SIM200 SENSATA | Alldatasheet

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SIM200™ The SIM200 Insulation Monitoring Device (IMD) is designed for continuous active monitoring of unearthed (Isolated Terra) DC systems including charging stations, electric vehicles, and any other system with a nominal operation above 60 VDC. The SIM200 is UL2231 recognized to ensure safety at the highest standards and responds to electric hazards quickly and reliably with a patented signal injection algorithm and processing for continuous “Always On” monitoring of insulation. Additionally, this IMD provides robust self-diagnosis of its monitoring functions, modular CAN 2.0B interface for detailed system information, warning alarm with configurable level, fault alarm at 100 Ω/V and configurable CAN ID for flexibility. Safety

  • Continuous, “Always On” system monitoring of insulation
  • Dedicated fault state output via PWM
  • Stored capacitive energy monitoring
  • Digital out to indicate internal IMD error Usability
  • Warning alarm with configurable level
  • Fault alarm at 100 Ω/V (Configurable fault threshold available; See Ordering Options)
  • Configurable CAN ID Performance
  • Modular CAN 2.0B interface
  • Robust self-diagnosis of monitoring functions Active Insulation Monitoring Device Charging Station Truck Bus

SIM200™ Parameter Min Ty p i c a lMax Unit Conditions / Comments Power and General Characteristics Operational Supply voltage 9 12-24 30 V Operational supply current - 60 28 - mA 12 V supply

24 V supply

Operating temperature range -40 - +85 °C Input Impedance Rin - 2720 2720 1000 272 - kΩ xNx xKx xPx xQx Input impedance varies based on the device voltage configuration (hardware configured). The input impedance of the monitor is the parallel impedance imposed by the SIM200 between each rail and the chassis. See “Ordering Options” for more information. Isolation Monitoring Function Time to initial isolation estimate - 4.5 5.5 Seconds Response time to warning condition 4.3 - 5 Seconds Applies to the detection of warning (500 Ω/V) condition from a stable initial state under typical operating conditions. Response time to fault condition - 5.3 5.8 Seconds Applies to the detection of fault (100 Ω/V) condition from a stable initial state under typical operating conditions. Response time to short condition - - 6.5 Seconds Time needed to confirm short condition, for equivalent resistances for each variant see “Reporting of Short Condition”. Application Voltage Range (Vb) 1000 600 300 1363 1000 510 140 1568 1150 582 161 V xNx xKx xPx xQx “Typical” value is the max nominal system voltage to meet IEC 61557-8 and allow for operation at 115% of nominal. Total Y-capacitance 0.2 0.2 0.9 1.2 1.2 4.2 6.2 4.2 4.2 14.2 14.2 uF xNx xKx xPx xQx See “Y-Capacitors” section for more information. If higher Y-capacitance is desired, contact Sensata for further discussion. Isolation Resistance Measurements Reporting range 0 - 2720 2720 1000 272 kΩ xNx xKx xPx xQx The SIM200 provides the total resistance value for each HV rail, including that imposed by the SIM200 module itself, which is the upper bound for system insulation. Measurement resolution - 1 - kΩ Measurement accuracy - ±15 ±15 ±15 xNx xKx xPx xQx Listed accuracies are achieved when system isolation is stable and under typical operating conditions. Measurement update period - 250 - ms Reporting of short condition - 1.5 0.4 - kΩ xNx xKx xPx xQx Short condition will be reported when the isolation resistance of one of the High Voltage rail falls below the listed value. Reporting of short condition – low voltage mode - 0.8 - kΩ xNx xKx xPx xQx Low voltage mode when battery voltage < 15 V. T otal Capacitance Measurement Reporting range 0.2 1 - µF The total capacitance of the system is defined as the sum of all Y-capacitance in the system. Measurement resolution - 1 - nF Measurement accuracy - ±10 - % Typical accuracy is achieved when the system time constant is between 0.5 s and 1.5 s and under typical operating conditions, and capacitive measurement uncertainty is reported <10% confidence interval. Measurement update period - 250 - ms

