Pawin 32 E

Programming manual
Windows Software
for the devices
GLP3
MTC2
MTC3
DSP1000
DSP2000
SCHLEICH
ANTRIEBS- UND STEUERUNGSTECHNIK GmbH
An der Schleuse 11 D-58675 Hemer
Tel. 02372 / 9498-0 Fax 02372 / 9498-99
Im Internet: http://www.schleich.com
Copyright by Schleich GmbH
Programming manual for WIN32
Index
1.
Safety ............................................................................................................... 8
1.1. Safety symbol................................................................................................. 8
1.2. Attention........................................................................................................ 8
1.3. Regulations for safety at work .......................................................................... 9
1.4. Important information for users of high voltage testing equipment .......................10
1.5. Notes for the operation of testing devices according to VDE 0104.........................12
1.6. Liability .........................................................................................................13
1.7. General information........................................................................................13
1.8. Copyright ......................................................................................................13
1.9. Release of the tester ......................................................................................14
2.
Programming mode ........................................................................................ 15

2.1. Explanations regarding the manual...................................................................15
2.2. Activation of the programming mode ................................................................16
2.3. Input of set values .........................................................................................18
2.3.1.
2.3.2.
3.
Selection of the set value that is to be changed .................................................................... 18

Changing set values or entering new ones............................................................................ 20
Explanation of the individual commands ........................................................ 21

3.1. Main menu: Test ............................................................................................21
3.1.1.
3.1.2.
3.1.3.
3.1.4.
3.1.5.
3.1.6.
3.1.7.
3.1.8.
3.2.
Command:
Command:
Command:
Command:
Command:
Command:
Command:
Command:
Start test......................................................................................................... 21
Input of order data ........................................................................................... 22
Single step (on/off)........................................................................................... 23
Teach in .......................................................................................................... 24
Delete go / no go counter .................................................................................. 24
Disable test methods ........................................................................................ 25
Diagnosis......................................................................................................... 26
HV-adjustment ................................................................................................. 26
Main command: database ...............................................................................26
3.2.1.
3.2.2.
3.2.3.
3.2.4.
3.2.5.
3.2.6.
Command:
Command:
Command:
Command:
Command:
Command:
3.2.6.1.
3.2.6.2.
3.2.6.3.
3.2.6.4.
3.2.6.5.
3.2.6.6.
3.2.6.7.
3.2.6.8.
Load set values ................................................................................................ 27

Save set values ................................................................................................ 29
Delete test program.......................................................................................... 29
Backup ............................................................................................................ 30
Restore ........................................................................................................... 31
Results and statistics ........................................................................................ 32
Search criteria ............................................................................................................................32

Filter..........................................................................................................................................33
Export data.................................................................................................................................34
Indication of individual results.......................................................................................................35
Indication of statistics results........................................................................................................36
Explanation of some statistical terms .............................................................................................37
Trend indication ..........................................................................................................................41
Distribution indication ..................................................................................................................42
3.2.7. Command: Detect reference curve ...................................................................................... 42

3.2.8. Command: Enable processing............................................................................................. 42
3.2.9. Command: Export measure results ..................................................................................... 44
3.2.10. Command: Compare measure curves ................................................................................. 44
3.3.
Main command: set values ..............................................................................45
3.3.1.
Command: General parameters .......................................................................................... 45
3.3.1.1.
3.3.1.2.
Type ..........................................................................................................................................45
Programmer ...............................................................................................................................45
Never touch test objects or test leads during the test!!!

All statutory safety regulations must be followed!

3.3.1.3.
3.3.2.
3.3.3.
3.3.3.1.
3.3.3.2.
3.3.3.3.
3.3.3.4.
3.3.3.5.
3.3.4.
Name.........................................................................................................................................52
Lower limit value .........................................................................................................................52
Cancel........................................................................................................................................52
Test time....................................................................................................................................52
Test voltage................................................................................................................................52
Test connection (as option) ..........................................................................................................52
Test type....................................................................................................................................52
Test with test probe.....................................................................................................................52
Test message..............................................................................................................................52
Picture file ................................................................................................................................52
With repair (as option) ...............................................................................................................52
Repair message (as option) ........................................................................................................52
Additional outputs......................................................................................................................52
Command: Leakage current test ......................................................................................... 53
3.3.6.1.
3.3.6.2.
3.3.6.3.
3.3.6.4.
3.3.6.5.
3.3.6.6.
3.3.6.7.
3.3.6.8.
3.3.6.9.
3.3.6.10.
3.3.6.11.
3.3.6.12.
3.3.6.13.
3.3.6.14.
3.3.6.15.
3.3.7.
Name.........................................................................................................................................50
Upper limit value .........................................................................................................................50
Cancel........................................................................................................................................50
Test time....................................................................................................................................50
Test current (as option) ...............................................................................................................50
Lenght of lead.............................................................................................................................50
Connection for test probe .............................................................................................................50
Test connection ...........................................................................................................................50
Test message..............................................................................................................................50
Picture file ................................................................................................................................50
With repair ...............................................................................................................................50
Reaction time (as option) ...........................................................................................................51
Start type .................................................................................................................................51
Command: Insulation resistance test................................................................................... 52
3.3.5.1.
3.3.5.2.
3.3.5.3.
3.3.5.4.
3.3.5.5.
3.3.5.6.
3.3.5.7.
3.3.5.8.
3.3.5.9.
3.3.5.10.
3.3.5.11.
3.3.5.12.
3.3.5.13.
3.3.6.
Name.........................................................................................................................................48
Text field ....................................................................................................................................48
Program .....................................................................................................................................49
Picture file ..................................................................................................................................49
Show additional input line.............................................................................................................49
Command: Earth wire test ................................................................................................. 50
3.3.4.1.
3.3.4.2.
3.3.4.3.
3.3.4.4.
3.3.4.5.
3.3.4.6.
3.3.4.7.
3.3.4.8.
3.3.4.9.
3.3.4.10.
3.3.4.11.
3.3.4.12.
3.3.4.13.
3.3.5.
Further inputs for the motor tester ................................................................................................46
Command: User messages ................................................................................................. 47

Command: Visual check..................................................................................................... 48
Name.........................................................................................................................................53
max. leakage current ...................................................................................................................53
Voltage ......................................................................................................................................53
Test type....................................................................................................................................53
Norm (as option).........................................................................................................................53
Starting time ..............................................................................................................................53
Measuring time ...........................................................................................................................53
Test probe ..................................................................................................................................53
Switch off ...................................................................................................................................53
Additional outputs (as option) .....................................................................................................54
Test message............................................................................................................................54
Picture file ................................................................................................................................54
Cancel......................................................................................................................................54
Command: Resistance test................................................................................................. 55
3.3.7.1.
3.3.7.2.
3.3.7.3.
3.3.7.4.
3.3.7.5.
3.3.7.6.
3.3.7.7.
3.3.7.8.
3.3.7.9.
3.3.7.10.
3.3.7.11.
3.3.7.12.
3.3.7.13.
3.3.7.14.
3.3.7.15.
3.3.7.16.
3.3.7.17.
3.3.7.18.
Principal informations...................................................................................................................55
Resistance test at an armature......................................................................................................57
Name.........................................................................................................................................57
Test type (as option) ...................................................................................................................58
Nominal resistance ......................................................................................................................58
Variation range (normally only for stators and motors) ....................................................................58
Upper / lower limit value ..............................................................................................................58
+/- %-Tolerance .........................................................................................................................58
Cancel........................................................................................................................................58
Stabilization time.......................................................................................................................58
Test connection (as option).........................................................................................................58
Test message............................................................................................................................58
Picture file ................................................................................................................................59
Error code (as option) ................................................................................................................59
Mode (at armature testers).........................................................................................................59


3.3.8.
Command: High voltage test .............................................................................................. 60
3.3.8.1.
3.3.8.2.
3.3.8.3.
3.3.8.4.
3.3.8.5.
3.3.8.6.
3.3.8.7.
3.3.8.8.
3.3.8.9.
3.3.8.10.
3.3.8.11.
3.3.8.12.
3.3.8.13.
3.3.8.14.
3.3.8.15.
3.3.8.16.
3.3.8.17.
3.3.8.18.
3.3.8.19.
3.3.8.20.
3.3.9.
Command: Continuity test ................................................................................................. 66
3.3.9.1.
3.3.9.2.
3.3.9.3.
3.3.9.4.
3.3.9.5.
3.3.9.6.
3.3.9.7.
3.3.9.8.
3.3.9.9.
3.3.9.10.
3.3.10.
Name .......................................................................................................................................67
Test type ..................................................................................................................................67
Current consumption..................................................................................................................67
Apparent power.........................................................................................................................67
Active power .............................................................................................................................67
CosPhi......................................................................................................................................67
Upper / lower limit.....................................................................................................................67
+/- %-tolerance ........................................................................................................................67
Cancel......................................................................................................................................67
AC/DC (as option)....................................................................................................................67
Starting voltage.......................................................................................................................67
Starting time ...........................................................................................................................67
Test voltage ............................................................................................................................67
Waiting time............................................................................................................................67
Correction (as option) ..............................................................................................................68
Test message ..........................................................................................................................68
Picture file...............................................................................................................................68
With repair (as option) .............................................................................................................68
Repair message (as option).......................................................................................................68
Additional outputs (as option) ...................................................................................................68
Rotational speed (min) .............................................................................................................68
Rotational speed (max) ............................................................................................................68
Sense of rotation .....................................................................................................................68
Command: Mechanical tests.............................................................................................. 69
3.3.11.1.
3.3.11.2.
3.3.11.3.
3.3.11.4.
3.3.11.5.
3.3.11.6.
3.3.11.7.
3.3.11.8.
3.3.11.9.
3.3.12.
Name.........................................................................................................................................66
Evaluation ..................................................................................................................................66
Continuity resistance ...................................................................................................................66
+/- %-tolerance ..........................................................................................................................66
Cancel........................................................................................................................................66
Test time....................................................................................................................................66
Test connection 1 / 2 (as option)...................................................................................................66
Additional outputs (as option) .......................................................................................................66
Test message..............................................................................................................................66
Picture file ................................................................................................................................66
Command: Function test .................................................................................................. 67
3.3.10.1.
3.3.10.2.
3.3.10.3.
3.3.10.4.
3.3.10.5.
3.3.10.6.
3.3.10.7.
3.3.10.8.
3.3.10.9.
3.3.10.10.
3.3.10.11.
3.3.10.12.
3.3.10.13.
3.3.10.14.
3.3.10.15.
3.3.10.16.
3.3.10.17.
3.3.10.18.
3.3.10.19.
3.3.10.20.
3.3.10.21.
3.3.10.22.
3.3.10.23.
3.3.11.
Principal informations...................................................................................................................60
Name.........................................................................................................................................63
AC/DC (as option) .......................................................................................................................63
Transformer (as option) ...............................................................................................................63
Voltage ......................................................................................................................................63
Ramp time (as option) .................................................................................................................63
Test time....................................................................................................................................63
Measure delay.............................................................................................................................63
Test ...........................................................................................................................................63
Test connection 1 / 2 (as option) .................................................................................................63
Feedback control 1 / 2 (as option) ...............................................................................................63
Spot check (as option) ...............................................................................................................63
Min. current (as option)..............................................................................................................64
Max. current .............................................................................................................................64
Capacity ...................................................................................................................................64
Error code (as option) ................................................................................................................64
Test message............................................................................................................................64
Picture file ................................................................................................................................65
Cancel......................................................................................................................................65
Name .......................................................................................................................................69
Set value ..................................................................................................................................69
+/- %-tolerance ........................................................................................................................69
Cancel......................................................................................................................................69
Calliper number.........................................................................................................................69
Test message............................................................................................................................69
Spot check (as option) ...............................................................................................................69
Command: Rotary field test .............................................................................................. 70
3.3.12.1.
3.3.12.2.
3.3.12.3.
3.3.12.4.
Name .......................................................................................................................................70
Voltage.....................................................................................................................................70
Sense of rotation .......................................................................................................................70
Rotary field ...............................................................................................................................70


