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GLP3 Safety and Functional Testing Systems
High-end testing systems for complex applications
GLP3- Windows® test equipment is a fully automated, high-end system for testing a wide variety of complex products. Common applications include run-in test benches and the testing of electronic assemblies, power supplies, cables, and washing machines. The GLP3 is ideal for complex test benches and integrated assembly and testing lines.
Thanks to its many intelligent functions, the testing system covers all application areas of modern safety and functional testing technology. It is ideally suited for production, laboratories, test fields, quality assurance, automation, and much more.
Flexible test plan creation, test order data entry, result storage, 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 virtually no limits to integration into demanding manufacturing processes.
Key Facts:
- Customizable testing system and special solutions
- Protective conductor testing up to 200 A
- Insulation testing up to 10 kV
- High-voltage testing AC up to 100 kV
- High-voltage testing DC up to 100 kV
- Leakage current test 30 mA to 1 MHz
- Functional testing 1- and 3-phase up to 1,000 A
- Security checks of all kinds
- Testing of physical quantities: pressure, temperature, leakage…
- Optical inspection systems
- Up to 500 programmable test points
- Test setups for all types of testing methods
- PL e, SIL 3, Cat. 4 safety circuit
- High process reliability
- Multi-stations with up to 50 testing stations
- Ideal for complex test benches or linked assembly and testing lines
Diverse testing solutions for diverse applications
Electrical engineering requires countless applications – and The GLP3 testing system adapts to these challenges. It masters a wide variety of safety and functional testing tasks.
You have the option to configure hardware and software features. The result is a customized testing system that is tailored to your needs and also within your budget.
The GLP3 testing system combines all testing methods in a single device. This feature makes it possible to test electrical products for all possible defects in a single test run.
The interplay of different testing methods with our award-winning innovations ensures the quality of your production.
Testing solutions for diverse applications
A deep look into the electrical product
The workflow in the GLP3 world
Testing technology without limits
Hardware and software are developed and manufactured in-house by SCHLEICH. The software and database are based on the latest, proven Microsoft® technology. Our diverse innovations continually set technological standards for modern test benches running Windows® . The system provides the operator with a clear, concise overview of the test, while the setup technician has extensive input and configuration options at their disposal.
Quality assurance is also a key focus. A comprehensive statistical analysis is integrated into the testing system, leaving virtually nothing to be desired. Finally, you can document the tested quality for your customers with a variety of different report printouts.
The GLP3 testing systems are manufactured according to your requirements based on the SCHLEICH MODULAR CONCEPT. The necessary testing methods can be selected from the pool of available options as needed.
Whether for manual or automatic single, double, or multiple testing stations – with or without a test hood or test table – or for testing in automated production lines, the GLP3 is the ideal solution. The GLP3's versatility is virtually limitless. Its exceptional hardware and software flexibility allows for a cost-effective and precisely tailored testing system to your specific requirements.
Standard equipment
Function and Technology
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High-performance industrial PC
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SQL or Access database without limits
- Clear screen display without sensory overload
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Microsoft® Windows operating system
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High-performance test plan processing
- Automatic logbook and management of the test plan history
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Integrated plausibility checks of all parameters
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Fast, precise measurement technology
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Enormous configuration options
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Script editor for maximum flexibility
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Securely store test plans and test results
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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 national languages
Communication
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USB ports on the front and back
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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 OK and not OK
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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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Starting entrance
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Dual-circuit safety entrances 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 lights
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Safety and Warning Messages
The SCHLEICH MODULAR CONCEPT
Custom-designed testing systems
Based on the SCHLEICH MODULAR CONCEPT, the GLP3 testing systems offer a wide range of combinations of various safety and functional testing methods. Your specific testing requirements determine the testing methods you select from a large pool of options.
Whether you need one test method or a variety – you determine the configuration! For example, your GLP3 can be configured as a specialized high-voltage tester with numerous test outputs. For more complex testing tasks, you might require a combination of all possible test methods.
The SCHLEICH MODULAR CONCEPT allows you to assemble precisely the testing equipment you need. This is achieved not only by installing various individual testing devices in an oversized test rack, but also by integrating all tests into a compact, modular housing. The housing size is determined by 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 test device's connections. With the 19" container and especially the 19" industrial cabinet, the measurement connections can be mounted on any side of the test device. This allows us to meet all spatial requirements.
