Trafox SUPERINTEND IM-05DCCT User manual

Superintend IM-05DCCT Manual v1.1 English Rights to modify the content reserved
© Copyright Muuntosähkö Oy - Trafox 5.9.2022
SUPERINTEND IM-05DCCT
IMD Insulation Monitoring device for non-grounded (IT) electrical
networks of electric vehicles, charging stations or DC drives
Instructions for installation and use v1.1
AC/DC

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Table of Contents
INSTRUCTIONS ..................................................................................................3
SYSTEM DESCRIPTION .......................................................................................4
INSTALLATION ...................................................................................................4
PHYSICAL CONNECTION ..................................................................................... 4
USE ....................................................................................................................7
IM-05DCCT UNIT ............................................................................................... 7
STATUS OUTPUT ............................................................................................ 7
PWM OUTPUT................................................................................................. 7
CAN BUS REMOTE CONTROL ............................................................................ 9
TECHNICAL SPECIFICATIONS...........................................................................11
IM-05DCCT UNIT ............................................................................................. 11
MECHANICAL DIMENSIONS ............................................................................... 12

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INSTRUCTIONS
These instructions for use are intended for trained electrical engineering professionals.
The IM-05DCCT devices are marked with the symbol shown below, which indicates that
if the device has been installed incorrectly or used in violation of instructions, safety
could be jeopardised. The description of the symbol is presented in this manual instead
of on the device due to space constraints. Such sections are marked with the symbol
shown below.
A symbol indicating possible danger. A description of the symbol may be
placed on the device or provided in the instructions for use.

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SYSTEM DESCRIPTION
IM-05DCCT is a device with which the insulation resistance and capacitance of floating
electricity networks can be measured and monitored in electric vehicle, charging station
or DC drive applications.
INSTALLATION
PHYSICAL CONNECTION
The devices are connected to the electrical network, which may contain
dangerous voltage. The device may be installed by a trained electrical
engineering professional only. The device contains no user-serviceable parts
and must not be opened. Using the device in violation of these instructions
may compromise safety.
The IM-05DCCT unit is the main unit of the system. Two IM-05DCCT devices may not be
installed galvanically in the same network, for example on the same DC network. The
connection is performed as presented in Figure 1. If required by the installation site, the
installation and wiring should be performed in accordance with standards IEC 60364 as
well as EN 50110.
The IM-05DCCT unit comes with the connections shown in the following table.
Connectors
A
PCB connector type
TE Connectivity Micro MATE-N-LOK 2-1445088-
8
Crimp contacts
8 x TE Connectivity Micro MATE-N-LOK 1-
794606-1
Housing for crimp contacts
TE Connectivity Micro MATE-N-LOK 1445022-8
Pin 1
Chassis ground / electronic ground
Pin 2
Supply voltage
Pin 3
Chassis ground
Pin 4
Chassis ground (must be separate wire)
Pin 5
PWM output (high side), (only for special
orders)
Pin 6
PWM output (low side)
Pin 7
not connected
Pin 8
Status output (high side)
B
PCB connector type
TE Connectivity Micro MATE-N-LOK 2-1445088-
2
Crimp contacts
2 x TE Connectivity Micro MATE-N-LOK 1-

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794606-1
Housing for crimp contacts
TE Connectivity Micro MATE-N-LOK 1445022-2
Pin 1
HV line +
Pin 2
HV line +
C
PCB connector type
TE Connectivity Micro MATE-N-LOK 2-1445088-
2
Crimp contacts
2 x TE Connectivity Micro MATE-N-LOK 1-
794606-1
Housing for crimp contacts
TE Connectivity Micro MATE-N-LOK 1445022-2
Pin 1
HV line -
Pin 2
HV line -
D
PCB connector type
TE Connectivity Micro MATE-N-LOK 2-1445088-
2
Crimp contacts
2 x TE Connectivity Micro MATE-N-LOK 1-
794606-1
Housing for crimp contacts
TE Connectivity Micro MATE-N-LOK 1445022-2
Pin 1
CAN_L
Pin 2
CAN_H
A
B
8
7
6
5
4
3
2
1
2 1
C
2 1
1 2
D

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Figure 1. System connection.