3.3.12.5.
3.3.13.
3.3.14.
3.3.15.
3.3.15.1.
3.3.15.2.
3.3.15.3.
3.3.15.4.
3.3.15.5.
3.3.15.6.
3.3.15.7.
3.3.15.8.
3.3.15.9.
3.3.15.10.
3.3.15.11.
3.3.16.
3.3.17.
3.3.18.
3.3.19.
3.4.
Name .......................................................................................................................................73
Set value ..................................................................................................................................73
+/- Tolerance............................................................................................................................73
Measure channel........................................................................................................................73
Evaluation.................................................................................................................................73
Voltage.....................................................................................................................................73
Waiting time .............................................................................................................................73
Measure time ............................................................................................................................74
Test message............................................................................................................................74
Picture file...............................................................................................................................74
Cancel ....................................................................................................................................74
Command:
Command:
Command:
Command:
3.3.19.1.
3.3.19.2.
3.3.19.3.
3.3.19.4.
3.3.19.5.
3.3.19.6.
3.3.19.7.
3.3.19.8.
3.3.19.9.
3.3.19.10.
3.3.19.11.
3.3.19.12.
3.3.19.13.
3.3.19.14.
3.3.19.15.
3.3.19.16.
3.3.19.17.
3.3.19.18.
3.3.19.19.
3.3.19.20.
3.3.20.
3.3.21.
3.3.22.
3.3.23.
Cancel......................................................................................................................................71
Command: Insulation resistance test with the surge tester ................................................... 72

Command: Surge test ...................................................................................................... 72
Command: Analog test..................................................................................................... 73
Define motor parameters ................................................................................. 75

Setup motor test............................................................................................. 76
Define cycle.................................................................................................... 78
Characteristic of a motor in curve-form .............................................................. 79
Dynamometer ...........................................................................................................................79
Voltage.....................................................................................................................................79
Test method .............................................................................................................................79
Rotational speed........................................................................................................................79
Torque .....................................................................................................................................79
Current ....................................................................................................................................79
Power.......................................................................................................................................79
Cycle........................................................................................................................................79
P-, I-, D-regulating parameter.....................................................................................................80
Max. current, max. torque, max. rotational speed, max. temperature ............................................80
Test message ..........................................................................................................................80
Picture file...............................................................................................................................80
Starting time ...........................................................................................................................80
Total test time .........................................................................................................................80
Number of cycles .....................................................................................................................80
Completion message ................................................................................................................80
Braking speed .........................................................................................................................80
Braking time ...........................................................................................................................81
Activate manual mode ..............................................................................................................81
Cancel total test if the result of the test is no go .......................................................................81
Command:
Command:
Command:
Command:
Additional programs (option) ............................................................................ 82

Define test sequence ....................................................................................... 83
Label print-out ................................................................................................ 85
New test program ........................................................................................... 89
Main command: Setup ....................................................................................90
3.4.1.
3.4.2.
3.4.3.
Command: Manual mode ................................................................................................... 90

Command: On/Off display .................................................................................................. 90
Command: Options ......................................................................................................... 92
3.4.3.1.
3.4.3.2.
3.4.3.3.
3.4.3.4.
3.4.3.5.
3.4.3.6.
3.4.3.7.
3.4.3.8.
3.4.3.9.
3.4.3.10.
3.4.3.11.
3.4.3.12.
3.4.3.13.
3.4.3.14.
3.4.3.15.
3.4.4.
3.4.5.
3.4.6.
3.4.7.
3.4.8.
Command: Options - General information ....................................................................................93

Command Options - Display .......................................................................................................94
Command: Options - Tests.........................................................................................................96
Command: Options... - Tests - Set test methods.............................................................................97
Command: Options... - Tests - Compile test programs.....................................................................99
Command: Options - Test results .............................................................................................. 100
Command: Options - Language................................................................................................. 109
Command: Options - Print........................................................................................................ 110
Command: Options - Label Printing ........................................................................................... 112
Command: Options - Data...................................................................................................... 113
Command: Options - Test programs ........................................................................................ 124
Command: Options - Hardware............................................................................................... 125
Command: Options - Signals .................................................................................................. 132
Command: Options - Blackbox Test......................................................................................... 133
Command: Options - Additional .............................................................................................. 134
Command:
Command:
Command:
Command:
Command:
Setup data storage ......................................................................................... 139

Setup dynamometer ....................................................................................... 140
System information ...................................................................................... 141
Event log ....................................................................................................... 141
Exit............................................................................................................... 142


4.
Calibration.................................................................................................... 143
4.1. Calibration................................................................................................... 143
5.
Miscellaneous ............................................................................................... 144

5.1. Directory tree of the tester ............................................................................ 144
5.2. Explanations of directories............................................................................. 145
5.3. Re-generate databases ................................................................................. 146
5.4. Working with limited user rights ..................................................................... 146
5.5. Protocol of I/O-interfaces .............................................................................. 147
5.5.1.
5.5.2.
5.6.
5.7.
Communication via I/O-interface....................................................................................... 147

Communication via the serial RS232 interface .................................................................... 150
Shortcuts .................................................................................................... 158

Definitions and explanations .......................................................................... 159
6.
Subject index ............................................................................................... 160
7.
Annex ........................................................................................................... 163
File
State
Last revision
Editor
:
:
:
:
Q:\WINWORD\USER\ML\BAWIN32\PAWIN32\PaWin32E.doc
1.15
14.03.2007
M. Lahrmann, G. Schellnack, St. Siepmann


Date of print-out
: 11/4/2013

1. Safety
1.1.
Safety symbol
You will find this symbol with all safety precautions and warnings in this operating manual where danger to life and
limb exists. Please follow these warnings and act particularly careful in these cases. All safety precautions and
warnings need to be passed on to other users. Apart from the information in this operating manual, the generally
applicable valid safety and accident prevention regulations must be observed.
Upon an electrical test, it must always be considered that there is a potential danger. The operator must always be
aware of this fact.
1.2.
Attention
You will find this Attention ! sign at places in this operating manual which must be observed very carefully, so that
the guidelines, regulations and indications and the correct operating process is observed. This is also necessary to
prevent that the testing device and/or other parts of the equipment are damaged or destroyed.
It will also be used where important additional notes are made.

1.3.
Regulations for safety at work
The following regulations for safety at work are to be strictly adhered to:
The tester has been designed according to the latest developments in technology and is operationally reliable.
However, should this testing device be used by unqualified personnel, in an inappropriate way or for improper use,
this testing device can be dangerous.
Each person in the factory of the user that deals with the installation, the operation and the maintenance of the
testing device GLP 2, must have read and understood the complete operating manual and particularly the
information on safety. We recommend that the user has this confirmed in writing (see annex).
Part of the intended usage is to follow the installation-, operating- and maintenance/repair conditions specified by
the manufacturer/supplier.
The tester may only be operated, maintained and repaired by authorized, trained and instructed personnel, which
must have participated in a special training about all possible risks (e.g. in case measure leads are damaged at the
outside, the test hood is damaged or doesn't close correctly etc.).
Upon any kind of work concerning commissioning, operation, repairs and maintenance, the switching-off and
switching-on procedures indicated in the operating manual must be considered.
Any working manner that impairs the safety of the testing device must be refrained from.
The user is obliged to immediately report any change at the testing device that impairs the safety.
Unauthorised modifications and changes which impair the safety of the testing device are not allowed.
All work on the testing device must be done when it is voltage-free and switched-off.
Before commissioning and after maintenance/repairs it must be checked, whether all protection devices are
installed properly and functional. Protection devices must never be removed.
For the operation of the tester, take particular note of the regional safety regulations and regulations for prevention
of accidents.

1.4.
Important information for users of high voltage testing equipment
Caution! High voltage!

Touching high voltage can result in the loss of life. Equipment and accessories must be in perfect
condition and need to be checked regularly. The equipment may only be used in dry state and in dry
rooms. Only suitable qualified personnel or trained personnel under supervision of specialists should
work on this equipment.
1) Usage
The relevant regulations, above all VDE 0104, must be followed strictly. Every day before starting work,
equipment, accessories and supply line must be visually examined to ensure perfect condition. Every
user must familiarize himself with the safety notices in this manual and should be aware of all risks. He
is obliged to protect himself and others against accidents. Because of the necessary personal
responsibility, all users must be selected carefully and need to be trained in detail at least once a year.
The training must be put on record. Maintenance and alterations are reserved to the manufacturer.
(Unauthorized alterations endanger safety).
For checking, the test pistols can be sent (postage paid) to the manufacturer.
2) Working with test pistols
High voltage test pistols are only delivered with connected high voltage cable.
You will have full accident protection if you always use the test pistols in pairs, one in each hand. It is
very dangerous to connect the test object tightly at one pole, to work with only one test pistol or to take
two test pistols in one hand.
The test object which is supplied by the test pistols with high voltage must not be touched! Its
insulation could break down during the test. Do not test on metal surfaces because the voltage of the
test object could be carried over to the surface.
During non-working time the high voltage must be switched off!
The test pistols are well insulated, but as protection insulated devices not grounded. Therefore the user
may feel a tingling or a slight vibration if he doesn't hold a test pistol tight after switching-on the
voltage, but touches it only slightly or has a very short distance from test pistol to the supply line. In
this case you can feel the electric field. A capacitive blind current of max. 0.08 mA could be flowing in
the capacity. (There is no danger up to 3.0 mA according to VDE 0104 !).
Only use test pistols in perfect condition with new value cable! Check test pistols and cable for obvious
damage every day before starting work! Faulty test pistols (even with the slightest fault at the device or
at the lead!) have to be put out of operation immediately and must be sent back to the manufacturer!
Attention!
For personal safety reasons, a 3mA test current limitation can only be done via hardware integrated in
the testing device. An adjustment of the maximum test current to 3mA by software, at which the device
is to switch off, does not serve for personal protection since the current can also reach higher values for
a short period of time.
Only a limitation by hardware of the max. possible current is allowed for personal protection.
This is done optionally inside the testing device by the means of a resistance. Only in this case the
otherwise necessary protection measures can be done without.

10

3) Working with test hoods
When working with test hoods, please always take care that the high voltage cant get out of the test
hood.
This can happen if, for example, the contact sheet for the case contact of the test object is lead to the
outside.
It is also necessary to take care that absolutely no measure leads and connection leads go to the
outside.
Test covers must have no damages like cracks or even holes.

