KWG -ISO5 Operating Manual

Insulation monitor

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KWG-ISO5

Insulation monitor

Operating Manual

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Page 1 Powerful. Innovative. KWG-ISO5 Insulation monitor Operating Manual...
Page 2: Manufacturer Address
Operating Manual Imprint Document type: Operating Manual Document name: KWG_ISO5_Operating-Manual_V2-0_EN Version: V2.0 Language: Number of pages: 42 Pages Created by: Tim Kurz Created on: 06.07.2024 Modified by: Tim Kurz Modified on: 09.09.2024 Copyright Copyright © 2024 KW-Generator GmbH All rights reserved. Manufacturer address KW-Generator GmbH Bänglesäcker 24...
Page 3: List Of Changes
Operating Manual List of changes Index Modified by Stand Amendment V1.0 Michael Kurz 10/2021 First edition V2.0 Tim Kurz 09/2024 New layout; adaptation of texts Version: V2.0 Doc.name: KWG_ISO5_Operating-Manual_V2-0_EN Page 3 from 42...
Page 4: List Of Illustrations
IST OF ILLUSTRATIONS IST OF TABLES OREWORD AND GENERAL INFORMATION BOUT THESE OPERATING INSTRUCTIONS ISPLAY OF WARNINGS RESENTATION CONVENTIONS 2.3.1 XTENDED SYMBOLISM KWG-ISO5 NTENDED USE OF THE 2.4.1 TANDARDS AND REGULATIONS UARANTEE UARANTEE AFETY INSTRUCTIONS UALIFICATION OF STAFF AFE OPERATION...
Page 5 Operating Manual 1 - Table of contents 7.3.1 KWG-ISO5 OCCUPANCY PLAN 7.3.2 KWG-ISO5 P IN ASSIGNMENT INTERFACE 7.4.1 ARDWARE 7.4.2 MESSAGES 7.4.3 NTERFACE TO THE MONITOR OPTIONAL CURRENT TRANSFORMER EQUIPMENT SSEMBLY 7.5.1 LANGE MOUNTING 7.5.2 RAIL MOUNTING KWG-ISO5 ONNECTION OF THE 7.6.1...
Page 6: Table Of Contents
Operating Manual 1 - Table of contents 1.1 List of illustrations Illustration 1: KWG-ISO5 - Structure - Overview Connections ............18 Illustration 2Type plate KWG-ISO5 (example) ................19 Illustration 3KWG-ISO5 allocation plan ..................28 Illustration 4Assembly - Flange mounting ..................33 Illustration 5Mounting - DIN rail mounting ...................33 Illustration 6Connection: All-pole disconnection with tripping device and with pre-warning ..34...
Page 7 1 - Table of contents 1.2 List of tables Table 1KWG-ISO5 Structure Overview ..................18 Table 2: KWG-ISO5 - Explanation ....................19 Table 3Technical data - Mechanical data ..................20 Table 4Technical data - Electrical data - Input ................20 Table 5Technical data - Electrical data - Measuring circuit ............20 Table 6Technical data - Permissible climatic conditions ...............20...
Page 8 The safety and hazard information and the general data apply to all KWG-ISO5 and must always be observed. Following the instructions in this operating manual helps to avoid hazards, unnecessary repair costs and downtime that could result from incorrect installation or operation.
Page 9 Operating Manual 2 - Foreword and general information 2.2 Display of warnings For better differentiation, hazardous risks are identified in the instructions by the following warning signs and signal words. DANGER Disregarding such warnings can lead to serious injury or even death. WARNING Disregarding such warnings can lead to serious injury or even death.
Page 10 Operating Manual 2 - Foreword and general information 2.3 Presentation conventions The presentation conventions described below are used: Name Representation Function Instruction for action 1), 2) etc. Prompts an action. 1st level Instruction for action a), b) etc. Denotes a section in a sequence of actions. 2nd level ➢...
Page 11 The KWG-ISO5 monitors the insulation resistance of an unearthed AC system in the wide voltage range from 85 V to 300 V to earth with DC components, which is fed by a KWG generator. Only one KWG-ISO5 insulation module may be connected in each conductively connected system.
Page 12: Standards And Regulations
DIN VDE0100-551. Guarantee The KWG-ISO5 may only be used for the applications specified here and only in accordance with the information in these operating instructions. KW-Generator GmbH accepts no liability for improper or abusive use of the KWG-ISO5.
Page 13: Safety Instructions
3 - Safety instructions AFETY INSTRUCTIONS Always observe the safety instructions listed in this chapter when working with the KWG-ISO5. These are supplemented by additional specific warnings that only apply to certain actions and activities. These specific warnings are indicated at the relevant points in the manual and are highlighted accordingly.
Page 14 Operating Manual 3 - Safety instructions 3.3.1 Safety rules for working on electrical systems Always follow the five safety rules for working on electrical systems when working on the KWG- ISO5: ➢ Unlock. ➢ Secure against switching on again. ➢ Check that there is no voltage.
