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GLP3 safety and function test systems
The high-end test systems for complex applications
GLP3-Windows® test devices are fully automatic high-end systems for testing a wide variety of complex products. Common applications include run-in test benches, the testing of electronic assemblies, power supplies, cables, or washing machines. The GLP3 is ideal for complex test benches as well as linked assembly and test lines.
Thanks to many intelligent functions, the test system covers all application spaces of modern safety and function test technology. It is ideally suited for production, laboratory, test field, quality assurance, automation, and much more.
Flexible test plan creation, test order data entry, results database, serial number assignment, freely configurable label printing, barcode functions, and many other features leave nothing to be desired. Thanks to various interfaces to the modern IT world, there are hardly any limits to integration into demanding manufacturing processes.
Key Facts:
- Customer-specifically configurable test system and special solutions
- Protective conductor test up to 200 A
- Insulation test up to 10 kV
- High voltage test AC up to 100 kV
- High voltage test DC up to 100 kV
- Leakage current test 30 mA up to 1 MHz
- Function test 1- and 3-phase up to 1,000 A
- All types of safety tests
- Testing of physical measured variables: pressure, temperature, leakage …
- Optical inspection systems
- Up to 500 programmable test connections
- Switching matrices for all types of test methods
- PL e, SIL 3, Cat. 4 safety circuit
- High process safety
- Multiple stations with up to 50 test stations
- Ideal for complex test benches or linked assembly and test lines
Diverse test solutions for manifold applications
Electrical engineering requires countless applications – and the GLP3 test system adapts to these challenges. It masters the most diverse tasks of safety and function tests.
You have the option to configure hardware and software features. The result is a customized test system that is tailored to your needs and also budget-friendly.
The GLP3 test system combines all test methods in one device. This feature offers the possibility to test electrical products for all possible faults in a single test run.
The interaction of the different test methods with our award-winning innovations ensures the quality of your production.
Test solutions for diverse applications
A deep insight into the electrical product
The workflow in the GLP3 world
Test technology without limit
SCHLEICH develops and produces its own hardware and software. The software and memory are based on the latest proven Microsoft® technology. Our diverse innovations consistently set technological standards for modern test systems running on Windows®. The system provides the operator with a clear, well-structured display of the test – while extensive input and configuration options are available to the setup technician.
Quality assurance is also given due attention. For this purpose, comprehensive statistical evaluation is built-in to the test system, leaving virtually no wishes unfulfilled. Furthermore, you can document the tested quality for your customers with a variety of different protocol printouts.
The GLP3 test systems are manufactured according to your requirements based on the SCHLEICH MODULAR CONCEPT. From the pool of possible test methods, the required different test methods can be put together as needed.
Whether manual or automatic single, double, or multiple test stations – with or without a test cover or test table – or testing in automatic production lines, the GLP3 is the best solution. There are no limits to the application versatility of the GLP3. Precisely due to the enormous flexibility of hardware and software, the test system is cost-effective and precisely tailored to your specific task.
The Standard Equipment
Function and technology
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High-performance industrial PC
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SQL or ACCESS memory without limits
- Clear screen display without information overload
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Microsoft® Windows operating system
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Powerful test plan editing
- Automatic logbook and management of test plan history
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Built-in plausibility checks for all parameters
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Fast, precise measurement technology
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Extensive configuration options
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Script editor for maximum flexibility
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Save test plans and test results securely
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Storage locally or on the network
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Monitoring of switching cycles according to Industry 4.0
- Remote maintenance and remote calibration via remote access
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Numerous languages
Communication
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USB interfaces on the front and rear
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RS232 and LAN/Ethernet automation interface
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Digital I/O interface
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Result outputs for GO and NOGO
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Interfaces for barcode scanners and label printers
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CAN bus
Optional automation interfaces:
- EtherCAT
- PROFIBUS
- PROFINET
- and more
safety
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Start input
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Two-channel safety inputs according to EN50191
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Design for Performance Level "e"
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Connection for external dual-circuit emergency stop
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Connections for warning and result lamps
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Safety and warning messages
The SCHLEICH MODULAR CONCEPT
Custom test systems
Based on the SCHLEICH MODULAR CONCEPT, the GLP3 test systems provide a variety of combination options for various safety and function test methods. Your custom test task determines the test methods that you select from a large pool of test possibilities.
Whether one test method or a multitude – you determine the configuration! For example, your GLP3 can be configured as a specialized high voltage test device with many test outputs. For more complex test tasks, you might need a combination of all possible test methods.