SIM200™ Parameter Min Ty p i c a lMax Unit Conditions / Comments Noise Immunity of Measurements Common mode voltage on the battery terminals 20 - - VPK-PK No observable effect on isolation resistance value. Measured with square, ramp, and sine wave test signals from 1 kHz to 100 kHz. Common mode noise below 1 kHz expected to interfere with isolation resistance measurement. Differential mode voltage on the battery terminals (battery voltage variations) - 100 - VPK-PK No observable effect on isolation resistance value. Tested with battery-voltage driving profile that has multiple instantaneous voltage changes up to ±100 V and overall slow battery voltage fluctuation from 910 V to 480 V. Communication and Connectors Parameter Spec Speed T ermination CAN Communication 2.0B 500 or 250 kbit/s 120 Ω termination resistor (optional). Connectors Parameter Manufacturer Position Part Number Description COM & power on board Molex 6 705510040 P1: 6 pos. right angle single header, shrouded connector (2.54 mm) through hole tin. COM & power mating connector Molex 6 50579406 Use appropriate crimp contacts (available for AWG 22, 24 and 26). Voltage sensing on board Molex 2 705510036 J1, J3, J4: MINIFIT JR HDR 02P 94V-0 30AU Voltage sensing mating connector Molex 2 50579402 MINIFIT JR RCPT DR SIDETABS 2 CKT 94V-0. Crimp contacts available for AWG 22. Voltage Measurements Measurement range ±1627 ±1168 ±599 ±164 ±1652 ±1186 ±608 ±167 - V xNx xKx xPx xQx Applies to HV rail measurements with respect to chassis. Offset error -100 ±50 +100 mV Over operating temperature range. Gain error -2 ±0.5 +2 % Over operating temperature range. Measurement resolution (compact reporting) - 1 - V Measurement resolution (high-resolution reporting) - 100 - µV Measurement update period - 10 - ms T emperature Measurement Absolute measurement error -5 ±0.5 +5 °C Over operating temperature range. Measurement resolution - 10 - m°C Measurement update period - 250 - ms

SIM200™ Resistance Measurement Accuracy – xNx and xKx Variants Isolation excluding input impedance of IMD. Accuracies for operation under nominal conditions, battery voltage ≥ 15 V. Accuracy under 0 V operation ≤ 15% error for fault detection, compliant with IEC 61557-8. % Error Test Resistance (kΩ) xNx and xKx Absolute Error - Asymmetrical Absolute Error 1.2 uF Absolute Error 2.2 uF Absolute Error 4.2 uF 50 70 130 250 500 1000 5000 15000 7 7 10 10 10 5 5 5 5 5 5 20 140 150 1000 5000 15000 xPx Absolute Error - Asymmetrical Absolute Error 1.2 uF Absolute Error 4.2 uF Absolute Error 8.2 uF Absolute Error 14.2 uF % Error Test Resistance (kΩ) 5 5 5 5 5 7 7 15 15 20 140 150 500 1000 5000 15000 xPx Absolute Error - Symmetrical Absolute Error 1.2 uF Absolute Error 4.2 uF Absolute Error 8.2 uF Absolute Error 14.2 uF Test Resistance Rn = Rp (kΩ) % Error 5 5 5 5 5 5 7 7 % Error Test Resistance Rn = Rp (kΩ) Absolute Error 1.2 uF Absolute Error 2.2 uF Absolute Error 4.2 uF xNx and xKx Absolute Error - Symmetrical 50 70 130 250 500 1000 5000 15000 5 5 5 5 Non test side resistance leakage = 15 MΩ ± 10 kΩ for resistances < 50 kΩ ± 15 kΩ for resistances < 50 kΩ Non test side resistance leakage = 15 MΩ ± 3 kΩ for resistances <20 kΩ ± 3 kΩ for resistances <20 kΩ Resistance Measurement Accuracy - xPx Isolation excluding input impedance of IMD. Accuracies for operation under nominal conditions, battery voltage ≥ 15 V. Accuracy under 0 V operation ≤ 15% error for fault detection, compliant with IEC 61557-8.