Page 15 (including existing auxiliary circuits). ➢ Protective panelling must not be removed and protective devices must not be disabled. ➢ Unauthorised persons, children and animals must not have access to the KWG- ISO5 during and after operation of the KWG-ISO5. Version: V2.0 Doc.name: KWG_ISO5_Operating-Manual_V2-0_EN...
Page 16: Personal Protective Equipment
Operating Manual 3 - Safety instructions 3.4 Personal protective equipment Personal protective equipment is required and must be used for various activities on the appliance/system. The specialised companies must provide sufficient protective equipment for their personnel and supervisors must check that it is worn. Command sign Meaning Explanation...
Page 17 Operating Manual 3 - Safety instructions Command sign Meaning Explanation Use head A safety helmet must be worn wherever falling, protection M014 swinging, toppling or flying objects are likely to hit your head and cause injury. Long hair can cause serious accidents if it is caught by machines or machine parts.
Page 18: General Structure
4 - Description of the ESCRIPTION OF THE 4.1 General structure The KWG-ISO5 is designed as a single-board solution and is therefore mouldable. A µController takes over the control and evaluation. All connections are pluggable. The housing can be flange-mounted or DIN rail-mounted.
Page 19: Type Plate
Operating Manual 4 - Description of the 4.2 Type plate Each KWG-ISO5 has a type designation, serial number, firmware and parameter version. These and other technical details can be found on the type plate. NOTE Please have the type designation, serial number, firmware and parameter version ready in case of queries, repeat orders or spare parts orders.
Page 20: Technical Data
4 - Description of the 4.3 Technical data The following tables provide an overview of the general data of the KWG-ISO5. If no other data is listed in the type-specific data sheet, the data of the  Table 3 to Table 10 Validity.
Page 21 Operating Manual 4 - Description of the Regulations: DIN EN 61557-8 DIN EN 61326-2-4 DIN EN ISO 13766-1 DIN EN 60529 Table 7Technical data - Regulations Data relay outputs: 4000 Vrms Dielectric strength between contacts and coil VDE Cert. No 40011901, UL E2140251 Type: PE014024 Rated voltage: 250 VAC (max.
Page 22 Operating Manual 4 - Description of the 4.4 Overview of protection classes (IP code) NOTE Enclosed is an extract from the EN 60529 standard (degrees of protection provided by enclosures (IP code)). Further information on the protection classes can be found in the current version of the EN 60529 standard.
Page 23 Operating Manual 4 - Description of the Protection from water: 2. code Designation - Explanation number No protection. Protected against dripping water: Vertically falling drops must not have any harmful effects. Protected against dripping water when the housing is tilted up to 15°: Vertically falling drops must not have any harmful effects if the housing is inclined by an angle of up to 15°...
Page 24: Transport And Storage
Components may be damaged by moisture. ➢ During transport and storage, ensure that all covers and/or packaging are properly closed. ➢ If the KWG-ISO5 is not put into operation immediately, it must be stored in a protected, clean, dry and vibration-free location. Permissible temperatures: Transport -30 °C to +85 °C...
Page 25 KWG-ISO5 UNCTIONAL DESCRIPTION The KWG-ISO5 generates a pulse-shaped measuring voltage. This is superimposed on the IT system to be monitored via terminals L1 / L2 (N) and PE. Insulation faults between the IT system and earth close the measuring circuit.
Page 26: Installation And Commissioning
➢ Before carrying out any work on the appliance, switch it off completely and secure it against unintentional switching on again. ➢ The KWG-ISO5 may only be operated with correctly fitted protective covers. ➢ Do not operate the KWG-ISO5 in potentially explosive atmospheres.
Page 27: Before Installation
7 - Installation and commissioning Before installation Before installation, check that: • the plug connections on the KWG-ISO5 are correctly plugged in and firmly engaged. • the mechanical assembly is correct. • the connections on the terminal board/terminal strip are made correctly (if present).
Page 28: Illustration 3Kwg-Iso5 Allocation Plan
Operating Manual 7 - Installation and commissioning 7.3 Circuit diagram KWG-ISO5 7.3.1 KWG-ISO5 occupancy plan Illustration 3KWG-ISO5 allocation plan page 28 from 42 Doc.name: KWG_ISO5_Operating-Manual_V2-0_EN Version: V2.0...
