High-voltage testing equipment
High-voltage testing equipment is an indispensable tool for quality assurance of electrical products, whether in industrial manufacturing, in the laboratory, in product development or at certification bodies.
SCHLEICH's high-voltage testing equipment meets all relevant testing standards and can be individually adapted to your testing processes – whether manual or fully automated. Our systems are tailored to your requirements and offer maximum flexibility and absolute reliability.
Rely on technology that sets standards – for safe, compliant and efficient high-voltage testing.
Key Facts:
- Standard-compliant high-voltage testing with AC or DC
- Manual and automated test procedures
- Test duration: seconds, minutes, hours, days, or months
- Graphical display of measured values
- Expandable for complex test objects with multiple test points
- Relay matrices with hundreds of test points
- Ideal for production testing and end-of-line testing
- Ideal for acceptance testing and quality assurance
- Dual-channel safety function – compliant with PLe / SIL3
GLP1-g High-Voltage Testers
High-voltage test equipment 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 guns
- Testing in a test hood, test booth
- Fully automated test stations
- OEMs, plant engineering
- Communication with
«» PC
«» PLC
«» LabVIEW ®
GLP2-BASIC
High-voltage test equipment AC and DC
AC
- 6 kV
- 3,100 mA
DC
- 6 kV
- 6,100 mA
Ideal for
- Manual testing with high-voltage test guns
- Testing in a test hood, test booth
- Fully automated test stations
- OEMs, plant engineering
- Communication with
«» PC
«» PLC
«» LabVIEW ®
«» MES / ERP
«» Fieldbus e.g. E.g. PROFIBUS...
«» Industrial Ethernet e.g. B. PROFINET, EtherCAT, EtherNet/IP, Modbus TCP ...
GLP2-MODULAR High-VoltGLP2-MODULAR
High-voltage test equipment 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 guns
- Testing in a test hood, test booth
- Fully automated test stations
- OEMs, plant engineering
- Communication with
«» PC
«» PLC
«» LabVIEW ®
«» MES / ERP
«» Fieldbus e.g. E.g. PROFIBUS...
«» Industrial Ethernet e.g. B. PROFINET, EtherCAT, EtherNet/IP, Modbus TCP ...
The right solution for every requirement
Thanks to our wide range of high-voltage testing equipment, we have the right solution for almost every application – from individual testing devices to individual testing systems and complete high-voltage testing fields.
Individual testers
Single high-voltage test instruments are ideal for applications where only high-voltage testing is required.
- Suitable for:
- Manual testing with test guns
- Test voltages up to 100,000 V and more
- Automation
- Laboratories
- Advantages:
- Low purchase cost
- Easy to use
- Compact design
- Disadvantage:
- Each test method requires a specific testing device
Multifunction testers
Multifunction testers offer advantages for applications where multiple test methods need to be combined in a single device.
- Common combinations:
- High-voltage test + insulation test + protective conductor test + functional test
- Ideal for:
- End-of-line test stations
- Mass production
- Automation
- Laboratories
- Advantages:
- Higher upfront costs, but more cost-effective than multiple individual testers
- Centralized Control and Documentation
- Greater efficiency through fast, automated testing procedures
- Integration of automatic test method switching
- Integration of automatic measurement path switching
- High flexibility
- More space-saving than multiple individual test units
Test equipment with separate high-voltage transformer
This design is typical for high test voltages and currents, and the resulting large HV transformers.
In this configuration, the HV transformers are usually operated in individual test setups, test chambers or test fields.
Complete solutions with test chambers
High-voltage testing in a test chamber is particularly well-suited for small to medium-sized test objects. The chamber is encased in metal – either only on the inside or also on the outside – thus providing reliable protection against contact in accordance with applicable safety standards.
The testing device and test booth can be flexibly positioned on a height-adjustable worktable to enable ergonomic working conditions. Furthermore, the system can be expanded using matrix switching to allow for automated and efficient testing at multiple test points.
- Ideal for applications requiring complete contact protection.
- Suitable for:
- Test voltages up to 50,000 V and more
- production
- laboratory
- Material testing
- Advantages:
- Automated checks
- Secure testing
- Compact design
- Viewing window for observation
- Height-adjustable workstation
- Extension to multiple matrix points
- Safe, standards-compliant door monitoring
- With door lock if required.