11
1.5.
Notes for the operation of testing devices according to VDE 0104
Testing devices may only be operated under supervision and attendance of a electrical specialist. This applies to the
operation of test stations with and, in particular without automatic touch-guard. An automatic touch-guard is, for
example, a completely closed test hood under which the test takes place.
For the operation of testing devices it is necessary that operating manuals are available near the location of the
device.
Before every use, the operating material must be checked regarding possible damage that can be seen from the
outside.
Faulty or damaged testing devices that endanger personal safety may not be used.
All damage and faults at the operating material and at components of the testing device that have been detected
must immediately be eliminated by an electrical specialist or reported to the person in charge.
Only electrical specialist are entitled to do the maintenance of testing devices. This should, if possible be done in
coordination with Messrs. Schleich. We should like to point out that maintenance that is not followed by adjustment
of the devices could influence the accuracy of the measure results and the go / no go evaluation.
The safety equipment must be checked by an electrical specialist in appropriate time intervals, at least once a year,
regarding its perfect condition and efficiency.
In case of test stations where safety test probes are used, the testing personnel must also be informed about the
additional special risks.
The test setup must be in a way that a voltage carry-over to other conductive parts is not possible. We recommend
to use only measure leads with complete touch-guard and to insulate the test setup.
Before starting work, safety equipment must be checked whether it is completely operational.
If safety test probes are used, the user must check whether the test probes and the leads of the test probes are of
perfect condition before he starts work.
If there is a possible danger because of electric arcs, it is necessary to take measures to prevent personal injuries.
The electrical specialist in charge must convince himself that his instructions have been executed correctly before
the testing device is started.
It is not allowed to do maintenance and testing at the same time if this creates risks.
In case of faults it is possible that also parts of the test object and of the test station that are during regular
operation not carrying voltage take over dangerous voltages. If, in special cases, it needs to be worked on these
parts, suitable protection and helping aids are to be used (see DIN VDE 0105 part 1/07.83, sections 4 and 12).

12
1.6.
Liability
The testing device has been designed according to the latest developments in technology, checked and is therefore
operationally reliable. In case the tester is maintained or repaired improperly by persons not authorized by Schleich
GmbH, the liability will in any case be passed on to the owner. The same applies if the testing device is operated in
any other way than described in this manual. (see chapter Operative range and appropriate usage).
The user is obliged to operate the tester only in perfect condition. Messrs. Schleich GmbH is liable for mistakes and
omissions, with the exception of further claims, only within the framework of the guarantee commitments in the
order confirmation (respectively the commitments in the offer).
In view of the permanent development and improvement of our products, we reserve the right for technical
modifications at any time. Such modifications, mistakes and misprints do not imply a claim for damages.
Furthermore only original Schleich GmbH spare parts and accessories may be used. For any damage arising from
non-observance of the instructions in this operating manual Messrs Schleich GmbH do not assume liability. The
above information does not extend the liability- and guarantee agreements of the conditions of sale and delivery of
Messrs. Schleich GmbH.
This operating manual has been drawn up with the utmost care. However, Messrs. Schleich GmbH can not be hold
liable for possible mistakes in this operating manual and their consequences.
1.7.
General information
This operating manual has been written with the intention to be read and understood in all details by those
responsible for the tester, for its setup and for its maintenance.
The complete documentation should always be kept within easy reach of the testing device. Details of great
importance for operating the tester are pointed out to in this operating manual.
Only the knowledge of this operating manual will ensure that mistakes with this testing device can be avoided and
guarantee trouble-free operation. It is therefore of great importance that this operating manual is known to the
relevant persons.
We recommend careful reading of this operating manual because we will not accept liability for any damage or
operating trouble resulting from disregarding this operating manual. Should you nevertheless have difficulty with
the operation, please do not hesitate to contact our service department.
Please note, that in case of temperatures around 0 Celsius (32 Fahrenheit) (e.g. when delivered in winter) the
tester should warm up to room temperature before being switched on.
1.8.
Copyright
Messrs. Schleich GmbH hold the copyright for this operating manual. This operating manual has been
written for the operating and supervising personnel of the tester. It contains instructions and technical
illustrations which may neither completely nor partly be copied, distributed or used for competition
purposes or given to a third party.

13
1.9.
Release of the tester
Before the tester is released for production, it is absolutely necessary that some settings must be correct. Above all
these are the settings from chapter Options selection.
In case of an order-related storage of the results, the type of order inquiry and input should be firmly determined.
Changes that are made at a later time could lead to data losses.
It is absolutely necessary that before being released for production the tester is checked by the user for
all functions and found o. k.
Basically, the tester is, of course, always to be checked before switching on. There are various
possibilities for a selftest available at the tester. A very important measure is to check the tester via a
blackbox after switching on. With the aid of the blackbox it is possible to check the complete measuring
technique of the tester with great accuracy.
The blackbox test needs to be generated by the user. A test program named Blackbox is stored in the
database. This test program contains individual test steps, which check the individual connection leads.
The blackbox should be equipped in a way that, if possible, all connection leads of the tester are
checked.
Directly after switching on the tester software, the test note of the program that has just been loaded,
appears.

14
2. Programming mode
2.1.
Explanations regarding the manual
The screen displays in this manual are to be looked at only as an example.

Since our testers can be configured in a great variety of ways, the screen displays in this manual can
deviate from the actual screen displays at your tester.
The tester works under the operating system WINDOWS 95, WINDOWS 98 or WINDOWS NT from
MICROSOFT. For the description of the tester it is assumed that working with Windows is known.
Windows knowledges are assumed to be existing for the complete operation of the tester.
This manual contains examples of possible screen displays, which might slightly differ from the screen display of
your tester. The reason for this is not an inaccurate operating manual but the great variety of possible designs of
the GLP3 (or MTC3, DSP2000 or DSP1000). We therefore suggest to pay attention only to that part of the screen,
which is being explained in the operating manual.
In the manual, often buttons are being mentioned that are shown on the screen. These buttons always contain a
text. Within the manual, the text of a button is marked as follows:
Buttons:
Print
or
Exit
Button in tool bar
Button
(On special demand it might be possible to use a different Windows operating system.)

15
The manual also explains the various commands. Commands are marked as follows:
Commands:
Index
or
view orders
main command
command
In case a key of the keyboard is to be activated, the key is marked as follows:

Keyboard: , ,
In case an operating switch at the tester itself is to be activated, this switch will be marked as follows:
Operating switch: [Start]
2.2.
Activation of the programming mode
The tester makes no difference between test mode and programming mode. This has the advantage that it is
always possible to do tests. In addition to testing, it is also possible to change the settings in the programming
mode.
Whether programming (i.e. changing of the test program) is activated in addtion to testing, is determined by the
position of the key switch [test/input]. The key switch is on the front panel of the tester.
In the programming mode, you basically work with the data base and the test process for a test object is entered
at the PC. In addition it is possible to change various parameters and settings.
The programming mode is to be used only by the person who sets the tester up. During normal production it is
thus not possible for the operator to change data.
As long as the programming mode is activated, there will be the respective message on the screen. This message
informs the setter that changing data is enabled.
You can also see that the programming mode is activated, because the texts of some commands have a different
color. Disabled commands are gray, enabled commands are black.

16
Programming active
Programming active,
because the text is black

17
2.3.
Input of set values
Taking the input of the resistance test as an example, you will find below an explanation of how to do an input.
Upon doing the input, you will be asked for the password.
PASSWORD
New devices will at least always have the user name: Schleich with the password: 123.
Please note: if the user Schleich is deleted from the list of users, it will automatically be re-generated when the
tester is updated.
2.3.1.
Selection of the set value that is to be changed
The input can be initiated in 3 different manners.

1. via the menue
2. by doulble-clicking with the left mouse button on the test step that is to be changed
3. by clicking with the right mouse button on the test step that is to be changed and selecting the command Edit in
the context menue
1. via the menue
Click on the command menue Set values. Now a window opens up under this menue. With the mouse you can
now for instance select the resistance test (Widerstandsprfung) and click on it.
Select and start Resistance test
Now a further window opens up which indicates a test step selection.
List of test steps to select

End input of set values
Initiate input of set values
Copy selected test step
Delete selected test step
Insert copied and selected test step

18

This selection shows a list of the entered test steps. The test steps are numbered consecutively. The next new
free test step is at the bottom of the list (without test step text). If a new test step is to be selected, this free
test must be selected. The command Edit activates the input of the new set values.
Operation via mouse
The test step that is to be changed is clicked on with the mouse. Double-clicking on the test step immediately
starts the input. Alternatively you can click on the button OK_ .
This leads you to the input of the resistance values for this test step also.
Operation via keyboard

The test step that is to be changed is selected with the arrow buttons of the keyboard
Pressing the
button immediately starts the input of the selected test step.
The selection can be cancelled immediately by pressing the ^ (ESC) button.
Of course, it is also possible to use both mouse and keyboard "at the same time".
or .
2. Double click on test step

Double-clicking on the test step that is to be changed, immediately activates the input for the selected test
step. This is a very fast way.
3. Pop-up menu of the test step

If you click on the test step that is to be changed with the right mouse button, the pop-up menu opens up.
After selecting the command Edit, the input for the selected test step is immediately activated.

19
2.3.2.
Changing set values or entering new ones
Changing set values is always done after the same basic pattern. Depending on the type of input, the window for
entering the set values can be of varying size and have a varying number of inputs. However, the principle of input
does not change.
The input of set values consists of various individual inputs, which are listed one below the other. There is a help
text for every input, which appears in the bottom field of the input window.
End input of set values
Cancel input of set values

without accepting the values
Print-out of set values of this

test step on paper
When the mouse pointer is held over an input, the help text for this input appears automatically.
Operation with the mouse

The input value that is to be changed is clicked on with the mouse. After this the cursor (vertical stroke) jumps into
the selected field. Now the value is changed.
Operation via keyboard

With the (tabulator button) you can jump from one input to the next.
With
you can jump from one input to the next.
Pressing
(Enter button) automatically ends the complete input.
Pressing ^ (ESC button) ends the complete input without accepting the values.
It is of course also possible to use the keyboard and the mouse "at the same time".

20
3. Explanation of the individual commands

3.1.
Main menu: Test
With the commands of the main menu Test, the person who does the setting up has the possibility to set various
frame conditions for test.
In the following you might find some commands that do not appear in your tester. The reason for this can be that
your tester doesn't have the respective hardware configuration.
Example: if there is no label printer connected to your tester, the command for label print-out doesn't appear.
However, in this manual the command will be explained.
We hope you will understand that it is not possible for us to make a programming manual for every single tester.
Our testers can be combined out of a great variety of hardware and software configurations. You have also the
possibility to configure the tester yourself. This programming manual is therefore a universal manual for all possible
applications.
3.1.1.
Command: Start test
The command Start test directly starts the test process.

The test process can also be started via the triangle symbol at the very left in the symbol bar.
The test can, of course, also be started via the start button or, at testers with test hoof, via closing he test hood

21
3.1.2.
Command: Input of order data
In case the person who does the setting-up has activated the input of order data, all order data is entered after resetting the tester for a new test object.
Attention
Order data will only be interrogated if the tester has been configured accordingly.
See Setup Select options index card Storage option Input of order data.
and
See Setup Parameters Test methods Order input.
The list of the above order inputs is only an example, because the sequence of interrogation and the data can be
defined by the operator.
Upon entering the order data, there are three possibilities:
1. Nothing is entered, but the -key is activated
No order is generated. However, after this during the test, no result storage takes place either.
2. The entered order already exists

In this case, work will be continued at an order that already exists in the database. This could for example be the
case after an order interruption, caused by working on a new order.
After the order that already exists in the database has been called again, all new test results are stored to this "old"
order.
3. The entered order is new

In this case a new order is generated in the database.