SIM200™ Non test side resistance leakage = 15 MΩ ± 1.5 kΩ for resistances <15 kΩ ± 1.5 kΩ for resistances <15 kΩ Resistance Measurement Accuracy - xQx Isolation excluding input impedance of IMD. Accuracies for operation under nominal conditions, battery voltage ≥ 15 V. Accuracy under 0 V operation ≤ 15% error for fault detection, compliant with IEC 61557-8. CAN Interface SIM200 module utilizes a simple CAN “polling” interface in which the system controller requests desired information according to a library of “Operation Codes” or “Op Codes”. The CAN interface can be utilized by the system to obtain detailed system status information, as well as detailed diagnostic information. Description Op_Code Get isolation state 0xE0 Get isolation resistances 0xE1 Get system Y-capacitances 0xE2 Get HV rail measurements 0xE3 Get battery voltage 0xE4 Get error flags 0xE5 Get dynamic electrical isolation 0xE6 Get dynamic capacitive energy 0xE7 Example Op Codes SIM200 Reported Uncertainties Along with the isolation resistance and system Y-capacitance estimate, the SIM200 reports an “uncertainty” value. The uncertainty measure provided should be understood as a measure of the suitability of the model (or lack of suitability), rather than as a measure of accuracy. In application, it is suggested that this uncertainty may be used in the following ways: Estimates with high levels of uncertainty should be ignored. A recommended threshold is ≤ 10% uncertainty for the estimate of interest. This is already handled on the SIM200 by the “High Uncertainty” status bit, which is set to 1 when one or more isolation estimate uncertainty is above 10% (see CAN protocol for detail). For most applications monitoring the resistive leakage path, no direct monitoring of the uncertainties is needed – only applicable monitoring of the status byte. For applications that require more certainty in the isolation estimate, an uncertainty threshold of less than 10% can be used. For sudden changes in the isolation parameters the IMD is monitoring, the uncertainty on the isolation parameters will spike until the change has settled and the IMD can resolve the parameters. A spike in the uncertainties (in a properly installed SIM200) indicates a sudden change in the isolation parameters or measurement circuit. 15 40 1000 5000 15000 xQx Absolute Error - Asymmetrical Absolute Error 1.2 uF Absolute Error 6.2 uF Absolute Error 14.2 uF % Error Test Resistance (kΩ) 3 3 3 15 40 1000 5000 15000 xQx Absolute Error - Symmetrical Absolute Error 1.2 uF Absolute Error 6.2 uF Absolute Error 14.2 uF Test Resistance Rn = Rp (kΩ) % Error 3 3 3 3 5 5 5

SIM200™ Presence of Y-capacitors PWM Fault Output Connection to Isolated T erra (IT) Power System and ChassisY-capacitors should be connected directly to the IT power lines. Connecting them on the SIM200 board instead would impair the ability of the monitor to detect disconnection from the monitored IT power lines. SIM200 includes a dedicated Pulse-Width-Modulation output for reporting of system state, including Warnings and Faults. The SIM200 should connect through J1 at two separate chassis points. The SIM200 relies on this type of connection to detect proper connection to the chassis. DSO_1 PWM DSO_0 State Description 20% 0 Isolation Status Unknown: unable to determine isolation resistance (expected for up to response times during isolation transitions), SIM is disabled, or a hardware error is detected (e.g. missing connection) 40% 0 Electrical isolation below fault threshold (iso_fault_thr) 60% 0 Electrical isolation below warning threshold (iso_warning_thr) and above fault threshold 80% 0 Electrical isolation status OK – above Warning Threshold Any 1 Isolation Status Unknown - SIM Internal Error %DC = 100* T_hi /T_Period T_period T_hi PWM is falling edge referenced T_period = 10 ms (100 Hz) Y-Capacitors Y-capacitance in un-earthed DC systems The Y-capacitances in an IT DC system are the total capacitances that exist between the high voltage conductors (+/-) and the chassis (or protected earth) of that system. The values in each system are the total of the parasitic capacitances associated with the particular system design, including loads, conductor routing, etc, as well as the physical Y-capacitor components designed into such systems for Electromagnetic Interferece (EMI) and converter noise suppression. Presence of Y-capacitors The SIM200 relies on the presence of the ubiquitous Y-capacitors in the application system to perform its safety function of self-diagnosing its proper connections to the high voltage system. Absence of Y-capacitors with the minimum total value listed in the datasheet will generate a connection diagnostic. Y Cap of minimum value

SIM200™ Mounting Pattern and Connectors Handling and Installation Instructions Dimensions in mm Mounting Specifications