The SCHLEICH MODULAR CONCEPT makes it possible to assemble exactly the test device you need. And not just by installing various individual test devices into an oversized test rack, but by integrating all tests into a compact modular housing. The housing size results from the type and scope of the various tests.
The flexibility of the GLP3 test systems is evident not only in the housing but also in the number and arrangement of the connections of the device. With the 19" container and especially with the 19" industrial cabinet, the measurement connections can be attached to all sides of the device. This allows us to meet all spatial requirements.
Every test device incorporates experience from many thousands of installations. This experience is consistently implemented at SCHLEICH, with passion and without compromise.
This is “customer based technology”.
Configuration examples
Your custom requirement defines the housing size
The test devices provide a variety of test options in just one housing, despite their very compact design. The combination of test methods according to the SCHLEICH MODULAR CONCEPT therefore also includes a modular housing concept.
Depending on the requirement, your application can be housed in a compact desktop device, a 19” rack-mount device, a 19” container, or a 19” industrial cabinet. For the professional and secure installation of the test technology, we use precisely fitting housing components from renowned German manufacturers as well as components from our own production.
The automatic test method switch-over and Mechatronics
Test technology from SCHLEICH has proven itself thousands of times in daily use. It is among the most reliable products on the market and provides high utility value through excellent performance and accuracy.
To save time, all Connections of the device under test can be connected using a contacting adapter. Subsequently, the test device performs the intended tests fully automatically without manual intervention. This is achieved by the SCHLEICH-typical automatic test method switch-over.
For devices under test with multiple Connections, it is more economical to connect all Connections of the device under test immediately to the test device. The test device then performs all tests fully automatically between all Connection points. This approach reduces the required cycle rate and thus the cost of a test. The switch-over between the various Connections is achieved by flexible switching matrices.
To minimize the time required for the connection of a device under test with many connections, we implement the frequently requested double or multi-station systems. In this setup, loading and discharge occur in one station while testing simultaneously in the other stations. In this way, very economical results can be achieved even with complex and extensive tests.
Test method switch-over
Depending on the type and scope of the test methods, we provide a variety of switch-overs. These ensure a fast and automatic change between the different test methods. Since the voltage differences between the test methods can be very large, safety is paramount for the switch-overs. A Resistance test with 3 V is switched just as reliably to the device under test as a high voltage test with 6000 V. To protect your employees and the device under test. And without compromise! Therefore, for switch-overs and matrices, we use only tens of thousands of times proven, high-quality components from our own production or from renowned manufacturers.
Matrices
We provide the suitable relay matrix for almost every task. The matrices differ in the number of connections and in the level of the TEST VOLTAGE to be switched. A matrix must switch 6000 V just as safely and reliably disconnect as millivolt signals. This is exactly what our engineers developed the matrices for. The matrices are designed for two- and four-wire applications. They can be cascaded to increase the number of connections as desired. Matrices with more than 100 connection points are not uncommon. The same applies to matrices as to test method switch-overs: Only the best quality is used.
Station switch-over
Instead of using two or more test devices, station switch-overs can represent an economical alternative, for which we also set the highest safety requirements. While testing is running in one test station, the other test station is loaded or discharged. In doing so, the operator inevitably touches terminals and Connection leads. Touching the terminals and Connection leads can pose an electrical hazard. Therefore, the measurement leads to the stations where no testing is currently taking place must be safely disconnected. Furthermore, it is recommended to additionally earth the Connections to the device under test.
Mechatronics | Script Control
In addition to hardware, the software also offers enormous flexibility. With the built-in script commands, you can implement additional PLC functionalities within the device. Similar to a PLC, inputs can be queried, outputs can be set, and logical operations can be created.
The economic advantage lies in the direct control of mechatronic functional sequences. You can switch valves, query limit switches, evaluate measured values yourself, and much more. The test device is thus able to generate additional functional sequences before, during, and after the test. This is ideal for custom test setups or for integration into automated manufacturing.
The Test Methods
protective earth resistance test
The protective conductor test is performed with an electronically controlled, constant Test current. From the voltage drop across the protective earth conductor and the measured current, the device calculates the protective conductor resistance. This must not exceed the maximum value specified in the standards.
Using a test tip, the operator sequentially probes the protective earth connections on the device under test. The Measurement is performed between the PE contact of the test socket or the central PE connection of the device under test and the test tip – fast, precise, and reliable.
Tests can also be run fully automatically – thanks to a built-in relay matrix, which precisely and reliably switches all required measurements.