22
3.1.3.
Command: Single step (on/off)
With the command Single step you have the possibility to have a stop after every test step. This might be helpful in
a service case. After the command has been called, the new command Single step on appears. This indicates that
now the Single step mode is activated.
After starting the test process, the following picture appears before the start of the individual test steps:
The picture shows various details, which are very helpful for our service personnel. For the operator, a more
detailed explanation would be too far-reaching here.

23
3.1.4.
Command: Teach in
With the command Teach In Off it is, e.g. at the surge test, possible to teach in new surge waves automatically.
This saves a lot of time. After the command has been called, the new command Teach In On appears. This indicates
that now the Teach In is activated.
Please note: The Teach In can be used, when the key switch is set to Program or the programming mode has
been activated in a different way.
After activating the Teach In, the test process is started as usual. As soon as the test process is finished, the
detected surge waves are automatically taken as reference. After this, the Teach In is automatically deactivated.
Test methods Order input.
Please note: In the respective test method the Teach In can only be used if it was activated in the options.
See also Setup Select options index card Test
Compile test programs ...
Select test method (e.g. surge
voltage)
3.1.5.
Command: Delete go / no go counter
The "go" (OK) and "no go" (not OK) piece number counters are usually deleted upon re-setting the tester for a new
test object.
If the completion of the order takes several shifts or days, you can for example also use the counter as shift or day
counter.
With the command Delete go / no go counter the counters can be re-set to zero.
After calling the command, you will be asked whether the counter is really to be deleted.
See also Setup Select Options
index card Storage
How to store actual values?
Here you can configure how the counter is to act upon a change of types or upon order input.

24
3.1.6.
Command: Disable test methods
Even if test steps and set values for measure methods (like resistance test or function test) are pre-set, there is the
possibility to disable them. This might be helpful in case there is always the same error at a test object within the
current series, but testing is to be continued.
In the following picture you can see how disabling is selected.
The test methods where the check mark is set are disabled.
This test method is disabled
One or more test steps of this test

method are disabled, but not all of
them.
This locking disables all test steps of a test method at the same time. If you have for example a test with, amongst
others, 3 resistance test steps, this method disables all 3 resistance test steps at the same time.
If you do not want to disable all test steps of a test method at the same time, it is also possible to disable a test
step individually.
To do so, you go to the desired test step with the mouse, then you click on it with the right mouse button. Now the
following picture appears:
This test method is disabled
The test step is disabled

by clicking here with the
left mouse button
The disabled test step appears on the screen in gray writing instead of black writing. During the test process, the
disabled test steps are omitted.

25
3.1.7.
Command: Diagnosis
By means of the selftest it is possible to start an automatic internal test of the tester. Some testers do not have
this option.
3.1.8.
Command: HV-adjustment
This command is only visual at testers with a high voltage test and manual adjustment of the voltage. After calling
the command, the voltage necessary for the test (set value) and the present actual value is indicated. By turning
the adjusting switch for the high voltage, the voltage is adjusted until it matches the set value.
The adjustment of the high voltage can also be activated via the lightning symbol (if it has been acticated) in the
symbol bar.
3.2.
Main command: database
With the commands of the main command Database, the person who does the setting up has the possibility to
execute various database tasks, which are explained in the following chapters.

26
3.2.1.
Command: Load set values
There are various possibilities for loading a test program out of the database.
1. Go on the loading symbol with the mouse and open the index by clicking on it with the left mouse button.
2. As an alternative it is also possible to call the command Load set values under the menu point Database.
3. The test program can also be loaded via barcode, without using the keyboard. As soon as a barcode has been
read-in, loading a new test program takes place automatically.
See also Setup Select options index card Storage Option weitere Optionen Istwertspeicherung
Here you configure, if and how a test program is to be read in with a barcode.

27

After calling the command Load set values, you will see a list of the test programs stored in the database.
With the keys, you can select the test program that is to be loaded. Activating the button Load starts the
loading process.
The test program can also be loaded by double-clicking on the desired test program.
In case there is a large number of test programs stored in the database, you have the possibility to filter the
desired test program with the help of the quick-search. Please enter the first signs (or the complete name) of the
test program that is to be loaded. After this you will see in the list only those test programs that match the filter.
Example:
473 was entered
The test programs 4001320, 4731212, 4731213, 48511 are in the database.
After the input, the selection will only show the test programs 4731212 and 4731213.
Quick search
List of test programs
Cancel loading a test program
Print all test program definitions

on one page in the form of a list

28
3.2.2.
Command: Save set values
For storing a test program in the database there are various possibilities.
1. Go to the storing symbol with the mouse and start the storing process by clicking on it with the left mouse
button.
2. As an alternative you can call the command Save set values under the menue point Database.
3. After changing data you don't store specifically, the program is started directly. The tester will recognize that
data has been changed but not yet stored. You will be asked whether you want to store the data first.
Upon storing, the tester will always check whether the test program already exists in the database. If yes, you will
be asked whether these data are to be written over.
3.2.3.
Command: Delete test program
For deleting a test program out of the database, after initiating the command you first need to enter the password
(upon delivery: 123).
Now a list with the stored test programs is indicated (similar to the list, which you see upon loading a test
program).
Now select the test program that is to be deleted. The test program is irrevocably deleted out of the database by
activating the button Delete .

29
3.2.4.
Command: Backup
With this back-up function it is possible to back-up databases, programs etc.

The desired back-up jobs need to be defined in a special setup menue (see below) by the person who does the
setting up. Some back-up jobs already exist when the tester is delivered.
The defined data backup jobs are indicated on the screen in the form of a list.
List of data back-up jobs
The order is clicked on with the mouse. After this, the background of the order is blue.
After selecting a job, it is started by activating the OK button. After this the operator will be lead through the backup.
Attention
Formatted diskettes or data carriers that are already carrying data will be overwritten and thus all data
will be irrevocably deleted.
Important: In order to make sure that current data stocks of the tester are not overwritten by older
data backups later on, the date of a data backup should always be noted down on the label of the
diskette.
This is how you will find the setup menu:
See also Setup Parameter Databases Setup backup jobs
Here you configure, what, when and how everything is to be stored in a backup job.

30
3.2.5.
Command: Restore
After calling this command, the following window appears:

Here the file name is entered
under which the backup has
been stored.
Show contents of the selected

file
The file name can also be

selected out of a directory tree
Select target drive / target

directory into which the data
backup is to be re-stored
Attention
Important: In order to make sure that current data stocks are not overwritten by older data backups,
the date of a data backup should always be noted down.
Proceeding:
1. Via the button Selection , the file that is to be re-stored is selected. This file contains the compressed data.
This compressed file can contain several individual files.
2. Now the contents of the backup file can be indicated via the button Information .
3. After the file that is to be re-stored has been selected, you also need to select the target drive / the target
directory. For the structure of the directories, please see the annex.
4. Activating the button OK starts re-storing the data.
5. If the process is to be interrupted, activate the button Cancel .
Note:
For re-storing at the tester, you would usually select drive C: and the path C:\ . With this setting, the backup
makes sure that the secured files are copied into the correct directories.

31
3.2.6.
Command: Results and statistics
All measuring results of every test are stored in actual value databases.
The data can individually be viewed and statistically evaluated. After calling the command, the following picture
appears:
Selection of search criterion
Selection of filter
(e.g. time period)
Export of the data into a

customer-specific database
3.2.6.1.
Search criteria
There are various possibilities for filtering the necessary data for the display or the statistics out of the enormous
quantity of data.
1. Type
In order to search for the data via the type, please enter the desired name of test object. In addition to the type
it is also possible to enter a time period from ... to ... on the index card "Filter". It is thus possible to analyze
the results over a desired period of time.
2. Serial number
For searching and indicating the results of a test object with a serial number, the desired serial number needs to
be entered. A statistic, however, can then (because only an individual piece) not be drawn up, because it is an
individual result.
3. Order
For analyzing the data of a certain order, the order number needs to be entered.
4. Shift number
For searching and indicating the results of a shift, the desired shift number needs to be entered. In addition it is
also possible to enter a time period on the index card "Filter". In order to be able to use the shift number
evaluation, it is necessary to activate the option for the shift input!
See also Setup Select options index card Storage option Input of order data
with shift number
By activating the button OK
, the search for the data is started. The result of the search is described in chapter
3.2.6.4. In case viewing data and orders is to be ended, activate the End

button.
32
3.2.6.2.
Filter
For filtering the necessary data for the display or the statistics out of the enormous quantity of data (of the
collected test results), it is possible, in addition to the search criteria, to enter further filters, which filter the
amount of data to a larger extent. BILD
1. Date
For searching data it is possible to enter a time period in days from ... to ... . It is thus possible to analyze the
results over a desired time period in days.
2. Time
For searching data it is possible to enter a time period from ... to ... . It is thus possible to analyze the results
over a desired time period.
3. Operator
For searching data that has been tested by a certain operator, it is possible to enter the name of the operator.
It is thus possible to analyze the results related to a certain operator.
4. Testing device
For searching data that has been tested by a certain testing device (in a network), it is possible to enter the
testing device. It is thus possible to analyze the results related to a certain testing device, or, at a double
station, related to one of the test stations.
5. Result
In case maybe only all "good" test results are to be statistically evaluated, you can here enter the respective
filter.

33
3.2.6.3.
Export data
This function serves for searching data out of the enormous quantity of data and summarize them to a an individual
database. Comprising the data to a new file is called Export".
The complete export job is stored in a configuration file. It is possible to generate various export configuration files
for various export solutions.
If the configuration file for the export already exists, it can be read in with the "loading" symbol.
Now you need to determine or change the data that you want to export into your own database. Similar to the
Mocrosoft-Explorer, a window is opened on the left side. In this window you can select the data that is to be
included in your new database. On the right side of the window you can see a list of the selected data. You can
change the order by "Drag and Drop". In the export database it is possible to allocate a different field name to
every data filed.
After generating the configuration, it is stored. Now the generation of the export database is called.
Activate the OK button.