Every testing device embodies the experience gained from thousands of installations. At SCHLEICH, this experience is consistently, passionately, and without compromise applied.
That is "customer-centric technology."
Configuration Examples
Your individual requirements define the case size
Despite their very compact design, these testers offer a wide range of testing options in a single housing. The combination of testing methods based on the SCHLEICH MODULAR CONCEPT therefore also incorporates a modular housing design.
Depending on your requirements, your application can be housed in a compact benchtop unit, a 19-inch rack-mount unit, a 19-inch enclosure, or a 19-inch industrial cabinet. To ensure the proper and safe installation of the test equipment, we use custom-fit enclosure components from renowned German manufacturers as well as components manufactured in-house.
Automatic test method switching and mechatronics
Testing technology from SCHLEICH has proven itself time and again in daily use. It ranks among the most reliable products on the market and offers high utility value thanks to its outstanding performance and accuracy.
To save time, all connections on the test object can be made using a contact adapter. The tester then performs the specified tests fully automatically without any manual intervention. This is made possible by SCHLEICH’s signature automatic test method switching.
For test objects with multiple connections, it is more cost-effective to connect all of the test object’s connections to the test equipment immediately. The test equipment then performs all tests between all connection points fully automatically. This approach reduces the required clock rate and thus the cost of a test. Switching between the various connections is achieved using flexible switching matrices.
To minimize the time required to connect a test object with numerous connections, we implement the frequently requested dual-station or multi-station systems. In these systems, loading and unloading take place at one station while testing is performed simultaneously at the other stations. This approach enables highly cost-effective results even for complex and extensive tests.
Test method switching
Depending on the type and scope of the testing methods, we offer a variety of switching options. These ensure a fast and automatic changeover between different testing methods. Since the voltage differences between the testing methods can be very large, safety is our top priority during switching. A resistance test at 3 V is applied to the device under test just as reliably as a high-voltage test at 6000 V. This protects both your employees and the test object. And we do so without compromise! That's why we use only high-quality components for switching devices and matrices, components that have proven themselves tens of thousands of times over, either from our own production or from renowned manufacturers.
Dies
We offer the right relay matrix for virtually any application. The matrices differ in the number of connections and the test voltage they can switch. A matrix must switch 6000 V just as safely and reliably as it does millivolt signals. That is exactly why our engineers developed these matrices. The matrices are designed for two- and four-wire applications. They can be daisy-chained to increase the number of connections as needed. Matrices with more than 100 connection points are not uncommon. The same principle applies to matrices as to test method switches: only the highest quality components are used.
Station switching
Instead of using two or more test units, station switching can be a cost-effective alternative, for which we also impose the highest safety requirements. While testing is underway at one test station, the other test station is being charged or discharged. In doing so, the operator inevitably comes into contact with terminals and connecting cables. Touching the terminals and connecting cables poses a potential electrical hazard. Therefore, the test leads to the stations where no test is currently in progress must be safely disconnected. In addition, it is recommended to ground the connections to the test object.
Mechatronics | Script Control
In addition to the hardware, the software also offers tremendous flexibility. Using the built-in script commands, you can implement additional PLC functions in the test device. Just as with a PLC, you can read inputs, set outputs, and create logical connections.
The economic advantage lies in the direct control of mechatronic functional sequences. You can activate valves, check limit switches, evaluate measured values yourself, and much more. The test device is thus capable of generating additional functional sequences before, during, and after the test. This is ideal for custom test setups or for integration into automated production.
Test Methods
Protective conductor resistance test
The protective conductor test is performed using an electronically controlled, constant test current. The test device calculates the protective conductor resistance from the voltage drop across the protective conductor and the measured current. This resistance must not exceed the maximum value specified in the standards.
Using a test probe, the operator sequentially scans the protective conductor connections on the device under test. The measurement is taken between the PE contact of the test socket or the central PE connection of the device under test and the test probe – quickly, precisely, and reliably.
Tests can also be carried out fully automatically – thanks to an integrated relay matrix that switches all required measurements precisely and reliably.