Insulation Resistance Test
cold or warm
The insulation test is performed with an electronically controlled, constant TEST VOLTAGE. From the voltage drop across the insulation and the measured current, the device calculates the insulation resistance, which must not fall below the minimum value specified in the standards.
The measurement can be run:
- Between all electrical conductors (Protection Class I)
- Between electrical conductors and insulated housing parts (Protection Class II)
The operator probes with a test tip successively the housing parts to be tested. At the end of the Test, an automatic discharge of the device under test always takes place – for maximum safety.
Tests can also be run fully automatically – thanks to a built-in relay matrix, which precisely and reliably switches all required measurements.
DC High Voltage Test
cold or warm
The insulation test is run with an electronically controlled, constant DC high voltage test. During the measurement, the Test current must not exceed a specified maximum value. If the current rises above this, the Test is automatically Cancelled.
At the end of the Test, an automatic discharge of the device under test always takes place – for maximum safety.
Tests can be run manually or fully automatically – thanks to a built-in relay matrix, which precisely and reliably switches all required measurements.
AC High Voltage Test
cold or warm
The insulation test is run with an electronically controlled, constant AC high voltage test. During the measurement, the Test current must not exceed a specified maximum value. If this value is exceeded, the device automatically Cancelled the Test.
At the end of the Test, an automatic discharge of the device under test always takes place – for maximum safety.
Tests can be performed manually or fully automatically. Thanks to the built-in relay matrix, all required measurements are precisely and reliably switched.
φFunction test
1- to 3-phase
The function test is performed under nominal voltage and is based on the measurement of:
- Current consumption
- cos φ (power factor)
- Power consumption, active power, reactive power, apparent power
For each measured variable, set values are defined with ±tolerances. If the measured values are within the tolerance, the test result is GO.
Additionally, other parameters such as rotational speed, vibration, or other functional characteristics can be acquired in parallel with the function test – for comprehensive quality control.
leakage current test
1- to 3-phase
The leakage current test is performed in parallel with the function test. This verifies whether the leakage current from the conductors to the PE (earth leakage current) or to insulated enclosure parts (enclosure leakage current) is below the permissible limit values.
The leakage current must not exceed the maximum value specified in the standards – even considering various fault conditions.
Standard-compliant measuring circuits (MDs) according to EN, UL, and other international regulations are used for measurement.
The test software
The software is based on the Microsoft Windows® operating system. The optimized user interface enables operator-friendly creation of test plans, printing of test protocols, and statistical evaluation of the tests.
In automatic mode, all tests are performed fully automatically. The measurement results are continuously displayed and evaluated during the test. The clear GO/NO-GO display visualizes the automatic evaluation.
The test sequence is edited by simply adding or removing test steps. This allows the test sequence to be optimally adapted to different requirements. Each individual test step can be quickly edited and modified by double-clicking on the respective test step.
The comprehensive built-in operator management ensures that only authorized persons can make these changes. Additional work instructions make the GLP3 the perfect ISO 9001-compliant test equipment.
The Input
To edit test steps, a single mouse click on the test step is sufficient to change parameters and adjust tests. The use of a cumbersome test plan editor is not required. Settings are displayed to every operator but can only be changed by authorized personnel. All changes are saved in the history management and the logbook.
The Data
The GLP3 stores test plans and test results either locally on the hard drive or in an SQL memory on the network. We recommend networking the test devices due to the following advantages:
- All testing devices on the network access a common memory for test plans and test results.
- All test devices test according to the same specifications.
- A central memory for all test systems in a global network makes it easier for you to ensure the quality of your products worldwide. Regardless of location.
- At the same time, you gain insight into all test results worldwide from one or more locations.
- Through easy connection to ERP, PPS, or CAQ systems, the test systems can be optimally integrated into factory planning and production control.
Statistics
Meaningful statistics can be calculated based on a large number of test results. Therefore, during the development of the GLP3, great importance was placed on sensible and well-conceived storage of test results over a long period. Freely configurable search filters enable each operator to quickly and easily find the relevant data in the memory. Individual evaluations or summaries of test results over a longer, freely definable period with subsequent statistical analysis are possible.
Trend plots and Gaussian distributions provide clear information about the qualitative state of production. The GLP3 can display your data on a daily, weekly and monthly basis save and evaluate and display them on an order- or batch-by-order basis. With the integrated, extensive export functions, data from the memory in order to transfer them to other databases or further process them in Excel® format. This gives you the opportunity to also carry out your own evaluations.
