Prüfmethoden-Standard EN Rev1.2

Test Method Handbook
for safety and functioning testers
Copyright SCHLEICH GmbH * SCHLEICH GmbH * An der Schleuse 11 * 58675 Hemer * Tel. +49 (0) 2372 9498-0 * Fax +49 (0) 2372 9498-99 * www.SCHLEICH.com *
info@SCHLEICH.com
During the test the test object and test leads must not be touched!
The safety measures required by law have to be observed! |2
Copyright
SCHLEICH GmbH holds the copyright of this Test Method Handbook. This Test Method Handbook supplements the operating manual and is intended for the
tester’s operating and monitoring staff. It includes regulations and technical pictures which must not be copied completely or in parts, distributed or used for
competition purposes without permit or given to any third party.
The specifications of this product and the contents are subject to change without prior notice
file Prüfmethoden-Standard_EN.docx
revision 1.2
editor Martin Lahrmann / Simone Schmitz
printing date 24.02.2015
Please always perform your tests according to the up-to-date VDE-, EN-, or UL-standards.
STOP The statements in this Test Method Handbook are only for your information and are NOT a normative standard.
If there are any faults in this Test Method Handbook no legal claim can result from this.
DANGER
Testers might generate dangerous test voltages!
 Improper operation can lead to death!

 Please read the chapter Safety Instructions to prevent accidents!
 Please always keep this manual and the test method handbook close to the tester!
Definitions / glossary
GO = the test is ok
NO GO = the test is not ok
DUT = device under test / test object
PE = protective earth (ground bond)
EVU = electric supply company
device = your product when used at your customer‘s
IL = current through the test object

ILKG = leakage current
UN = mains voltage – supply voltage
RPE = protective earth resistance
UB = possibly occurring touch voltage
1
Content
1. Content
1. Content ....................................................................................................................... 5
2. For your safety ......................................................................................................... 10

2.1. Safety symbols ................................................................................................................................ 10
2.2. Red warning light ............................................................................................................................. 10
2.3. Test cover ........................................................................................................................................ 10
3. PE resistance test .................................................................................................... 12

3.1. Explanation of the PE resistance test ............................................................................................. 12
3.2. Four-wire measuring ....................................................................................................................... 14
3.3. Typical limit value at PE resistance tests ........................................................................................ 15
3.4. Which test value is displayed and evaluated? ................................................................................ 15
3.5. How does the tester react if too high resistances occur during the test? ....................................... 16
3.6. Voltage drop at the test lead ........................................................................................................... 18
3.6.1. Determination of the maximum measurable resistances ............................................................................................................................18
3.6.2. Determination of the resistances in the input lead ......................................................................................................................................19
3.7. PE resistance test in the EN 60204 | Machinery directive ............................................................. 20
3.8. Voltage check during the test .......................................................................................................... 21
3.9. Test at winded cables ...................................................................................................................... 21
3.10. Test at long winded test probe cables ........................................................................................... 22
3.11. Correcting the test tip resistance ................................................................................................... 22
3.12. Application examples of the PE resistance test ............................................................................ 23
3.12.1. Manual test of PE resistances...................................................................................................................................................................23
3.12.2. Automatic test of PE resistances ..............................................................................................................................................................25
3.13. Black box test ................................................................................................................................ 26
3.13.1. Black box test with ± tolerance limit ..........................................................................................................................................................26
3.13.2. Black box test with GO and NO GO-test...................................................................................................................................................27
4. Insulation resistance test ........................................................................................ 29

4.1. Explanation of the insulation resistance test ................................................................................... 29
4.2. Typical limit value at insulation resistance tests .............................................................................. 31
4.4. Insulation resistance test in the EN 60204 | Machinery directive .................................................... 33
4.5. Insulation resistance test at test objects with one capacity ............................................................. 34
4.6. Voltage check at very well insulated test objects ............................................................................ 35
4.7. Warm insulation resistance test ...................................................................................................... 37
4.8. Faults at the insulation resistance test caused by condensation .................................................... 38
4.9. Application examples of the insulation resistance test .................................................................... 39
4.9.1. Manual test at protection class II-test objects .............................................................................................................................................39
4.9.2. Automatic test ..............................................................................................................................................................................................40
4.10. Black box test ................................................................................................................................ 41
4.10.2. Black box test with GO and NO GO-test...................................................................................................................................................42
5. High-voltage test AC (alternating voltage) ............................................................ 44

5.1. Explanation of the high-voltage test AC .......................................................................................... 44
5.2. Voltage level at the high-voltage test AC ........................................................................................ 45
5.3. Which voltage is displayed? ............................................................................................................ 45
5.4. Discharge ........................................................................................................................................ 46
5.5. Voltage ramps and voltage profiles ................................................................................................. 47
5.6. Potential-free – not potential-free? .................................................................................................. 48
5.7. Current as evaluation criterion ........................................................................................................ 49
5.8. Typical current limit values at the high-voltage test ........................................................................ 50
5.9. Which current value is displayed and evaluated? ........................................................................... 51
5.10. Disruptive breakdown / Overcurrent .............................................................................................. 51
5.11. Burning .......................................................................................................................................... 52
5.12. Testing without protection against contact .................................................................................... 53
5.12.1. Safety current limitation max. 3 mA AC ....................................................................................................................................................53
5.12.2. Power limitation to max. 350 mJ ...............................................................................................................................................................54
5.13. Voltage check ................................................................................................................................ 55
5.14. Warm high-voltage test AC ........................................................................................................... 57
5.15. Application examples of the high-voltage test ............................................................................... 59
5.15.1. Manual test ................................................................................................................................................................................................59
5.15.2. Automatic test ............................................................................................................................................................................................61
5.16. Black box test ................................................................................................................................ 62
5.16.2. Black box test with GO- and NO GO-test .................................................................................................................................................63
5.17. High-voltage test higher than 10 kV .............................................................................................. 64
6. High-voltage test DC (direct voltage) ..................................................................... 66

6.1. Explanation of the high-voltage test DC .......................................................................................... 66
6.2. Voltage level at the high-voltage test DC ........................................................................................ 67
6.3. Which voltage is displayed? ............................................................................................................ 68
6.4. Which DC-voltage types are available? .......................................................................................... 68
6.5. Discharge ........................................................................................................................................ 70
6.6. Voltage ramps and voltage profiles ................................................................................................. 70
6.7. Potential-free – not potential-free? .................................................................................................. 71
6.8. High-voltage test DC at test objects with a capacity ....................................................................... 72
6.9. Current as evaluation criterion ........................................................................................................ 73
6.10. Insulation resistance as evaluation criterion ................................................................................. 73
6.11. Typical current limit values at the high-voltage test ...................................................................... 74
6.12. Which current value is displayed and evaluated? ......................................................................... 74
6.13. Disruptive breakdown / Overcurrent .............................................................................................. 75
6.14. Burning .......................................................................................................................................... 75
6.15. Testing without protection against contact .................................................................................... 76
6.15.1. Safety current limitation to max. 12 mA DC ..............................................................................................................................................76
6.15.2. Power limitation to max. 350 mJ ...............................................................................................................................................................77
6.16. Warm high-voltage test DC ........................................................................................................... 78
6.17. Voltage check at very well insulated test objects .......................................................................... 80
6.18. Application examples of the high-voltage test ............................................................................... 83
6.18.1. Manual test ................................................................................................................................................................................................83
6.19. Black box test ................................................................................................................................ 85
6.19.2. Black box test with GO- and NO GO-test .................................................................................................................................................86
7. ARC-Detection ......................................................................................................... 88
7.1. What are ARCs?.............................................................................................................................. 88
7.2. How are the ARCs measured and evaluated? ................................................................................ 88
8. Leakage current test ................................................................................................ 90

8.1. Explanation of the leakage current test ........................................................................................... 90
8.2. Ground leakage current & cabinet leakage current......................................................................... 92
8.3. Measuring of the leakage current according to EN 60990 .............................................................. 93
8.4. First and second fault condition....................................................................................................... 94
8.5. Leakage current test at grounded test object .................................................................................. 96
8.6. Advantages of the leakage current test with isolating transformer ................................................. 96
8.7. Typical current limit value at the leakage current test ..................................................................... 97
8.9. Which test voltage is to be used?.................................................................................................... 98
8.9.1. Test voltage at EN60990 .............................................................................................................................................................................98
8.9.2. Test voltage at EN60601 .............................................................................................................................................................................98
8.10. Leakage current tests according to EN 60990 ............................................................................ 100
8.10.1. Principal circuits 1-phase ........................................................................................................................................................................100
8.10.2. Principal circuits 3-phase ........................................................................................................................................................................101
8.11. Leakage current test acc. to standard EN 60601 | Medical leakage current test ....................... 102
8.11.1. Measuring circuit for the medical leakage current test ...........................................................................................................................102
8.11.2. Typical structure of a medical appliance .................................................................................................................................................102
8.11.3. Ground-, cabinet- and patient leakage current as well as patient auxiliary current at EN 60601 ..........................................................103
8.11.4. PE resistance test at the EN 60601 ........................................................................................................................................................109
8.11.5. Insulation resistance test at the EN 60601 .............................................................................................................................................111
8.12. Black box test .............................................................................................................................. 113
8.12.1. Black box test with ± tolerance limit ........................................................................................................................................................113
8.12.2. Black box test with GO- and NO GO-test ...............................................................................................................................................114
9. Substitute leakage current test ............................................................................ 116

9.1. Explanation of the leakage current test ......................................................................................... 116
10. Short-circuit test .................................................................................................... 118

10.1. Explanation of the short-circuit test ............................................................................................. 118
11. Functioning test ..................................................................................................... 120

11.1. Explanation of the functioning test .............................................................................................. 120
11.2. Voltage sources of the functioning test ....................................................................................... 120
11.2.1. Voltage supply directly from the mains ...................................................................................................................................................120
11.2.2. Voltage supply controlled directly via the mains .....................................................................................................................................121
11.2.3. Voltage supply via isolating transformer .................................................................................................................................................121
11.2.4. Voltage supply controlled via isolating transformer ................................................................................................................................122
11.2.5. Electronic voltage supply controlled via isolating transformer ................................................................................................................122
11.3. Testing parallel to the functioning test ......................................................................................... 123
11.4. Black box test .............................................................................................................................. 124
11.4.1. Black box test with ±-tolerance limit ........................................................................................................................................................124
11.4.2. Black box test with GO- and NO GO-test ...............................................................................................................................................125
12. Continuity test........................................................................................................ 127

12.1. Explanation of the continuity test ................................................................................................ 127
13. Residual voltage test ............................................................................................. 129

13.1. Explanation of the residual voltage test ...................................................................................... 129
13.2. Automatic performance of the test .............................................................................................. 130
13.3. Manual performance of the test................................................................................................... 130
14. Resistance test ...................................................................................................... 132

14.1. Explanation of the resistance test ............................................................................................... 132
14.2. Four-wire measuring ................................................................................................................... 132
14.3. Kelvin clamp resistance test ........................................................................................................ 133
14.4. Evaluation at the resistance test ................................................................................................. 134
14.5. Influence of the temperature on the resistance test .................................................................... 135
14.5.1. Conversion formula for copper ................................................................................................................................................................135
14.5.2. Conversion formula for temperature sensor ...........................................................................................................................................136
14.6. Resistance test at inductivities .................................................................................................... 136
14.7. Application examples of the resistance test ................................................................................ 137
14.7.1. Kelvin tongs at a motor ...........................................................................................................................................................................137
14.7.2. Kelvin tongs block at a motor ..................................................................................................................................................................137
14.7.3. Kelvin tongs at a terminal board of a motor ............................................................................................................................................137
14.8. Black box test .............................................................................................................................. 138
15. Visual test ............................................................................................................... 140

15.1. Explanation of the visual test....................................................................................................... 140
16. Mathematical test................................................................................................... 142

16.1. Explanation of the mathematical test .......................................................................................... 142
16.2. Example: NTC-temperature measuring ...................................................................................... 142
16.3. Example: PTC-temperature measuring ....................................................................................... 142
16.4. Example: PT100-temperature measuring ................................................................................... 143
16.5. Example: temperature behavior of copper leads ........................................................................ 143
16.6. Example: minimum, maximum, average value & scatter band ................................................... 143
17. Test method switchover, matrices, multi-stations.............................................. 145

17.1. General functioning description ................................................................................................... 145
17.2. Test method switchover .............................................................................................................. 146
17.3. Matrices ....................................................................................................................................... 147
17.3.1. Functioning of a matrix in two-wire technique .........................................................................................................................................147
17.3.2. Functioning of a matrix in four-wire technique ........................................................................................................................................148
17.4. Station switchover ....................................................................................................................... 149
17.5. Mechatronics ............................................................................................................................... 149
18. Calibration .............................................................................................................. 151

18.1. Standard-calibration .................................................................................................................... 151
18.2. Online service .............................................................................................................................. 152
18.3. Remote calibration ...................................................................................................................... 152
2
For your safety!
2. For your safety
2.1. Safety symbols

For the safe use and safe maintenance of this tester the following symbols are used throughout this handbook and on the product. Note the meaning of each
of the symbols to ensure the safe use of the product. (Some symbols are not used depending on the product.)
This symbol indicates that a high-voltage (above 1000 V) is used. Touching such a component may lead to a fatal electric shock. In case you have to touch
this component make sure that no high-voltage is connected.
! DANGER This symbol indicates an imminent dangerous and even fatal situation if it is ignored.
!
WARNING
This symbol indicates a potentially dangerous situation which may result in death, serious injury, or damage to the product or any other property if this symbol
is ignored.
Generally you have to be aware that there is always a possible danger when running an electrical test. The operator has to be aware of this or has to be made
aware of this by the owner.
This symbol is placed at areas of this operating manual that have to be especially considered so that the directives, regulations, notes and the correct work
STOP process is observed as well as any damage of the test station and/or other testing parts is avoided.
In addition it is used when important additional notes are mentioned.
This symbol indicates special know-how.
2.2. Red warning light
This red light of the warning light always flashes when a dangerous test voltage is connected to the test object!
If the test object is discharged after the test the warning light flashes until the voltage drops beyond a safe residual
voltage.
If the warning light is designed as signal light the green light flashes in a voltage-free condition.
2.3. Test cover
Testers with an additional test cover are equipped with a mandatory protection against contact. It can only be
tested when the test cover is closed.
As soon as the cover is opened the test object is immediately disconnected from voltage. That is why test covers
do not require a red warning light. But it can be ordered in addition.
The safety measures required by law have to be observed! | 10
3
PE resistance test
3. PE resistance test
3.1. Explanation of the PE resistance test
The PE resistance test is used for test objects of the protection class I. Testers of
this protection class I feature a PE conductor. Testers of the protection class II have
a protective insulation and do not feature a PE conductor.
Testers of the protection class II are marked with this symbol .
It is tested whether the PE resistance is below a limit value stipulated in the

RPE standards.
The test is performed to check whether leakage currents that might occur in the test
object are correctly conducted to the ground.
PE12 © SCHLEICH
EVU DUT
Definitions
L
IL + IAbl IAbl EVU : electric supply company (power plant)
IL
UN DUT : Device Under Test | test object
IL : current through the test object

N
IAbl : leakage current

PE
UN : mains voltage
RPE IAbl
RPE : PE conductor resistance
UB
UB : possibly occurring touch voltage
Ber2 © SCHLEICH
If the PE conductor connection is not ok the contact voltage at the tester’s cabinet might become too high. When touching the metallic cabinet parts a
dangerous touch current might flow through the person to ground.
EVU DUT In addition it might occur that the insulation within the tester deteriorates during the
tester’s operation. This could lead to a short circuit between the current-conducting
L IAbl
IL + IAbl leads and the tester’s cabinet. Consequently the tester’s cabinet would be under
IL voltage (UB). In the worst case the cabinet could also be under complete mains
UN voltage at this fault. If a person touches the cabinet at this kind of fault this could
lead to a considerable and even fatal danger.
N
At the above mentioned faults the PE conductor is meant to protect the person by
! DANGER creating a safe connection to the ground. The high short circuit current that might
PE
RPE > 0,2W flow in this case has to be conducted reliably to the ground by the PE conductor.
IPE
IB
UB
Iso1 © SCHLEICH
For testing the PE conductor a test current is lead into the PE conductor. The test current’s level is usually from 10A to30 A. The current can be AC or DC, but
in most cases it is AC. The idle voltage must be max. 6 Volt or 12 Volt.
There are different standards and test regulations for various testers. The minimum current level as well as the test time are stipulated in these
STOP regulations.
The test current generates a voltage drop at the PE conductor that is measured. The PE resistance is continuously calculated from the test current’s level and
the voltage drop during the test time.
Prüfgerät
The PE resistance test is always performed in a 4-wire-technique. This is necessary
Tester in order to exactly determine the PE resistance without the influence of the test
L
leads.
At the 4-wire-technique the test is performed via four leads. Here two leads are used
for supplying the test current and two leads are used for measuring the voltage drop
N via the PE conductor.
PE1s
IPE
PE1
RPE
V
PE2
A
PE2s
PE1 © SCHLEICH
3.2. Four-wire measuring
The resistance is calculated from the resistance of the voltage drop and the conducting current via the “Ohm‘s law”.
The graphic shows the measuring under perfect conditions. The current is supplied into the resistor at two points. The voltage is picked off at two other points
again. The transition resistances that always occur at the four contact points are irrelevant for the measuring.
This measuring is called four-wire technique.
A
UPE
V RPE =
IPE
IPE
RPE UPE
PE13 © SCHLEICH
Explanation of the four-wire measuring:

At the four-wire measuring the voltage drop is measured with a very high-ohmic voltmeter via the PE resistance. The voltmeter’s internal resistance is in a very
high MΩ- to several GΩ-range. Consequently the current through the voltmeter is extremely low and thus hardly influences the total current Itotal.
Itotal is composed of IPE + IU-Meter. The current Itotal is measured by the tester. Preferably this should exactly correspond to the current IPE.
The current through the voltmeter is only a few nA to μA due to the high voltmeter’s internal resistance. This is almost nothing compared to the 10 to 30 A total
current. The occurring measuring fault is below one millionth. Thus it can be completely neglected.
The very low measuring current that flows through the volt meter also does not generate any relevant voltage drop at the contact points of both voltage test
leads. Thus the displayed voltage corresponds to the voltage drop at the PE resistance to be measured.
This is the advantage of the four-wire measuring.
Itotal
A
V
IU-Meter
IPE
RPE UPE
PE3 © SCHLEICH
3.3. Typical limit value at PE resistance tests
Typical PE resistances are in the range of 0.02 Ω to 0.1 Ω. This resistance value directly depends on the lead’s length and diameter.
The maximum allowed limit value (RLimit) is 0.2 Ω.

ATTENTION – this is only a guiding value! For your tester please take the test parameters and the allowed limit value of the regulations!
STOP
All the test values between 0 Ω and the limit value RLimit are ok.
The limit value must not be exceeded during the complete test time!
The test time is usually 1sec.

STOP ATTENTION – this is only a guiding value! For your tester please take the test parameters of the regulations!
RPE
RLimit
PE7 © SCHLEICH
3.4. Which test value is displayed and evaluated?