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USE
IM-05DCCT UNIT
The IM-05DCCT unit independently measures the insulation resistance and capacitance
of the IT network to be monitored, in relation to protective earth. The measurement is
performed by feeding two summed low frequency alternating voltages between the
network and the PE conductor. These generate a low current that travels through the
insulation resistance and capacitance to be measured. The insulation resistance and
capacitance are calculated by FFT analysing the current and then measuring the
amplitude and phase. The insulation resistance values are filtered with averaging filter.
The network voltage is monitored and undervoltage conditions are detected. Connection
of the earth wires is monitored. A self test is executed automatically every 5 minutes.
The overall status of the system is signaled with status output. The measured insulation
resistance value is signaled with PWM output. In case of error, the error type is also
signaled with PWM output.
Measurement values can be monitored and settings can be changed using the CAN bus
interface.
STATUS OUTPUT
The status output signalises the overall condition of the system. The operating principle
of the status output is high side, and an external pull-down resistor is needed. The
status output has the following states:
High
System ok, insulation resistance above alarm level
Low
Alarm situation:
•insulation resistance below alarm level
•system fault
•earth wire disconnected
•system undervoltage
•supply voltage disconnected
PWM OUTPUT
Under normal conditions, the PWM output signalises the measured insulation resistance.
Under special conditions, the PWM output signalises some information about the
condition. The PWM output has two possible configurations:

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Low side
Pin 6
Pull-up resistor needed
Default configuration
High side
Pin 5
Pull-down resistor needed
Manufactured only for special orders
The PWM output works according to the following table. PWM duty cycle is always
determined based on the active time (PWM signal low at the low side configuration and
PWM signal high at the high side configuration).
0 Hz
Low side
High: shorted to supply voltage line
Low: device started but the first measurement result is not
yet available
High side
(only for
special orders)
Low: shorted to ground line
High: device started but the first measurement result is not
yet available
10 Hz
•System ok
•System voltage ok
•Insulation resistance RFcan be determined from the PWM duty cycle
using the following formula:
𝑅𝐹=90% ×1200𝑘Ω
𝐷𝑃𝑊𝑀 +1200𝑘Ω −1200𝑘Ω
DPWM = PWM duty cycle (5…95%)
PWM duty cycle 5 % = ∞
PWM duty cycle 50 % = 1200 kΩ
PWM duty cycle 95 % = 0 kΩ
20 Hz
•System ok
•System undervoltage condition
•Insulation resistance RFcan be determined from the PWM duty cycle
using the same formula as with the 10 % frequency
30 Hz
•Device started and the first measurement result is available with the
following PWM duty cycles:
PWM duty cycle 5…10 % = insulation resistance above the alarm level
PWM duty cycle 90…95 % = insulation resistance below the alarm level
•The first measurement result is a rough estimate. When the PWM
frequency is 30 Hz, the device is performing a calibration. After the
calibration, the PWM frequency is changed to 10 Hz or 20 Hz and the
PWM duty cycle is set according to the accurate measurement result.
40 Hz
•System fault
PWM duty cycle 47,5…52,5 %
50 Hz
•Earth wire disconnected
PWM duty cycle 47,5…52,5 %

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CAN BUS REMOTE CONTROL
The CAN bus interface of IM-05DCCT uses the OBD II frame format with the following
specifications:
•CAN speed: 250 kbps
•Standard frame
•CAN ID: 0x7F1
The following services are supported:
Service 0x60
PID
(hex)
Units
Nbr
Data
bytes
Input
Bytes
returned
Output
0x01
IMD status
mask
-
2
See below "IMD status mask"
0x02
Insulation
resistance
kΩ
-
2
256 * A + B (16 bit unsigned integer)
0x03
Leakage
capacitance
0.1
uF
-
2
8 bit signed integer
0x04
Network
voltage
V
-
2
256 * A + B (16 bit unsigned integer)
0x05
FW version
-
2
(256 * A + B)/100 -> 123 = 1.23
IMD status mask
Bit
Description
Status
0
Self test activity
0=inactive, 1=active
1
Last self test status
0=pass, 1=fail
2
Device condition
0=ok, 1=fault
3
Ground wire connection
status
0=ok, 1=fault
4
Insulation alarm status
0=inactive, 1=active
5
Insulation warning status
0=inactive, 1=active
6
Network voltage status
0=ok, 1=undervoltage
7
Calibration activity
0=inactive, 1=active