34

3.2.6.4.
Indication of individual results
After ending the data search in the database the following picture appears:
Linear regulator for choosing a

test step
Number of the test object of

which the results are currently
being displayed
Linear regulator for choosing a

certain tested test object
It shows the two test steps of an example test program. For every test step the following data is indicated:
Name of test step
Test method
Set value
+ Tolerance (highest allowed value)
- Tolerance (smallest allowed value)
Actual value
Were there repairs made in the test step?
What was the result?
Was the test step disabled and therefore omitted?
Date
Time
For generating the statistics for a test step, the desired test step needs to be selected first. The selection of the test
step is done by clicking on it with the mouse.
By activating the button Print
, a print-out of the actual values of the currently indicated test object takes place.
In case the sliding regulator is adjusted, the results of a further test in this test order are being indicated. The
selection of the test step is done by clicking on it with the mouse.
By activating the button Statistics
, the statistics calculation for the selected test step is started afterwards.
If the viewing of data and orders is to be ended, activate the End

button.
35
3.2.6.5.
Indication of statistics results
After ending the statistical calculations, the following picture appears:

Store statistics in file
Print-out with statistics
parameters Cp, Cpu, Cpo, Cpk
Print-out without statistics
parameters Cp, Cpu, Cpo, Cpk
Details
Trend calculation
Distribution calculation
Here you can see the test steps of an example test program. For every test step, the following statistical data is
indicated:
Name of test step
Set value
+ Tolerance (highest allowed value)
- Tolerance (smallest allowed value)
Actual value
largest measured value
smallest measured value
Range (difference between the largest and the smallest measured value)
Average
Standard deviation
Variance
Cp, Cpu, Cpo, Cpk
Number of "go" tests of this test step
Activating the button
Export
stores the indicated statistic values in a database file. Before doing this it is
necessary to insert a diskette into the drive. This file is using the ACCESS-2.0 format.
After activating the button
button
Print
Print with Cp
or Print
the statistic table is printed on the standard printer. If the
, the statistic parameters Cp, Cpu, Cpo and Cpk are not printed.
Activating the button
Detail
opens a window in which further measure results for the respective test step are
indicated. Every test step can store up to six results. In the statistic window, however, only the first value is
indicated.
Via activating the button
Trend
, the indication of the trend development of all measure results of one test step
takes place.
Via activating the button
Distribution
, the indication of the frequency distribution of all measure results takes
place.

button.
36
3.2.6.6.
Explanation of some statistical terms
Within the evaluation of quality characteristics, it is often necessary to check, whether the machines and processes
are able to keep pre-set tolerances. For this purpose there is a capability analysis, which distinguishes between
Machine capability investigations and
Process capability investigations.

Machine capability investigations only inspect the short-term behavior of a machine or a system. E. g. at new or
repaired machines it serves as a proof of the capability to keep the pre-set tolerances.
Process capability investigations investigate the long-term behavior of a process and consider the process with all
its influencing variables (e. g. man, machine, methods, material, environmental conditions).
On the assumption that the process is stable and continuously generates units with a N(,s2)-allocated quality
characteristic X, an inadequate machine or process capability can be the result of he fact that:
The process spread s is, in comparison to the tolerance To - Tu too large.
The process level (average) is too far away from the center (To + Tu)/2 of the tolerance interval.
To = upper tolerance limit
Tu = lower tolerance limit
At both capability analysis, a spread index and a level index are the evaluation criteria. The level index characterizes
the position of the process average within the tolerance interval between the upper and the lower limit value (To ;
Tu). The process average should be adjusted to the set value, so that statistical spreads in the production result
dont lead to an exceeding of the tolerance limits. The spread index describes the spread of the process in
comparison to the breadth of the tolerance interval. Ideal is a process spread, which is small compared to this
value, because in this case the possibility of characteristic values outside of the tolerance is also small.
Process capability
The process capability is a measure for the long-term characteristic spread, which is caused by all influence values
of a production process.
For the process capability, the following measures are used:
Spread index cp (capability process)
Level index cpk
The larger cp , the larger the length of the tolerance range in comparison with the process spread. Thus, this is a
good result.
For a capable process, often cp < 3/4, d h. To-Tu>8 s is required. Already in an interval with the length 6s, which is
centered around the set value, approx. 99.74% of all results are at a N(, s2) - allocated random variable. The
minimum requirement Cp = 1 means that the 6S-spread range of the process fills out the tolerance interval
completely. In this case, an average of 0.27% of the characteristic values are outside of the tolerance. For "ideal"
processes, in general Cp > 1.33 is required. This equals a tolerance utilization of less than 75%.

37
Picture: rejection parts and the respective cp

cpk is a third of the smaller of the two distances of the production level to the two tolerance limits, measured in sunits. The larger the cpk-value, the more favorable the influence to the process.
The above calculations are only valid, if production level and production spread s are known a priori and do not
change in their time history; especially (t) = 0 is assumed.
The Cp or Cpk is determined as follows:

38

The following picture shows, which process capability parameters result from individual process spreads and
positions of the averages.
Machine capability
At the machine capability, only the machine-related influences to the production process are investigated. Other
process-influencing variables, e.g. environment influences must be kept constant for the test.
For the machine capability, the following measures are used:
Spread index cm (capability machine)
and the level index cmk.

39

40
3.2.6.7.
Trend indication
After calling the trend indication, the following picture appears:
Selected test step
Adjustment of the lower scaling

limit
Lower tolerance limit
Change between linear or
logarithmic display
Upper Tolerance limit

Adjustment of the upper scaling
limit
It shows trend graphics of the selected test step. The test step was selected via mouse click in the preceding mask.

button.
41
3.2.6.8.
Distribution indication
After calling the distribution indication, the following picture appears:
Selected test step
Lower tolerance limit
In this example all measure

results are 3% larger than the
set value.
Upper tolerance limit
It shows the distribution graphics of the selected test step. The test step was selected via mouse click in the
preceding mask.
At test steps with a set value and a surrounding +- tolerance on the left side, the picture always refers to the
deviation to the set value. Therefore the vertical axis in the middle is indicated with 0%. This equals 0% deviation
from the set value (i.e. exactly the set value). Upwards the measured values were smaller, downwards they were
greater that the set value. The percentage value indicates by how many percent they have been off the set value.
At test steps with a limit value that must not be exceeded or fallen below, the picture refers to the limit value on
the left side. Therefore the vertical axis is not scaled in percent but in the unit that is to be indicated (e.g. in Ohm).
3.2.7.
button.
Command: Detect reference curve
This command will only appear and is only necessary at surge testers.
In case, at the surge test, the test result was go, this command can be called. All detected surge curves are
automatically averaged with the already existing references to a new reference curve. This takes place
automatically per surge test step.
This way it is possible to generate an average of the reference curves from various stators, without having to
execute them individually per test step.
3.2.8.
Command: Enable processing

42
At testers with the release of the input of set values via the key symbol it is also possible to use the command
Enable processing. This command also activates the release of the processing.

43

3.2.9.
Command: Export measure results
(only for motor testers)
Serves to release manually a data storage of the current measure values in Excel. This is also possible if the
preceding test was cancelled and the data export didnt take place automatically. At this export it is also possible to
enter, whether the complete measure value table or only an excerpt (every x. measure value) is to be transmitted.
3.2.10. Command: Compare measure curves

(only for motor testers)
This function serves for restoring the measure curves generated in the Excel forms. Up to 10 individual test results
can be indicated at the same time.
The following indications are necessary:
used configuration, this gives you the position of the stored data in the Excel form
which data are indicated on the X-axis (torque, rotational speed, etc.)
which data are indicated on the Y-axis (rotational speed, torque, etc.)
resolution of the X-axis

44
3.3.
Main command: set values
With the set value commands, the person who does the setting-up has the possibility to determine the complete
test program.
In the following list you might find some commands that are not included in your tester. The reason for this is that
for example your tester doesnt have the according hardware configuration.
For example the command for the resistance test doesnt appear if the tester is not equipped with a resistance test.
We hope you will understand that it is not possible for us to make a programming manual for every single tester.
Our testers can be combined out of a great variety of hardware and software configurations. You have also the
possibility to configure the tester yourself. This programming manual is therefore a universal manual for all possible
applications.
The basic proceedings for the input of set is described in the chapter: "Changing set values or entering new ones"
3.3.1.
Command: General parameters
The essential input here is the type name of the test object.
Below please find a list of the various inputs:
3.3.1.1.
Type
Under the type name, which can be a text of up to 40 digits, the test object is stored in the database. By entering
this name, the test object can later be searched for and loaded.
Please note:
If the type name of a loaded test object is changed, the other set values stay the same. Thus you have the very
helpful possibility to load an already existing test program, which is similar to the one that is to be newly
generated, and re-load it under a new name.
3.3.1.2.
Programmer
Here the name of the programmer can be entered. However, this is relevant for the function of the tester.

45
3.3.1.3.
Further inputs for the motor tester
Connection
Indicates, which kind of supply is active for the test object. In the indicated example, there is a selection between
Mains supply and External supply.
Motor definition
(only applies to motor testers)
The Motor definition is the connection between test program and motor data. I.e. it is possible to generate
individual test programs for the same motor.
(see chapter Define motor parameters)
Configuration
Here it is determined, which data configuration (measure value recording and data storage) is to be used for the
current test program.

46
3.3.2.
Command: User messages
Test notes are notes or working instructions, which the user has to execute before the beginning of the test.
In this explanation, e.g. the instructions for the re-setting of a test station to a new type or test process is
indicated.
These processes can here be entered in the form of any text with several lines.
After loading a new type out of the database, the test notes appear once on the screen.
Control character
It is also possible to enter control commands into the helping texts.

In case the helping text is to be divided into various individual notes that are to be worked on in a sequence, the
control command "#" needs to be put in.
Owing to the control command, the operator can only see the notes after pressing the button.
With the above example this would be as follows:
Adaptor 3 needs to be installed.
Please wait until the button has been activated. Now the following note appears:
Now the rotation field probe needs to be pushed onto the upper limit spot.
Please wait until the button has been activated, etc. ....
In the framework of ISO 9000ff, the testing notes are an important aid, because it is possible to enter type-related
working instructions in the tester.
When the testing notes are to appear, must be determined in the Setup of the tester.
Siehe hierzu Setup Select options
index card Display

option When are the testing notes to be displayed?.
47
3.3.3.
Command: Visual check
Visual test steps serve for the visual examination of the test object. They are part of the test program, however,
they do not run off automatically.
Display during definition:
Display during test process:
The following data needs to be entered:

3.3.3.1.
Name
The name is the most important input of a test step. Although maybe set values have been entered, the test step
will not be executed if no name has been put in.
The name therefore serves as activation of the individual test step.
During the test, the name appears as headline of the test window.
For the name, a text of up to 40 digits is entered. During the test, this text also appears as the name of the test
step on the screen.
3.3.3.2.
Text field
In this test field you can enter any text. Via the button Font it is possible to change the form of this text

48
3.3.3.3.
Program
The input field "Program" is necessary in case special switch functions are to be executed. Since this is usually not
the case, this input is omitted.
3.3.3.4.
Picture file
In addition to a text display (or instead of a text display), it is possible to indicate a graphic. This photograph or
drawing is for example read in at a PC with a scanner and stored in the form of a file. This file should be copied
onto the hard disk of the testing device into the sub-directory c:\Schleich\Bilder\ .
Here the name of the file is to be entered. As an alternative it is possible to open a file-selection window via the
neighbouring button "...".
The file can be existant as BMP-, JPG-, or GIF-format.
3.3.3.5.
Show additional input line
After selecting this option, an additional input line will become active, which allows the operator to make a note of
additional measure values.
Attention: Only numerical values will be stored, possible units and other inputs will be ignored.
After activating the option "additional input line", a further input field will appear. The text that is entered here, will
appear during the test as an explanation of the additional input line.