If the test value fluctuates during the PE resistance test this is irrelevant for the measuring as long as the test current does not drop below the set test current
level. The resistance value at the measuring’s end is taken for the evaluation. This resistance must be lower or maximum equal to the allowed upper limit RLimit.
RPE
RLimit
Rtest
Start Ende
t
Prüfzeit z.B. 1sek
1
PE18 © SCHLEICH
3.5. How does the tester react if too high resistances occur during the test?
If the resistance value exceeds the preset limit during the PE-resistance test the operating test time is interrupted.
This situation often occurs when operating with a PE-resistance test probe. When contacting the test object with the test probe current interruptions might
occur for a short-hand of time at the contact point. This is often inevitable as the test probe sometimes has to go through a lacquer coat at first to get PE-
contact.
As soon as the test time is interrupted a contacting time runs instead which can be preset. During this time the resistance has to be decreased below the limit.
Otherwise the test result is NO GO.
As soon as the resistance is decreased below this limit the test time starts again. Thus it is guaranteed that the resistance is always below the limit during the
complete test time.
RPE
Kontaktierzeit This picture shows a too high PE-resistance in the middle of the test time (1). The
z.B. 0,5sek
contacting time continues to run automatically.
As soon as the PE-resistance decreases below the limit again within the contacting
RLimit time the test time (2) restarts with the preset time.
Rtest
Start Ende
t
Prüfzeit Prüfzeit z.B. 1sek
1 2
PE19 © SCHLEICH
Kontaktierzeit If the PE-resistance does not decrease below the limit within the contacting time the
RPE z.B. 0,5sek result after the contacting time is NO GO.
Rtest
RLimit niO
Start Ende
t
Prüfzeit
1
PE21 © SCHLEICH
Kontaktierzeit If the PE-resistance exceeds the limit multiple times within the contact time (1) + (2)
RPE z.B. 0,5sek the test time (2) + (3) always restarts after the resistance decreased below the limit.
RLimit This process is continued until the contacting time finally elapsed.
Rtest
Start Ende
t
Prüfzeit Prüfzeit z.B. 1sek
1 2 3
PE20 © SCHLEICH
Kontaktierzeit If the PE-resistance exceeds the limit again after the contacting time elapsed
RPE z.B. 0,5sek the test result is NO GO and the test is cancelled ahead of time.
RLimit Rtest
niO
Start Ende
t
Prüfzeit
1 2 3
PE22 © SCHLEICH
3.6. Voltage drop at the test lead
Test objects sometimes have long connecting leads. Products of this kind are building site main cabinets, cable reels, wet-pit pumps, etc.
It also often happens that the testers to be tested are large. Products of this kind are for example hotel kitchens, large tool machines, switchboards, etc.
Based on these conditions there are quite high PE resistances in the test objects.
In connection with the tester’s test leads there are even higher resistances in total. Principally this is no problem. However, it should be considered that a test
current of 10 to 30 A still has to flow based on the total resulting resistance. At the same time the maximum drop must not be larger than 6 V / 12 V!
3.6.1. Determination of the maximum measurable resistances
At the PE resistance test there is one basic question: “Which PE resistances can still be measured depending on the current level, the idle voltage, the test
lead’s diameter, and the test lead’s length?”
The answer to this question can be determined by calculations.

Thus, for the determination of the maximum measurable PE resistance the technical limit conditions need to be clarified at first. After this, the calculations can
be performed based on two equations.
The following technical conditions have to be clarified:

1. maximum PE test current?
2. maximum idle voltage?
3. highest PE resistance (or limit value RLimit) to be measured at the test object?
4. maximum cable length between tester and test object?
Based on Ohm’s Law the maximum measurable total resistance (Rmax) is determined at first. The total resistance is composed of the PE resistances and the
test leads’ resistances.
The following table shows the resistances depending on the idle voltage and the PE test current.
Remember: The “Ohm’s law” for calculating resistances is: R = U / I.
idle voltage max. measurable resistance at max. measurable resistance at max. measurable resistance at
PE-test current = 10 A PE-test current = 25 A PE-test current = 30A
Umax = 6 V Rmax = 0,6 Ω Rmax = 0,24 Ω Rmax = 0,2 Ω
table: RPE
A A
IPE IPE
Stromquelle V ULeer Stromquelle V UPE

RPE
PE-test in idle state (Uleer = 6 V or 12 V) PE-test (UPE = RPE * IPE)

Stromquelle = current source
As indicated in the table only total resistances up to certain maximum values can be measured at the PE test depending on idle voltage and test current.
Theoretically this would only be the PE resistance value. However, under practical conditions also the resistances in both input leads up to the test object and
the relay transition resistances have to be considered.
3.6.2. Determination of the resistances in the input lead
The input lead’s resistances depend on the input lead’s length and diameter.
The equation for calculating an input lead’s resistance is: R = L / (κ * A).
Explanation: κ is the electric conductance value or conductance. For copper the value is Wert 56, for aluminum it is 36.
This calculation is valid by assuming that copper leads are used. L is the input lead’s length and A is the lead’s diameter.
The following table shows some example resistances for input leads depending on length and diameter.
lead’s diameter length of the input length of the input length of the input length of the input length of the input
lead = 1 m lead = 2 m lead = 5 m lead = 10 m lead = 20 m
A = 0.7 mm² Rmax = 0.024 Ω Rmax = 0.048Ω Rmax= 0.12 Ω Rmax= 0.24 Ω Rmax= 0.48 Ω
A = 1,5 mm² Rmax = 0.012 Ω Rmax = 0.024Ω Rmax= 0.06 Ω Rmax= 0.12 Ω Rmax= 0.24 Ω
A = 2,5 mm² Rmax = 0.007 Ω Rmax = 0.014Ω Rmax= 0.036 Ω Rmax= 0.07 Ω Rmax= 0.14 Ω
A = 4 mm² Rmax = 0.004 Ω Rmax = 0.009Ω Rmax= 0.022 Ω Rmax= 0.045 Ω Rmax= 0.089 Ω
table RZu
When calculating the input lead’s length please consider that there is always a way forward and a way back.
The leads to the PE test probe as well as the leads to the opposite side of the PE resistances to be measured have to be considered!
At equal lead diameters both lengths have to be added (total length).
At different lead diameters both resistances have to be determined individually and added afterwards.
RZu1 Ltotal = Lzu1 + Lzu2 (at equal diameter)

Rtotal = Rzu1 + Rzu2
A
IPE Example: The table shows that a relatively high total resistance of 0.48 Ω occurs at an
input lead’s diameter of 0.75 mm2 and an input lead’s length of 20 m!
Stromquelle V ULast
RPE This resistance together with the PE resistance to be tested results in the maximum
measurable total resistance (like shown in the table RPE – see previous page).
Example:
An idle voltage of 6 Volt and a maximum current of 10 Ampere results in a maximum
RZu2 measurable resistance of 0.6 Ω (see table RPE).
If now a 20 m input lead is used at a lead’s diameter of e.g. 0.75 mm2 the result is that
the maximum measurable PE resistance is only 0.12 Ω! The reason is: 0.6 Ω - 0.48 Ω = 0.12 Ω!
However, if the PE resistance to be tested at the test object can be 0.2 Ω it cannot be measured anymore. In this case you can only increase the input lead’s
diameter or shorten the input lead. If you choose not to do this the resistance would be principally measurable but the test current would be reduced
correspondingly. This would not correspond to the regulation [I= 6 V / (0.48 Ω+0.2 Ω) = 8.8 A].
When increasing the lead’s diameter to 1.5 mm2 the following conditions would be set:
R at 20 m and 1.5 mm2 = 0.24 Ω
RPEmax = 0.6 Ω - 0.24 Ω = 0.36 Ω
This means that PE resistances can be measured up to 0.36 Ω according to the standards. The PE test current would be set below 10 A only at resistances
higher than 0.36 Ω.
3.7. PE resistance test in the EN 60204 | Machinery directive
At the EN 60204 test the two test methods PE resistance and insulation resistance test are alternately switched between the PE ground and the test probe.
This allows to test the PE resistance as well as the insulation resistance to the machine’s cabinet via a ground connection of the test object.
Prüfgerät
Tester The picture shows a PE / IR tester with test probe. The operator can switch between
both test methods via the switchover in the tester. The test’s reference point is
Iso always the common cabinet ground point.
PE2
PE2s
PE The PE resistance is measured from all grounded sheet parts (e.g. doors) and all
ground clamps against this ground point.
V U
The insulation resistance is measured by all electric leads against this ground point.
A A V
RPE
PE1s
PE1
PE-Iso3 © SCHLEICH
Prüfgerät
This picture principally shows the “inner life“ of a machine.
Tester Electric components are connected with each other and effect a function.
PE / Iso The insulation resistance is measured against ground by all electric leads. The
PE2
measuring can be performed at many points within the circuit. These points can be
PE2s scanned with the test probe.
DUT
Prüfling
L
The PE resistance is measured at all points that have to be connected to PE. The
V U
measuring can be performed at many points within the circuit. These points can be
scanned with the test probe.
A A V
N
RIso1 RIso2
PE1s
PE1 PE RPE1
1
RPE2
2
PE-Iso2 © SCHLEICH
3.8. Voltage check during the test
How can you be sure that the test was performed properly?
This is very simple at the PE resistance test.
If the test current does not flow through the PE or the test current is too low the test result is not ok.
The test current must not be below the value stipulated in the standards during the complete PE resistance test!
Prüfgerät
Tester
DUT
Prüfling
L
N
PE1
PE1s
PE2
PE2s
PE14 © SCHLEICH
3.9. Test at winded cables

If the PE-resistance of e.g. a cable drum is to be measured it has to be considered that the winded cable acts like a coil.
The cable winded to a coil acts like an inductivity that is not negligible. The inductivity might have such a strong effect that the test current of e.g. 10A AC at 12
V connected voltage is not able to conduct anymore.
However, the mere DC resistance of the PE-conductor is low enough (e.g. 0.15 W) but the AC-resistance (the impedance) is so high that the requested
current is not able to conduct.
In such cases there are two options to maintain the current at the level required in the standards:
1. Option:
The test voltage is increased until the requested current conducts again. This can e.g. be a test voltage of 18 V AC or 24 V AC.
2. Option:
Instead of using an alternating voltage (AC) for testing the PE-resistance a direct voltage (DC) is used. When testing with DC the effect of the coil is zero.
The direct current is only limited by the mere ohmic resistance of a PE-conductor. It is also easily possible to test winded cable drums with direct current
without restrictions.
3.10. Test at long winded test probe cables
The same difficulty like at long winded test object PE-conductors also occurs at long winded test probe cables (see previous chapter).
We often supply test probes with a cable length of 10 m and more.
In order not to have any inductivity during the winding the cables have to be winded
bifilary. In doing so the inductivities of both cable halves abolish each other.
For this purpose please mark the middle of the cable and start to wind the cable at
this point on a cable drum.
PE23 © SCHLEICH
3.11. Correcting the test tip resistance

The complete resistance measuring is performed in four-wire technology as explained in chapter 3.2.
For this the cables are designed in four-wire technology up to the test probe.
At the front of the test probe there is the test tip. The four-wire technology ends here. Thus the resistance of the test tip is included in the result of the PE-
resistance test.
In most cases this is not important.
R However, if the resistance of the test tip is also to be corrected for a very precise
measuring the test tip’s resistance can be entered in the setup of the tester. It is
deducted from the measuring value.
The test tip’s resistance is within the range of approx.10 mΩ. Higher resistances
should not be entered here.
PE24 © SCHLEICH
3.12. Application examples of the PE resistance test
3.12.1. Manual test of PE resistances
The manual PE resistance test is usually performed with a PE test probe.
The test object’s input mains lead is connected to the tester at first.
This can either be done via the front socket (the mains socket is plugged in here) or via the industrial plug connector at the tester’s rear. In order to connect
the test object via the industrial plug connector a connecting adaptor is often used. This connecting adaptor is connected to the industrial plug connector via a
cable. In the connecting adaptor there are various standard sockets, quick fastening clamps, etc.
Prüfgerät
Tester
L
N
DUT
Prüfling
PE1
PE1s
R R
PE
RIso
RIso
PE / Iso
PE2
PE2s
PE8 © SCHLEICH
The picture shows a test object with mains lead. The test object is connected in an appropriate way at the main plug.
The operator contacts the PE test points to be tested with the PE test probe one after another.
The test is started by activating the start button in the test probe. Alternatively the test can also be started automatically by touching the test object’s metal
parts with the test probe directly. This depends on the tester and its configuration. For more details please look in the operating manual of your tester.
After the PE resistance test the test result is displayed.

If the test result is ok the subsequent test step can be performed.
If the test result is not ok the test can be repeated again if required. You can determine the corresponding process in the setup parameters. For this please
look in the operating manual of your tester.
The picture shows a typical test of a
switchboard. Various test points in the
switchboard are contacted with the PE test
probe.
The test’s counterpole is the switchboard’s

ground.
If the tester is equipped with a PE resistance

and an insulation resistance test the low-
ohmic PE resistance and the high-ohmic
insulation resistance to the cabinet can be
directly measured with the same test probe.
This picture shows this case.
The SCHLEICH Handheld tester is used

here. Both test methods are integrated.
3.12.2. Automatic test of PE resistances
At the automatic PE resistance test you connect the test object completely once.
After this you start the automatic test process.
All PE resistance measurings are automatically performed one after another. The tester needs to have a corresponding automatic switchover for this in order
to switch between the test points.
Before performing the automatic test you have to prepare the automatic test process. The test process consists of individual test steps. The test steps can be
of different kinds. Depending on the tester’s feature of different test methods you can used different test methods in the test process.
Prüfgerät
Tester
L
N
DUT
Prüfling
PE1
PE1s
PE2 R R
PE
RIso
RIso
PE2s
PE / Iso
PE3
PE3s
PE10 © SCHLEICH
3.13. Black box test
It is important that safety tests are performed reliably. It has to be avoided that damaged test objects are not detected.
How can such a failure happen?

It may occur that the test object’s contacting shows any damage or the input lead was interrupted or had a short circuit.
SCHLEICH tries to detect such fault conditions automatically by corresponding measures in the tester itself. Furthermore, the corresponding test centers
require to perform regular test measurings for control reasons. These test measurings are called dummy or black box test.
A black box contains test resistors whose values are to be exactly determined by the tester.
For checking the PE resistance test a 0.1 Ω resistance is for example assembled in the black box. Black boxes of SCHLEICH GmbH are supplied with
calibration documents. They inform you about the resistance value that is installed in the black box. You can then enter the exact resistance value in the
corresponding point in your tester.
The following pictures show different kinds of black boxes:
3.13.1. Black box test with ± tolerance limit
At this kind of black box test the resistance value has to be measured with a very high accuracy in a tight tolerance band!
RPE
In case the deviation is too high there is a fault and the tester locks automatically for
nicht in Ordnung | not okay
any further tests. Only after the fault reason is removed and another black box test is
passed with GO, the tester is unlocked again.
Rnominal
okay
Some test centers do not accept this kind of black box test. They request a test with
nicht in Ordnung | not okay GO and NO GO-detection.
PE17 © SCHLEICH
3.13.2. Black box test with GO and NO GO-test
At this kind of black box test the test is performed in two test steps.
At first it is tested whether a fault is detected. Afterwards it is tested whether “GO” is detected.
A special black box with a GO and a NO GO resistance is used for this. Both resistances are either installed in one cabinet or in two separate cabinets.
If both conditions are not detected precisely there is a fault and the tester locks automatically for any further tests. Only after removing the fault reason and
another correct black box test it is unlocked again.
1. NO GO-test
A bottom limit for the PE resistance of e.g. 0.1 Ω is entered in the tester. A test resistance that is slightly above this limit is connected to the tester. The
resistance has e.g. 0.11 Ω.
RPE This “too high PE resistance “has to be detected correctly as NO GO. However it
must not be too high!
RniO
okay
RLimit
PE16 © SCHLEICH
2. GO-test
A test resistance is connected to the tester for the testing that is slightly below this limit. The resistance has e.g. 0.09 Ω.
RPE
This “PE resistance “that is slightly below the limit has to be detected correctly as
GO.
However it must not be too low! Otherwise a short circuit in the test lead or a
RLimit problem in the contacting would not be detected reliably.
RiO okay
PE15 © SCHLEICH
4
Insulation resistance test
4. Insulation resistance test
4.1. Explanation of the insulation resistance test
The insulation resistance test is used for test objects of the protection class I or II.
RIso Testers of protection class I feature a PE conductor. Testers of the protection class
RIso II have a protective insulation and do not feature a PE conductor.
It is tested whether the ohmic insulation resistance is above a limit value stipulated
in the standards.
RIso The test is performed to check whether leakage currents against ground or between
electric leads might occur in the test object.
Iso13 © SCHLEICH
If the insulation resistance is too low (and there is possibly also a PE fault) a too high touch current could occur at the tester’s metallic parts. When touching
these metallic parts the so-called touch current would flow through the person to the ground.
Especially at test objects of the protection class II insulating faults at metallic parts can be dangerous as a current conduction into the PE is not possible.
EVU DUT
Definitions
L IAbl
IL + IAbl EVU : electric supply company (power plant)
IL
N IL : current through the test object

PE
RPE UN : mains voltage
IAbl

UB
Ber2 © SCHLEICH
EVU DUT EVU DUT
L IAbl L IAbl
IL + IAbl IL + IAbl
.
IL IL
UN UN
N N
! DANGER
RPE > 0,2W

PE PE
IPE
IB IB
UB UB
Iso1 © SCHLEICH Iso2 © SCHLEICH
The picture shows a protection class I-tester with dangerous The picture shows a protection class II-tester with dangerous
leakage current through the operator as the PE resistance leakage current through the operator.
is too high.
For testing the insulation resistance a test voltage is connected to the insulation. The test voltage is very often 500 Volt DC. The test is often performed with
STOP jumpered leads against PE.
There are different standards and test regulations for various testers. The voltage level is stipulated in these regulations.
The test voltage lets the current flow through the insulation resistance. The insulation resistance is continuously calculated based on the level of the test
voltage and the current during the test time.
IIso1
Prüfgerät If, as shown in the picture, the current-conducting leads are jumpered to each other
Tester
L the total resistance of all simultaneously switched insulation resistances against PE
is detected.
A As the test is performed with DC-voltage the insulation capacities do not influence
the test in any way. Only the ohmic insulation resistances are detected.
N
V U
UIso If the insulation capacities are quite high the insulation resistance test has to take
IIso IIso2 some time so that the insulation capacities can be charged at the beginning of the
PE1
test. This may take some 1/10 seconds as the test current at the insulation
RPE resistance test is usually limited to max. 3 mA due to safety reasons.
Iso3 © SCHLEICH
4.2. Typical limit value at insulation resistance tests
The lowest limit value is often at 2 MΩ.

ATTENTION – this is only a guiding value! For your tester please take the test parameters and the allowed limit value of the regulations!
STOP
All the test values that are in the range between ∞ (infinite) and the limit value RLimit are ok. The limit value must not be underrun during the complete test
time!
The test voltage is often 500 Volt. However it can also be up to 1000 Volt.
ATTENTION – this is only a guiding value! For your tester please take the test parameters and the allowed upper limit value of the regulations!
In order to measure high insulation resistances it definitely makes sense to test with the high voltage as the currents are also higher then. This simplifies the
measuring evaluation.
Based on the following example the electric relations can be clearly explained:
test voltage : 500 V
insulation resistance : 100 MΩ
Thus the test current is : I = U / R => 0,000005 A => 5 µA (5 millionth Ampere)!
Thus you can see that the currents to be measured are often very low. This is the reason why the exact measuring of insulation resistances above is 1 GΩ
quite complex. For this case SCHLEICH uses appropriate test circuits and test leads as shield.
The test time is usually 1sec.

RIso
RLimit
Iso4 © SCHLEICH
If the test value fluctuates during the insulation resistance test this is irrelevant for the measuring. After the test time the available resistance value is evaluated
and displayed. This resistance must be higher or minim equal to the allowed lower limit (RLimit).
RIso
Rtest
RLimit
Start Ende t
Iso5 © SCHLEICH
RIso
The following process is NOT possible! The tester would interrupt the test as the
lower limit value is underrun.
ö
RLimit
Rtest
Start Abbruch t
Iso26 © SCHLEICH
However, it may occur that test objects underrun the limit value especially at the start of the measuring. This is the case when the test object is highly
capacitive and the capacities have to be charged at first.
RIso
In such cases a delay (test break) at the beginning of the measuring can help. It
makes sure that there is no evaluation during the delay time.
Rtest
RLimit
Start Ende t
Delay
Iso27 © SCHLEICH
4.4. Insulation resistance test in the EN 60204 | Machinery directive
At the EN 60204 test the two test methods PE resistance and insulation resistance test are alternately switched between the PE ground and the test probe.
In doing so the PE resistance as well as the insulation resistance to the machine’s cabinet can be tested at one test object connection.
The picture shows a PE / IR tester with test probe. The operator can switch
Prüfgerät between both test methods via the switchover in the tester. The test’s reference
Tester
point is always the common cabinet ground point.
PE2 The PE resistance is measured from all grounded sheet parts (e.g. doors) and
PE2s all ground clamps against this ground point.
The insulation resistance is measured by all electric leads against this ground
V U point.
A A V
RPE
PE1s
PE1
PE-Iso3 © SCHLEICH
This picture shows the “inner life“ of a machine.