- Test chamber suitable for TE testing
Test fields
Our testing equipment is primarily used in test bays, especially for medium to large test objects. A test bay offers optimal conditions for large and/or heavy test objects and can be flexibly designed, for example with multiple access gates or variable equipment.
The grounded protective grid ensures reliable protection against contact and meets the highest safety requirements in 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 testing
- Advantages:
- Automated checks
- Secure testing
- Safe, standards-compliant door monitoring
- With door lock(s) if required.
Customized solutions
Whether it's high-voltage testing on rail vehicles, insulated power tools, or specially wound coils for the automotive industry:
Tell us your testing requirements – we'll deliver the right solution.
Thanks to our many years of experience and the successful implementation of numerous projects, we are a reliable and competent partner for demanding testing tasks.
Good to know:
The high-voltage test
Why high-voltage testing is so important.
Washing machines, electric motors, lights, and almost all other electrical products and installations can only be operated safely if they have high electrical insulation resistance. Poor insulation can, in the worst case, lead to electrical accidents with serious injuries or even death, or cause significant product damage. High-voltage testing allows you to determine the insulation quality and dielectric strength of your test object. Electrical products are tested using voltages typically up to 6,000 V.
To cover virtually all areas of high-voltage testing, SCHLEICH offers a very comprehensive range of high-voltage testing equipment from 3,000 to 100,000 V.
Where testing is performed on the test object.
Testing is performed between all live conductors and from live conductors to the housing.
Wouldn't an insulation resistance test also work? In principle, yes, since both tests measure between the same test points. However, the high-voltage test uses significantly higher test voltages, which represents a real stress test for any object being tested!
Furthermore, high-voltage testing with alternating current places a particularly high stress on the test object. This rigorous quality analysis reliably detects insulation weaknesses.
These faults are detected by high-voltage testing.
- Insulation clearances are too small
- Insufficient dielectric strength
- Insulation weaknesses between any electrical conductors and the protective conductor / device housing
- Insulation defects between electrical conductors
- Poor insulation in air gaps and creepage distances
- High-energy and low-energy breakthroughs
- Micro-discharges that may only develop into damage later during operation
What are the "good"/"bad" criteria?
The assessment 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 defect is present.
High-voltage testing 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. Often, testing with DC voltage is also permissible. In this case, the test voltage must be increased by 1.5 times the AC test voltage. This may seem significantly higher at first glance. However, considering that the AC test voltage is an RMS value, this becomes less of an issue. The peak value of the AC test voltage is the RMS value multiplied by √2, or 1.41 times the RMS value.
Test objects often have unavoidable capacitances that are due to filter capacitors or their physical construction.
During high-voltage AC testing, a high capacitive leakage current can flow through these capacitances. However, this is not necessarily a fault, as the physical design of the test object naturally allows this leakage current to flow. To disregard the component of the imaginary current through the capacitance of the device under test, SCHLEICH high-voltage testers can distinguish between active and reactive current.
However, when testing with DC, capacitance plays only a minor role. After the capacitor is charged, only a very small insulation current flows through the insulation resistance. This current, just as with AC testing, must not exceed a predefined limit. Furthermore, SCHLEICH high-voltage testers determine the insulation resistance from the test voltage and the leakage current. Therefore, during high-voltage testing with DC, the tester also functions as a megohmmeter.
How is the high-voltage test performed?
Whether manual, semi-automatic, or fully automatic: SCHLEICH high-voltage testing devices enable all testing tasks to be carried out quickly and efficiently. They are all designed according to the "KISS principle," which stands for "Keep It Simple and Smart." This principle serves as the guiding principle for all SCHLEICH products.
Manual testing is performed using high-voltage test guns. The operator guides the safety test guns manually from test point to test point. Despite the manual process, the test can be fully documented. A typical application is the inspection of electrical products, control cabinets, and machines in accordance with the Machinery Directive EN 60204.
For the requirements of production facilities, semi- or fully automated high-voltage testing devices or testing machines are more suitable. These are equipped with a relay switching module (relay matrix) that automatically switches the high voltage to the desired test points.