49

3.3.4.
Command: Earth wire test
The following data can be entered:

3.3.4.1.
Name
The name is the most important input of a test step. If no name is entered, even if maybe set values have been
entered, the test step will not be executed.
I.e. the name serves as complete activation of the individual test step.
For the name a text of up to 40 digits is entered. During the test, this text also appears on the screen as the name
of the test object.
3.3.4.2.
Upper limit value
During the earth wire test, a maximum resistance of the earth wire must not be exceeded.
3.3.4.3.
Cancel
In case a fault has been detected at the test object in a test step, it might sometimes be sensible to cancel further
testing. In order to cancel, please set the check mark in the respective check box.
3.3.4.4.
Test time
The measuring time in seconds indicates, for how long the test current is to flow through the earth wire before the
resistance measuring takes place. If, during the test, the lower limit of the necessary test current is fallen below,
the earth wire test will be interrupted as "no go".
3.3.4.5.
Test current (as option)
Here you need to select the test current. If this selection does not appear, the testing device has only one current
for the earthe wire test (e.g. 10A).
3.3.4.6.
Lenght of lead
Here you need to enter the length of the mains lead to the test object. This way the resistance of the lead will be
considered for the test.
3.3.4.7.
Connection for test probe
Here you select, whether the PE test probe at the front of the testing device will be used (manual scanning of PE
test points). If the PE test probe is set to "back", the connection for the test probe is at the connection plug HA10.
3.3.4.8.
Test connection
The input "Test connection" determines, whether the test object is connected at the front socket or via the
connection "HA10" at the back of the device or via the additional device.
At testing devices with a switch matrix or switch-over it is , with this input, also possible to determine at which test
connections the test is to take place.
3.3.4.9.
Test message
It is possible to show a message before every test. The test will be stopped at this point and it will be waited for a
reaction of the operator.
3.3.4.10.
Picture file
In addition to the text display it is possible to indicate a graphic. This photograph or drawing is read in at a PC with
a scanner and stored in the form of a file. This file should be copied onto the hard disk of the testing device into the
sub-directory "c:\Schleich\Bilder\" .
Here the name of the file must be entered. The file can be existent as BMP-, JPG-, or GIF-format.
If no picture file name is entered, only the help message appears.
3.3.4.11.
With repair
In case of certain types of faults, it is possible to repair the test object directly at the place where it is tested. In
case a single repair attempt is to be allowed, "j" for yes needs to be entered. In case of a fault at the test object,
the repair message will appear on the screen. After the repair, the test step will be repeated. In case the fault still
exists, a second repair is not possible.

50
3.3.4.12.
Reaction time (as option)
If there are several PE-points, the reaction time makes sure that, the operator does not (e.g. for reasons of
convecience) leave the test probe on one PE-point. Owing to the reaction time, a certain time period runs off after
a test step. Only after this time period, the next PE-point can be scanned.
3.3.4.13.
Start type
The start type determins in which way the PE test process is to be started.
If the setting is at "0", the start takes place via the switch in the PE test probe.
If the setting is at "1", the start takes place via the switch in the PE test probe or via contacting the PE-point that is
to be tested with the test pin. Here a minor release current is used as continuity test to the PE-point. If the current
starts to flow via contact, the test current will automatically be increased to 10A and the actual PE-test starts.
Attention: in order to be able to use this function, in Options : Settings of the tester the selection with Start via
PE-touch must be activated.

51
3.3.5.
Command: Insulation resistance test

3.3.5.1.
Name
For the name a text of up to 40 digits is entered. During the test this text appears on the screen also as the name
of the test object.
3.3.5.2.
Lower limit value
During the insulation resistance test, a pre-set resistance must not be fallen below. The input of the resistance is
done in Megohm.
3.3.5.3.
Cancel
testing. In order to cancel in case of "no go", please set the check mark inside the respective check box.
3.3.5.4.
Test time
The measuring time in seconds indicates, for how long the test current is to flow through the earth wire before the
resistance measuring takes place.
3.3.5.5.
Test voltage
This input appears in case the tester has different test voltages for the insulation resistance test (e.g. 500V and
1000V).
3.3.5.6.
Test connection (as option)
At testers with a switch matrix or switch-over it can be determined with this input, at which test connections the
test is to be done.
At testers with a switch matrix, both test connection 1 and test connection 2 exist. They indicate the connection
points between which the test voltage is to be connected.
3.3.5.7.
Test type
Here you select, whether the insulation resistance is to be measured between L, N or L/N to the PE.
3.3.5.8.
Test with test probe
At devices of protection class 2 (no protective conductor) it is also possible to determine the insulation resistance.
The PE test probe is used for this. The test probe needs to be held to conductive case parts inside the test object.
3.3.5.9.
Test message
3.3.5.10.
Picture file
Here the name of the file must be entered. The file can be existant as BMP-, JPG-, or GIF-format.
3.3.5.11.
With repair (as option)
3.3.5.12.
Repair message (as option)
In case a repair is allowed, a repair message can be entered here. If there is a repair to be done, this message
might facilitate the search for the fault.
3.3.5.13.
Additional outputs

52

This input determines, whether freely switchable additional outputs are to be activated in the test step. (for
meaning and function see chapter on additional outputs.) If nothing is entered, all relays are switched-off.
In order to switch on for example relay 2, a 2 needs to be entered. It is also possible to switch on several relays at
the same time. In order to switch on the relays 1, 3 and 7, enter 1, 3 and 7.
3.3.6.
Command: Leakage current test

3.3.6.1.
Name
For the name a text of up to 40 digits is entered. During the test this text appears on the screen also as the name
of the test object.
3.3.6.2.
max. leakage current
During the leakage current test, a pre-set current must not be exceeded. The input of the current is done in mA.
3.3.6.3.
Voltage
The input "Voltage" determines the test voltage. For the leakage current test it is usually 10% over the nominal
voltage. In most cases thus "253V" needs to be entered.
3.3.6.4.
Test type
The input "connection" determines which connection type is to be used. It can be choosen between the cold and the
warm leakage current test and between different contactings.
3.3.6.5.
Norm (as option)
At testers that can do the leakage current test according to various standards, this input determines according to
which standard the tests are to be done.
3.3.6.6.
Starting time
The starting time in seconds indicates, for how long the test voltage is to be connected to the test object before the
leakage current test takes place.
3.3.6.7.
Measuring time
The starting time in seconds indicates, for how long the leakage current is to be tested. As measure result, the
max. measured current measured within this time appears.
3.3.6.8.
Test probe
At devices of protection class 2 (no protective conductor) it is also possible to measure the leakage current via the
PE test probe. The test probe needs to be held to conductive case parts inside the test object.
3.3.6.9.
Switch off
This control box must be activated in case a further leakage current test step (or function test step) is to take place
afgter this leakage current test step and the test voltage at the test object is not to be switched off.
3.3.6.10.
case a single repair attempt is to be allowed, "1" for yes needs to be entered. In case of a fault at the test object,
3.3.6.11.

53
3.3.6.12.
Additional outputs (as option)
3.3.6.13.
Test message
3.3.6.14.
Picture file
3.3.6.15.
Cancel
testing. In order to cancel in case of "no go", please set the check mark inside the respective check box.

54

3.3.7.
3.3.7.1.
Command: Resistance test

Principal informations
The picture shows a resistance Rx and 2 test probes. The test probes have 2 contact tips each, which are insulated against each
other. Thus the resistance Rx has 4 connection points altogether.
At the 4-wire resistance measurement (also called Kelvin measurement), the contact resistance at the contact point
between the test probes and the test object is compensated, because the contact tip touches the test object with
two separate contacts.
One contact serves for supplying the test current into the resistance and the other contact serves to pick off the
voltage drop at the test object. Since the contact resistance for the test current transfer is behind the pick-off of
the voltage droop, it doesnt influence the measuring of the voltage drop.
The pre-condition of the measurement of the voltage drop is, however, a high-resistance voltage tester. Through
this, the contact resistance at the contact point for the voltage test is, expressed in percentages, in comparison to
the resistance of the voltage meter, completely irrelevant.
This method is always applied if very small resistances (below approx. 1) are to be measured. This applies to
measurements at motors of greater power and thus low-resistance winding resistances.
If it is possible to execute the contacting of the test object in 4-wire configuration only with great effort, it will still
make sense to have the supply leads going to the test object in 4-wire configuration. This way, the test result will
not be influenced by the length of the test leads and by indeterminable contact resistances in the testing device
(e.g. relays).

55
The picture shows the individual resistances real circuit. Resistance 1 and 4 are the contact resistances at the
contact points of the connections for the current. Resistance 2 and 3 are the contact resistances in the voltage
measuring circle.
You can see clearly that at the voltage drop test at resistance Rx, the resistances 1 and 4 dont have any effect. As
described above, the interior resistance of the voltage meter must be very high in relation to the resistances 2 and
3, so that no major measure error occurs.
For connecting the test object in 4-wire configuration, SCHLEICH offers a variety of contacting devices.
Below please find pictures of Kelvin clamps for connecting wires and bolts and Kelvin test probes for testing
armatures.
4-wire resistance with Kelvin clamps
4-wire resistance with special probes

56
3.3.7.2.
Resistance test at an armature
Since at armatures more than one coil resistance is measured, the resistance test is difficult.
At an armature with 8 lamellas, the picture gives you a simplified impression

of the problem. Each lamella has a contact resistance to the winding the socalled welding resistance. This resistance is created at the welding point (or
soldering point, squeezing point between winding and lamella). The actual
winding is connected to the welding resistance.
If you now measure the resistance between two adjacent lamellas, you will get
a measure value coming from 2 (sometimes even unequal welding
resistances) and the coil between the two lamellas and the remaining parallel
winding parallel.
The tester thus does not directly show only one coil resistance, but
always the combinations of resistances.
When comparing the resistances between the lamellas, for the relative
comparison of the values, however, this is not very important.
Except if the individual coils have varying winding numbers or there is
an equalizing winding.
For comparing the resistances it is thus absolutely necessary to be
familiar with the design of the winding. If not, it is possible that wrong conclusions are drawn from the test results.
Another measure error can be that it is assumed that the resistance between 2 lamellas is half as large as
between the 1st and the 3rd lamella, etc. The schematics below are supposed to explain this mistake. For
better understanding it is assumed that the coil resistance is 1 Ohm and the welding resistance is 0 Ohm.
Rmeas=0.875
Rmeas=1.5
Rmeas=2
It can be seen clearly that, owing to the series connection and the parallel connection
of the winding components the correlation doubled distance of lamellas = doubled resistance doesnt exist.
3.3.7.3.
Name

57

For the name a text of up to 40 digits is entered. During the test, this text appears on the screen also as the name
of the test object.
3.3.7.4.
Test type (as option)
The parameter "Test type" determines wheter, in this test step, the measured resistance is to be compared to the
nominal value or whether the last 3 resistance test steps are to be compared amongst themselves. The variation
range results from the deviation of the resistance values amongst themselves. The largest deviation is detected
and evaluated.
3.3.7.5.
Nominal resistance
The nominal resistance indicates, which resistance is to be measured at the test object.
3.3.7.6.
Variation range (normally only for stators and motors)
The variation range is a tolerance indication in per cent. It presents the greatest allowed deviation between the 3
resistances measured before.
The determination of the variation range is a mathematical process based on the individual resistance tests
executed before.
This tolerance indication is normally smaller than the + tolerance or the tolerance.
3.3.7.7.
Upper / lower limit value
Within a pre-settable tolerance range, the measure result may deviate from the set value. The upper and lower
limit can be pre-set as a numerical value.
If the limit value is entered, the tester automatically calculates the tolerance in per cent.
3.3.7.8.
+/- %-Tolerance
The tolerances can also be entered in %-values. After the input of the %-values, the computer automatically
detects the according numerical values.
If the %-tolerance is entered, the tester automatically calculates the limit value.
3.3.7.9.
Cancel
testing. In order to cancel in case of "no go", please set the check mark in the respective check box.
3.3.7.10.
Stabilization time
The waiting time is set in seconds and serves for stabilizing the measuring current before it is used for the
calculation of the resistance. Especially at inductive test objects, the connected current needs a time T, to reach its
end value (DC).
We should like to point out that the waiting time runs off before the current is measured. Zero is allowed because
the system has non-adjustable fixed times in its sequential programme. Times over one second are also not
necessary, because the measuring process is programmed in a way that the measuring current is not interrupted
during the whole test. Therefore strong variations of the measuring current and thus interfering inductive influences
are minimised. Owing to this fact, even measuring times of 0 seconds are possible. In practice, zero seconds are at
least 10 ms, the chatter time of the relays.
3.3.7.11.
Test connection (as option)
At testers with a switch matrix or switch-over it can be determined with this input, at which test connections the
test is to be done.
3.3.7.12.
Test message