The memory can be based on SQL or ACCESS®. For larger data volumes or for use in networks, we recommend using Microsoft® SQL.
The GLP3 in the Network
Test plans and test results can be stored locally or on a central server. This ensures high data security and optimal data exchange between different test systems.
The GLP3 operates optimally in all network infrastructures. This feature provides the ideal platform for collecting, managing, analyzing, and distributing information.
Proven and widely used Microsoft® technologies are used as memory.
The testing devices can also be ideally networked with ERP, PPS, and CAQ systems. For all requirements, we provide extensively tested and customer-optimized standard solutions.
Network Failure
Each test device automatically saves local copies of the current server test plan memory to continue working in the event of a network failure.
In the event of a network failure, local test plans are used, and the test results are stored locally on the test device.
After the network connection is restored, the test device automatically transfers the test results back to the server, so that the server memory is up-to-date again.
The GLP3 in Complex Global Network Integration
The Windows®-based GLP3 test devices can be operated in arbitrarily complex network topologies. You can install any number of test devices at various company locations worldwide, all working with a central server memory for test plans and test results. Our extensive experience in globally networking our test devices provides you with the safety to offer the same product quality regardless of the production location.
Naturally, all test plan, printing, labeling, and statistics tasks can also be run on the individual testing devices. However, to avoid disrupting the production process, it is advisable for networked systems to use separate workstations for these tasks. These workstations operate with the same software as the testing devices to achieve the highest possible ease of use.
The label templates can also be stored centrally on a server. The testing device loads the appropriate label according to the respective test plan and transfers the data to a thermal transfer printer after the test. The labels can also be designed according to your specifications.
In the event of remote maintenance (via Remote Access), we can temporarily dial into your network if required and switch directly to the individual test device. We then see the screen content of your test device directly at our location. With your permission, we also have access to the mouse and keyboard. These tasks are, of course, carried out only in consultation with you and require your separate access authorization.
Automation
Fully Automatic GLP3 Test Systems in Production
The GLP3 test systems can be excellently integrated into automated production. Automation, in particular, is a special strength of SCHLEICH due to its company structure.
In addition to software, electronics, and systems engineering, automation also involves mechanics and mechatronics. These services are provided by SCHLEICH mechanical design, our CNC machining centers, and mechanical assembly.
GLP3 built-in in your existing automation
You have an automated production and want to integrate the GLP3 into your production. For this purpose, the test device can be completely remotely controlled by a PLC via interfaces. If required, test plans and test parameters can also be transferred to the test device. The feedback of the test results is provided both qualitatively and quantitatively.
GLP3 built-in in a SCHLEICH test system
We supply test systems consisting of the test device, the contacting of the device under test, and the complete mechanical automation. Everything turnkey from a single source. All automation components are developed, designed, manufactured, assembled, and commissioned in-house at SCHLEICH.
Often, in addition to testing, the GLP3 also takes over the sequence control of the automation. For higher degrees of automation, a PLC is used as an alternative. We address customer wishes and requirements in a highly customized manner.
The result is a solution precisely tailored to the task.
Data exchange in automation
The GLP3 is ideally suited for integration into automation systems. For this purpose, it offers an enormous variety of interfaces for communication with various automation systems.
Typical requirements are:
- Control of complete processes and components
– Processing of inputs, signal generators, scanners, RFID readers…
– Setting outputs for e.g. cylinders…
– Control of electric Motors and drives… - Exchanging Start, Stop, and result signals
- Direct communication with a PLC control
- Bidirectional communication
– Receiving test plans and test parameters
– Sending qualitative and quantitative test results
– Sending raw data - Communication with robots, cameras …
These tasks are fulfilled by our configurable standard software modules, which reduce the effort for integrating the GLP3 into automation systems to a minimum.
Data exchange with IT systems
Data exchange between GLP3 and other IT systems is carried out via proven solutions.
Typical applications:
- Importing production orders from ERP systems
- Automatic dynamic generation of test plans from production orders and bills of material
- Automatic dynamic generation of test plans from composite sub-test plans
- Automatic generation of serial numbers from production order data
- Reporting of results to ERP systems
- Receiving label data for label printing
- Communication with specialized systems in the automotive industry
Traceability in the production chain
Traceability provides you with the ability to obtain clear and complete information about the entire manufacturing process, even retrospectively. In the event of quality problems during production or after delivery, traceability offers you the option to respond in a targeted manner.
We provide responses to the following questions:
- Which end products, assemblies, and components are affected?