Insulation Resistance Test
cold or warm
The insulation test is performed using an electronically controlled, constant test voltage. From the voltage drop across the insulation and the measured current, the test instrument calculates the insulation resistance, which must not fall below the minimum value specified in the standards.
The measurement can be performed:
- Between all electrical conductors (protection class I)
- Between electrical conductors and insulated housing parts (protection class II)
The operator uses a test probe to scan each of the housing parts to be tested. At the end of the test, the test object is always automatically discharged – for maximum safety.
Tests can also be carried out fully automatically – thanks to an integrated relay matrix that switches all required measurements precisely and reliably.
DC High-Voltage Test
cold or warm
The insulation test is performed using an electronically controlled, constant DC high voltage. During the measurement, the test current must not exceed a specified maximum value. If the current exceeds this value, the test is automatically terminated.
At the end of the test, the test object is always automatically unloaded – for maximum safety.
Tests can be performed manually or fully automatically – thanks to an integrated relay matrix that switches all required measurements precisely and reliably.
AC High-Voltage Test
cold or warm
The insulation test is performed using an electronically controlled, constant AC high voltage. During the measurement, the test current must not exceed a specified maximum value. If this value is exceeded, the test instrument automatically terminates the test.
At the end of the test, the test object is always automatically unloaded – for maximum safety.
Tests can be performed manually or fully automatically. Thanks to the integrated relay matrix, all necessary measurements are switched precisely and reliably.
φFunctional test
1- to 3-phase
The functional test is performed under nominal voltage and is based on the measurement of:
- Power consumption
- cos φ (power factor)
- Power consumption, active power, reactive power, apparent power
For each measured quantity, target values with ± tolerances are defined. If the measured values are within the tolerance, the test result is OK (OK).
In addition, further parameters such as speed, vibration or other functional characteristics can be recorded in parallel with the functional test – for comprehensive quality control.
Leakage current test
1- to 3-phase
The leakage current test is performed in parallel with the functional test. This test verifies whether the leakage current from the conductors to the PE (earth leakage current) or to insulated housing parts (housing leakage current) is below the permissible limits.
The leakage current must not exceed the maximum value specified in the standards – even when taking into account various fault conditions.
For measurement, standard-compliant measuring circuits (MDs) according to EN, UL and other international regulations are used.
The testing software
The software is based on the Microsoft Windows® operating system. The optimized user interface enables user-friendly execution of test plan creation, printing of test reports, 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 pass/fail indicator 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 integrated user management system ensures that only authorized personnel can make these changes. Additional work instructions make the GLP3 the perfect ISO 9001-compliant testing instrument.
The input
To edit test steps, a single mouse click on the step is all it takes to change parameters and adjust tests. There's no need to use a cumbersome test plan editor. The settings are displayed to every operator but can only be changed by authorized personnel. All changes are saved in the history log and the logbook.
The data
The GLP3 stores test plans and test results either locally on the hard drive or in an SQL database on the network. We recommend networking the test equipment due to the following advantages:
- All testing devices in the network access a common database for test plans and test results.
- All testers test according to the same specifications.
- A central database for all testing 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 access to all test results worldwide from one or more locations.
- The simple connection to ERP, PPS or CAQ systems allows the testing systems to be optimally integrated into factory planning and production control.
The statistics
Based on a large number of test results, meaningful statistics can be calculated. Therefore, during the development of GLP3, great emphasis was placed on the sensible and well-designed storage of test results over an extended period. Freely configurable search filters enable every user to quickly and easily find the data relevant to them in the database. Individual evaluations or summaries of test results over a longer, freely definable period with subsequent statistical analysis are possible.
Trend representations and Gaussian distributions provide clear information about the qualitative status of production. The GLP3 can store your data on a daily, weekly and monthly basis and evaluate and display it on an order- or batch-by-order basis. With the integrated, extensive export functions, data can be extracted from the database in order to transfer it to other databases or to process it further in Excel® format. This gives you the opportunity to implement your own evaluations.
The database can be based on SQL or Access® . For larger datasets or network applications, 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 testing systems.