Prüfgerät
Tester Electric components are connected with each other and effect a function.
PE / Iso The insulation resistance is measured against ground by all electric leads. The
PE2 measuring can be performed at many points within the circuit. These points can
PE2s be scanned with the test probe.
DUT
Prüfling
L
The PE resistance is measured at all points that have to be connected to PE.
V U
The measuring can be performed at many points within the circuit. These points
can be scanned with the test probe.
A A V
N
RIso1 RIso2
PE1s
PE1 PE RPE1
1
RPE2
2
PE-Iso2 © SCHLEICH
4.5. Insulation resistance test at test objects with one capacity
The insulation resistance test is performed at a RC-part under theoretical examination. The RC-part is an idealized form of the test object’s rates.
I U, I U Why?
UDC
The test object features an insulation resistance between both test points. This is the
resistance RIso. This resistance is usually very high and is at several 100 MOhm and
higher. In addition the test object also has a capacity between both test points. They
IC IISO
are created either between the leads to be tested or from the electric leads to the
body. Between the leads it is usually lower than from the leads to the body.
C RIso t
Iso6 © SCHLEICH
The charging current flows in the capacitor during the switching on or the increase of the test voltage to the requested voltage. When the voltage does not
change anymore there is also no charging current anymore. Only the current in the ohmic resistance RIso flows.
A constant charging current flows at a uniform voltage increase in form of a ramp. In addition there is also the current through the insulation resistance during
the “charging phase”. It rises proportionally to the voltage increase. At the end of the charging phase this leakage currents remains as insulation current.
Based on these physical facts it is clear that the measuring of the insulation resistance cannot be done immediately at test objects with capacities. It has to be
waited for the complete charging process. Only after this process the insulation resistance can be measured correctly. If it is measured too early the resistance
value are too low.
L Capacities occur between insulated metal surfaces. The bigger the surface is and/or
the lower the distance between the metal surfaces towards each other is the bigger
N
is the capacity. Within the test object the electric leads form one metal surface and
the test object’s cabinet the other one. The larger the test object the higher are the
surfaces and thus also the capacity.
L
N
Iso7 © SCHLEICH
Test objects can also feature capacitors and mains filters on the mains leads for the
L interference rejection. These always have capacities against PE (ground) and often
also between the leads.
N
Iso8 © SCHLEICH
4.6. Voltage check at very well insulated test objects
This is very simple at the PE resistance test. If the test current is too low or does not flow through the PE or the test current is too low the resistance is ∞
(infinite) and thus NO GO.
This is quite different at the insulation resistance test. If no test current flows this results in an infinite and therefore perfect insulation resistance. As the test
object is not connected the test result seems to be ok although the test object might be defect!
Prüfgerät At manual tests the operator can also avoid contacting faults by his conscientious
Tester
working.
DUT
Prüfling
L
However, at automatic tests other measurements have to be taken to be sure that
N
the test technically ran without any problems.
Automatic tests with an automatic contacting are especially critical. The contacting
PE1
can be defect and all tests are always ok!
PE1s
Iso11 © SCHLEICH
RIso It might be that the operator is “lucky“ and the test object shows a typical insulation
Rmax
offen / nicht in Ordnung | open / not okay resistance that is lower than infinite. In these cases you can set a maximum
insulation resistance for control reasons. If this value is exceeded the test result is
NO GO as the test value is too high.
okay
RLimit
zu niedrig / nicht in Ordnung | to low / not okay
Iso15 © SCHLEICH
Prüfgerät Unfortunately this is hardly the case. The insulation is that good in many cases so
Tester
that a good test object features insulation resistances in the similar height as at a
DUT
Prüfling fault measuring without connected test leads. In order to test properly in such cases
L
you can connect an additional insulation resistance during the test.
N
PE1
PE1s
100MW
100MW
Iso16 © SCHLEICH
We now assume that the test object has an insulation resistance of 10 GΩ. At the configuration shown in the picture the tester would for example be set to
Rmax = 150 MΩ. The minimum value is stipulated in the standard and is typically set to e.g. 2 MΩ. In case of a missing contacting the resistance is infinite and
thus clearly higher than 150 MΩ. The test result is NO GO. At a correctly connected test object a parallel switching of the insulation resistance and the 100 MΩ
resistance results in the measuring.
The 10 GΩ insulation resistance parallel to the 100 MΩ resistance amount together

Prüfgerät
Tester to approx. 99 MΩ. Thus the value is between Rmin (2 MΩ) and Rmax (150 MΩ).
DUT Therefore the result is GO.
Prüfling
L
N However, this also has a disadvantage when the test demand is quite high. Although
the test object features 10 GΩ only 99 MΩ are displayed. This would not be
accepted in the automotive and aerospace industry.
PE1 But there are of course ways to solve this. After a first control measuring detected
PE1s the correct contacting a second precise measuring is performed. For this the tester
100MW
switches the two 100 MΩ test resistances automatically off and afterwards
determines the real insulation resistance of the test object.
100MW
Iso17 © SCHLEICH
Prüfgerät
Tester It is very important that both test resistances are not directly assembled to the
DUT contacting. This would be pointless. Both test resistances always have to be
L
Prüfling connected via a second separate contacting to the test object. Only in that case you
N can be sure that the test current also flows through the test object up to the test
resistances.
PE1 The test resistances and the automatic switch on/off are usually within the tester.
PE1s The tester has to provide the corresponding contacts for the second contacting.
100MW
100MW
Iso18 © SCHLEICH
Prüfgerät
Tester
DUT The voltage return measuring is an alternative to the leakage control with a test
Prüfling
L resistance.
N
For this the voltage connected by the insulation resistance test is returned to the
tester and checked. Here it is important as well that the return measuring is not
PE1 performed at the same point at which the test voltage is fed in.
PE1s Some operators also call it an insulation resistance test in four-wire technique. Two
leads lead the test voltage to the test object and two leads pick it off at another point.
V
The voltage is controlled after the test time’s elapse.
The tester has to provide the corresponding contacts as well as the corresponding
V measuring technique for the second contacting.
Iso25 © SCHLEICH
4.7. Warm insulation resistance test
The insulation resistance test can also be performed in a warm condition of the test object. ATTENTION! This is only valid at a corresponding tester design!
What does warm insulation resistance test mean?
STOP During the insulation resistance test the test object is connected to operating voltage at the same time. Thus the test object is operated functionally and at the
same time the insulation resistance against the cabinet is checked.
ATTENTION! You cannot perform any insulation resistance test at test objects that are operated in a current mains and are connected to mains voltage!
The tester itself has to supply the necessary test voltage to the test object.
The definition “warm insulation resistance test” can for example be explained with an iron that becomes warm during operation. At the same time it is also
connected to the test voltage.
For which applications does that make sense?
There are test objects whose insulation resistance decreases with increasing
RIso temperature. The test object can have an insulation resistance of 2 GΩ in a cold
Temp condition and in a hot condition the insulation decreases to 5 MΩ and lower!
Typical products are for example tubular radiators. They are used for immersion
Temperatur heaters, coffee machines or for the water heating in washing machines etc.
Isolation
Rmin
Start
t
HVDC28 © SCHLEICH
There are test objects at which heatings and parts extend in a hot condition. In the cold condition the clearance and leakage paths are still ok but in the hot
condition the distances decrease below the limit stipulated in the standards.
There are complex test objects like e.g. washing machines with a lot of internal
wiring. If the insulation resistance test is performed from the outside against the
cabinet via the input lead not all of the internal wirings are tested. Feed paths to
M
heatings, motors, etc. are still open so that these components cannot be tested at
the same time.
1 2 3
 This point can still be tested without any problems.
Iso
 This point can only be tested when the test object’s main switch is switched on.
 This point cannot be tested as the mains voltage is switched off. The electronics
disconnects the motor from the mains and the insulation fault cannot be detected!
Iso22 © SCHLEICH
This point can only be tested when the test object would be operated with mains
voltage simultaneously to the insulation resistance test. Under this condition the test is called “warm insulation resistance test”.
The “warm insulation resistance test“ is of course only possible when the test object is disconnected from the mains. Otherwise the test voltage would return to
the mains. An isolating transformer guarantees the disconnection.
L1 L1 1-phase tests
DUT The insulation resistance test is performed in two test steps.
PE
Prüfling
N N  N  PE
1 2
 L  PE
+
1.
Iso
Iso24 © SCHLEICH
L1 L1
3-phase tests
L2 L2
DUT
The insulation resistance test is performed in four subsequently operating test steps.
L3 L3
Prüfling
N  N PE
1 2 3 4
PE  L1  PE
+  L2  PE
Iso  L3  PE
Iso23 © SCHLEICH
4.8. Faults at the insulation resistance test caused by condensation
Especially when measuring high insulation resistance values (higher 1 GΩ) the physical effect caused by condensation might have to be considered.
When does condensation occur at test objects?

During fast changes from a cold, dry surrounding to a humid, warmer surrounding condenser water is formed that might condense on the test object.
Everybody knows this effect when glasses become steamy. When you come from a cold and dry surrounding and enter into a warm room condense water is
formed on the glasses.
The humid condensation could cause two disadvantageous effects:

1. It might partly reduce the test object’s surface resistance considerably.
2. It might lead to short-circuits between the electrical contacts.
RIso
108
107
106
MegaOhm
105
104
103
102
101
100
0 5 10 15 20 25 30 35
t
Iso30 © SCHLEICH
The complete test object’s insulation resistance is composed of the parallel circuit of
at least 2 resistors.
These are:
RIso = RIso-innen RIso-Oberfläche 1. the resistance within the insulation medium (e.g. in the insulating plastic)
and
2. the resistance on the test object’s surface
Iso28 © SCHLEICH
The surface resistance is usually very high.

Among others it depends on the distance between the electric leads.
RIso = RIso-innen RIso-Oberfläche RIso-Tau However, due to condensation it is considerably reduced.
Iso29 © SCHLEICH
This condensation effect has to be considered especially at large test objects like e.g. open electric motors. Open electric motors are direct current machines
or slip ring motors. At these motors the electric connections not insulated but are free so that the condenser water can condense directly on the connection.
When e.g. in a cold season this kind of electric motor is taken from a cold stock and brought to a warm production a condensation takes place almost always.
Measuring the insulation resistance might not be possible in the best way given these circumstances. The displayed values are too low. Moreover flashover
might also occur due to the too high test voltage.
4.9. Application examples of the insulation resistance test
4.9.1. Manual test at protection class II-test objects
The insulation test can be performed with the PE test probe when the tester is correspondingly set.
During the test one pole of the insulation resistance test is connected to the jumpered current-conducting leads L + N. The other pole is the PE test probe with
which the individual test points are scanned now. All touchable metal parts of the test object are scanned which could be under voltage due to a fault in
production.
Prüfgerät
Tester
L
DUT
N Prüfling
RIso
R
RIso
PE1
PE1s
Iso9 © SCHLEICH
Another typical example is a drilling machine. All screws that hold the cabinet parts together are checked regarding a reasonable insulation.
Prüfgerät
Tester
DUT
L Prüfling
N
PE1
PE1s
Iso14 © SCHLEICH
4.9.2. Automatic test
At the automatic insulation resistance test the tester automatically jumpers the test object’s line conductor and its neutral conductor and measures it against
the test object’s PE.
Depending on the respective tester it is also possible to test the line and the neutral conductor individually against the test object’s PE. A test between the line
and the neutral conductor is also possible.
Prüfgerät
Tester
DUT
Prüfling
L
N
PE1
PE1s
Iso10 © SCHLEICH

It may e.g. occur that the test object’s contacting shows any damage or the input lead was interrupted.
SCHLEICH tries to detect such fault conditions automatically by corresponding measures in the tester itself. However, the corresponding test centers require
in addition performing regular test measurings for control reasons. These test measurings are called dummy or black box test.
A black box often contains test resistors whose values are to be exactly determined by the tester.
For checking the insulation resistance test a high-voltage-resistant 2 MΩ resistance is often assembled in the black box. Black boxes of SCHLEICH GmbH are
supplied with calibration documents. They inform you about resistance value that is installed in the black box. You can then enter the exact resistance value in
the corresponding point in your tester.
The following pictures show some possible black boxes. The pictures show combined black boxes for the PE resistance and the insulation resistance test.
RIso
In case the deviation is too high there is a fault and the tester locks itself
automatically for any further tests. Only after the fault reason is removed and
nicht in Ordnung | not okay another black box test is passed with GO the tester is unlocked again.
Rnominal
okay
GO and NO GO-detection.
Iso19 © SCHLEICH
4.10.2. Black box test with GO and NO GO-test
If both conditions are not detected precisely there is a fault and the tester locks itself automatically for any additional tests. Only after removing the fault reason
and another correct black box test it is unlocked again.
1. NO GO-test
A bottom limit for the insulation resistance of e.g. 2 MΩ is entered in the tester. A test resistance is connected to the tester for the testing that is slightly below
this limit. The resistance has e.g. 1.9 MΩ.
RIso This “too low insulation resistance“ has to be detected correctly as NO GO. However
it must not be too low! Otherwise a short circuit within the lead or a contacting
problem would not be detected reliably.
RLimit
okay
RniO
Iso20 © SCHLEICH
2. GO-test
A test resistance is connected to the tester for the testing that is slightly above this limit. The resistance has e.g. 2.1 Ω.
RIso
This “insulation resistance“ that is slightly above the limit has to be detected
nicht in Ordnung | not okay correctly as GO.
However it must not be too high! Otherwise a break in the test lead or a problem in
RiO
okay the contacting would not be detected reliably.
RLimit
Iso21 © SCHLEICH
5
High-voltage test AC
5. High-voltage test AC (alternating voltage)
5.1. Explanation of the high-voltage test AC
The high-voltage test is used for test objects of the protection class I and II. Testers
HV of the protection class I feature a PE conductor. Testers of the protection class II
HV have a protective insulation and do not feature a PE conductor.
It is tested whether the insulation features a withstand voltage that is stipulated in the
standards.
HV The test is performed to check whether leakage currents against ground or between
HVAC1 © SCHLEICH
If the insulation is too low (and there is possibly also a PE fault) a too high touch current could occur at the tester’s metallic parts. When touching these
metallic parts the so-called touch current would flow through the person to the ground.
Especially at test objects of the protection class II insulating faults at metallic parts can be dangerous as a current conduction into the PE is not possible.
EVU DUT Definitions

L
EVU : electric supply company (power plant)
IL + IAbl IAbl
IL DUT : Device Under Test | test object

UN

N
PE UN : mains voltage
RPE IAbl
UB
Ber2 © SCHLEICH
EVU DUT EVU DUT
L IAbl L IAbl
IL + IAbl IL + IAbl
.
IL IL
UN UN
N N
! DANGER
RPE > 0,2W

PE PE
IPE
IB IB
UB UB
is too high.
5.2. Voltage level at the high-voltage test AC

The required test voltage is stipulated in the test regulation for your tester. Please set this test voltage at your tester.
The high-voltage test is basically performed at the same connecting points like at the insulation resistance test.
However, in contrast to the insulation resistance test the high-voltage test is performed with considerably higher test voltages.
The test voltage is connected to the insulation for testing the insulation strength.
STOP
Generally we can give you the following information:
In many cases the test voltage’s level is in the range of 1000 to 1800 Volt AC. This is an effective value!
5.3. Which voltage is displayed?

The high-voltage’s effective value (U2) is usually displayed.
In a harmonic-free mains the effective value is in a clear relation to the peak value.
UHV This is: U1 = U2 * √2.
+U1
U2 As soon as harmonics occur in a mains this is not the case anymore. Here
harmonics are often included in the high-voltage. For example at a 50 kV-tester they
are transmitted from the primary side to the secondary side of the high-voltage
transformer.
Thus the peak value does not have a clear √2-relation to the effective value.
t
However, in some applications the peak value is the essential level that stresses the
test object.
In order to test these applications properly as well most of the SCHLEICH-testers
-U1 have the option of switching between the peak value and the effective value
presentation. .
HVAC14 © SCHLEICH
5.4. Discharge
The test object should be discharged after a high-voltage test with AC. As many test objects often have a capacitive part this is permanently charged and
recharged in the alternating voltage’s rhythm.
If the test is performed with test probe and the probes are disconnected under voltage there can still be a residual voltage in the test object. If the probes are
disconnected just in the sine-peak value of the high-voltage the residual voltage is URes = UHV *√2!
! DANGER In order to avoid dangerous residual voltages after a test the discharge is mandatory. The easiest discharge can be reached by connecting the connections
with which it was tested with each other. ATTENTION! This can damage some test objects.
HVAC36 © SCHLEICH HVAC37 © SCHLEICH
Discharge at the blue lead at which the test was performed before. ATTENTION! It may be better to discharge all connections. Sometimes it
occurs that also not-tested leads are charged due to parasitic capacities.
In any case it is better to disconnect the test probes only without voltage. If you connect the test probes at first, then start the test e.g. via the foot switch and
then wait until the test time elapsed the high-voltage tester is discharged. The transformer’s winding is still connected to the test object after the test. This
winding discharges the test object now via the internal resistance within the winding.
If the tester is also equipped with an actual voltage measuring of the test object’s
Prüfgerät
Tester
voltage the red warning light is only switched off after the discharge.
DUT
HVAC38 © SCHLEICH
At test systems with automatically operating test the tester’s internal process makes sure that it is discharged. The voltage-free secondary winding of the high-
voltage transformer remains connected to the test object until it is discharged. The test object’s matrix relays are switched off only after this discharge.
5.5. Voltage ramps and voltage profiles
It is advisable not to switch the test voltage abruptly on at the test object but to increase the high-voltage smoothly in form of a ramp.
Almost all SCHLEICH testers are equipped with this function.
UHV Rampendauer Prüfzeit

ramp time Test time
URes
Start
t
HVDC14 © SCHLEICH
In addition to the individual ramps with subsequent test times you can also string several of such sequences arbitrarily together.
Voltage profiles are combined of these sequences. Many SCHLEICH testers are equipped with this function.
UHV
Sequenz 1 Sequenz 2 Sequenz 3 Sequenz 4 Sequenz 5
Start Ende t
HVDC15 © SCHLEICH
5.6. Potential-free – not potential-free?
Whether potential-free or not depends on the standard’s requirement or is set in your application.
Most of the applications up to 6000 V are potential-free. In addition the high-voltage is often one-way connected to ground.
SCHLEICH supplies high-voltages up to 12 kV potential-free.
The potential-free high-voltage is safer than the potential-afflicted. The high-voltage transformer acts like an isolating transformer at the potential-free high-
! voltage. A certain limited protection is given by this.