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Service 0x61
PID
(hex)
Units
Nbr
Data
bytes
Input
Bytes
returned
Output
0x01
Set Alarm
level (must
be equal or
lower than
warning
level)
kΩ
2
256 * A + B (16 bit
unsigned integer),
100…1000
-
0x02
Set Warning
level (must
be equal or
higher than
alarm level)
kΩ
2
256 * A + B (16 bit
unsigned integer),
100…1000
-
0x03
Set
Averaging
factor
1
8 bit unsigned integer,
1…10
-
0x04
Set
Undervoltage
level
V
2
256 * A + B (16 bit
unsigned integer), 0,
50…500 (0 =
undervoltage
detection inactive)
-
0x05
Self test
1
8 bit unsigned integer,
1 = start self test
-
Input values outside the allowed range are ignored
Service 0x62
PID
(hex)
Units
Nbr
Data
bytes
Input
Bytes
returned
Output
0x01
Get Alarm
level
kΩ
-
2
256 * A + B (16 bit unsigned integer),
100…1000
0x02
Get Warning
level
kΩ
-
2
256 * A + B (16 bit unsigned integer),
100…1000
0x03
Get
Averaging
factor
-
2
8 bit unsigned integer, 1…10
0x04
Get
Undervoltage
level
V
-
2
256 * A + B (16 bit unsigned integer),
0…500 (0 = undervoltage detection
inactive)

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TECHNICAL SPECIFICATIONS
IM-05DCCT UNIT
Voltage ranges
Operating voltage [US]
10…36VDC
Maximum voltage at the measurement connectors M1 and M2 [UN]
690VAC / 1000VDC
Frequency range of the network to be monitored
DC, 10…500Hz
Input power
2W
Alarm parameters (set at factory or with the CAN bus interface)
Alarm limit [Ran]
100kΩ…1MΩ
Hysteresis
25%
Averaging factor
1…10
Undervoltage detection threshold
OFF / 50…500V
Measuring specifications
Measuring range
0kΩ…10MΩ
Relative uncertainty
±20kΩ @ 0…50 kΩ
±15% @ 50kΩ... 2MΩ
±25% @ 2MΩ…10MΩ
Measuring voltage UM
±25V
Measuring current IMat RF= 0
50uA
Impedance Ziat 50 Hz
≥500kΩ
Internal DC resistance Ri
≥500kΩ
System leakage capacitance Ce (nominal measurement
specifications)
≤1uF
Response time tan (RF= 10 MΩ to Ran/2; at Ce< 1 μF)
5s
Response time tan (RF= 10 MΩ to Ran/2; at Ce< 2 μF)
10s
Response time tan (RF= 10 MΩ to Ran/2; at Ce< 3 μF)
15s
Outputs
Status output
High side (external pull-down resistor required)
High = system ok, insulation resistance above alarm level
Low = alarm situation (insulation resistance below alarm level, system fault,
earth wire disconnected, system undervoltage or supply voltage
disconnected)

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PWM output
Low side (external pull-up resistor required) (High side for special orders)
Indication of the measured insulation resistance and possible fault conditions
CAN bus interface
High speed CAN, internal terminating resistor 120 Ω
Outputs are short circuit proof and galvanically isolated from the HV side
Other details
Operating temperature
-40…+85°C
Operating humidity (max.)
95% without condensation
Mounting
M4 metal screws
Maximum dimensions - Height
22mm
Maximum dimensions - Width
60mm
Maximum dimensions - Length
140mm
Weight
63g
Standards
Measurements
IEC 61557-8:2014 (requires alarm indicator and
test button implemented at the customer’s
installation)
Safety
IEC 61010-1:2010 (3rd Edition), IEC 60664-1
EMC
IEC 61326-2-4, ISO 10605
Electrically propelled road vehicles - Safety
specifications
ISO 6469-3:2021
Road vehicles —Environmental conditions and
testing for electrical and electronic equipment
ISO 16750-1, ISO 16750-2, ISO 16750-3
Environmental tests
IEC 60068-2-14, IEC 60068-2-27, IEC 60068-2-
30, IEC 60068-2-38, IEC 60068-2-64
MECHANICAL DIMENSIONS