The GLP3 works optimally in all network infrastructures. This characteristic provides the ideal platform for collecting, managing, analyzing, and distributing information.
The database uses proven and widely used technologies from Microsoft® .
The testing devices can also be ideally integrated with ERP, PPS, and CAQ systems. We offer tried and tested, customer-optimized standard solutions for all requirements.
network outage
Each testing device automatically saves local copies of the current server test plan database so that it can continue operating in the event of a network outage.
In the event of a network outage, the local test plans are used and the test results are saved locally on the test device.
Once the network connection is restored, the testing device automatically sends the test results back to the server, ensuring that the server database is up to date.
The GLP3 in the complex global network
The Windows® - based GLP3 test instruments can be operated in network topologies of any complexity. You can install any number of test instruments at different company locations worldwide, all of which operate with a central server database for test plans and test results. Our extensive experience in globally networking our test instruments gives you the assurance of being able to offer the same product quality regardless of the production location.
Naturally, all test plan, printing, labeling, and statistical tasks can also be performed on the individual testing devices. However, to avoid disrupting the production process, it is advisable to use separate workstations for this purpose in networked systems. These workstations run the same software as the testing devices to ensure maximum ease of use.
The labels 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 case of remote maintenance (via remote access), we can temporarily connect to your network and directly access the individual test device as needed. We can then view the screen content of your test device directly from our location. With your permission, we also have access to your mouse and keyboard. Naturally, this work is only carried out in consultation with you and requires separate access authorization from you.
Automation
Fully automated GLP3 testing systems in production
The GLP3 testing systems can be seamlessly integrated into automated production. Automation is a particular strength of SCHLEICH, given the company's structure.
Automation encompasses not only software, electronics, and plant engineering, but also mechanics and mechatronics. These services are provided by SCHLEICH mechanical design, our CNC machining centers, and mechanical assembly.
GLP3 integrates into your existing automation
You have an automated production line and want to integrate the GLP3 into your production process. The testing device can be fully remotely controlled via interfaces from a PLC. If required, test plans and parameters can also be transferred to the testing device. Test results are provided both qualitatively and quantitatively.
GLP3 integrated into a SCHLEICH testing system
We supply complete testing systems consisting of the test instrument, the contacting of the device under test, and the entire mechanical automation. Everything is turnkey and provided from a single source. All automation components are developed, designed, manufactured, assembled, and commissioned in-house at SCHLEICH.
The GLP3 often handles not only the testing but also the process control of the automation. For higher levels of automation, a PLC is used as an alternative. We cater to individual customer needs and requirements.
The result is a solution precisely tailored to the task.
Data exchange in the automation
The GLP3 is ideally suited for integration into automation systems. It offers a huge variety of interfaces for communication with a wide range of automation systems.
Typical requirements include:
- Control of complete processes and components
– Processing of inputs, signal transmitters, 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 controller
- Bidirectional communication
– Receiving test plans and test parameters
– Sending qualitative and quantitative test results
– Sending raw data - Communication with robots, cameras…
These tasks are performed by our configurable standard software modules, which minimize the effort required to integrate the GLP3 into automation systems.
Data exchange with IT systems
Data exchange between GLP3 and other IT systems takes place via proven solutions.
Typical applications:
- Importing production orders from ERP systems
- Automatic dynamic generation of test plans from production orders and bills of materials
- Automatic dynamic generation of test plans from composite sub-test plans
- Automatic generation of serial numbers from production order data
- Feedback of results to ERP systems
- Receiving label data for label printing
- Communication with special systems of the automotive industry
Traceability in the production chain
Traceability allows you to obtain clear and complete information about the entire manufacturing process, even after the fact. In the event of quality problems during production or after delivery, traceability enables you to react appropriately.
We provide answers to the following questions:
- Which end products, assemblies, and components are affected?
- Which customers own the end products, assemblies, and components?
- Which assemblies and components are used in the final product?
- When, where, and by whom were which parts processed during the manufacturing process?
- Who manufactured or supplied the assemblies and components?
- What test results are available for the individual assemblies and the final product?
Answering these questions requires the unique identification of each component, assembly, and finished product with a number or code. Additional information such as customer number, supplier number, batch number, etc., may be necessary for improved traceability and searchability.