- Which customers have the end products, assemblies, and components?
- Which assemblies and components are built into the end product?
- When, where, and by whom were which parts processed in the manufacturing process?
- Who manufactured or supplied the assemblies and components?
- Which test results are available for the individual assemblies and the end product?
A prerequisite for the response to these questions is the unique identification of each component, assembly, and final product with a number or code. Additional information such as customer number, supplier number, batch number, etc., may be required for improved traceability and search functionality.
GLP3 test systems are capable of capturing these identifiers and additional information, e.g., via barcode input, and saving them along with the test results, test date, and operator name in the memory of the test device or on the network. Based on this information, it can later be traced where, when, and by whom components were processed or delivered in the manufacturing process.
All Facts at a Glance
Customer-specific multifunction test systems
Testing technology perfected
- Protective conductor test up to 200 A
- Insulation test up to 10 kV
- High voltage test AC up to 100 kV
- High voltage test DC up to 100 kV
- Leakage current test 30 mA up to 1 MHz
- Function test 1- and 3-phase up to 1,000 A
- Ideal for complex test benches or linked assembly and test lines
- All types of safety tests
- Testing of physical measured variables: pressure, temperature, leakage …
- Optical inspection systems
- Up to 500 programmable test connections
- Switching matrixes for all types of test methods
- PL e, SIL 3, Cat. 4 safety circuit
- High process safety
- Multiple stations with up to 50 test stations
- Fast, high-precision measurements using state-of-the-art DSP technology (Digital Signal Processor)
- High-resolution measurement technology for all test methods
- Freely programmable outputs and inputs
- Built-in industrial PC with Windows 7® or Windows 10®
- Central memory for millions of test plans and test results – SQL server
- Most extensive statistical evaluations – Trending, Gaussian distribution, FPY…
- Traceability of all device under test components
- Operator management
- Configurable test protocol printing
- Freely configurable label printing for thermal transfer printers
- Multiple label printers controllable
- Reading of any 1D and 2D barcodes
- Remote control: RS232, PLC, PROFIBUS, PROFINET, CAN, DeviceNet, Ethernet, EtherCat, USB…
- Communication with the device under test: RS232, PROFIBUS, PROFINET, CAN, Ethernet, EtherCat, USB, analog, PWM…
- Full network connectivity
- Data exchange with ERP and CAQ systems
- Connection to MES systems
- Optimal OEM prerequisites for easy integration into automated lines
- Option for remote maintenance and remote calibration
Project examples
Test system for refrigerators
- Safety and function test
- Function test AC and DC with battery simulation
- Measurement of standby power
- Contacting via pneumatic terminals
- Light curtain
- EN 60335
Test system for complex luminaires
- Safety and function test up to 6000 V
- Lamp replacement circuit near the luminaire under the table
- Thermal transfer label printing for device under test identification
- Printing of packaging labels
- SQL memory on the network
- "Pick by light" – Adapter selection
- Pneumatic control of automatic adapters
- Freely programmable mechatronic functions
- Light curtain for operator protection
- EN 60598
Fully automatic test system for frequency converters
- Safety and function test up to 6000 V
- Converter load test
- Vibration test during operation
- Verification of operating points with load simulation
- Infrared interface for data exchange
- Adjustment and programming of frequency converters
- Setting and reading of test bits in the device under test
- Version and serial number storage in the device under test
- Complete conveyor system from SCHLEICH
- Pallets including test fixtures from SCHLEICH
- Contacting solutions from SCHLEICH
- Lifting tables for ergonomic working height
Test system for power strips
- Electrical safety test
- Wiring test: continuity, open circuit, and miswiring
- Current consumption measurement of built-in components
- Automatic contacting of the sockets
- Central data storage on SQL server
- VDE 0620
- IEC 884-1
- EN 60664-1
Test system for luminaires
- Safety and function test
- Lamp substitute circuit
- Thermal transfer label printing for device under test identification
- Printing of packaging labels
- SQL memory on the network
- Pneumatic control of automatic adapters
- Freely programmable mechatronic functions
- Light curtain for operator protection
- EN 60598
Downloads
German PDFs
- Schleich Modular Concept
- Housing Variants GLP3
- Software GLP3
- Test method switch-over GLP3
- Wiring Harness Test GLP3
- Lamp Replacement Load GLP3
- Project Examples GLP3
- Brochure Test covers | Test cabins | Protection devices
- Safety and function test devices » Device comparison
- Safety and function test devices » Product overview
- SCHLEICH » The company brochure
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