Page 29 Operating Manual 7 - Installation and commissioning 7.3.2 KWG-ISO5 Pin assignment Manufactur Number of Connection Type Function poles/spec. X1.1 CAN_Low X1.2 CAN_High AMP Mate-NLOK Tyco 4-pole 350792-1 X1.3 CAN_GND X1.4 VDD_CAN (12 - 24 V) X2.1 Alarm OUT / optocoupler X2.2...
Page 30 Operating Manual 7 - Installation and commissioning 7.4 CAN interface 7.4.1 Hardware: No terminating resistor (120 Ohm) is fitted as standard. The CAN interface is electrically isolated. For communication, a External supply voltage must be connected to X1 (U-GND). 7.4.2 CAN messages 7.4.2.1 Overview DA/PS PF LEN Description of the...
Page 31 Operating Manual 7 - Installation and commissioning 7.4.2.2.1 STATUS: ISO Status message Byte 7 Byte 6 Byte 5 Byte 4 Byte 3 Byte 2 Byte 1 Byte Calib ParaDef ParaNC ParaMod BuzzerOn IsoWarn IsoFault Table 20CAN - STATUS: ISO status message Byte 6 Calib: Calibrated - The ISO value is calibrated.
Page 32 KWG generator controller. The insulation value is output via the controller CAN bus. At the same time, the insulation value can be further processed in the KWG generator controller and used to control relays, for example. Independently of this, the insulation value can also be read directly from the CAN bus of the insulation monitor.
Page 33: Illustration 4Assembly - Flange Mounting
Operating Manual 7 - Installation and commissioning 7.5 Assembly 7.5.1 Flange mounting Height = All units in mm. Illustration 4Assembly - Flange mounting 7.5.2 DIN rail mounting Dimensions: 125.5 x 79 x 43 All units in mm. Illustration 5Mounting - DIN rail mounting Version: V2.0 Doc.name: KWG_ISO5_Operating-Manual_V2-0_EN Page 33 from 42...
Page 34: Illustration 6Connection: All-Pole Disconnection With Tripping Device And With Pre-Warning
Operating Manual 7 - Installation and commissioning 7.6 Connection of the KWG-ISO5 NOTE The illustrations shown in the current chapter are symbolic images for connection examples of the KWG-ISO5 isowatcher. 7.6.1 All-pole disconnection with tripping device and with advance warning Connection example Isowatcher KWG-ISO5.
Page 35: Illustration 7Connection: Monitoring With Advance Warning And Alarm In Vehicles
Operating Manual 7 - Installation and commissioning 7.6.2 Monitoring with advance warning and alarm in vehicles Connection example Isowatcher KWG-ISO5. All-pole disconnection with tripping device and advance warning. to the Load from the Generator - MOTOR VEHICLE + on-board voltage...
Page 36: Illustration 8Connection: All-Pole Disconnection With Main Contactor And With Pre-Warning
Operating Manual 7 - Installation and commissioning 7.6.3 All-pole disconnection with main contactor and with pre-warning Connection example Isowatcher KWG-ISO5. All-pole disconnection with tripping device and advance warning. ALG (energised in the event of a fault) to the Load from the...
Page 37: Maintenance
ATTENTION Damage to components due to water ingress possible. ➢ Moisture and wetness on the circuit board of the KWG-ISO5 or on the circuit board encapsulation can destroy the KWG-ISO5. Cleaning the switch box or the switch cabinet with high-pressure cleaners is strictly prohibited.
Page 38: Troubleshooting
5) Determine error states with the aid of the indicator lights / CAN bus. If a fault occurs, the ISO fault must be located in the alternator or in the switch box circuit. -> Contact KWG. b) If no fault occurs, the ISO fault is to be found in the electrical equipment (load).
Page 39 ➢ Before working on the appliance, it must be de-energised and disconnected from the power supply! ➢ Work on electrical systems and on the KWG-ISO5 may only be carried out when the system is switched off and de-energised. Switched-off drive units must be secured against unintentional restarting (including existing auxiliary circuits).
Page 40 11 - Repair 11 R EPAIR No repair or maintenance work can be carried out on the KWG-ISO5 by the user. We strongly recommend that you remove the KWG-ISO5 for this work and send it to KW-Generator GmbH. page 40 from 42 Doc.name: KWG_ISO5_Operating-Manual_V2-0_EN...
Page 41: Waste Disposal
If necessary, commission a disposal company. Further information can be obtained from the responsible environmental authorities or from KW-Generator GmbH as well as from the type-specific data sheet. Designation Material KWG-ISO5 Disposal as industrial electronics scrap. KWG-ISO5 is lead-free and contains a hardened potting compound.
Page 42: Spare Parts
Operating Manual 13 - Spare parts 13 S PARE PARTS Please contact KW-Generator GmbH directly for spare parts due to the wide range of possible variants. page 42 from 42 Doc.name: KWG_ISO5_Operating-Manual_V2-0_EN Version: V2.0...