However it has to be respected that high-voltages with a current higher than 3 mA AC must NEVER be touched!
Prüfgerät
Tester The picture shows a potential-free high-voltage test with 2 safety probes. When a
high-voltage pole is touched there is theoretically still a limited safety. But
L
0...max.
HV
depending on the set high-voltage level there are already capacitive parasitic
currents that might be dangerous.
Thus please respect: Never touch the high-voltage!
HV
N
HVAC32 © SCHLEICH
! DANGER Prüfgerät
The picture shows the not-potential-free high-voltage test. The danger can directly
Tester
be seen.
L
0...max.
HV
HV
N
HVAC33 © SCHLEICH
! DANGER ATTENTION: When the potential-free high-voltage test is performed at a metallic production line for example one safety test probe is sometimes connected to
the metallic cabinet of the test object and the other one to the electric leads.
But the test object’s metallic cabinet stands on a metallic (hopefully) grounded production line. This neutralizes the potential freedom!
It is ALWAYS advisable to test the test object on an insulated load support on a production line. Then there is no voltage diversion!
Prüfgerät Prüfgerät
Tester Tester
L L
0...max. 0...max.
HV HV
D D
U U
T T
HV HV
N N
5.7. Current as evaluation criterion
The required test voltage for your tester is stipulated in the test regulation. This test voltage has to be set at the tester.
STOP The test voltage lets a current flow through the insulation resistance. This current is measured.
The level of the conducting current is the criterion for the insulation strength.
Prüfgerät
IIso1 If as shown in the picture the current-conducting leads are jumpered with each other
Tester the total current is determined by all simultaneously connected insulation resistances
L
and capacities against PE.
IC1
A
As the test is performed with alternating voltage the insulation capacities
considerably influence the test.
IC2
N
V The capacities are often high so that the capacitive leakage current is also very high.
UHV
This current is considerably higher than the current through the insulation resistance.
IHV IIso2
PE1 Therefore at the test with AC the current through the ohmic insulation resistance as
RPE well as through the capacities are determined.
The total current IHV of the ohmic and capacitive part is measured.
HVAC2 © SCHLEICH
Tester Especially at electric motors this can lead to the fact that a very high current is
required for the high-voltage test. But this high current only flows because the test
object’s capacity is very high.
C RIso
HVAC13 © SCHLEICH
L
Capacities occur between insulation metal surfaces. The larger the surface and/or
the lower the distance between the metal surfaces to each other, the bigger is the
N
capacity. Within the test object the electric leads form one metal surface and the
metallic cabinet of the test object the other one. The larger the test object the larger
the surfaces are and thus the capacity as well.
L
N
Iso7 © SCHLEICH
Test objects can be equipped with installed capacitors and mains filters on the mains
L leads for the interference suppression. They always have capacities against PE
N
(ground) and often also between the leads.
Iso8 © SCHLEICH
By combining capacities and insulation resistances the current flows out-of-phase to the high-voltage. The capacitive part clearly lets the current lead to the
voltage. Depending on the capacity’s level the current can lead up to almost 90°.
IC
IHV
UHV IHV
t

IR
UHV
This picture clearly shows how strongly shifted the capacitive current This picture shows the phase angle  between the high-voltage and
can be to the high-voltage. the current.
Some SCHLEICH-testers can measure the phase angle  between the voltage and the current. Based on the determined angle and the level of the
conducting current the testers can calculate the capacitive (IC) and ohmic (IR) part of the current. It is shown in the display. Depending on the tester’s setting
the current limit value can be evaluated to one of the three units: IHV , IC or IR.
If it is allowed according to the standard the test can be performed also with DC as an alternative to AC. This has the advantage that only the ohmic insulation
resistance can be determined similar to the insulation resistance test after the charging time of the capacitors.
5.8. Typical current limit values at the high-voltage test

The required test voltage is stipulated in the test regulation for your tester. This test voltage has to be set at the tester, either manually or automatically,
that does not matter.
The conducting current depends on the high-voltage level and on the electric insulation design of the test object. Thus the current strongly depends on the
product.
There may be products at which only a little leakage current flows or only high leakage current flows. However, both products are ok.
There is hardly any clear normative answer for the question regarding the allowed limit current.
The operator has to test at “GO”-sample objects which current flows at the test samples. The maximum limit current is determined based on this “GO”-current
plus a reserve.
ATTENTION – this is only a guiding value! For your tester please take the test parameters of the regulations!
STOP
All current test values that are within 0 and the limit value ILimit (including) are ok. The limit value must not be underrun during the complete measuring.
The test time is usually 1 sec.

IHV
ILimit
HVAC3 © SCHLEICH
5.9. Which current value is displayed and evaluated?
If the current value fluctuates during the high-voltage test the highest value that was measured during the complete test time is evaluated and displayed. That
means that the worst current value that occurred during the measuring is used for the evaluation. This current must be lower or maximum equal to the allowed
upper limit (ILimit).
IHV IHV
ILimit ILimit
Itest-max Itest-max
Start Ende t Start Ende t

Delay
At SCHLEICH-testers you can also set an evaluation delay (Delay (measuring break)). This should make sure that occurring higher currents that may occur for
a short-hand of time when switching the test voltage on do not have any effect.
5.10. Disruptive breakdown / Overcurrent

If the current exceeds the limit value at the high-voltage test the test is immediately interrupted automatically. Only in the mode “burning” there is no automatic
switch off.
The maximum upper limit of the current is entered in the tester corresponding to the test task.
IHV
ILimit
Start Abbruch t
Break
HVAC5 © SCHLEICH
5.11. Burning
The burning mode is used for locating faults at the test object. Due to the fact that SCHLEICH testers immediately interrupt the test in case of overcurrent to
protect the test object it may be difficult to locate the flash at the fault location.
The burning mode helps in these cases.
The tester does not switch off in case of a disruptive breakdown. There is continuous spark at the fault location. This helps you locating the fault.
ATTENTION! As the high-voltage is not switched off this mode is dangerous!
IHV
Imax
Start Ende t
HVAC12 © SCHLEICH
5.12. Testing without protection against contact
Testing with high-voltage usually requires a protection against contact. However, this is often annoying for the operators. Under certain conditions you can do
the test with protection against contact. These conditions are:
 safety current limitation to a maximum test current of 3 mA.

 power limitation to a maximum power of 350 mJ.
5.12.1. Safety current limitation max. 3 mA AC
According to the regulations of international standards and the Accident Prevention & Insurance Association very strict safety measures have to be observed
when operating test systems.
IHV It basically applies that alternating test currents above 3 mA can be fatal!
Thus all high-voltages at which more than 3 mA can flow have either to be protected
against contact or safety high-voltage probes have to be used.
GEFAHR
! Danger
3mA
HVAC6 © SCHLEICH
! DANGER IHV It has to be considered that a high-voltage tester e.g. for an output current of 100
mA can never be seen as safety current limited by presetting the limit current to 3
mA!
However, the high-voltage is switched off only some milliseconds after exceeding
the limit current (see Delay in the graphic) but the current can be highly dangerous
Delay during this switch-off time.
3mA
Start Aus t
Off
HVAC7 © SCHLEICH
5.12.2. Power limitation to max. 350 mJ
It has always to be considered that the power stored in the test object must never exceed 350 mJ. Safe means that both conditions, i.e. maximum current of 3
mA plus maximum power of 350 mJ have to be met.
What does 350 mJ mean? Joule is the unit for power. This energy has to be calculated according to the equation Q = ½ * C * U2.
Example: The power for the following mains filter has to be calculated.
Filter / DUT
L
Cy
PE
Cx Cx
Cy
N
HVDC22 © SCHLEICH
The test should be performed between L plus N (jumpered with each other) against PE.
The capacitors Cy should be 22 nF each in this example.
The capacitors Cx should be 100 nF each in this example.
This kind of filter is often tested with 1800 V AC. The calculation to the AC-peak value is approx. 1800 V * √2 = 2700 V DC.
By means of the bridge between L + N both Y-capacitors (Cy) are switched in parallel.
Ctotal = 22 nF + 22 nF = 44 nF.
Q = ½ * 44 nF * 2700 V * 2700 V = 160 mJ
The power stored in the filter after switching the high-voltage off is 160 mJ und is thus clearly below the allowed limit.
However a discharge is highly recommended. Most of the SCHLEICH testers therefore discharge automatically until the voltage is dropped below the safe
touch voltage.
A high-voltage test can also be performed between L and N.

X-capacitors often have a value of 100 nF.
The total capacity in this case is Ctotal = 100 nF + 100 nF + 11 nF = 211 nF. (The 11 nF are caused by the series connection of both 22 nF-capacitors.)
The typical test voltage between L and N is 1450 V DC.
This results in a power of Q = ½ * 211 nF * 1450 V * 1450 V = 222 mJ.
The power in the filter after the high-voltage is switched off is 222 mJ and is thus also below the allowed limit.
However, a discharge is highly recommended.
In addition a resistance is also installed in parallel to the capacitors within the filter. Why? It should make sure that a discharge also takes place via the filter. It
is discharged so fast that the voltage drops to the stipulated residual voltage in the normatively stipulated time.
In the example we assumed a maximum size of the Y-capacitors of 22 nF each which is allowed for devices of the protection class I with a maximum leakage
current of 3.5 mA.
This can be reconstructed mathematically:
At first we calculate the capacitive resistance that is: Xc = 1 / ( 2 * PI * f * C)
In the example with the above mentioned capacitors at 50 Hz this is: Xc = 1 / ( 2 * PI * 50 Hz *44 nF) = 72.34 KΩ.
At a mains voltage of 230 V this results in a current of: I = 230 V / 72.34 KΩ = 3.1 mA.
Thus the demand of staying below 3.5 mA is met.
5.13. Voltage check
How can you be sure that the test was performed correctly?
This is simple at PE resistance tests. If the test current is too low or does not flow through the PE conductor the resistance is infinite and thus NO GO.
This is completely different at the high-voltage test.
As the test object might not be connected the test result seems to be ok although the test object is possibly damaged!
Prüfgerät At manual tests the operator can avoid contacting faults by his conscientious
Tester
DUT working.
Prüfling
However, at automatic tests other measures have to be taken to be sure that the test
runs technically correct.
Automatic tests with an automatic operating contacting are especially critical. The
contacting can be damaged and all the tests are always ok!
HV1
.
HV2
HVAC17 © SCHLEICH
IHV
It might be that the operator is “lucky“ and the test object shows a clear capacity. A
Durchschlag / nicht in Ordnung | break / not okay
Imax corresponding leakage current flows through this capacity during the test.
In these cases you can set the capacitive leakage current as minimum current for
okay the voltage check. If the minimum current is exceeded you can assume that the test
object is connected. If the maximum current is exceeded the test object is defect.
Imin
offen / nicht in Ordnung | open / not okay
HVAC16 © SCHLEICH
Prüfgerät In cases which the capacity is quite low and thus almost no current flows you have to
Tester
choose another way.
DUT
Prüfling
HV1
HV2
HVAC15 © SCHLEICH
Prüfgerät
Tester
In order to test these applications correctly you can connect an additional resistance
DUT
during the test.
Prüfling
HV1
With this additional resistance you make sure that a minimum current flows during
the test again. You can set this at the tester.
If the minimum current is exceeded you can assume that the test object is
HV2
connected. If the maximum current is exceeded the test object is defect.
1MW
HVAC19 © SCHLEICH
However, this also has a disadvantage when the test demand is quite high. Although the test object may not have a leakage current 1 to X mA are displayed.
This would not be accepted in the automotive and aerospace industry.
But there are of course ways to solve this. After a first control measuring detected the correct contacting a second precise measuring is performed. For this the
tester switches the two 1 MΩ test resistances automatically off and afterwards determines the real leakage current of the test object.
Prüfgerät It is very important that both test resistances are not directly assembled to the
Tester
contacting. This would be pointless. Both test resistances always have to be
DUT
Prüfling
connected via a second separate contacting to the test object. Only in that case you
L
can be sure that the test current also flows through the test object up to the test
N resistances.
The test resistances and the automatic switch on/off are usually within the tester.
PE1
The tester has to provide the corresponding contacts for the second contacting.
1MW
1MW
HVAC20 © SCHLEICH
Prüfgerät The voltage return measuring is an alternative to the leakage control with a test
Tester
resistance.
DUT
Prüfling
L
For this the voltage connected by the high-voltage test is returned to the tester and
N
checked. Here it is important as well that the return measuring is not performed at
the same point at which the test voltage is fed in.
Some operators also call it a high-voltage test in four-wire technique. Two leads lead
PE1
the test voltage to the test object and two leads pick it off at another point.

V
The tester has to provide the corresponding contacts as well as the corresponding
measuring technique for the second contacting.
HVAC39 © SCHLEICH
5.14. Warm high-voltage test AC
The high-voltage test can also be performed in a warm condition of the test object. ATTENTION! This is only valid at a corresponding tester design!
What does warm high-voltage test mean?
STOP During the high-voltage test the test object is connected to operating voltage at the same time. The test object is operated functionally and at the same time
the insulation resistance against the cabinet is checked.
ATTENTION! You cannot perform any high-voltage test at test objects that are operated in a current mains and are connected to mains voltage!
The definition “warm high-voltage test” can for example be explained with an iron that becomes warm during operation. At the same time it is connected to the
high-voltage.
RIso temperature. The test object can have an insulation resistance of 2 GΩ in a cold
Temp condition and in a hot condition the insulation decreases to 5 MΩ and lower!
Typical products are tubular radiators. They are used for immersion heaters, coffee
Temperatur machines or for the water heating in washing machines etc.
Isolation
Rmin
Start
t
HVDC28 © SCHLEICH
There are test objects at which heatings and parts extend in a hot condition. In the cold condition the clearance and leakage paths are still ok. In the hot
wiring. If a high-voltage test is performed from the outside against the cabinet via the
input lead not all of the internal wirings are tested. Feed paths to heatings, motors,
M
etc. are still open so that these components cannot be tested at the same time.
 This point can be tested without any problems.
1 2 3
HVAC29 © SCHLEICH
voltage simultaneously to the high-voltage test. Under this condition the test is called
“warm high-voltage test”.
The “warm high-voltage test“is of course only possible when the test object is disconnected from the mains. Otherwise the high-voltage would return to the
mains. An isolating transformer guarantees the disconnection.
L1 L1
1-phase tests
DUT In order to avoid that the high-voltage stresses the test object only partially the high-
PE
Prüfling voltage has to be supplied in the middle of the isolating transformer according to the
N N standard. Thus the high-voltage against ground is added to the mains voltage.
L2 The sine signals of the high-voltage and the functioning test add and subtract to and
from each other. This is caused by the phasing of the sine signals. The standard
stipulates that the functioning test is supplied by phase L1 and the high-voltage
L3
source by the phases L2-L3.
HVAC30 © SCHLEICH
L1 L1
2 DUT 1-phase test
PE
Prüfling Another alternative is selecting at which point the high-voltage is to be supplied via
N N relay in the test program.
1 3
L2
L3
HVAC40 © SCHLEICH
L1 L1
DUT 1-phase tests
PE
Prüfling It is also possible to perform the warm high-voltage test manually via a probe. For
N N this 3 supply points are lead out of the tester to contact pads. The test probe is
manually contacted to these contact pads.
L2
L3
HVAC41 © SCHLEICH
L1 L1 3-phase tests
L2 L2  The high-voltage is supplied in four subsequently running test steps at N, L1, L2,
L3 L3
DUT and L3. The counterpole is the cabinet.
Prüfling
N
1 2 3 4
PE
+
HVAC
HVAC31 © SCHLEICH
5.15. Application examples of the high-voltage test
5.15.1. Manual test
The high-voltage test is usually performed with safety test probes.
One high-voltage pole is contacted to the jumpered current-conducting leads L+N.

With the other safety test probe all contactable metal parts of the test object are scanned.
Prüfgerät
Tester DUT
Prüfling
RIso
R
HV1
RIso
HV2
HVAC21 © SCHLEICH
Another typical example is an electric motor. Here all

Prüfgerät
phases are tested against the cabinet and all phases
Tester
are also tested against each other.
DUT
Prüfling
HV1
HV2
HVAC22 © SCHLEICH
Please consider at the manual test that the test object is NOT contacted with the test probes at switched-on high-voltage. High voltage peaks could occur that
might destroy the test object.
Some tenth millimeter before the operator contacts the test object the spark starts to jump over. In combination with the test object’s capacities and
inductivities this might lead to voltage peaks.
Voltage peaks are higher as the high-voltage supplied by the tester. Thus the test
object could be damaged.
It is better to connect the test probes to the test object at first and then start the test
via the foot switch.
This has two advantages:

1. no voltage peaks
2. The test object is only connected to high-voltage for the time you have also set in
the tester. No longer but also not shorter as well.
HVAC23 © SCHLEICH
The manual test always has the problem of the safe discharge. After switching the high-voltage off the test pistols remain contacted to the test object for a
short time. Only this handling guarantees a safe discharge.
In any case it is recommended to jumper the test connections among each other manually in order to be sure that the test object is discharged.
(see chapter 5.4 Discharge!)
5.15.2. Automatic test
During the automatic high-voltage test the outer conductor and the neutral conductor of a test object are automatically jumpered by the tester and measured
against the test object’s PE conductor.
Depending on the tester it is possible to test the outer conductor and the neutral conductor individually against the PE conductor of the test object. The test
between outer and neutral conductor is also possible.
Prüfgerät
Tester
After the test it is discharged automatically.
DUT
Prüfling
L
N
PE1
PE1s
HVAC24 © SCHLEICH

It may occur that the test object’s contacting shows any damage or the input lead was interrupted.
SCHLEICH tries to detect such fault conditions automatically by corresponding measures in the tester itself. The corresponding test centers require in addition
performing regular test measurings for control reasons. These test measurings are called dummy or black box test.
For checking the high-voltage test a high-voltage resistant 2 MΩ resistance is for example assembled in the black box. Our black boxes are supplied with
calibration documents. They inform you about the resistance value that is installed in the black box. You can then enter the exact resistance value in the
The following pictures show some possible black boxes. The pictures show combined black boxes for the PE resistance, high-voltage, and insulation
resistance test.
IHV
another black box test is passed with GO the tester is unlocked again.
Inominal
okay
HVAC25 © SCHLEICH
5.16.2. Black box test with GO- and NO GO-test
If both conditions are not detected precisely there is a fault. The tester locks itself automatically for any additional tests. Only after removing the fault reason
1. NO GO-test
A top limit for the current of e.g. 2mA is entered in the tester. A test resistance is connected to the tester for the testing that lets a current flow that is slightly
above this current value.
IHV

This too high current has to be detected correctly as NO GO.
However it must not be too high! Otherwise a short circuit in the test lead or a
IniO problem in the contacting would not be detected reliably.
okay
ILimit
HVAC26 © SCHLEICH
2. GO-test
A test resistance is connected to the tester for the testing that lets a slightly lower current flow.
IHV
This current that is slightly below the limit ILimit has to be detected correctly as GO.
nicht in Ordnung | not okay However it must not be too low! Otherwise a break in the test lead or a problem in
the contacting would not be detected reliably.
ILimit
IiO okay
HVAC27 © SCHLEICH
5.17. High-voltage test higher than 10 kV
High-voltage tests with voltages higher 10 kV are often realized with an external high-voltage transformer.
This high-voltage transformer is usually filled with the insulating oil Shell DIALA D. This oil does not have to be exchanged.
The high-voltage transformer has to be connected with the PE conductor of the cabinet or the cabinet installation in addition (at least 4 mm²).
The test object is directly connected to the transformer. One test connection is the high-voltage tube the other test connection is the transformer’s cabinet
(PE).
The high-voltage transformer and the test object have to be in a closed test station secured against contact.
For the safety distances the following guiding values are valid (0.20 m / 10 KV):
- at 10 kV distance at least 0.20 m

The door or protective cover of this test station has to be equipped with two safety contacts that are connected to the tester. An emergency stop button can be
connected to the tester in addition.
A warning light connection is also installed at the tester.
For more information please look in the standard EN 50191 “Erection and operation of electrical test equipment“.
6
High-voltage test DC
6. High-voltage test DC (direct voltage)
6.1. Explanation of the high-voltage test DC
The high-voltage test is used for test objects of the protection class I and II. Testers
HV of the protection class I feature a PE conductor. Testers of the protection class II
HV have a protective insulation and do not feature a PE conductor.
It is tested whether the insulation features a withstand voltage that is stipulated in the
standards.
HV The test is performed to check whether leakage currents against ground or between
HVAC1 © SCHLEICH
If the insulation is too low (and there is possibly also a PE fault) a too high touch current could occur at the tester’s metallic parts. When touching these
At test objects of the protection class II insulating faults at metallic parts can be dangerous as a current conduction into the PE is not possible.
EVU DUT Definitions

L
EVU : electric supply company (power plant)
IL + IAbl IAbl
IL DUT : Device Under Test | test object

UN

N
PE UN : mains voltage
RPE IAbl
UB
Ber2 © SCHLEICH
EVU DUT EVU DUT
L IAbl L IAbl
IL + IAbl IL + IAbl
.
IL IL
UN UN
N N
! DANGER
RPE > 0,2W

PE PE
IPE
IB IB
UB UB
is too high.
The high-voltage test with DC is basically very similar to the insulation resistance test.
The insulation resistance can also be determined with the high-voltage test DC.
Alternatively to the insulation resistance presentation and insulation resistance evaluation you can change to a current presentation with current evaluation.
6.2. Voltage level at the high-voltage test DC
The required test voltage is stipulated in the test regulation for your tester. Please set this test voltage at your tester.
The high-voltage test is basically performed at the same connecting points like at the insulation resistance test.
However, in contrast to the insulation resistance test the high-voltage test is performed with considerably higher test voltages.
The test voltage is connected to the insulation for testing the insulation strength.
STOP
Generally we can give you the following information:
In many cases the level of the test voltage AC is in the range of 1000 to1800 Volt AC. This is an effective value. In order to reach a similar testing accuracy
with DC the DC-voltage is set based on the peak value of the AC’s effective value.
HVDC = HVAC * √2
As √2 = 1.414 is approx. 1.5 you can also say: HVDC = HVAC * 1,5
6.3. Which voltage is displayed?
The arithmetic average value is displayed. The high-voltage test with DC is usually not a rectified AC-high-voltage. The almost battery voltage similar high-
voltage is generated via special circuits.
UHV The DC-high-voltage of SCHLEICH testers has a very low ripple!