  • Electrical connections made with three 2-pin Molex connectors and one 6-pin Molex connector.
  • Electrical harness connections validated up to 10 disconnect-reconnect cycles.
  • Mounting through hole diameter: 4.19 ± 0.05 mm.
  • All mechanical validation with SIM200 was completed using 18-8 Stainless Steel Screws with 8-32 thread size.
  • Mounting torque shall not exceed 35 N cm.
  • Nylon washers may be used between screws and PCB for improved isolation between application chassis and board but are not required for device function.
  • For applications with vibration requirements, thread lock solution may be used on screws to prevent screws backing out over device life. Installation Considerations
  • SIM200 devices are designed to operate in high voltage applications that may present a shock hazard to users.
  • High voltage applications shall be unpowered before accessing SIM200 devices.
  • Access to SIM200 devices shall be restricted to trained operators only.
  • SIM200 devices are ESD (electrostatic discharge) vulnerable devices. Operators shall wear ESD bracelets when interfacing with SIM200 devices.
  • SIM200 devices contain exposed surface mounted components.
  • An operator’s hands and tools shall avoid interfacing with surface mounted components and only touch safe handling areas (see diagram) on edges of SIM200 PCBs.
  • SIM200 devices include intentional isolation cutouts (see diagram) to meet creepage and clearance requirements.
  • Materials with dielectric strength less than air (3 MV/m) shall not pass through isolation cutouts. Connector ID Manufacturer Part Number Mating Connector PN Mating Connector W/TPA PN P1 Molex 705510040 50579406 50579706 J1, J3, J4 Molex 705510036 50579402 50579702

SIM200™ Connector Pinout LED Indications Creepage and Clearance For reference, pinout information is also printed on the backside of the PCB: Chassis 1 One of two independent connections to chassis Chassis 2 One of two independent connections to chassis VX1 (Vp) HV supply + VX2 (Vn) HV supply - DSO_1 PWM output (must be pulled-up to 5-12 V with 5 k resistor) DSO_0 Digital output (must be pulled-up to 5-12 V with 5 k resistor) VCC Supply voltage CANL CAN low pin CANH CAN high pin GND GND Sequence 1 Sequence 2 Sequence 3 Sequence 4 SIM200 operating state LED 1 LED 2 LED 1 LED 2 LED 1 LED 2 LED 1 LED 2 ON OFF OFF ON ON OFF OFF ON Normal operation (period = 2 seconds) ON ON ON OFF OFF OFF OFF ON SIM diagnostic state (period = 3 seconds) The minimum creepage/clearance distance is 3 mm (nonhomogeneous) between the HV and LV sections of the board. *Note - The SIM200 is not an isolated measuring device. Between HV+ and HV- and chassis there exists a resistance equal to the input variance of the specific variant.HV+ to HV- Basic insulation Isolation between CAN bus, DSO, LV PWR and HV Connections 5 kV

SIM200™ Regional head offices: United States of America Sensata Technologies Attleboro, MA Phone: 508-236-3800 E-mail: support@sensata.com Netherlands Sensata Technologies Holland B.V. Hengelo Phone: +31 74 357 8000 E-mail: support@sensata.com China Sensata Technologies China Co., Ltd. Shanghai Phone: +8621 2306 1500 E-mail:support@sensata.com Datasheets provided by Sensata Technologies, Inc., its subsidiaries and/or affiliates (“Sensata”) are solely intended to assist third parties (“Buyers”) who are developing systems that incorporate Sensata products (also referred to herein as “components”). Buyer understands and agrees that Buyer remains responsible for using its independent analysis, valuation, and judgment in designing Buyer’s systems and products. Sensata datasheets have been created using standard laboratory conditions and engineering practices. Sensata has not conducted any testing other than that specifically described in the published documentation for a particular datasheet. Sensata may make corrections, enhancements, improvements, and other changes to its datasheets or components without notice. Buyers are authorized to use Sensata datasheets with the Sensata component(s) identified in each particular datasheet. HOWEVER, NO OTHER LICENSE, EXPRESS OR IMPLIED, BY ESTOPPEL OR OTHERWISE TO ANY OTHER SENSATA INTELLECTUAL PROPERTY RIGHT, AND NO LICENSE TO ANY THIRD PARTY TECHNOLOGY OR INTELLECTUAL PROPERTY RIGHT, IS GRANTED HEREIN. SENSATA DATASHEETS ARE PROVIDED “AS IS”. SENSATA MAKES NO WARRANTIES OR REPRESENTATIONS WITH REGARD TO THE DATASHEETS OR USE OF THE DATASHEETS, EXPRESS, IMPLIED, OR STATUTORY, INCLUDING ACCURACY OR COMPLETENESS. SENSATA DISCLAIMS ANY WARRANTY OF TITLE AND ANY IMPLIED WARRANTIES OF MERCHANTABILITY, FITNESS FOR A PARTICULAR PURPOSE, QUIET ENJOYMENT, QUIET POSSESSION, AND NON-INFRINGEMENT OF ANY THIRD PARTY INTELLECTUAL PROPERTY RIGHTS WITH REGARD TO SENSATA DATASHEETS OR USE THEREOF. All products are sold subject to Sensata’s terms and conditions of sale supplied at www.sensata.com. SENSATA ASSUMES NO LIABILITY FOR APPLICATIONS ASSISTANCE OR THE DESIGN OF BUYERS’ PRODUCTS. BUYER ACKNOWLEDGES AND AGREES THAT IT IS SOLELY RESPONSIBLE FOR COMPLIANCE WITH ALL LEGAL, REGULATORY, AND SAFETY-RELATED REQUIREMENTS CONCERNING ITS PRODUCTS, AND ANY USE OF SENSATA COMPONENTS IN ITS APPLICATIONS, NOTWITHSTANDING ANY APPLICATIONS-RELATED INFORMATION OR SUPPORT THAT MAY BE PROVIDED BY SENSATA. Mailing Address: Sensata Technologies, Inc., 529 Pleasant Street, Attleboro, MA 02703, USA sensata.com Copyright © 2025 Sensata Technologies, Inc. Rev.05/22/2025 Ordering Options

