Your local contact:High Voltage Test Devices
High voltage test devices are an indispensable tool for quality assurance of electrical products, whether in industrial manufacturing, laboratories, product development, or at certification bodies.
SCHLEICH's high voltage test devices comply with all relevant test standards and can be custom adapted to your test processes – whether manual or fully automatic. Our systems are tailored to your requirements and provide you with maximum flexibility and absolute reliability.
Trust in technology that sets standards – for safe, standard-compliant, and efficient high voltage tests.
Key Facts:
- Standard-compliant High Voltage Test with AC or DC
- Manual and automated test sequences
- Test duration: seconds, minutes, hours, days, or months
- Graphical trend display of measured values
- Expandable for complex devices under test with multiple test points
- Relay matrices with hundreds of test points
- Ideal for series production tests and EOL tests
- Ideal for type approval tests and quality assurance
- Two-channel Safety Function – compliant with PLe / SIL3
GLP1-g high voltage test devices
High voltage test devices AC and DC | 18 device variants
AC
- 6 – 50 kV
- 3 – 200 mA
DC
- 4 – 10 kV
- 6 – 20 mA
Ideal for
- Manual tests with high voltage test probes
- Testing in a test cover, test cabinet
- Fully automatic test stations
- OEMs, systems engineering
- Communication with
«» PC
«» PLC
«» LabVIEW®
GLP2-BASIC high voltage test devices
High voltage test devices AC and DC
AC
- 6 kV
- 3, 100 mA
DC
- 6 kV
- 6, 100 mA
Ideal for
- Manual tests with high voltage test probes
- Testing in a test cover, test cabinet
- Fully automatic test stations
- OEMs, systems engineering
- Communication with
«» PC
«» PLC
«» LabVIEW®
«» MES / ERP
«» Fieldbus e.g. PROFIBUS ...
«» Industrial Ethernet e.g. PROFINET, EtherCAT, EtherNet/IP, Modbus-TCP ...
GLP2-MODULAR high voltage test devices
High voltage test devices AC and DC
AC
- 6 – 100 kV
- 3 – 5000 mA
DC
- 4 – 100 kV
- 6 – 1000 mA
Ideal for
- Manual tests with high voltage test probes
- Testing in a test cover, test cabinet
- Fully automatic test stations
- OEMs, systems engineering
- Communication with
«» PC
«» PLC
«» LabVIEW®
«» MES / ERP
«» Fieldbus e.g. PROFIBUS ...
«» Industrial Ethernet e.g. PROFINET, EtherCAT, EtherNet/IP, Modbus-TCP ...
The right solution for every requirement
Thanks to our broad product range of high voltage test devices, we have the right solution for almost every application – from individual test devices and custom test systems to complete high voltage test fields.
Individual test devices
Individual high voltage test devices are ideal for applications where only the high voltage test is required.
- Suitable for:
- Manual testing with test probes
- Test voltages up to 100,000 V and more
- Automation
- Laboratories
- Advantages:
- Low acquisition costs
- Easy operation
- Compact design
- Disadvantage:
- For multiple test methods, a separate test device is needed for each.
Multifunction test devices
Multifunction test devices provide advantages for applications where multiple test methods are to be combined in one device.
- Typical combinations:
- High voltage test + insulation test + protective conductor test + function test
- Ideally suited for:
- End-of-line test benches
- Series production
- Automation
- Laboratories
- Advantages:
- Higher acquisition costs, but more economical than multiple single test devices.
- Central control and documentation
- Higher efficiency through fast automated test sequences.
- Integration of automatic test method switch-over
- Integration of automatic measurement channel switch-over
- High flexibility
- More space-saving than multiple individual test devices
Test devices with separate high-voltage transformer
This design is typical for high test voltages and currents, as well as the resulting large HV transformers.
In this configuration, HV transformers are typically operated in custom test setups, test cabins, or test fields.
Complete solutions with test cabins
The high voltage test in a test cabin is particularly well suited for small to medium-sized devices under test. The cabin is metal-clad – either only internally or additionally externally – and thus offers reliable contact protection in accordance with applicable safety standards.
The test device and test cabin can be flexibly positioned on a height-adjustable workbench to enable ergonomic work. Through the use of matrix switch-overs, the system can also be expanded so that tests at multiple test points can be run automatically and efficiently.
- Ideal for applications with complete contact protection.
- Suitable for:
- Test voltages up to 50,000 V and more
- Production
- Laboratory
- Material tests
- Advantages:
- Automated tests
- Safe testing
- Compact design
- Viewing window for observation
- Height-adjustable workstation
- Expansion to multiple matrix points
- Safe standard-compliant door monitoring
- With door interlock, if required.