This is the precondition for high-quality measurings and the measuring of very high-
Umittel
ohmic insulation resistances.
HVDC1 © SCHLEICH
6.4. Which DC-voltage types are available?

There are basically two options of the DC-high-voltage generation.
1. The voltage is generated by rectifying the mains voltage.
2. The voltage is generated by means of special high-frequent transmitter with rectifying cascades and filter.
The first version is the simplest. This version does not offer the option of a precise insulation resistance measuring. This voltage has too much ripple for this. It
can only be tested regarding withstand voltage and disruptive breakdown.
UHV The mains voltage serves as start for the rectification. This can be available 50 Hz or
60 Hz. Electronic solutions with higher frequencies like e.g. 300 Hz are also
possible.
HVDC3 © SCHLEICH
In the simplest case the DC-voltage is generated by a rectification. This is typical for one-side grounded high-voltage applications. The high-voltage
transformer is e.g. grounded on one side at an 80 kV-DC system. Thus the only option is to rectify positively or negatively via a diode.
UHV UHV
t t
+ -
AC DC AC DC
HVDC4 © SCHLEICH HVDC5 © SCHLEICH
Positive one-way rectification Negative one-way rectification

The pictures show the original start voltage in pale color in the background.
If the high-voltage transformer is not grounded at the secondary terminals but is potential-free a bridge rectification can also be used. This is typical for
systems from approx. 10 to 20 kV DC.
A transformer with center grounding can alternatively be used for higher voltages. DC-voltages up to 100 kV can be generated with it.
UHV UHV
t t
+ +
AC DC AC DC
B -
r HVDC7 © SCHLEICH HVDC6 © SCHLEICH
d
bridge rectification average rectification
The rectified high-voltage can additionally be evened with a capacitor (so-called filter capacitor). However, the ripple is still critical here. Another special
disadvantage is that the ripple depends on the applied load.
E
UHV
AC DC
-
HVDC8 © SCHLEICH
The optimum case is a generation of a very “smooth” direct voltage with a special circuit made by SCHLEICH. This provides the optimum precondition for the
perfect high-voltage test with DC. It is insensitive regarding mains voltage fluctuations and against high load variations.
UHV
t
HVDC9 © SCHLEICH
6.5. Discharge
A discharge has to be performed after a high-voltage test with DC. As mentioned above test objects are often capacitive and thus they are charge during the
test!
In order to avoid dangerous residual voltages after a test a discharge is mandatory.
Regarding this topic there are clear statements in the standards VDE 0104 or EN 50191.
UHV Entladung SCHLEICH-testers always discharge after a high-voltage test with DC. Most of the
Discharge models also measure the residual voltage and finish the test process only when the
voltage dropped to a shock-proof residual voltage.
URes
Ende Sicher
End Safe t
HVDC10 © SCHLEICH
6.6. Voltage ramps and voltage profiles

It is advisable not to switch the test voltage abruptly on at the test object but to increase the high-voltage smoothly in form of a ramp.
Almost all SCHLEICH testers are equipped with this function.
UHV Rampendauer Prüfzeit

ramp time Test time
URes
Start
t
HVDC14 © SCHLEICH
In addition to the individual ramps with subsequent test times you can also string several of such sequences arbitrarily together.
Voltage profiles are combined of these sequences.
Many SCHLEICH testers are equipped with this function.
.
UHV
Sequenz 1 Sequenz 2 Sequenz 3 Sequenz 4 Sequenz 5
Start Ende t
HVDC15 © SCHLEICH
6.7. Potential-free – not potential-free?
Whether potential-free or not depends on the standard’s requirement or is set in your application.
Most of the applications up to 6000 V are potential-free. In addition the high-voltage is often one-way connected to ground.
SCHLEICH supplies high-voltages potential-free up to 12 KV and higher.
The potential-free high-voltage is safer than the potential-afflicted. The HVDC-electronics acts like an isolating transformer at the potential-free high-voltage. A
! certain limited protection is given by this.

However it has to be respected that high-voltages with a current higher than 12 mA DC must NEVER be touched!
Prüfgerät
Tester The picture shows a potential-free high-voltage test with 2 safety probes. When a
high-voltage pole is touched there is theoretically still a limited safety. But depending
L
0...max. 0...max. on the set high-voltage level there are already capacitive parasitic currents that
HV+
might be dangerous.
Thus please respect: Never touch the high-voltage!
HV-
N
HVDC20 © SCHLEICH
! DANGER Prüfgerät
Tester The picture shows the not-potential-free high-voltage test. The danger can directly
be seen.
L
0...max. 0...max.
HV+
HV-
N
HVDC21 © SCHLEICH
! DANGER ATTENTION: When the potential-free high-voltage test is performed at a metallic production line for example one safety test probe is sometimes connected to
the metallic cabinet of the test object and the other one to the electric leads.
But the test object’s metallic cabinet stands on a metallic (hopefully) grounded production line. This neutralizes the potential freedom!
It is ALWAYS advisable to test the test object on an insulated load support on a production line. Then there is no voltage diversion!
Prüfgerät Prüfgerät
Tester Tester
L L
0...max. 0...max. 0...max.
HV+ HV+
D D
U U
T T
HV- HV-
N N
HVDC19 © SCHLEICH HVDC18 © SCHLEICH
6.8. High-voltage test DC at test objects with a capacity
The high-voltage test is performed at a RC-part under theoretical examination. The RC-part is an idealized form of the test object’s rates.
I U, I U Why?
UDC
The test object features an insulation resistance between both test points. This is the
resistance RIso. This resistance is usually very high and is at several 100 MOhm and
higher. In addition the test object also has a capacity between both test points. They
IC IISO
are created either between the leads to be tested or from the electric leads to the
body. Between the leads it is usually lower than from the leads to the body.
C RIso t
Iso6 © SCHLEICH
The charging current flows in the capacitor during the switching on or the increase of the test voltage to the requested voltage. When the voltage does not
change anymore there is also no charging current anymore. Only the current in the ohmic resistance RIso flows.
A constant charging current IC flows at a uniform voltage increase in form of a ramp. In addition there is also the current through the insulation resistance
during the “charging phase”. It rises proportionally to the voltage increase. At the end of the charging phase this leakage currents remains as insulation
current.
Based on these physical facts it is clear that the measuring of the insulation resistance cannot be done immediately at test objects with capacities. It has to be
waited for the complete charging process. Only after this process the insulation resistance can be measured correctly. If it is measured too early the resistance
value are too low.
L Capacities occur between insulated metal surfaces. The bigger the surface is and/or
the lower the distance between the metal surfaces towards each other is the bigger
N is the capacity. Within the test object the electric leads form one metal surface and
the test object’s cabinet the other one. The larger the test object the higher are the
surfaces and thus also the capacity.
L
N
Iso7 © SCHLEICH
Test objects can also feature capacitors and mains filters on the mains leads for the
L interference rejection. These always have capacities against PE (ground) and often
N
also between the leads.
Iso8 © SCHLEICH
Tester Especially electric motors feature high capacities.

You can say: The bigger the motor the bigger is its capacity.
C RIso
HVAC13 © SCHLEICH
6.9. Current as evaluation criterion
The level of the conducting current is the criterion for the insulation strength.
Prüfgerät
IIso1 If as shown in the picture the current-conducting leads are jumpered with each other
Tester the total current is determined by all simultaneously connected insulation resistances
L
and capacities against PE.
IC1
A As the test is performed with direct voltage the insulation capacities do not influence
the test. Only the ohmic insulation resistances are determined.
IC2
N
V U If the insulation capacities are relatively high the insulation resistance test has to
UHV
IHV
take a little bit longer so that the insulation capacities can be charged at the
IIso2
PE1 beginning of the test. This can take up to 1/10 seconds.
RPE
HVAC2 © SCHLEICH
6.10. Insulation resistance as evaluation criterion

The insulation resistance is calculated from the current and the connected voltage. This is the criterion for the insulation strength.
If as shown in the picture the current-conducting leads are jumpered with each other the total resistance is determined by all simultaneously connected
insulation resistances against PE.
As the test is performed with direct voltage the insulation capacities do not influence the test. Only the ohmic insulation resistances are determined.
If the insulation capacities are relatively high the insulation resistance test has to take a little bit longer so that the insulation capacities can be charged at the
beginning of the test. This can take up to 1/10 seconds.
6.11. Typical current limit values at the high-voltage test
The required test voltage is stipulated in the test regulation for your tester. This test voltage has to be set manually or automatically at the tester.
The conducting current depends on the test voltage level and on the electric insulation design of the test object. The current strongly depends on the product.
There may be products at which only a little leakage current flows and vice versa. However, both products are ok.
There is hardly any clear normative answer for the question regarding the allowed limit current.
The operator has to test at “GO”-sample objects which current flows at the test samples. The maximum limit current is determined based on this “GO”-current
plus a reserve.
ATTENTION – this is only a guiding value! For your tester please take the test parameters of the regulations!
STOP
All current test values that are within 0 and the limit value ILimit (including) are ok. The limit value must not be underrun during the complete measuring.
The test time is usually 1 sec.

IHV
ILimit
HVAC3 © SCHLEICH
6.12. Which current value is displayed and evaluated?

If the current value fluctuates during the high-voltage test the highest value that was measured during the complete test time is evaluated and displayed. That
IHV IHV
ILimit ILimit
Itest-max Itest-max
Start Ende t Start Ende t

Delay
At SCHLEICH-testers you can set an evaluation delay (Delay (measuring break)). This should make sure that occurring higher currents that may occur for a
short-hand of time when switching the test voltage on do not have any effect.
6.13. Disruptive breakdown / Overcurrent
If the current exceeds the limit value at the high-voltage test the test is immediately interrupted automatically. Only in the mode “burning” there is no automatic
switch off.
The maximum upper limit of the current is entered in the tester corresponding to the test task.
IHV
ILimit
Start Abbruch t
Break
HVAC5 © SCHLEICH
6.14. Burning
The burning mode is used for locating faults at the test object. Due to the fact that SCHLEICH testers immediately interrupt the test in case of overcurrent to
protect the test object it may be difficult to locate the flash at the fault location.
The burning mode helps in these cases.
The tester does not switch off in case of a disruptive breakdown. There is continuous spark at the fault location. This helps to locate the fault.
ATTENTION! As the high-voltage is not switched off this mode is dangerous!
IHV
Imax
Start Ende t
HVAC12 © SCHLEICH
6.15. Testing without protection against contact
Testing with high-voltage usually requires a protection against contact. This is often annoying for the operators. Under certain conditions you can perform the
test with protection against contact. These conditions are:
 safety current limitation to a maximum test current of 12 mA.

 power limitation to a maximum power of 350 mJ.
6.15.1. Safety current limitation to max. 12 mA DC
According to the regulations of international standards and the Accident Prevention & Insurance Association very strict safety measures have to be observed
when operating test systems.
IHV It basically applies that alternating test currents above 12 mA are fatal!
Thus all high-voltages at which more than 12 mA can flow have either to be
protected against contact or safety high-voltage probes have to be used.
GEFAHR
! Danger
15mA
HVAC13 © SCHLEICH
! DANGER IHV
It has to be considered that a high-voltage tester e.g. for an output current of 50 mA
can never be seen as safety current limited by presetting the limit current to 12 mA!
However, the high-voltage is switched off only some milliseconds after exceeding
the limit current (Delay / test break)) but the current can be highly dangerous during
this switch-off time.
Delay
15mA
Start Aus t
Off
HVDC11 © SCHLEICH
6.15.2. Power limitation to max. 350 mJ
It has always to be considered that the power stored in the test object must never exceed 350 mJ. Safe means that both conditions, i.e. maximum current of
12 mA plus maximum power of 350 mJ have to be met.
What does 350 mJ mean? Joule is the unit for power. This energy has to be calculated according to the equation Q = ½ * C * U 2.
Example: The power for the following mains filter has to be calculated.
Filter / DUT
L
Cy
PE
Cx Cx
Cy
N
HVDC22 © SCHLEICH
The test should be performed between L plus N (jumpered with each other) against PE.
The capacitors Cy should be 22 nF each in this example.
The capacitors Cx should be 100 nF each in this example.
This kind of filter is often tested with 1800 V AC. The calculation to DC is approx. 1800 V * √2 = 2700 V DC.
By means of the bridge between L + N both Y-capacitors (Cy) are switched in parallel.
Ctotal = 22 nF + 22 nF = 44 nF.
Q = ½ * 44 nF * 2700 V * 2700 V = 160 mJ
The power stored in the filter after switching the high-voltage off is 160 mJ und is thus clearly below the allowed limit.
However a discharge is highly recommended. SCHLEICH testers therefore discharge automatically until the voltage is dropped below the safe touch voltage.
A high-voltage test can also be performed between L and N.

X-capacitors often have a value of 100 nF.
The total capacity in this case is Ctotal = 100 nF + 100 nF + 11 nF = 211 nF. (The 11 nF are caused by the series connection of both 22 nF-capacitors.)
The typical test voltage between L and N is 1450 V DC.
This results in a power of Q = ½ * 211 nF * 1450 V * 1450 V = 222 mJ.
The power in the filter after the high-voltage is switched off is 222 mJ and is thus also below the allowed limit.
However, a discharge is highly recommended.
In addition a resistance is installed in parallel to the capacitors within the filter. Why? It should make sure that a discharge also takes place via the filter. It is
discharged so fast that the voltage drops to the stipulated residual voltage in the normatively stipulated time.
In the example we assumed a maximum size of the Y-capacitors of 22 nF each which is allowed for devices of the protection class I with a maximum leakage
current of 3.5 mA.
This can be reconstructed mathematically.
At first we calculate the capacitive resistance that is: Xc = 1 / ( 2 * PI * f * C)
In the example with the above mentioned capacitors at 50 Hz this is: Xc = 1 / ( 2 * PI * 50 Hz *44 nF) = 72.34 KΩ.
At a mains voltage of 230 V this results in a current of: I = 230 V / 72.34 KΩ = 3.1 mA.
Thus the demand of staying below 3.5 mA is met.
6.16. Warm high-voltage test DC
The high-voltage test can also be performed in a warm condition of the test object. ATTENTION! This is only valid at a corresponding tester design!
STOP What does warm high-voltage test mean?

During the high-voltage test the test object is connected to operating voltage at the same time. The test object is operated functionally and at the same time
the insulation resistance against the cabinet is checked.
ATTENTION! You cannot perform any high-voltage test at test objects that are operated in a current mains and are connected to mains voltage!
The definition “warm high-voltage test” can for example be explained with an iron that becomes warm during operation. At the same time it is also connected
to the high-voltage.
RIso temperature. The test object can have an insulation resistance of 2GΩ in a cold
Temp condition and in a hot condition the insulation decreases to 5MΩ and lower!
Typical products are for example tubular radiators. They are used for immersion
Temperatur heaters, coffee machines or for the water heating in washing machines etc.
Isolation
Rmin
Start
t
HVDC28 © SCHLEICH
There are test objects at which heatings and parts extend in a hot condition. In the cold condition the clearance and leakage paths are still ok but in the hot
wiring. If a high-voltage test is performed from the outside against the cabinet via the
input lead not all of the internal wirings are tested. Feed paths to heatings, motors,
M
etc. are still open so that these components cannot be tested at the same time.
 This point can still be tested without any problems.
1 2 3
HVAC29 © SCHLEICH
voltage simultaneously to the high-voltage test. Under this condition the test is called
“warm high-voltage test”.
The “warm high-voltage test“ is of course only possible when the test object is disconnected from the mains. Otherwise the high-voltage would return to the
mains. An isolating transformer guarantees the disconnection.
L1 L1 1-phase tests
DUT In order to avoid that the high-voltage stresses the test object only partially the high-
PE
Prüfling voltage has to be supplied in the middle of the isolating transformer according to the
N N standard. Thus the high-voltage against ground is added to the mains voltage.
+ The sine signals of the high-voltage and the functioning test add and subtract to and
HVDC from each other. This is caused by the phasing of the sine signals. Thus the
standard stipulates that the functioning test is supplied by phase L1 and the high-
voltage source by the phases L2-L3.
HVDC16 © SCHLEICH
L1 L1
2 DUT 1-phase tests
PE
Prüfling An alternative is selecting at which point the high-voltage is to be supplied via relay
N N in the test program.
1 3
+
HVDC
HVDC24 © SCHLEICH
L1 L1
DUT 1-phase tests
PE
Prüfling It is possible to perform the warm high-voltage test manually via a probe. For this 3
N N supply points are lead out of the tester to contact pads. The test probe is manually
contacted to these contact pads.
+
HVDC
HVDC25 © SCHLEICH
L1 L1 3-phase tests
L2 L2 The high-voltage is supplied in four subsequently running test steps at N, L1, L2,
L3 L3
DUT and L3. The counterpole is the cabinet.
Prüfling
N
1 2 3 4
PE
+
HVDC
HVDC17 © SCHLEICH
6.17. Voltage check at very well insulated test objects
This is very simple at the PE resistance test. If the test current is too low or does not flow through the PE or the test current is too low the resistance is ∞
(infinite) and thus NO GO.
This is quite different at the DC high-voltage resistance test. If no test current flows this results in an infinite and therefore perfect insulation resistance. As the
test object is not connected the test result seems to be ok although the test object might be defect!
Prüfgerät At manual tests the operator can avoid contacting faults by his conscientious
Tester
working.
DUT
Prüfling
L
However, at automatic tests other measurements have to be taken to be sure that
N
the test technically ran without any problems.
Tests with an automatic contacting are especially critical. The contacting can be
PE1
defect and all tests are always ok!
PE1s
Iso11 © SCHLEICH
RIso It might be that the operator is “lucky“ and the test object shows a typical insulation
Rmax
offen / nicht in Ordnung | open / not okay resistance that is lower than infinite. In these cases you can set a maximum
insulation resistance for control reasons. If this value is exceeded the test result is
NO GO as the test value is too high.
okay
RLimit
zu niedrig / nicht in Ordnung | to low / not okay
Iso15 © SCHLEICH
IHV
If it is evaluated based on the current a maximum current must not be exceeded but
Zu hoch / nicht in Ordnung | break / not okay
ILimit a minimum current has to flow.
okay
Imin
offen / nicht in Ordnung | open / not okay
HVDC23 © SCHLEICH
Unfortunately this is hardly the case. The insulation is that good in many cases so
Prüfgerät
Tester
that a good test object features insulation resistances in the similar height as at a
DUT fault measuring without connected test leads. In order to test properly in such cases
L
Prüfling you can connect an additional insulation resistance during the test.
N
PE1
PE1s
100MW
100MW
Iso16 © SCHLEICH
We now assume that the test object has an insulation resistance of 10 GΩ. At the configuration shown in the picture the tester would for example be set to
Rmax = 150 MΩ. The minimum value is stipulated in the standard and is typically set to e.g. 2 MΩ. In case of a missing contacting the resistance is infinite and
thus clearly higher than 150 MΩ. The test result is NO GO. At a correctly connected test object a parallel switching of the insulation resistance and the 100 MΩ
resistance results in the measuring.
The 10 GΩ insulation resistance parallel to the 100 MΩ resistance amount together

Prüfgerät
Tester to approx. 99 MΩ. Thus the value is between Rmin (2 MΩ) and Rmax (150 MΩ).
DUT Therefore the result is GO.
Prüfling
L
N However, this also has a disadvantage when the test demand is quite high. Although
the test object features 10 GΩ only 99 MΩ are displayed. This would not be
accepted in the automotive and aerospace industry.
PE1 But there are of course ways to solve this. After a first control measuring detected
PE1s the correct contacting a second precise measuring is performed. For this the tester
100MW
switches the two 100 MΩ test resistances automatically off and afterwards
determines the real insulation resistance of the test object.
100MW
Iso17 © SCHLEICH
It is very important that both test resistances are not directly assembled to the
Prüfgerät
Tester contacting. This would be pointless. Both test resistances always have to be
DUT connected via a second separate contacting to the test object. Only in that case you
L
Prüfling can be sure that the test current flows through the test object up to the test
N resistances.
The test resistances and the automatic switch on/off are usually within the tester.
PE1
PE1s
100MW
100MW
Iso18 © SCHLEICH
Prüfgerät The voltage return measuring is an alternative to the leakage control with a test
Tester resistance.
DUT
Prüfling
L For this the voltage connected by the high-voltage test is returned to the tester and
N checked. Here it is important that the return measuring is not performed at the same
point at which the test voltage is fed in.
Some operators call it a high-voltage test in four-wire technique. Two leads lead the
PE1 test voltage to the test object and two leads pick it off at another point.
PE1s
V
Iso25 © SCHLEICH
6.18. Application examples of the high-voltage test
6.18.1. Manual test
The high-voltage test is usually performed with safety test probes.
One high-voltage pole is contacted to the jumpered current-conducting leads L+N.