58
3.3.7.13.
Picture file
Here the name of the file must be entered. The file can be existent as BMP-, JPG-, or GIF-format.
3.3.7.14.
Error code (as option)
If this test step becomes "no go" (bad), it is possible to show and error code.
3.3.7.15.
3.3.7.16.
3.3.7.17.
3.3.7.18.
Mode (at armature testers)
Under the main command Set values/Resistance test, the set values for both coil resistances and welding
resistances are pre-set. The system, however, measures both resistances at the same time, so that the welding
resistance is more or less a mathematical waste product of the actual resistance test. At the latest upon the
evaluation of the resistances it must be known, whether it is a coil resistance or a welding resistance. This is
specified by the entry field Mode:
0 = measure armature resistance
1 = measure welding resistance

59

3.3.8.
3.3.8.1.
Command: High voltage test

Principal informations
Electrical motors are usually highly capacitive. The highest capacity is between the winding and the frame. There is
also a smaller capacity between the windings.
You can basically say: the larger the motor, the larger the capacity.
Depending on between which points it is currently tested, the capacities are loaded, during
the test, to the level of the test voltage. At the high voltage test with AC, especially the
high capacities of the motors result in a high test current, which consists of the capacitive
current and the current through the insulation resistance.
At the high voltage test with DC, the capacitive current is only important for connecting or
adjusting the test voltage. After the capacitor has been charged, only the usually very low
current flows through the insulation resistance.
During the test it is

charged also. This
and the frame could
Especially for PTCcould damage theses
possible that parts, which are not involved in the test, are
means that for example a ground short circuit test between U
charge the other components to a certain extent, also.
resistors and KTY-sensors this could be critical. The charging
sensors.
Before testing, the

with each other. If
leads of these sensors therefore always need to be shorted

necessary, they can also be directly connected to the casing.

60
ATTENTION! After the test, the test object therefore must be discharged in all parts. Otherwise, the
operator could suffer an electric shock when touching the test object.
ATTENTION! Touching the measure leads and the tester at the same time, could also cause a weak
(but harmless) discharge. Although the measure leads are insulated, their insulation resistance is
limited. The operator could charge and discharge, also.
Tester

61

Further detailed information on the high voltage test
Theoretically, the high voltage test is thus executed at an RC element. The RC element is the idealized form of the
conditions at the test object.
Why?
The test object has an insulation resistance between the two test points: the resistance Riso. With some 100Mohm
and more, this resistance is usually very high. In addition, the test object has a capacity between the two test
points. This capacity develops either between the windings to be tested or from winding to frame. Between the
windings it is usually smaller than from winding to frame. Capacities are produced between insulated metal
surfaces. The larger the surface or the shorter the distance of the metal surfaces, the larger the capacity. In stators,
the windings are one surface and the casing is the other surface. Large stators have large surfaces and thus large
capacities.
If the high voltage test is executed with AC, a high capacitive recharge current is flowing in the stator (RC element).
Very often, this capacitive recharge current is much higher than the leakage current through the ohmic resistance
Riso (being extremely high-ohmic). I.e., owing to the capacitor the continuously flowing recharge current, at the
high voltage test with AC through the capacitor, strongly overlaps the fault current that is actually to be tested with
the resistance.
The capacitive recharge current is no fault current, but a current based on physical laws. It is always existent and is
no quality characteristic of a stator. Certainly, the current must not be too high, but is gives no reliable information
about the quality of the insulation.
Via the high voltage test with DC (direct voltage), the recharge current can be avoided. Weak fault effects there
become more evident.
The schematics of the insulation system of the motor (see below) serves for a better understanding of the
conditions at the insulation resistance test. On the left side of the schematics, you can see a sketch of the motor.
The motor consists of windings and the insulation system to the casing. The schematics of the insulation system
consist of a resistance and a capacitor. As described above, the capacity derives form the physical and mechanical
conditions at the motor. The resistance, which is within a range of several 100 MegaOhms, is an indicator of the
insulation quality.

Riso
62

In case of manual adjustment, the high voltage is manually adjusted to a pre-set value.
In case of automatic adjustment, the adjustment of the high voltage value is done by the tester.
The automatic adjustment also allows the adjusting of various high voltage values via ramps of varying steepness.
According to the design, various inputs are necessary.

3.3.8.2.
Name
of the test object.
3.3.8.3.
AC/DC (as option)
At devices with switch-over between direct and alternating voltage, you can here switch over.
3.3.8.4.
Transformer (as option)
Some devices with manual high voltage test have two high voltage transformers. With this parameter you can
switch over between them.
3.3.8.5.
Voltage
Here the high voltage value needs to be entered, which is connected to the test object during the test. At devices
with automatic high voltage adjustment, this is the voltage at the end of the ramp
3.3.8.6.
Ramp time (as option)
At the automatic high voltage adjustment, the high voltage is set within the ramp times entered here.
3.3.8.7.
Test time
The test time determines, how long the voltage is to be connected to the test object. During this time, there must
be no disruptive breakdown at the test object.
3.3.8.8.
Measure delay
This input determines after which time period the current is to be evaluated (on exceeding the upper current limit).
This input might be helpful in case the test object has, at the beginning, a short current impulse upon connecting
the test voltage, which is not to be evaluated.
3.3.8.9.
Test
Indicates, between which connection it is to be tested.
3.3.8.10.
Test connection 1 / 2 (as option)
At testing devices with a switch matrix or switch-over this input determines, between which test connections the
test is to be done.
3.3.8.11.
Feedback control 1 / 2 (as option)
At testing devices with a switch matrix or switch-over and a high voltage feedback control, these inputs determine,
between which test connections the high voltage feed control is supposed to take place.
3.3.8.12.
Spot check (as option)
The spot check determines, after how many test objects the test is to be done with high voltage. If "1" is entered,
the test is done at every test object; if for example "10" is entered, the test is done at every 10th test object.

63
3.3.8.13.
Min. current (as option)
In order to ascertain, whether the test object has been contacted properly, it is possible to enter a minimum current
via the input "Min. current". If this current is not reached during the test, it is assumed that the test object was not
connected properly and the respective message will be indicated.
At devices with electronic ramp, "Min. current" refers to the ramp time.
3.3.8.14.
Max. current
Upon the application of the high voltage value to the test object, the maximum current (Imax) must not be
exceeded, otherwise there is a disruptive breakdown.
At a high voltage test with max. 3mA through a resistance current limitation, it must be made sure that the max.
current of 3mA only flows at 6000V (or at 3000V devices at 3000V). If the test voltage is for example half of the
maximum voltage of the device, the maximum current that may flow is only half of 3mA. Upon the input of the
breaking current for the breakdown recognition, this must absolutely be considered. In case of half test voltage it is
therefore not possible to enter a breaking current of e.g. 2mA, because this current, also in case of full high voltage
short circuit, can not flow.
max. Strom bei 3000V

Gerten
max. Strom bei 6000V

Gerten
6000V
6000V
5000V
5000V
4000V
4000V
3000V
3000V
2000V
2000V
1000V
1000V
Strom
Strom
0,5mA
1mA
1,5mA
2mA
2,5mA
3mA
0,5mA 1mA
1,5mA
2mA
2,5mA 3mA
Devices with electronic ramp require the input on "Max. current 1" and "Max. current 2". "Max. current 1" indicates
the maximum current during the high voltage ramp; "Max. current 2" indicates the maximum current after the
ramp.
The additional paramter "Time Current 1" determines the time at which it is changed between the limit value "Max.
current 1" and "Max. current 2". It should be somewhat longer than the ramp time.
3.3.8.15.
This input determines, whether freely switchable additional outputs are to be activated in the test step. (For
3.3.8.16.
Capacity
At the high voltage test with electronic ramp, the capacity of the test object can be pre-set. The influence on the
adjusting parameters of the high voltage source is that the regulation is optimised. In relation to the test object,
with this parameter you can set, whether more stress is layed on a fast increase of the voltage or on a low
overswing. A higher value leads to a larger edge steppness, but also to a larger overswing of the voltage.
3.3.8.17.
Error code (as option)
If this test step is "no go" (bad), it is possible to indicate an error code. This a special function, which is only set at
the factory.
3.3.8.18.
Test message

64
3.3.8.19.
Picture file
3.3.8.20.
Cancel

65
3.3.9.
Command: Continuity test
The continuity test serves for doing a rough resistance test at the test object. It does not serve for an accurate
determination of resistances - it is only a rough check (e.g. whether there is a short circuit at the test object).
The evaluation depends on the type of assessment.
In order to test whether there is a short circuit at the test object, the assessment needs to be set to "larger than set
value".
If the resistance value is fallen below, the following function test (current consumption or power) will not be
executed any more.
The continuity test is not very accurate. Its main purpose is to evaluate a resistance. It also needs to be taken into
consideration that the continuity test is done with AC.
3.3.9.1.
Name
of the test object.
3.3.9.2.
Evaluation
With the evaluation you determine, how the measured resistance is evaluated in comparison to the pre-setting.
3.3.9.3.
Continuity resistance
The set value indicates, which continuity resistance is to be measured between the connections of the test object.
3.3.9.4.
+/- %-tolerance
Maximum +/- deviation from the pre-set value in percent.
3.3.9.5.
Cancel
3.3.9.6.
Test time
This waiting time is indicated in seconds and serves for stabilizing the measure current. After this time has run off,
the resistance is determined.
3.3.9.7.
Test connection 1 / 2 (as option)
At testing devices with a switch matrix or switch-over with this input it can be determined, at which test connections
the test is to be done.
3.3.9.8.
3.3.9.9.
Test message
3.3.9.10.
Picture file
In addition to the text display, it is possible to indicate a graphic. This photograph or drawing is read in at a PC with