- Test chamber suitable for PD tests
Test fields
Our test devices are primarily used in test fields, especially for medium to large devices under test. A test field offers optimal conditions for large and/or heavy devices under test and can be flexibly designed, for example, with multiple access gates or variable equipment.
The grounded protective grid ensures reliable contact protection and meets the highest safety requirements for high voltage tests.
- Ideal for applications requiring complete contact protection. Typical examples include large Motors, cable drums, high voltage insulators…
- Suitable for:
- Suitable for TEST VOLTAGES up to 100.00 V and more
- Production
- Laboratory
- Material tests
- Advantages:
- Automated tests
- Safe testing
- Safe standard-compliant door monitoring
- With door interlock(s), if required.
Custom solutions
Whether it concerns high voltage tests on rail vehicles, insulated power tools, or specialized wound coils for the automotive industry:
Present us with your test requirement – we will provide the suitable solution.
Thanks to our many years of experience and the successful implementation of numerous projects, we are a reliable and competent partner for demanding test tasks.
Good to know:
The high voltage test
Why the high voltage test is so important.
Washing machines, electric motors, luminaires, and almost all other electrical products and systems can only be operated safely if they have high electrical insulation strength. In the worst case, poor insulation can lead to electrical accidents with severe injuries or even fatalities, or cause significant product damage. With the help of the high voltage test, you can determine the insulation quality and dielectric strength of your device under test. The inspection of electrical products is carried out with TEST VOLTAGEs typically up to 6,000 V.
To cover almost all space of high voltage testing, SCHLEICH offers a very extensive range of high voltage test devices from 3,000 to 100,000 V.
Where testing is performed on the device under test.
Testing is performed between all current-carrying conductors, as well as from current-carrying conductors to the housing.
Can this not also be performed with an insulation resistance test? In principle, yes, as both tests measure between the same test points. However, significantly higher TEST VOLTAGES are used in the high voltage test, which represents a true stress test for every device under test!
Furthermore, the high voltage test with AC voltage places a particularly high load on the device under test. This rigorous quality analysis reliably uncovers insulation weaknesses.
The high voltage test detects these faults.
- Insufficient insulation clearances
- Inadequate dielectric strength
- Insulation weaknesses between any electrical conductors and the protective earth conductor / device housing
- Insulation weaknesses between the electrical conductors
- Poor insulation on air and leakage paths
- High-energy and low-energy breakdowns
- Micro-discharges that can later develop into damage during operation
What are the "Good"/"Bad" criteria?
The evaluation of the high voltage test is always based on the current flowing between the two poles of the high voltage. This current is also referred to as leakage current. It must not exceed an adjustable limit. If this limit is exceeded, an insulation weakness exists.
High voltage test with AC or DC?
Whether an AC or DC voltage can be used as the test voltage depends on the standard applicable to the product being tested. It is often permissible to test with DC voltage as well. In this case, the test voltage must be increased by 1.5 times the AC test voltage. At first glance, this seems significantly higher. However, considering that the AC test voltage is an RMS value, this is put into perspective. The peak value of the AC test voltage is the RMS value multiplied by √2, i.e., 1.41 times.
Devices under test often have unavoidable capacitances, which are attributable to filter capacitors or their physical design.
During the high voltage test with AC, these capacitances can cause a high capacitive leakage current to flow. However, this does not necessarily indicate a fault, as the physical design of the device under test naturally allows this leakage current to flow. To disregard the imaginary current component due to the device under test's capacitance, DC HiPot testers from SCHLEICH can distinguish between active current and apparent power.
If, on the other hand, testing is performed with DC, capacitance plays only a minor role. After the capacitance is charged, only a very small insulation current flows through the insulation resistance. This current, just like in an AC Test, must not exceed a predefined limit. Furthermore, SCHLEICH DC HiPot testers determine the insulation resistance from the test voltage and the leakage current. Thus, during a high voltage test with DC, the tester also becomes a Megohmmeter.
How is the high voltage test run?
Whether manual, semi-automatic, or fully automatic: All test tasks can be run quickly and efficiently with SCHLEICH high voltage test devices. They are all designed according to the “KISS principle”. That is, based on the motto: “Keep It Simple and Smart”. This principle serves as a guiding motif for all SCHLEICH products.
A manual Test is performed with high voltage test probes. For this purpose, the operator guides the safety test probes manually from test point to test point. Despite the manual process, the Test can be documented flawlessly. A typical application is the inspection of electrical products, control cabinets, and machinery according to the Machinery Directive EN 60204.
For the requirements of production facilities, partially or fully automated high voltage test devices or test systems are more suitable. These are equipped with a relay switching field (relay matrix). This automatically switches the high voltage to the desired test points.
Test systems of this type have up to 1,000 test connections depending on the application.