With the other safety test probe all contactable metal parts of the test object are scanned.
Prüfgerät
Tester DUT
Prüfling
RIso
R
HV1
RIso
HV2
HVAC21 © SCHLEICH
Another typical example is an electric motor. Here all phases are tested against the cabinet and all phases are also tested against each other.
Prüfgerät
Tester
DUT
Prüfling
HV1
HV2
HVAC22 © SCHLEICH
Please consider at the manual test that the test object is NOT contacted with the test probes at switched-on high-voltage. Here high voltage peaks could occur
that might destroy the test object.
Some tenth millimeter before the operator contacts the test object the spark starts to jump over. In combination with the test object’s capacities and
inductivities this might lead to voltage peaks.
Voltage peaks are higher as the high-voltage supplied by the tester. Thus the test
object could be damaged.
It is better to connect the test probes to the test object at first and then start the test
via the foot switch.
This has two advantages:

1. no voltage peaks
2. The test object is only connected to high-voltage for the time you have also set in
the tester. No longer but also no shorter as well.
HVAC23 © SCHLEICH
The manual test always has the problem of the safe discharge. After switching the high-voltage off the test probes remain contacted to the test object for a
short time. Only this handling guarantees a safe discharge.
In any case it is recommended to jumper the test connections among each other manually in order to be sure that the test object is discharged.
(see chapter 6.4 Discharge!)

A black box often contains test resistors whose values are to be exactly determined by the tester.
For checking the high-voltage test a high-voltage resistant 2 MΩ resistance is for example often assembled in the black box. Our black boxes are supplied with
calibration documents. They inform you on the exact resistance value that is installed in the black box. You can then enter the exact resistance value in the
The following pictures show some possible black boxes. The pictures show combined black boxes for the PE resistance, high-voltage, and insulation
resistance test.
IHV
In case the deviation is too high there is a fault. The tester locks itself automatically
for any further tests. Only after the fault reason is removed and another black box
test is passed with GO the tester is unlocked again.
Inominal
okay
HVAC25 © SCHLEICH
If both conditions are not detected precisely there is a fault. The tester locks itself automatically for any additional tests. Only after removing the fault reason
1. NO GO-test
A top limit for the current of e.g. 2 mA is entered in the tester. A test resistance is connected to the tester for the testing that lets a current flow that is slightly
IHV

However it must not be too high! Otherwise a short circuit in the test lead or a
IniO problem in the contacting would not be detected reliably.
okay
ILimit
HVAC26 © SCHLEICH
2. GO-test
IHV
ILimit
IiO okay
HVAC26 © SCHLEICH
7
ARC-Detection
7. ARC-Detection
7.1. What are ARCs?
ARCs are micro-discharges and no complete disruptive breakdowns with significant overcurrent.
The high-voltage test AC can also be equipped with a discharge detector in addition.
Slight flashing without an important current increase and without a ground

IHV connection is the most critical kind of high-voltage faults.
The flashes or discharge current are sometimes only very short as the insulation is
weakened but nevertheless has a certain resistance.
There are often current pulses of only 10 μs. These pulses over a long time can
finally destroy the insulating material.
t
Considering that a half-wave only takes 10 ms in a 50 Hz mains the current pulses
of the discharge flashes are shorter by 1000 times. The standard test technique of a
high-voltage tester is not able to detect these short pulses.
ARC1 © SCHLEICH
7.2. How are the ARCs measured and evaluated?

For the measuring the tester is equipped with a discharge detector in addition to the high-voltage AC. The detector prepares these signals in an appropriate
way for the tester’s test technique.
The tester determines the discharge quantity per period (50 Hz => 20 ms or 60 Hz => 16.66 ms) and displays the counter value.
ARCs
The operator determines a limit value that must not be exceeded. The measuring
can be performed over several periods.
The ARC-detection can be integrated in testers of the GLP2-Class.
ARCLimit
ARC2 © SCHLEICH
8
Leakage current test
8. Leakage current test
8.1. Explanation of the leakage current test
Prüfgerät DUT
The leakage current test can be performed at test objects of the protection class I or
Tester Prüfling II. Testers of the protection class I feature a PE conductor. Testers of the protection
class II have a protective insulation and do not feature a PE conductor.
It is tested whether the leakage current is below a limit value stipulated in the
standards under operating conditions.
R The test is performed to check whether not too high leakage currents flow via the PE
L
RIso
conductor or the touchable cabinet parts within the test object.
IAbl
N
mA
PE
IAbl
Abl1 © SCHLEICH
If the leakage current is too high (and there is possibly also a PE fault) a too high touch current could occur at the tester’s metallic parts. When touching these
At test objects of the protection class II insulating faults at metallic parts can be dangerous as a current conduction into the PE is not possible.
EVU DUT
Definitions
L IAbl
IL + IAbl EVU : electric supply company (power plant)
IL
N IL : current through the test object

PE
RPE UN : mains voltage
IAbl

UB
Ber2 © SCHLEICH
EVU DUT EVU DUT
L IAbl L IAbl
IL + IAbl IL + IAbl
.
IL IL
UN UN
N N
! DANGER
RPE > 0,2W

PE PE
IPE
IB IB
UB UB
is too high.
The test object is operated with the corresponding test voltage at the leakage current test. The test voltage is usually the test object’s operating voltage or the
STOP operating voltage increased by 10 %.
8.2. Ground leakage current & cabinet leakage current
DUT
The ground leakage current flows in the ground conductor.
Prüfgerät
Tester Prüfling If the ground conductor is damaged the cabinet might be under high touch voltage.
R
L
RIso IAbl
N
mA
PE
IAbl
Abl2 © SCHLEICH
The cabinet leakage current flows to the outside via metallic cabinet parts.
Prüfgerät DUT
Prüfling
These metallic parts thus are under high touch voltage.
Tester
R
L
RIso IAbl
N
mA
PE
IAbl
Abl3 © SCHLEICH
8.3. Measuring of the leakage current according to EN 60990
The measuring is performed according to the measuring circuits stipulated in the standards.
STOP There are different standards and test regulations for various testers. The voltage level is stipulated in these regulations. The EN 60990 is
especially typical.
These measuring circuits simulate the human behavior in different situations. The standard EN 60990 defines three different measuring circuits. The
measuring is performed via these circuits. The abbreviation MD stands for measuring circuit.
The measuring circuit 1, 2, or 3 is switched automatically in the requested measurement path internally within the tester depending on the kind of
measurement.
Measuring circuit 1
unvalued leakage current according to EN 60990 (5) measuring circuit picture 3 (acc.
to the standards).
The two connections on the left-hand side are the connections of the mA-meter. The
Voltmeter symbolizes the voltage measuring in the tester. The current is determined
and displayed of the voltage via corresponding mathematical evaluations.
Measuring circuit 2
evalued according to perception and reaction EN 60990 (5) measuring circuit picture
(acc. to the standards).
4
Measuring circuit 3
evalued according to releasing EN 60990 (5) measuring circuit picture 5 (acc. to the
standards).
The measuring circuits have one thing in common: They strongly depend on the frequency. What is the reason? The human being also depends on the
frequency in his reaction and endangering. The higher the frequency the more uncritical is the current flowing through the human being.
A current of 3 mA at 50 Hz is already very critical. The same current at a frequency of 1 MHz is absolutely uncritical. At 1 MHz considerably higher currents
can flow through the human being before he is in danger.
The following test regulations are covered with these measuring circuits:
EN 60990 / VDE 0106
EN 60335-1 / VDE 0700-1 Measuring at household appliances
EN 60950 / VDE 0805 Measuring at office appliances (communication appliances)
EN 60598-1 / VDE 0711-1 Measuring at luminaires
SCHLEICH testers are typically designed for touch current frequencies of max. 500Hz!
The evaluation is performed regarding effective value, peak value, AC-part and DC-part.
8.4. First and second fault condition
It is stipulated in the standards that a possible pole-reversal of the plug in the socket has to be simulated in the leakage current test. The reason is that the
plug can be plugged into the socket in two positions in many countries. This automatically leads to an interchange of L and N.
The simulation of the pole reversal is very important! Depending on where the fault is located – either at L or N – it can be measured or not. In order to be
always sure that each fault is detected the pole-reversal between L and N is necessary.
EVU DUT measuring 1: L to L and N to N  the fault is not measurable.

L
IL
IL
UN
PE
MD
RPE Iabl = 0
Abl4 © SCHLEICH
EVU DUT
measuring 2: L to N and N to L  the fault is measurable.
L
But this picture also shows a problem:

IL
UN According to the picture the test object is directly supplied by the EVU. At the shown
insulation fault that lets a corresponding leakage current flow directly out of the
N
current mains, the ground fault circuit interrupter (GFCI) will most probably be
IL + IAbl
released as well as the fuse in case of a short circuit.
IAbl
PE
The picture shows that the fault is detected by the pole reversal but only due to the
IAbl
MD releasing of the fuses. Thus this kind of circuit is only marginally suitable.
RPE IAbl1
Another significant disadvantage of this circuit occurs when the test object’s cabinet
IAbl2 is grounded e.g. via the test table. In this case only a part of the leakage current
flows through the measuring circuit and this leads to a wrong measuring.
Abl5 © SCHLEICH
EVU DUT
This circuit with isolating transformer shows the perfect measuring condition for the
leakage current test. The isolating transformer makes sure that a fault at the test
L
object does not have any effects on the current mains.
IL
But there the problem that in case of a ground test object a part of the leakage
current does not return through the measuring circuit MD.
N IL + IAbl
This can only be avoided by insulating the test object against the ground. As the
standard requests the grounding of the MD the test object has consequently to be
insulated for the leakage current test!
PE IAbl
MD
RPE IAbl
Abl6 © SCHLEICH
The typical structure for a leakage current test is as follows:
Prüfgerät
DUT Within the tester there are the pole reversal (fault condition 1) and the simulation of
Tester
L
the interruption (fault condition 2) of the supply lead.
L Thus it is tested if no too high fault currents occur at only one mains connection at
the test object.
A leakage current test thus consists of 4 individual measurements:

N  no polarity reversal and tester connected to the mains
N
 polarity reversal and tester connected to the mains
 no polarity reversal and tester partially connected to the mains
PE
MD 1  polarity reversal and tester partially connected to the mains
RPE
MD 2
MD 3 None of these 4 measurements must have a leakage current above the allowed
PE
limit!
Isolation
It has to be considered that there is an isolator below the test object that avoids a
ground connection of the test object.
Abl18 © SCHLEICH
In addition it can be switched between different measuring circuits.
The pole reversal requested in the standards also has a disadvantage. When reversing the poles there is a short voltage-free phase in the test object. Only
after one relay is switched off and after a short delay time the other relay can be switched on. Otherwise there would be a short circuit between L and N during
the reversal.
For same test objects the voltage interruption can be of a disadvantage.

Test objects that for example are equipped with a PC or electronics might have to be shut down before the pole reversal. After the reversal the electronics has
to boot again.
This would be of a great disadvantage. A time-optimum testing would not be realistic for this kind of test object.
Prüfgerät
DUT The solution for this problem is to reverse the reference point for this measuring
Tester circuit instead of reversing L and N. This is equal to a polarity reversal.
L
L
The pole reversal relays still exist in the circuit. They serve for switching the L one
time to one side and then to the other side at the test object in case of an interrupted
N (the voltage supply is interrupted in any case).
N
N
PE
MD 1
RPE
MD 2
MD 3
PE
Isolation
Abl17 © SCHLEICH
Prüfgerät
DUT The test probe completes this picture.
Tester By means of this probe the ground leakage current and via switching to the test
L
L probe also the touch current can be measured.
ATTENTION! When testing with the test probe the test object’s PE is switchably
connected to the ground. Thus the touch current can be tested with and without
N connected PE.
N
MD 1
PE RPE
MD 2
MD 3
PE
Isolation
Abl28 © SCHLEICH
8.5. Leakage current test at grounded test object
The test object’s insulation against ground cannot be realized in some cases.
This is the case with large test object that are firmly connected to the ground.
In this case an isolating transformer between the supply voltage and the test object
DUT
Prüfgerät is mandatory for the leakage current test.
Tester
L
L
But this structure has the disadvantage that capacitive currents might occur in the
isolating transformer which are measured as well.
N
N
MD 1
PE
MD 2
MD 3
PE
Abl29 © SCHLEICH
For more information please look in the standard EN60990 chapter 4.2.
8.6. Advantages of the leakage current test with isolating transformer

It is an advantage of performing leakage current tests with an isolating transformer.
Why?
There are three important reasons for an isolating transformer:
1. If there is a fault between L  PE within the test object a ground fault circuit interrupter (GFCI) that is within the mains input lead would immediately be
released. A fault in the test object thus consequently leads to a switching off of the supply voltage by the GFCI. Any consumers that are also connected
to the supply voltage are also disconnected from the voltage. This can be fatal e.g. for PCs.
2. Another advantage is that only with an isolating transformer an “uninterruptible polarity reversal” is possible. Please see the previous chapter for more
information.
3. In the supply mains the N is usually connected to the PE in a very low-ohmic way. It is said that the mains is zeroized. However at a worse zeroisation or
higher currents on the neutral lead voltage differences may occur between ground and the neutral lead. If the voltage between the neural lead and the
ground is higher than 1% of the mains voltage this automatically leads to measuring faults at the leakage current test.
These statements argue for a separation between a supply mains and a test object with an isolating transformer.
8.7. Typical current limit value at the leakage current test
Typical limit values cannot be given.

ATTENTION! For your tester please take the test parameters and the allowed upper limit value of the regulations!
STOP
All test values that are within 0 and the limit value ILimit (including) are ok. The limit value must not be underrun during the complete measuring.
Typical test times cannot be given.

ATTENTION! For your tester please take the test parameters of the regulations!
STOP
IAbl
ILimit
Abl10 © SCHLEICH
If the leakage current fluctuates during the test object’s heating the highest value that occurred during the complete test time is evaluated and displayed. That
IAbl
ILimit
Itest-max
Start Ende t
Abl11 © SCHLEICH
IAbl The automatic polarity reversal is also often performed in one single leakage current
test. Thus the two currents are automatically measured –one time the not reversed
ILimit
leakage current and one time the reversed leakage current.
IN-max
The maximum of both current is determined. The highest of the two maximum
IL-max
values is displayed.
IL
IN
In the example on the left-hand side it would be the maximum value of the leakage
current IN.
Start Ende t
Abl12 © SCHLEICH
It may occur that the maximum leakage current should be measured and evaluated during the heating phase and at the end of the heating phase.
Due to the maximum value storage this is only possible when a second test is performed directly after the first test. The test time of the first test is the
complete heating phase of the test object.
The test time of the second test is principally zero, as you would only like to determine the final value of the leakage current test.
IAbl
ILimit
IN-max 1
IL-max 1
IN-max 2
IL
IN IL-max 2
Start Ende
Messung während der Erwärmung
t
Abl13 © SCHLEICH
8.9. Which test voltage is to be used?

The leakage current test is usually performed with a higher value than the tester’s nominal voltage. As voltage supply mains can have an overvoltage of up to
10% it would seem appropriate to perform the leakage current test with an up to +10% overvoltage as well.
STOP
Many leakage current tests are performed according to the standards EN 60990 and EN 60601. As these standards are considerably different in some parts
the answer regarding the test voltage’s level has to be given with reference to the standards.
8.9.1. Test voltage at EN60990
Three possible test voltages are stipulated in this standard:

 nominal voltage + 0%
In most cases you can assume that the leakage current also increases at increasing voltage. Therefore many SCHLEICH testers feature a firm voltage
increase of +10%. Thus the leakage current test can be performed with either +0% or +10%.
At testers with variable voltage setting the test voltage can alternatively be set to an arbitrary value.
This information is not normatively binding! Please always take the required test parameter for your tester of the corresponding standard.
STOP
8.9.2. Test voltage at EN60601
All leakage current tests according to this standard have to be performed with a +10% voltage increase.
This information is not normatively binding! Please always take the required test parameter for your tester of the corresponding standard.
STOP
8.10. Leakage current tests according to EN 60990
The general explanation of the previous chapters is again presented in the following principal circuit diagrams.
8.10.1. Principal circuits 1-phase
Ground leakage current test with or without external isolating transformer (the polarity reversal is not uninterruptable)
Prüfling The isolating transformer could also be installed internally within the tester.
Prüfgerät
Tester DUT
The test object is of protection class I.
L/N L
S5 The following fault conditions are simulated:

N/L N
 fault condition 1
S1
PE
MD
Probe
The tester has to be isolated against ground!
Abl19 © SCHLEICH
Cabinet leakage current test (touch current) with or without external isolating transformer (the polarity reversal is not uninterruptable)
Prüfling The isolating transformer could also be installed internally within the tester.
Prüfgerät
Tester DUT
L/N L

N/L N
S1  fault condition 2
MD Probe
PE PE
Abl20 © SCHLEICH
Ground leakage current test with external isolating transformer (the polarity reversal is uninterruptible)
Prüfgerät Prüfling The isolating transformer could also be installed internally within the tester.
Tester DUT

L/N L
S5
N/L N The following fault conditions are simulated:
S1
MD PE  fault condition 2
Probe The tester has to be isolated against ground!
Abl21 © SCHLEICH
Cabinet leakage current test (touch current) with external isolating transformer (the polarity reversal is uninterruptible)
The isolating transformer could also be installed internally within the tester.
Prüfgerät Prüfling
Tester DUT
L/N L

N/L N  fault condition 1
S1  fault condition 2
MD Probe
PE PE The tester has to be isolated against ground!
Abl22 © SCHLEICH
8.10.2. Principal circuits 3-phase
Ground leakage current test (tester with PE conductor)
Prüfgerät Prüfling The test object is of protection class I.

Tester DUT
L1
The following fault conditions are simulated:
L1
L2 L2  fault condition 1
L3 L3  fault condition 4
N N
PE
MD
Probe
Abl23 © SCHLEICH
Ground leakage current test (tester without PE conductor)
Prüfgerät Prüfling The test object is of protection class II.

Tester DUT
L1 L1 The following fault conditions are simulated:

L2
L2
L3
L3
N N  fault condition 4
MD The tester has to be isolated against ground!
Probe
Abl24 © SCHLEICH
8.11. Leakage current test acc. to standard EN 60601 | Medical leakage current test
The standard EN 60601 describes the leakage current test at medical products.
8.11.1. Measuring circuit for the medical leakage current test
This measuring is principally similar to the one at non-medical products.

A considerable difference is the different measuring circuit MD.
Further differences in the measuring are that medical appliances often have a more complex structure than standard products. Therefore there are more
points that have to be tested at this leakage current test.
8.11.2. Typical structure of a medical appliance
This measuring is principally similar to the one at non-medical products.