GLP3 testing systems are capable of capturing these markings and additional information, e.g., via barcode input, and storing them, along with the test results, test date, and tester names, in the test device's database or on the network. This information allows for later tracking of where, when, and by whom components were processed or delivered during the manufacturing process.
All the facts at a glance
Customized multifunctional testing systems
Testing technology in perfection
- Protective conductor testing up to 200 A
- Insulation testing up to 10 kV
- High-voltage testing AC up to 100 kV
- High-voltage testing DC up to 100 kV
- Leakage current test 30 mA to 1 MHz
- Functional testing 1- and 3-phase up to 1,000 A
- Ideal for complex test benches or linked assembly and testing lines
- Security checks of all kinds
- Testing of physical quantities: pressure, temperature, leakage…
- Optical inspection systems
- Up to 500 programmable test points
- Switching matrices for all types of test methods
- PL e, SIL 3, Cat. 4 safety circuit
- High process reliability
- Multi-stations with up to 50 testing stations
- Fast, highly precise measurements using state-of-the-art DSP technology (Digital Signal Processor)
- High-resolution measurement technology in all testing methods
- Freely programmable outputs and inputs
- Integrated industrial PC with Windows 7® or Windows 10®
- Central database for millions of test plans and test results – SQL Server
- Extensive statistical analyses – trending, Gaussian distribution, FPY…
- Traceability of all test specimen components
- User Management
- Configurable test report printout
- Fully customizable label printing for thermal transfer printers
- Can control multiple label printers
- Scanning any 1D and 2D barcodes
- Remote control: RS232, PLC, PROFIBUS, PROFINET, CAN, DeviceNet, Ethernet, EtherCAT, USB …
- Communication with the test object: RS232, PROFIBUS, PROFINET, CAN, Ethernet, EtherCAT, USB, analog, PWM…
- Full network connectivity
- Data exchange with ERP and CAQ systems
- Integration with MES systems
- Optimal OEM prerequisites for easy integration into automated lines
- Remote maintenance and calibration capability
Project Examples
Testing system for refrigerators
- Safety and Functional Testing
- Functional testing AC and DC with battery simulation
- Standby power measurement
- Contacting via pneumatic clamps
- Light curtain
- EN 60335
Testing system for complex luminaires
- Safety and functional testing up to 6000 V
- Emergency lamp circuit located near the light fixture under the table
- Thermal transfer label printing for test specimen identification
- Printing of packaging stickers
- SQL database on the network
- “Pick by light” – adapter selection
- Pneumatic control of automatic adapters
- Freely programmable mechatronic functions
- Safety light curtain
- EN 60598
Fully automatic testing system for frequency converters
- Safety and functional testing up to 6000 V
- Inverter load test
- Vibration test during operation
- Verification of operating points using load simulation
- Infrared interface for data exchange
- Adjustment and programming of the frequency converters
- Setting and reading check bits in the device under test
- Version and serial number storage in the test object
- Complete conveyor system from SCHLEICH
- Pallets including test nests from SCHLEICH
- Contacting SCHLEICH
- Height-adjustable tables for ergonomic workplace height
Testing system for power strips
- Electrical Safety Inspection
- Wiring test: continuity, open circuit and Swap
- Measurement of current consumption in built-in components
- Automatic connection of the outlets
- Centralized data storage on SQL Server
- VDE 0620
- IEC 884-1
- EN 60664-1
Testing system for lighting fixtures
- Safety and Functional Testing
- Lamp replacement circuit
- Thermal transfer label printing for test specimen identification
- Printing of packaging stickers
- SQL database on the network
- Pneumatic control of automatic adapters
- Freely programmable mechatronic functions
- Safety light curtain
- EN 60598
Downloads
German PDFs
- Schleich Modular Concept
- GLP3 housing variants
- Software GLP3
- Test method switchover GLP3
- GLP3 wiring harness test
- Lamp replacement load GLP3
- GLP3 project examples
- Brochure: Test Enclosures | Test Booths | Protective Equipment
- Safety and Functional Testers » Product Comparison
- Safety and Functional Testers » Product Overview
- SCHLEICH » The Company Brochure
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