101
XST8000
LEDs

19
iso1685P_D00003_00_M_XXEN / 04.2014
3. Installation, connection and commissioning
3. 1 Installation
Install the device using four M5 screws, also refer to the dimension diagram where the drilling holes
are illustrated. When operating he device, it has to be placed in vertical position with the system
coupling (L1/+, L2/–) on top.
All dimensions in mm.
Fig. 3.1: Dimension diagram of the enclosure with view on the plug-in terminals and alarm LEDs





[





Installation, connection and commissioning
20 iso1685P_D00003_00_M_XXEN / 04.2014
3. 2 Connection
Connect the device with the help of the connection and terminal diagram. Use the adjacent legend.
All enclosed plug-in terminals are labelled.
Fig. 3.2: Connection and terminal diagram
Risk of electric shock!
Touching uninsulated live conductors can result in death or serious in-
jury. Therefore avoid any physical contact with active conductors and
ensure compliance with the regulations for working on electrical instal-
lations.
I2+ I2- I1+ I1- A B S 31 32 34 21 22 24 11 12 14 E KE A1 A2
L1/+ L1+ L2/- L2/-
iso1685P
L1/+
L2/-
PE
U
S
A1 A2 ABSEKEI2+ I2- I1+ I1- L1/+ L2/-
K3 K2 K1
31 32 34 11 12 1421 22 24
1 A 1 A 6 A 6 A
k l kT lT