Medical appliances can have cabinet parts that touch the patient or various connections that can be connected to the patient. Connections that are connected
to the patient are called patient connections. These lead to a so-called application part within the medical appliance. This application part measures the signals
from the patient (e.g. ECG-signals) or sends signals to the patient (e.g. stimulation current). It must never occur that excess current comes out of the patient
connections under any critical condition.
Critical conditions are the same fault conditions like also at the “standard leakage current test”. Special additional fault conditions are generated in addition.
No excess current must for example flow out of the patient connections when they should be under voltage due to a fault. A medical appliance also often has a
signal part in addition. This part switches e.g. signal outputs on and off, evaluates inputs, or controls printers.
If any fault conditions e.g. a grounding of the signals or a voltage on the signals occur at these signal connections no excess current must flow out of the
patient connections as well. No excess current must also flow from one patient connection to the other.
SCHLEICH supplies a special cabinet version for the leakage current test at medical products. This version provides all required test connections for typical
medical products. These are especially 8 test connections (so called TP) for connecting the up to 8 patient connections or 8 cabinet connections. These
connections can be mixed, e.g. 3 cabinet connections and 5 patient connections.
8.11.3. Ground-, cabinet- and patient leakage current as well as patient auxiliary current at EN 60601
Definitions:
AP: application part (patient connections)
Example: the application part provides the connections to the patient.
Typical connections are stimulation current connections, ECG-leads, EEG-leads
SP: signal parts (signal input parts, signal output parts)
Example: foot switch input, warning light, printer connection, message button
MD: measuring circuit (measurement device)
For more information please look in the previous chapters regarding measuring circuits. Different measuring circuits for various tasks are
defined in the standard.
TP test connections (Test Points) for the up to 8 patient connections or cabinet connections
PE connection of the protective earth / protective ground
FE connection of a functional ground – this can for example be a special ground for shielding.
Probe 1 A test probe is connected here, e.g. to scan cabinet parts
Probe 2 A second test probe is connected here to measure leakage currents between Probe 1 and Probe 2. E.g. two cabinet parts can be scanned
with both probes to test whether an excess leakage current flows between them.
Ground leakage current (Appliance with integrated current supply)
Medical appliance structure:

The medical appliance features an integrated mains supply.
This voltage supply and the medical appliance’s electric circuit (application) are
installed in a mutual cabinet. The medical appliance might provide different patient
connections.
The leakage current is measured in the appliance’s PE conductor.
With the switch S5 the fault condition 1 (the polarity reversal) is realized.
With the switch S1 the fault condition 2 (the interruption) is realized.
With the switch S10 the appliance’s functional ground is interrupted.
With the switch S12 all patient connections are connected to ground.
The circuit conditions are switched in various combinations according to the

normative definition.
Ground leakage current (Appliance with separate current supply)
The medical appliance features a separate mains supply.
This voltage supply and the medical appliance’s electric circuit (application) are not
connections.
The leakage current is measured in the appliance’s PE conductor.
With the switches S2 and S3 the supply leads to the application part are switched on
and off.

Cabinet leakage current test scanned to ground with one test probe

connections.
The leakage current is measured at different cabinet parts of the tester against
ground. The cabinet parts are scanned one after another with the test probe.
With the switch S7 the cabinet’s PE conductor is interrupted.

Cabinet leakage current test scanned with two test probes between two cabinet parts

connections.
The leakage current is measured between different cabinet parts of the tester. The
cabinet parts are scanned one after another with both test probes.

Cabinet leakage current test with one test probe (signal parts a connected to voltage)

connections. The medical appliance features a signal part (e.g. warning light, a foot
switch, a printer connection, etc.).
The leakage current is measured at different cabinet parts of the tester against
ground. The cabinet parts are scanned one after another with the test probe.
With the switch S9 the voltage (phasing) is reversed in polarity at the signal part.

Cabinet leakage current test scanned with two test probes between two cabinet parts (signal parts are connected to voltage)

connections. The medical appliance features a signal part (e.g. warning light, a foot
switch, a printer connection, etc.).
The leakage current is measured between different cabinet parts of the tester. The
cabinet parts are scanned one after another with both test probes.

Cabinet leakage current test to ground without test probe (the cabinet parts to be tested are directly connected to the tester)

connections.
The leakage current is measured between different cabinet parts of the tester
against ground. The cabinet parts are scanned one after another automatically.

Cabinet leakage current test without test probe (the cabinet parts to be tested between cabinet parts)

connections.
The leakage current is measured between different cabinet parts of the tester. It is
automatically tested between the cabinet parts one after another.

Patient leakage current test

installed in a mutual cabinet. The medical appliance provides different patient
connections.
The leakage current is measured by the appliance’s patient connections against

ground. At this test cabinet parts can be connected to ground optionally with the
probe.
With the switch S13 cabinet parts are optionally connected to ground.

Patient leakage current test with an application part of type F according to standard

connections.
The leakage current is measured by the appliance’s patient connections against

ground. The patient connections are additionally connected to voltage. At this test
cabinet parts can be connected to ground optionally with the probe.
With the switch S13 cabinet parts are optionally connected to ground.

Patient leakage current test (internal voltage supply)

The medical appliance features an internal mains-independent voltage supply.
connections.
The leakage current is measured against different cabinet parts by the appliance’s
patient connections. You can scan the cabinet parts with the probe in this process.

Patient leakage current test (internal voltage supply | with an application part of type F)

connections.
The leakage current is measured against ground by the appliance’s patient

connections. The cabinet parts can be optionally connected to ground via the probe.
The signal part connections are all connected to ground.

Patient leakage current test (internal voltage supply | signal parts are connected to voltage)

connections.
The leakage current is measured against ground by the appliance’s patient

connections. The cabinet parts can be optionally connected to ground via the probe.
The signal part connections are all connected to ground.

Patient auxiliary current test

connections.
The leakage current is measured between different appliance’s patient connections.

Patient auxiliary current test (internal voltage supply)

connections.
The leakage current is measured between different appliance’s patient connections.

8.11.4. PE resistance test at the EN 60601
In addition to the special leakage current tests at medical appliances extended PE resistance tests are also requested for these appliances.
Definitions:
PE resistance test with a test probe
The test is performed between PE and different grounded cabinet parts.
PE resistance test between PE and FE
The test is performed between PE and functional ground.
PE resistance test between PE and different test points
The test is performed automatically between PE and different TP. In this case no
patient connections are connected to the TP but cabinet parts.
8.11.5. Insulation resistance test at the EN 60601
In addition to the special leakage current tests at medical appliances extended insulation resistance tests are also requested for these appliances.
Definitions:
Insulation resistance test between L&N against the PE conductor
The test is performed between the jumpered connections L and N against the PE
conductor.
Insulation resistance test between L&N against the functional ground FE
The test is performed between the jumpered connections L and N against the
functional ground.
Insulation resistance test between L&N against the test probe
The test is performed between the jumpered connections L and N against cabinet
parts that are scanned with the test probe.
Insulation resistance test between L&N against cabinet parts
The test is performed between the jumpered connections L and N against cabinet
parts. In this case no patient connections are connected to the TP but cabinet parts.
Insulation resistance test between PE and cabinet parts
The test is performed between the PE and cabinet parts. The different cabinet parts
are scanned with the test probe.

For checking the leakage current test a resistance is assembled in the black box. Our black boxes are supplied with calibration documents. They inform you
about the resistance value that is installed in the black box. You can then enter the exact resistance value in the corresponding point in your tester. Via the
connected voltage you get the corresponding current value via the resistance.
At this kind of black box test this current value has to be measured with a very high accuracy in a tight tolerance band!
IAbl In case the deviation is too high there is a fault and the tester locks itself
nicht in Ordnung | not okay another black box test is passed with GO the tester is unlocked again.
Inominal
okay
Abl25 © SCHLEICH
1. NO GO-test
IAbl
nicht in Ordnung | not okay However it must not be too high! Otherwise a short circuit in the test lead or a
problem in the contacting would not be detected reliably.
IniO
okay
ILimit
Abl26 © SCHLEICH
2. GO-test
IAbl
ILimit
IiO okay
Abl27 © SCHLEICH
9
Substitute leakage current test
9. Substitute leakage current test
9.1. Explanation of the leakage current test
The substitute leakage current test is a substitute for the standard leakage current test.
However, it can never achieve the test level of a standard substitute leakage test.
For testing the substitute leakage current tester supplies an alternating voltage of 30…50V AC. This voltage is connected to the test object’s jumpered
connections L + N against the test object’s cabinet. The current in the PE conductor is measured via a mA-meter (without special measuring circuit). The tester
measures the voltage as well as the current.
Via a simple calculation the tester converts the substitute leakage current Imess to the leakage current that would flow at nominal voltage or nominal voltage
+10%.
Unom
leakage current at nominal voltage : ILKC = ------------ X Imess
Umess
Unom *1,1
leakage current at nominal voltage + 10% : ILKC = ----------------- X Imess
Umess
DUT
Prüfgerät
Tester L
V
N
Umess
PE
mA
Imess RPE
Abl14 © SCHLEICH
10
Short-circuit test
10. Short-circuit test
10.1. Explanation of the short-circuit test

The short-circuit test is usually performed automatically before the functioning or leakage current test.
As the test object is operated with nominal voltage at the functioning or leakage current test it has to be made sure before connecting the voltage that there is
no short-circuit in the test object.
Such a fault within the test object does not affect the tester in any way. It is designed and protected correspondingly.
The device to be tested can be irreparably damaged by connecting the test voltage to the short-circuit.
DUT The short-circuit test is an ohmic resistance test between the connections L + N.
Prüfgerät
Tester L
.
PE
RPE
Fkt1 © SCHLEICH
RL-N
If the resistance value is too low there is a short-circuit.
The functioning test that would usually follow the short-circuit test is not performed
any more in order to protect the test object. The test is interrupted.
RLimit
Fkt2 © SCHLEICH
3-phase short-circuit test

At three-phase current test object the short-circuit test is performed in 3 test steps at the individual connections.
The detailed test process depends on the application.
The short-circuit test at three-phase current is typically as follows:

 short-circuit L1  N
or
 short-circuit L1  L2
11
Functioning test
11. Functioning test
11.1. Explanation of the functioning test

The electric specifications of the device are checked during the functioning test. For this test the device is operated under normal operating conditions. This
means that the tester supplies the device with a test voltage.
This test voltage can be either supplied directly from the mains or also via an isolating transformer or an adjusting transformer.
DUT
Prüfling The current consumption, the power, and the test object’s Cos φ are determined
during the functioning test. These values are compared to a set value considering a
tolerance.
L
R
N A
PE
Fkt4 © SCHLEICH
11.2. Voltage sources of the functioning test

The functioning test can be supplied from different sources.
11.2.1. Voltage supply directly from the mains
The easiest way for the voltage supply is the supply directly from the mains.
The following list shows the advantages and disadvantages of this option.
Advantage
 low costs
Disadvantage
 danger at contact – only the ground fault circuit interrupter (GFCI) protects.
 If the external GFCI of the sub-main distribution releases faster than the GFCI in the tester all connected consumers are disconnected from
voltage after the release. This can be critical for e.g. PCs.
 The operating voltage cannot be varied.
 Slow and fast mains fluctuations effect on the current consumption.
DUT
Prüfgerät
Tester
IFkt L
L A
UFkt
FI N
N
PE
PE
RPE
Fkt3 © SCHLEICH
11.2.2. Voltage supply controlled directly via the mains
The easiest way for the voltage supply is the supply directly from the mains.
Advantage
 the operating voltage can be varied
 slow mains fluctuations in the second or minute range can be adjusted.
Disadvantage
 danger at contact – only the ground fault circuit interrupter (GFCI) protects.
 If the external GFCI of the sub-main distribution releases faster than the GFCI in the tester all connected consumers are disconnected from
voltage after the release. This can be critical for PCs.
 Fast mains fluctuations effect on the current consumption.
DUT
Prüfgerät
Tester IFkt L
L A
UFkt
FI N
N
PE
PE
RPE
Fkt7 © SCHLEICH
11.2.3. Voltage supply via isolating transformer
An isolating transformer increases the safety at contact.

Advantage
 reduced danger at contact – it becomes critical when L + N are contacted at the same time.
 The external GFCI does not fail in case of a ground fault.
Disadvantage
 The operating voltage cannot be varied.
 Slow and fast mains fluctuations effect on the current consumption.
DUT
Prüfgerät
Tester IFkt L
L A
UFkt
N
N
PE
PE
RPE
Fkt5 © SCHLEICH
11.2.4. Voltage supply controlled via isolating transformer

Advantage
 The operating voltage can be varied.
 Slow mains fluctuations in a second or minute range are adjusted.
Disadvantage
 Fast mains fluctuations effect on the current consumption.
DUT
Prüfgerät
Tester
IFkt L
L A
UFkt
N
N
PE
PE
RPE
Fkt6 © SCHLEICH
11.2.5. Electronic voltage supply controlled via isolating transformer

Advantage
 The operating voltage can be varied.
 Slow and fast mains fluctuations are adjusted – thus there is no fluctuating current consumption.
Disadvantage
 more expensive
DUT
Prüfgerät
Tester
IFkt L
L A
UFkt
N
N
PE
PE
RPE
Fkt8 © SCHLEICH
11.3. Testing parallel to the functioning test
It often occurs that additional tests are performed simultaneously to the functioning test.
Here are some examples:

 pressure
 low-pressure
 temperature
 secondary voltages from a transformer
 secondary currents under load from a transformer
 rotation speed
 sense of rotation
 torque
 and many more …
For these tests analog test inputs are used. They serve for measuring the voltage. The voltages can be converted to arbitrary factors like current, pressure,
etc. by calculations within the tester. After the conversion the values are compared to tolerance limits.
It is important that functioning tests are performed reliably. It has to be avoided that damaged test objects are not detected.

Our black boxes are supplied with calibration documents. They inform you about the resistance value that is installed in the black box. You can then enter the
exact resistance value in your tester. Via the connected voltage you get the corresponding current value via the resistance.
11.4.1. Black box test with ±-tolerance limit
At this kind of black box test the current value has to be measured with a very high accuracy in a tight tolerance band!
IAbl In case the deviation is too high there is a fault. The tester locks itself automatically
for any further tests. Only after the fault reason is removed and another black box
nicht in Ordnung | not okay test is passed with GO the tester is unlocked again.
Inominal
okay
Abl25 © SCHLEICH
1. NO GO-test
IAbl
nicht in Ordnung | not okay However it must not be too high! Otherwise a short circuit in the test lead or a
problem in the contacting would not be detected reliably.
IniO
okay
ILimit
Abl26 © SCHLEICH
2. GO-test
IAbl
ILimit
IiO okay
Abl27 © SCHLEICH
12
Continuity test
12. Continuity test
12.1. Explanation of the continuity test

The continuity test is basically an ohmic resistance test.
The continuity test does not have to be as accurate as the “real ohmic resistance measuring”. This is the reason why the continuity test is usually only
performed in two-wire technique.
The continuity test is used for checking the wiring. Here it is tested whether the leads are interchanged. For this the test has to be connected to the leads via a
matrix.
Prüfgerät Prüfling GJ The continuity test is connected to the 4 leads to be tested in 4 subsequent test
Tester DUT steps.
L1
L2
With the continuity test the PE conductor canNOT by tested according to the
Durchgang
L3 standard as the test current is not high enough. For a PE test it has to be at least 10
Contnuity
N A. However the test at the continuity test the test current is at some mA only.
PE
For a correct test including PE conductor an additional PE-test has to be performed.
Dg1 © SCHLEICH
Prüfgerät Prüfling HL
Tester DUT
L1
L2
Durchgang
L3
Contnuity
PE
Dg2 © SCHLEICH
13
Residual voltage test
13. Residual voltage test
13.1. Explanation of the residual voltage test
At the residual voltage test it is tested whether the test object still possesses a dangerous residual voltage at the connecting leads or the mains plug after
switching the supply voltage off.
This residual voltage can occur through internal charging within the test object. In order to exclude any risk these charges have to be reduced within a time
stipulated in the standard.
Filter / DUT A typical example for testing the residual voltage would be a device with input filter.
L Input filters have to have capacitors against ground and between the current-
Cy conducting leads (otherwise it is not filtered). After disconnecting the device from the
PE
socket the capacitors are charged.
Cx Cx
N Cy
Rest1 © SCHLEICH
The charge depends on when the plug was plugged out of the socket in relation to
U the sine of the mains supply.
+U1
When the plug was plugged out during a sine maximum or minimum highest
+U2 voltages occur. These are the voltages +U1 and –U3 in the graphic.
The level corresponds to the mains voltage’s effective value * √2.
At 230 V this would be a maximum voltage of plus or minus 325 V!
All other voltages between these two maximum values are also possible of course.
t Thus also 0 V can be connected when the plug is plugged off in the sine zero
crossing.
-U3
Rest2 © SCHLEICH
As like mentioned above also 0 V could be connected after plugging the plug off it would be fatal to assume that it was properly discharged!
A measuring process is necessary which is based on the positive or negative maximum value. Here the operator is endangered to a maximum extent.
U The tester is designed in a way that the voltage is connected just at the maximum
which corresponds to the plugging off. This ensures a test that always assumes the
+U1 worst case, i.e. the maximum voltage.
Ueff
-U3
Rest3 © SCHLEICH
13.2. Automatic performance of the test
The tester switches the test voltage off at the sine maximum (off). Thus the test object is voltage-free and can discharge.
In the standard it is stipulated that the voltage at the test object connections has to drop below a certain value within a certain time.
ATTENTION! For your tester please take the test parameters of the regulations!
STOP The tester waits for the time in which the voltage has to drop. The operator has to
U Prüfzeit
Test time enter the time in the tester.
Umax
After the time elapsed (end) the voltage measuring is automatically switched to the
test object connections and measures the connected residual voltage.
This must be at least as high as the stipulated upper limit.
URes
aus Sicher Ende

off Safe End t
Rest4 © SCHLEICH
13.3. Manual performance of the test
At the manual test the tester does not switch the voltage off but the operator. However, this is not effected as controlled as at the automatic test at the sine
maximum but at an arbitrary voltage value in the sine.
In order to be sure to receive a high voltage value at least once (is possible the highest) the test is repeated -times. Thus the chance to hit the sine in the peak
value is increased. The worst residual voltage value of the measurings is evaluated at the end of the measuring sequence. This type of process also bears an
uncertainty factor.
14
Resistance test
14. Resistance test
14.1. Explanation of the resistance test
The resistance test serves for measuring the resistance and evaluating it afterwards.
W1
The evaluation is done as comparison with a set value and the corresponding
tolerance setting.
This resistance test is no safety-relevant test. It is relevant for testing the functioning
and quality.
W2
D
W3
R1 © SCHLEICH
In contrast to the continuity test also very low resistances can be measured and evaluated with the resistance test. Depending on the tester’s design the
lowest resistances can be measured in the 1 μΩ-range with SCHLEICH-testers.
In order to measure such low resistances without the influence of resistances in the measuring leads or contact transition resistances the four-wire measuring
has to be used.
14.2. Four-wire measuring

At the resistance test the resistance is calculated by the voltage drop and conducting current via the “Ohm’s law“.
The graphic shows the measuring under perfect conditions. The current is injected at two points in the resistance. The voltage is picked off at two other points
again. The transition resistances occurring at the four contact points are not important for this measuring. This measuring is called four-wire technique.
A
UR
V R=
IR
IR
R UR
R2 © SCHLEICH
Explanation of the four-wire measuring with theoretical information:

At the four-wire measuring the voltage drop over the resistance is measured with a very high-ohmic voltmeter.
A The picture above (R2) does not show the relations including all details.
Itotal Itotal = IR + IUmess
V
IUmess UR The voltmeter’s internal resistance is in a very high MΩ- to some GΩ-range. Despite
R=
IR Itotal the very high-ohmic internal resistance the current certainly flows through the
voltmeter. Thus the total current is composed of the current through the resistance
R and the current through the voltmeter. However, the current through the voltmeter is
UR
so low that we do not have to consider it.
R3 © SCHLEICH
A little calculation should show this:

Assuming that a resistance of 0.1 Ω with a test current of 2.5 A is measured. This results in a voltage drop of 0.25 V at the resistance.
Assuming in addition that the internal resistance of the voltmeter is 10 MΩ. This results in a measuring current through the voltmeter of 25 nA (Nanoampere!).
This accounts for a percentage of the total current of 0.000001%! Thus the current through the voltmeter does not need to be considered. Thus the current
through the voltmeter is extremely low and therefore does not influence the total current Itotal to an important extent.
A
Itotal The picture shows all the frame conditions.
Itotal = IR + IUmess
V It also includes the contact transition and lead resistors in addition.
IUmess UR
R= The current is influenced by the resistors RKI1 and RKI2. As the current is measured
RKU2
RKU1
RKI1
RKI2
Itotal
IR the influence is known and is not important anymore.
R UR The voltage is released at the resistors towards the voltmeter’s contacting. This
voltage is very low. In the previous example we assumed a current of approx. 25 nA
SCHLEICH
R4 ©
through the voltmeter. A contact resistor including test leads could be 1 Ω in a worse
case. As there are two contact resistors (RKU1 and RKU2) this amount to 2 Ω. This results in a voltage drop at the contact resistors of 0.05 μV.
Compared to the voltage drop of 0.25 V (0.1 Ω measured with 2.5 A) this is a voltage fault of 0.00002%. This fault is not important as well.
Thus the displayed voltage and the good approach correspond to the voltage drop above the resistor to be measured.
This is the advantage of the four-wire technique.
But this shows that the lead and transition resistance within the voltage measuring path (i.e. the sense leads) should not be too high. Otherwise the
percentaged voltage measuring fault would increase correspondingly.
Increasing the test current in order to receive a higher voltage drop at the test object would lead to an increased voltage drop but the percentaged voltage
measuring fault would remain. Thus there would only be the option of increasing the internal resistance of the Ohm-meter.
14.3. Kelvin clamp resistance test

In order to receive a perfect resistance test as described above the four-wire technique has to be used consequently.
This is especially valid for the contacting. Kelvin clamps are ideally used for the contacting. They have two contact points that are isolated from each other.
One contact point supplies the current to the resistor and the other contact point picks the voltage off at the resistor.
The picture shows 3 different sizes of SCHLEICH-Kelvin

tongs. You can clearly see one rear and one front contacting
matrix.
current supply
current pick-off
This picture shows several Kelvin clamps lying next to each

other. You can clearly see one rear and one front contacting
matrix.
current supply
current pick-off
14.4. Evaluation at the resistance test
It is evaluated based on the nominal-actual value comparison.
R
At this comparison the measured resistance has to be within the tolerance range
around the nominal value.
Zu hoch / nicht in Ordnung | too large / not okay
Rmax
Rsoll
The tolerance parameters can be quite asymmetrical. That means that the upper
okay and lower tolerance limits do not have the same percentage value and reference to
Rmin the nominal value. .
zu niedrig / nicht in Ordnung | too low / not okay In the picture on the left-hand side the tolerance to the top is lower than to the
bottom.
R5 © SCHLEICH
14.5. Influence of the temperature on the resistance test
There are many devices at which the resistor does not change at increasing temperature.
These are for example heaters. Heating wires are used here whose resistance only slightly depends on the temperature. Such a material would be e.g.
Konstantan©.
However, there are also products like e.g. electric motors in which copper wire is very often installed. The copper wire very clearly depends on the
temperature. It is a positive temperature coefficient thermistor (PTC). This means the higher the temperature the higher ohmic becomes the thermistor.
The temperature dependence of the copper way must not be neglected in any case at the resistance test. Otherwise very strong measuring faults occur. In
order to allow a temperature-independent comparison of winding products the ohmic information are related to a temperature. This is 20°C in many countries
in the world. In very hot regions it can also be 25°C sometimes.
If you know the temperature of the resistor to be measured the measured resistor value can be converted to the resistor that would exist at the reference
temperature.
There are conversion formulas for the various resistor types. They are stored in the SCHLEICH-testers.
14.5.1. Conversion formula for copper
The copper wire shows the temperature behavior that is shown on the left-hand
side. Increasing the temperature from 20°C to 30°C causes an increase of the
resistance of almost 5%.
At a tolerance limit of typically +5% the test object would not be within the tolerance
anymore in a production hall at 35°C in summer for example. A test is only possible
under such conditions via temperature compensation to 20°C.
The relation between the warm and cold copper resistor depends on the difference temperature and is as follows:
RTemp = R20 * (1 + α20 * ΔTemp)
The individual elements of this equation mean the following:

RTemp = resistor value at the temperature (Temp)
R20 = resistor value at 20°C
α20 = temperature coefficient of the resistor material
ΔTemp = temperature difference between the current resistor’s temperature and 20°C
This equation can, of course, be rearranged in a way that it can be converted to the resistor R20based on the measured warm resistor and the current resistor
temperature.
R20 = RTemp / (1 + α20 * ΔTemp)
The temperature can for example be measured contact-free at the test object with a
radiation pyrometer.
R7 © SCHLEICH
14.5.2. Conversion formula for temperature sensor
It often occurs that the resistance value of a temperature sensor is to be measured. The sensor temperature is known and it has to be tested whether the
measured sensor resistance matches the temperature.
There are conversion formulas for this as well. These are often complex as temperature sensor usually do not have a linear behavior.
14.6. Resistance test at inductivities

At resistance tests at winding goods of all kinds it has to be considered that the complete DC-test current does not flow immediately due to the inductivity. The
inductivity damps the current increase correspondingly.
Only when the current flows steadily the resistance can be measured correctly. If it is measured too early the resistance value is too high!
I The equivalent circuit diagram of the resistance test of winding goods is composed
of the inductivity and the ohmic resistance.
R
I
U U The inductivity acts like an inductor and lets the current increase with a delay in form
t of an e-function. The resistance acts exactly vice versa.
tW
R6 © SCHLEICH
The time delay should not be underestimated. The delay at motors with a high inductivity can for example be from 1 to10 seconds or more!
14.7. Application examples of the resistance test
14.7.1. Kelvin tongs at a motor
The strands of electric motors are contacted with Kelvin tongs.
14.7.2. Kelvin tongs block at a motor
The strands of an electric motor are contacted with Kelvin tongs that are assembled to
a modular block.
14.7.3. Kelvin tongs at a terminal board of a motor
The bolts of a motor terminal board are contacted with Kelvin tongs.
For this the Kelvin tongs are especially designed with a wedge-shaped matrix so that the threaded bolts can be
contacted in an optimum way.

For checking the resistance test a 0.1 Ω resistance is for example often assembled in the black box. Our black boxes are supplied with calibration documents.
They inform you about the resistance value that is installed in the black box. You can then enter the exact resistance value in your tester.
IHV
another black box test is passed with GO the tester is unlocked again.
Inominal
okay
HVAC25 © SCHLEICH
15
Visual test
15. Visual test
15.1. Explanation of the visual test
At a visual test the operator checks the test object himself visually.
Thus the test is subjective.
The test result is informed to the tester as GO or NO GO.

For entering the results various versions are available:
 GO and NO GO control panel via the touch display (if it exists depending on the design)
 keys on the tester’s front
 external keys
 keyboard
Instead of confirming the visual test with GO or NO GO it is also possible to enter the measuring values, depending on the test step’s configuration. These can
be measuring values of external measuring equipment like e.g. a caliper.
This visual test can be combined with the functioning test. Thus the operator can evaluate the test object while it is operated. It is mandatory to consider the
safety regulations of the standards in this process!
The visual test can be realized with the following tester classes:
 GL2-class
 GL3-class
 MTC2-class
 MTC3-class
16
Mathematical test
16. Mathematical test
16.1. Explanation of the mathematical test
A mathematical test is not an electric test in which a measuring value is taken up but measured values are used and charged with one
another. The result is compared to a set value and evaluated.
Here are some examples:

 The symmetry (scatter band) can be calculated and evaluated of the measuring values of several resistance tests.
 In order to evaluate the total power the powers of the three phases can be added
16.2. Example: NTC-temperature measuring
Temperatures within the test object are often measured with NTCs.
The NTC does not change its resistance linearly to the temperature. The
R
resistance decreases at increasing temperature.
The relation between temperature and resistance is described in a mathematical

form. This equation is stored in the tester.
The tester measures the resistance at first and then it calculates it to the
temperature.
The temperature value can be compared with the ± tolerance limit.
Temp
Math1 © SCHLEICH
16.3. Example: PTC-temperature measuring
Temperatures within the test object are often measured with PTCs.
R The PTC does not change its resistance linearly to the temperature. The resistance
increases at increasing temperature.
The relation between temperature and resistance is described either in a

mathematical or a table form. This equation or table is stored in the tester.
The tester measures the resistance at first and then it calculates it to the
temperature.
The temperature value can be compared with the ± tolerance limit.
Temp
Math2 © SCHLEICH
16.4. Example: PT100-temperature measuring
PT100-temperature sensors are often used for measuring the temperature in the test object.
R The PT100 changes its resistance linearly to the temperature in certain ranges. The
resistance increases at increasing temperature.
176
The relation between temperature and resistance is described in a mathematical
form. This equation is stored in the tester.
139 The tester measures the resistance at first and then it calculates it to the
temperature.
100 The temperature value can be compared with the ± tolerance limit.
0 100 200 Temp
Math3 © SCHLEICH
16.5. Example: temperature behavior of copper leads
Copper has a positive temperature coefficient. Its resistance changes linearly to the temperature in certain ranges. Its resistance increases at increasing
temperature.
Electric motors are coiled with copper or aluminum leads. If you know the resistance at a certain temperature you can measure the resistance at a hot motor
and calculate the increased temperature.
16.6. Example: minimum, maximum, average value & scatter band
With this function you can examine measured values in different test steps.
R The measuring values are examined based on the following criteria out of a number
of test steps:
max maximum
average value
minimum
min
1 2 3 4 5 6 Anzahl
Math4 © SCHLEICH
17
Test method switchover
matrix
station switchover
mechatronics
17. Test method switchover, matrices, multi-stations
17.1. General functioning description
SCHLEICH test technology proves itself in daily operation. The aim is to perform a test as fast and efficient as possible. Only this creates a high utility.
In order to save time the operator connects all connections of the test object by means of a contacting adaptor. Afterwards the tester automatically performs all
tests between all connections. The operator does not have to re-clamp any leads. This is realized by the automatic test method switchover that is typical for
SCHLEICH.
Complex test objects have more than three connections. You only need to think of a building site main cabinet with several sockets for example. Here it makes
sense and it is economic to connect all test objects’ connections with the tester. For the building site main cabinet example this means that the operator
connects all sockets via the corresponding connecting leads to the tester.
Afterwards the tester automatically performs all tests between all connecting points. For the building site main cabinet that is considerably more effective than
performing partial tests at each individual socket. The switchover between the different connections is realized by flexible switchover matrices.
It is obvious that test objects with several connections require more time for re-clamping than test objects with only one connecting lead. In order to gain time
in such cases we often realize double or multi-station systems. At one station it is loaded and unloaded and at the other stations it is tested simultaneously. In
this way, economic results can be achieved at complex and comprehensive tests.
17.2. Test method switchover
Compliant to type and extent of the test methods we provide a number of switchovers. They guarantee a fast and automatic change between the different test
methods.
As the voltage differences between the test methods might be very high the safety
has top priority when dealing with switchovers.
A PE resistance test with 12 V has to be switched to the test object as reliably as a

high-voltage test with 6000 V to protect the test object and, of course, the operator
as well.
There are no compromises here. We only use several thousand times proven top-
quality parts of our own production or from well-known German manufacturers for
switchovers and matrices.
This test method switchover is realized at combination tester of the following tester classes.
 GL1-class
 GL2-class
 GL3-class
 MotorAnalyzer
 MTC2-class
 MTC3-class
17.3. Matrices
For almost every task we supply the corresponding relay matrix. Matrices vary in the number of connections and the height of the test voltage that is to be
switched. A matrix has to switch and separate 6000 V as reliably as millivolt signals. Our engineers have developed the matrixes exactly for this situation.
Matrices are designed for two- and four-wire-applications. They can be strung
together to arbitrarily increase the quantity of connections. Matrices with more than
100 connecting points are no rarity. Like also at the test method switchover, only the
best quality is used for matrixes.
Matching to the kind of test method we supply many switchovers. This guarantees a
fast and automatic change between the different test methods.
The matrix switchover can be realized with the following tester classes:
 GL2-class
 GL3-class
 MTC2-class
 MTC3-class
17.3.1. Functioning of a matrix in two-wire technique
The picture shows the basic principle of a relay matrix. The two poles (HV1 – HV2) of the high-voltage tester are connected to a kind of bus. 2 relays per test
point are connected to this bus. The tester can contact each relay individually on the matrix. Thus it is possible to connect either HV1 or HV2 of the tester to
each connecting point.
The tester’s operator edits a test program for the testing. This test program consists of individual steps that run one after another during the test. In the test
program it is stipulated per test step which pole of the high-voltage tester is to be connected to which connecting point. Thus an arbitrary test combination of
the individual connecting points among each other is possible. You can say that it can be tested “each against each”. It is of course also possible to not only
test between 2 connecting points at the same time. An arbitrary number of connecting points can be included in one test step.
17.3.2. Functioning of a matrix in four-wire technique
It is, of course, also possible to design the matrix for the four-wire technique. In this case 4 relays instead of 2 relays are required per connecting point. The
expenditure is almost doubled as not only the measuring lead but also the sense lead has to be switched. The following picture shows the matrix in four-wire
measuring.
The advantage of the four-wire measuring is that the high-voltage connected to the test object has to be returned to the tester during the high-voltage test.
Thus a voltage check can be performed. Only when the voltage that is returned to the tester can be measured correctly the voltage is correctly connected to
the test object. This guarantees the necessary process safety at automatic test processes.
Instead of measuring the voltage that is returned to the tester the returned voltage can also be charged with a high-voltage-resistant load resistor. A
corresponding current flows through the load resistor at a correct functioning. This current can be evaluated as minimum current. This is explained in the
following picture:
17.4. Station switchover
Instead of using two or more testers, a station switchover is sometimes an economic alternative.
High safety demands are made for station switchovers. Simultaneously to a running
test at one station, the other station is unloaded and loaded again. During this
process the operator inevitably touches the clamps and connecting leads. An
electrical hazard of the operator has to be avoided in any case. For this the
measuring leads to the stations in which no test runs at this moment have to be
safely separated. Furthermore it is recommended to additionally ground the
connections to the test object.
The switchover to several test stations can be realized with the following tester classes:
 GL2-Klasse
 GL3-Klasse
 MTC3-Klasse
17.5. Mechatronics
The huge advantage is the direct control of mechatronic functional processes. You can switch valves, query final switches, evaluate measuring values yourself
and much more.
Many SCHLEICH-testers are able to generate additional functional processes before,

during, and after the test. This is perfect for own test setups or for the integration in
an automatic production.
This function can be realized with the following tester classes:
 GL2-class
 GL3-class
 MTC3-class
18
Calibration
18. Calibration
18.1. Standard-calibration
The monitoring of testing equipment is very important for every company. The regular
calibration of your testing equipment is an important precondition for assured quality.
Therefore, we calibrate the testing equipment for our customers according to the
standards.
We offer three possibilities for the calibration:

- “in-house calibration” means we calibrate at your site
- “at SCHLEICH calibration” means we calibrate at our site
- “online calibration” means we support the calibration via remote maintenance
at your site
For the calibration at our site we plan a short door-to-door time. If you have a standard
tester we can, upon request, place a loan tester at your disposal to fill the calibration
time. If required we are also able to calibrate devices of other manufacturers.
In case unacceptable deviations in test values are detected during the calibration we
adjust the tester as part of our calibration service of course. The test values before
and after the adjustment are documented in the calibration certificate.
Our calibration standards are traceable back to national standards. Our DIN EN
ISO9001 certified calibration center also works of course according to further
standards for example DIN EN ISO 10012, the regulation of requirements for
measurement processes and measuring equipment. If requested the calibration is
performed according to the DAkks/DKD standard (German calibration
authorities/standards).
18.2. Online service
All testers have to be calibrated within the product cycle. The occurring costs consist of calibration and travel costs.
In case the tester’s place of location is far away from SCHLEICH the travel costs might possibly be higher than the calibration costs. To keep your costs as low
as possible we combine the trips to several customers or use the online calibration service if possible. For this you do not need any SCHLEICH service
engineer at your site. One of your staff members can reliably perform the calibration himself according to our online instruction and control.
At online connections safety and data protection are of course important. Especially
when using the internet; it has to be set a high value on the fact that data are not
transferred into the wrong hands. Therefore, we use validated and reliably proven
remote control software of a well-known German software producer for the online
connection. Only for the time of the service a safe connection is established between
your tester and the service PC. During the service we can see the same screen
content on our service PC that is also displayed on your tester. If you allow it we are
able to enter data in your tester via our keyboard and mouse and to navigate through
the menus.
In addition it is also possible to communicate via a chat window. This is important to ask you questions or to give instructions. Alternatively this can also be
done via phone.
The online service can be performed directly from our head office as well as through a local SCHLEICH sales representative. In addition our online service can
also be used for software maintenance tasks.
18.3. Remote calibration
For the remote calibration we send you a measuring box with calibrated measuring resistances and a calibrated tester.
When starting the remote calibration online, connection via internet is established at first. After having established the connection you can perform the single
test steps under the online supervision of our service engineer. We can see the values measured by the tester also on our screen. Our engineer can control
whether the measured values are ok. In case of deviations our service engineer can directly adjust the measuring value online.
After the calibration, the measuring box is sent back to us again. We prepare the calibration certificate and e-mail it to you.
SCHLEICH GmbH
An der Schleuse 11
58675 Hemer | Germany
phone +49 (0) 2372-9498-0
fax +49 (0) 2372-9498-99
e-mail info@schleich.com
service service@schleich.com
calibration calibration@schleich.com
sales sales@schleich.com
web www.schleich.com

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Verfügbare Formate

Test Method Handbook

for safety and functioning testers

 Improper operation can lead to death!

IL = current through the test object

2. For your safety ......................................................................................................... 10

3. PE resistance test .................................................................................................... 12

4. Insulation resistance test ........................................................................................ 29

5. High-voltage test AC (alternating voltage) ............................................................ 44

6. High-voltage test DC (direct voltage) ..................................................................... 66

8. Leakage current test ................................................................................................ 90

9. Substitute leakage current test ............................................................................ 116

10. Short-circuit test .................................................................................................... 118

11. Functioning test ..................................................................................................... 120

12. Continuity test........................................................................................................ 127

13. Residual voltage test ............................................................................................. 129

14. Resistance test ...................................................................................................... 132

15. Visual test ............................................................................................................... 140

16. Mathematical test................................................................................................... 142

17. Test method switchover, matrices, multi-stations.............................................. 145

18. Calibration .............................................................................................................. 151

2.1. Safety symbols

This symbol indicates special know-how.

2.2. Red warning light

2.3. Test cover

3.1. Explanation of the PE resistance test

Testers of the protection class II are marked with this symbol .

It is tested whether the PE resistance is below a limit value stipulated in the

IL : current through the test object

IAbl : leakage current

Explanation of the four-wire measuring:

The maximum allowed limit value (RLimit) is 0.2 Ω.

The test time is usually 1sec.

3.4. Which test value is displayed and evaluated?

3.6.1. Determination of the maximum measurable resistances

The answer to this question can be determined by calculations.

The following technical conditions have to be clarified:

Stromquelle V ULeer Stromquelle V UPE

PE-test in idle state (Uleer = 6 V or 12 V) PE-test (UPE = RPE * IPE)

The equation for calculating an input lead’s resistance is: R = L / (κ * A).

RZu1 Ltotal = Lzu1 + Lzu2 (at equal diameter)

3.9. Test at winded cables

We often supply test probes with a cable length of 10 m and more.

3.11. Correcting the test tip resistance

3.12.1. Manual test of PE resistances

The manual PE resistance test is usually performed with a PE test probe.

After the PE resistance test the test result is displayed.

The test’s counterpole is the switchboard’s

If the tester is equipped with a PE resistance

This picture shows this case.

The SCHLEICH Handheld tester is used

How can such a failure happen?

The following pictures show different kinds of black boxes:

3.13.1. Black box test with ± tolerance limit

nicht in Ordnung | not okay

nicht in Ordnung | not okay

4.1. Explanation of the insulation resistance test

Testers of the protection class II are marked with this symbol .

N IL : current through the test object

IAbl : leakage current

RPE : PE conductor resistance

UB : possibly occurring touch voltage

EVU DUT EVU DUT

RPE > 0,2W