  • The following ordering options are available for SIM200-<XYZ> where: X = CAN communication Speed (A = 500 kbps, B = 250 kbps) Y = Voltage Range (See Below Table) Z = CAN Resistor Termination (A = 120 Ω Termination, B = No Termination)
  • Note the following definitions: Max Operational Voltage: The maximum voltage condition under which the SIM200 can monitor the system correctly – this should be the absolute highest voltage under which SIM200 is required to correctly monitor system insulation. Max Nominal System Voltage: The maximum permissible nominal system voltage for which a variant is suitable, given the requirements for an Insulation Monitor in IEC 61557-8. Application Voltage Range: The range of nominal system voltages for which a given variant is capable to reliably resolve Insulation Faults of 100 Ω/V.
  • Example: SIM200 is monitoring a DC charger with output up to 1000 V under typical conditions. According to IEC 61557-8, the SIM200 must be operational at voltages 115% of the nominal (1000 V) = 1150 V. Variant Max Nominal System Voltage Max Operational Voltage Minimum T otal Y-Capacitance (uF) Application Voltage Range Max Voltage Withstand Vx1 or Vx2 to CAN Max Voltage Withstand Vx1 to Vx2 Max Voltage Withstand Vx1 or Vx2 to Vch SIM200-xNx 1363 1568 0.2 1000-1363 V 5 kV 5 kV 2.5 kV SIM200-xKx 1000 1150 0.2 600-1000 V 5 kV 5 kV 2.5 kV SIM200-xPx 510 582 0.9 300-510 V 5 kV 3 kV 1.5 kV SIM200-xQx 140 161 2 60-140 V 5 kV 1 kV 0.5 kV SIM200-xKxX Reference SIM200-xKx specifications for hardware and performance details. Fault threshold is configurable and therefore this part is not UL compliant. See below notes on configuration. Configuration SIM200 features a “Setup Mode” where the CAN 2.0B interface can be used to configure the IMD. CAN speed, CAN ID, system max voltage, and the isolation warning threshold can all be configured from the default values if needed for the application. See CAN protocol “Setup Mode” and “Commands” for details on modifying the “Configuration Parameters”. Thresholds Fault (100 Ω/V) and warning (500 Ω/V default) thresholds are calculated using the configured system max voltage. If a higher voltage than the configured system max voltage is seen by the SIM200, the thresholds will be raised accordingly until the device is reset (via command or power cycle). When configuring warning threshold, ensure that any applicable safety standards are met by referring to the accuracies defined on the data- sheet. Fault threshold is locked* to comply with UL2231 recognition requirements. *For SIM200-xKxX, fault threshold is also configurable as described in the CAN protocol. Ensure that any applicable safety standards are met. Note that higher amounts of instability in isolation state output can be expected at very low thresholds in addition to the lesser accuracy spec- ified in the datasheet. SIM200 variants were validated to calculate fault thresholds within their respective application voltage ranges with 100 Ω/V fault threshold (e.g., 60 to 100 KΩ on SIM200-xKx) per UL2231. For fault resistances that are below this range, it is recommended to run application representative validation tests to ensure proper functionality.