Safe performance of the high voltage test.
Working with high voltage is dangerous. Therefore, the corresponding safety regulations and measures for contact protection must be strictly observed.
Safety measures can only be omitted if the current output of the high voltage test device is limited to a maximum safety current. The safety current limitation restricts the Test current to a maximum of 3 mA AC or 12 mA DC. However, such high voltage test devices may only be used if the leakage current already flowing in a good device under test is below the safety current limitation. Since many devices under test, such as electric motors, naturally exhibit a capacitive leakage current often significantly above 3 mA AC, a safety current limitation cannot be used for these devices under test. Therefore, a safety current limitation cannot be used for these devices under test.
However, a second criterion must also be considered. Due to their design, many devices under test have an unavoidable Capacitance. Capacitive leakage current flows through this Capacitance. However, the Capacitance can also store charges. Should this be the case, the maximum stored energy must not exceed 350 mJ (VDE 104/EN 50191). Otherwise, there is a risk of electric shock for the operator when touching the device under test due to the existing residual charge.
If a safety current limitation is not possible, test covers, test cabins, light curtains, or barrier chains are used as protective measures.
The potential-free high voltage test.
In most applications, the potential-free high voltage test is used. It is typical for safety test probes. It ensures the highest safety for the operator. Above a high voltage of 15,000 V, the high voltage is usually grounded on one side.
What needs to be considered during a high voltage test.
To correctly run the high voltage test, it must be ensured that the device under test is actually connected to the high voltage. The verification of a correctly run test can be performed in three different ways:
- Specification of a minimum current – advantageous for devices under test where a leakage current flows. If this minimum current flows, one can be sure that the device under test is also under voltage.
- With a DC test voltage, the leakage current is very low. However, contact monitoring can be run here by measuring the charging current at the beginning of the high voltage test.
- Measurement of the actual voltage applied to the device under test. For this purpose, two additional sense leads are connected to the device under test in addition to the test leads. This type of measurement is often called four-wire measurement. Over the two sense leads, the actual high voltage applied to the device under test is measured. This voltage is compared with a specified value. Therefore, we call this control procedure voltage feedback measurement.
The requirements for a standard high voltage test device.
Many national and international standards require a power output of > 500 VA with a continuous current of 100 mA AC and a short-circuit current of 200 mA AC. Typical maximum test voltages are 3,000 V or 6,000 V.
SCHLEICH high voltage test devices are equipped with a fast-reacting, electronic high voltage source. This allows for the precise, sequential execution of voltage profiles.
SCHLEICH high voltage test devices are based on over 30 years of experience. From the beginning, the measurement technology was designed digitally, not analog. Fundamentally, the latest technologies are always applied.
How to find the right high voltage test device.
The selection of high voltage test devices on the market is vast, and the number of configurable features is overwhelming.
However, with some fundamental considerations, you can easily find the right device.
If you exclusively want to run high voltage tests with AC or DC on your device under test, a single test device is the right choice. This contains only a single test method, namely the high voltage test.
However, if the device under test also requires a more comprehensive safety and function check, we recommend our combination test devices/multifunction testers. With these, various test methods, such as high voltage, insulation, and protective earth resistance test, can be conveniently combined in one device. The test method switch-over in the device ensures that no measurement leads on the device under test need to be manually re-clamped during the test.
Furthermore, a combination of safety and extensive function tests is also frequently found. For the function test, the test device additionally supplies the device under test with electrical operating voltage to also check the electrical operating characteristics.
Thanks to the intuitive and convenient operation of our high voltage test devices, each test is performed quickly, precisely, and cost-effectively.
The SCHLEICH product portfolio – Expect more!
High voltage test devices
- TEST VOLTAGE from 3000 V, 6000 V up to 120 KV AC/DC
- Power from 500 VA to 35 kVA
- With electronically automatically regulated high voltage
- With built-in discharge and discharge monitoring
- Standardized interfaces such as RS 232, Ethernet / LAN, USB for PC communication
- 24 V digital I/O for PLC communication
- Expandable to Industrial Ethernet and fieldbus systems for PLC communication
- Virtually unlimited storage space for test plans and test results
- All parameters are determined via the software
Custom test devices and systems
- Combination testers/Multifunction testers
- Automatic test systems/Test systems with small to complex relay matrix
- Complete test workstations
- Production lines with transfer systems
- EOL workstations
- Large-scale systems
Comprehensive service
- Professional consultation with technical expertise
- Thorough initial Commissioning
- Regular certified calibration
- After-sales support by our service team
- Service by phone, via remote maintenance, or on-site
- Tailored training courses
Do you require personal product consultation?
We gladly provide you with comprehensive support and advice on all our products and services.
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