Depending on the application, test systems of this type can have up to 1,000 test ports.
Safe execution of the high-voltage test.
Working with high voltage is dangerous. Therefore, the relevant safety regulations and measures for protection against electric shock must be strictly observed.
Protective 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 limit 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 present in a well-designed test object is below the safety current limit. Since many test objects, such as electric motors, inherently exhibit a capacitive leakage current often significantly exceeding 3 mA AC, a safety current limit cannot be used with these objects. Therefore, a safety current limit cannot be used with these test objects.
However, a second criterion must also be considered. Due to their construction, many test objects have an unavoidable capacitance. Capacitive leakage current flows within this capacitance. The capacitance can also store charge. If this is the case, the maximum stored energy must not exceed 350 mJ (VDE 104/EN 50191). Otherwise, the operator is at risk of electric shock upon touching the test object due to the residual charge.
If a safety current limit is not possible, test hoods, test booths, light curtains or barrier chains are used as protective measures.
The potential-free high-voltage test.
In most applications, potential-free high-voltage testing is used. This is typical for safety test guns. It ensures the highest level of safety for the user. From a high voltage of 15,000 V, the high voltage is generally grounded on one side.
What needs to be considered during a high-voltage test.
To perform the high-voltage test correctly, it must be ensured that the test object is actually connected to the high voltage. Verification of a correctly performed test can be carried out in three different ways:
- Specifying a minimum current is advantageous for test objects that exhibit leakage current. If this minimum current is flowing, it can be ensured that the test object is energized.
- At a DC test voltage, the leakage current is very low. However, contact monitoring can be performed by measuring the charging current at the beginning of the high-voltage test.
- Measurement of the actual voltage applied to the test object. For this purpose, two additional sense leads are connected to the test object, supplementing the test leads. This type of measurement is often called four-wire measurement. The high voltage actually applied to the test object is measured via the two sense leads. This voltage is then compared to a target value. Therefore, we call this control procedure voltage feedback measurement.
The requirements for a standard high-voltage test device.
Many national and international standards specify a power rating of > 500 VA at 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 instruments are equipped with a fast-responding, electronic high-voltage source. This allows for the precise, sequential scanning of voltage profiles.
SCHLEICH high-voltage testing equipment is based on over 30 years of experience. From the very beginning, the measurement technology has been digital, not analog. State-of-the-art technologies are always used.
Here's how to find the right high-voltage testing device.
The selection of high-voltage testing equipment on the market is large, and the number of configurable features is overwhelming.
However, with a few basic considerations, you can easily find the right device.
If you only want to perform high-voltage tests with AC or DC on your test object, a single-function tester is the right choice. This contains only one test method, namely high-voltage testing.
However, if the test object also requires a more comprehensive safety and functional check, we recommend our combination testers/multifunction testers. These allow you to conveniently combine various test methods, such as high-voltage, insulation, and protective conductor resistance testing, in a single device. The integrated test method switching function ensures that no test leads need to be manually reconnected on the test object during the test.
Furthermore, a combination of safety and comprehensive functional tests is also frequently used. For functional testing, the test device additionally supplies the test object with electrical operating voltage to also check its electrical operating characteristics.
Thanks to the intuitive and convenient operation of our high-voltage testing equipment, every test is carried out quickly, precisely and cost-effectively.
The SCHLEICH Product Portfolio – Expect More!
High-voltage testing equipment
- Test voltage from 3000 V, 6000 V up to 120 KV AC/DC
- Power output from 500 VA to 35 kVA
- With electronically automatically regulated high voltage
- With built-in discharge and discharge monitoring
- Standard interfaces such as RS-232, Ethernet/LAN, and USB for communication with a PC
- 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 set via the software
Custom testing equipment and systems
- Combination Tester/Multifunction Tester
- Automatic test machines/test systems with small to complex relay matrices
- Complete testing stations
- Production lines with transfer systems
- EOL workstations
- Large-scale facilities
Comprehensive service
- Professional consulting backed by expert knowledge
- Careful initial startup
- Regular certified calibration
- After-sales support from our service team
- Service by phone, via remote support, or on-site
- Customized training programs
Do you need personalized product advice?
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