66
3.3.10. Command: Function test

With the current consumption test (function test) it is possible to detect current consumptions, powers etc. at the
test object.
3.3.10.1.
Name
of the test object.
3.3.10.2.
Test type
The test type determines, what is to be evaluated in this test step. It is possible to choose between current,
apparent power, active power and power factor. Depending on the structure of the tester, here also further modes
can be found.
3.3.10.3.
Current consumption
The set value indicates, which current is to be measured at the test object. The value only needs to be entered if
the test type is set to current measurement.
3.3.10.4.
Apparent power
The set value indicates, which power is to be measured at the test object. The value only needs to be entered if the
test type is set to apparent power.
3.3.10.5.
Active power
The set value indicates, which power is to be measured at the test object. The value only needs to be entered if the
test type is set to active power.
3.3.10.6.
CosPhi
The set value indicates, which power factor is to be measured at the test object. The value only needs to be
entered if the test type is set to power factor.
3.3.10.7.
Upper / lower limit
Within a pre-settable tolerance range, the measure result may deviate from the set value. The upper and lower
limit can be pre-set as a numerical value.
3.3.10.8.
+/- %-tolerance
detects the respective numerical values.
3.3.10.9.
Cancel
3.3.10.10.
AC/DC (as option)
As standard, the test object is only operated with alternating voltage. As an option, a switch-over to direct voltage
is available. In this case, the paramter AC/DC determines, which supply voltage is to be connected to the test
object.
3.3.10.11.
Starting voltage
Here you need to enter the voltage, that the funciton test is to be done with.
3.3.10.12.
Starting time
The parameter "starting time" determines, how long it is to be waited before the measuring takes place.
3.3.10.13.
Test voltage
Here you need to enter the voltage, that the function test is to be done with.
3.3.10.14.
Waiting time

67

The paramter "waiting time" indicates, how long the actual measuring is to take. The starting time is thus followed
by the measuring time.
3.3.10.15.
Correction (as option)
By means of the correction indication it is possible to compensate net voltage fluctuations that affect the current
consumption.
Upon testing, the current consumption is usually related to the voltage. That means that a decreased voltage leads
to a decreased current and vice versa.
With correction option, the voltage deviation form the set value can be corrected mathematically. This will lead to a
correction of the measured current by the percentage of the voltage deviation. The measure result is thus independ
from net voltage fluctuations.
The following 3 inputs are possible
N: no correction
*: standard correction
The current consumption is corrected by the ratio of the voltage difference between
set voltage and actual voltage.
/: inverse correction
This correction is necessary for detecting the correct current at the electronic control gear
of lamps, which automatically increases the current in case of voltage decreases,
in order to keep the luminosity constant.
3.3.10.16.
Test message
3.3.10.17.
Picture file
3.3.10.18.
case a single repair attempt is to be allowed, "1" for yes needs to be entered. In case of a fault at the test object,
3.3.10.19.
3.3.10.20.
3.3.10.21.
Rotational speed (min)
Minimum rotational speed at a test object in rounds per minute.
3.3.10.22.
Rotational speed (max)
Maximum rotational speed at a test object in rounds per minute.
3.3.10.23.
Sense of rotation
Sense of rotation at the test object (left or right).

68
3.3.11. Command: Mechanical tests

With the mechanical test it is possible to measure mechanical dimensions at a test object with a calliper gauge at
various positions of the test object.
3.3.11.1.
Name
of the test object.
3.3.11.2.
Set value
The parameter "set value" indicates, which measure value is to be measured with the calliper.
3.3.11.3.
+/- %-tolerance
detects the respective numerical values.
3.3.11.4.
Cancel
3.3.11.5.
Calliper number
Since up to two callipers can be connected to the tester, here you need to enter the number of the calliper that is
to be used for this test step.
3.3.11.6.
Test message
3.3.11.7.
3.3.11.8.
3.3.11.9.
Spot check (as option)
Here you can enter, how often the test is to be done. 1 means at every test object, 2 means at every second test
object, etc...

69
3.3.12. Command: Rotary field test

The rotary field test serves to determine the sense of rotation of a stator. To do so an adjustable voltage is
connected to the desired test connections. This voltage can be either 3-phase alternating voltage or 1-phase
alternating voltage. By means of a rotary field probe, the alternating field that is generated in the stator is
measured and evaluated.
3.3.12.1.
Name
For the name a text of up to 40 digits is entered. Later this text appears during the test in the list of all test steps
that are to run off in a test program. Thus this input field serves on one hand as an indication, which test step has
been executed and on the other hand it is an indication for the controlling program that this step must be
executed.
3.3.12.2.
Voltage
Here the desired voltage is set, which will be used for the rotary field test. Normally even small voltages are
sufficient for the accurate measuring of a rotary field. The electronics inside the rotary field probes are sensitive
enough to detect even minor field intensities. In order to find out whether a voltage is sufficient, it is possible to
insert the probe at various points of the stator, and it is necessary that always the same sense of rotation is
indicated. If a rotary field is not recognized, neither right nor left appears in the column "actual value" of the test
process. In this case, the voltage needs to be increased. A possibly too high voltage can be recognized by too high a
deflection of the built-in ammeter. Not every tester has an ammeter. There are also testers, where the current is
measured and evaluated. In this case, a minimum current is additionally pre-set. This way the tester can check,
whether enough current is flowing during the test.
Attention
The voltage may only be set to a maximum level at which the total current of the device is not exceeded. The
standard maximum allowed current is 6A.
3.3.12.3.
Sense of rotation
For the sense of rotation only two indications are possible:
1 = right
2 = left
The indication of the set sense of rotation has nothing to do with the actual sense of rotation of the completely
assembled motor. It is only the sense of rotation as the rotary field probe presently recognizes it. The sense of
rotation depends on three factors: a) the sense of rotation of the test object, b) the sense of rotation of the
incoming supply voltage of the complete service cabinet and c) the position of the rotary field probe (at the front or
at the back). Since b) and c) do not change, a desired sense of rotation for a) can be pre-set, which all test objects
of the same type need to have.
3.3.12.4.
Rotary field
Here it is entered at which test connections the voltage for the rotary field probe is to be connected. Basically there
is
3-phase and 1-phase alternating voltage. All 3-phase voltages are abbreviated with DS (Drehstrom = rotary
current) and all 1-phase voltages with WS (Wechselstrom = alternating current). Other than for example at the
resistance test, the voltage can, however, not be connected to any test leads. A combination: L1 to lead 1, L2 to
lead 4 and L3 to lead 9 is thus not possible. Only one of the 6 suggested combinations is possible. These
combinations are numbered and have the meaning:

70
DSP1000 with 3 test connections

3-phase stators
DS1
phase L1
1
phase L2
2
phase L3
3
main winding
1
auxiliary winding
2
zero / neutral
3
phase L2
2
5
phase L3
3
6
zero / neutral
-
1-phase stators
WS1

3-phase stators
DS1
DS2
phase L1
1
4
zero / neutral
-
Please note: If the second rotary field is not programmed, the test connections 4, 5, 6 are connected in order to
connect possibly existing ends of windings to a star point.
1-phase stators
WS1
WS2
main winding
1
4
auxiliary winding
2
5
zero / neutral
3
6
phase L2
2
5
8
phase L3
3
6
9

3-phase stators
DS1
DS2
2DS1 (option)
phase L1
1
4
7
zero / neutral
-
Please note: If the second rotary field is not programmed, the test connections 4, 5, 6 are connected in order to
connect possibly existing ends of windings to a star point.
1-phase stators
WS1
WS2
main winding
1
4
auxiliary winding
2
5
zero / neutral
3
6
phase L2
2
5
8
11
phase L3
3
6
9
12

3- phase stators
DS1
DS2
2DS1 (option)
2DS2 (option)
phase L1
1
4
7
10
zero / neutral
-
Please note: If the second rotary field is not programmed, the test connections 4, 5, 6 and 10, 11, 12 are connected
in order to connect possibly existing ends of windings to a star point.
1-phase stators
WS1
WS2
3.3.12.5.
main winding
1
4
auxiliary winding
2
5
zero / neutral
3
6
Cancel

71

3.3.13. Command: Insulation resistance test with the surge tester

This test is only included in stator testers. Explanations can be found in the separate manual "Surge test".
3.3.14. Command: Surge test

This test is only included in stator testers. Explanations can be found in the separate manual "Surge test".

72
3.3.15. Command: Analog test

The analog test serves for detecting external measure values, i.e. measure values that are not detected within the
device. During this test, the testing device detects the voltage that is connected to the external measure inputs
within a pre-settable time period.
In order to be able to do an analog test, it is first necessary to parameterize the external measure inputs (see
7.2.11, Harware parameters analog test). Within these settings you determine once, which measure value is to be
detected, which unti must be used etc.
After selecting the command "Analog test", the following input window appears:
3.3.15.1.
Name
of the test object.
3.3.15.2.
Set value
The parameter "set value" indicates, which measure value is to be expected.
3.3.15.3.
+/- Tolerance
The measure result may deviate from the set value within a pre-settable tolerance range. The upper and lower
tolerance can be pre-set as %-value.
3.3.15.4.
Measure channel
The parameter "Measure channel" is the number of the hardware parameter set, that is to be used for the
measuring in this test step.
3.3.15.5.
Evaluation
The setting "Evaluation" determines, whether, within the measuring time, the minimum, the maximum or the
average of the measure signal is to be detected.
3.3.15.6.
Voltage
If the paramter "Voltage" is entered, during the analog test, the function voltage of the level indicated here is
connected to the test object. If a voltage value of "0" is entered, the function voltage will not be switched on.
3.3.15.7.
Waiting time
The parameter "Waiting time" determines the minimum time period that must run off before the test.

73
3.3.15.8.
Measure time
The "Measure time" determines the time window in which the measure value recording is done. Within this time
period, according to the parameter "Evaluation", either the maximum, the minimum or the average of the input
value is determined.
3.3.15.9.
Test message
3.3.15.10.
Picture file
3.3.15.11.
Cancel
testing. In order to cancel, please enter "1" for yes. The pre-setting is "0" for no.
1 = continue to test, even in case of "no go"
0 = cancel in case of "no go"

74
3.3.16. Command: Define motor parameters

Here you can enter numerous details of the respective motor. After every test, these details are transmitted,
together with the current measure data, into an Excel form (see also chapter: Setup -> Setup data storage). This
Excel form contains the name indicated under File. If this file already exists, an additional index (_1, _2, ...) is
added to the file. This makes sure, that already existing measure values of a series of tests that has already been
executed are not deleted.
Via the alphanumerical Motor protocol number the motor can be clearly identified.
File indicates the name of the file in which the results are stored. Double clicking this text field opens a file
selection dialog, in which the file or the respective directory is selected.
Please note:
It is always necessary to enter the motor protocol number and the file! All the other inputs are only used in the
output protocol and are not relevant for the function of the program.
Activating the button New type generates an empty form, into which the respective inputs need to be entered.
The button Close closes the input window and takes the inputs over to the main window.

75
3.3.17. Command: Setup motor test

In this configuration window, the configuration of measure devices that are to be used is determined. The following
settings exist:
Configuration
Under configuration, the name of the current configuration is indicated. After entering a new name, the currently
displayed configuration is copied.
Delete
Via the button Delete, the currently indicated configuration can be deleted out of the database.
The table below shows a relation between a channel identification, the measure hardware (measure device) and the
indication of the measure value. The following indications are necessary:
No.
Continuous number of the measure value (in the picture above, 10 are indicated).
Definition
The definitions of the respective measure value can be chosen freely. If the definition is deleted, the measurement
of this measure value is deactivated (deleted).
Function
If the measure value is not only to be displayed, but also to be processed within the program, here the respective
allocation can be done. The following table shows an overview of the available functions:
Function
N
M
I1, Idc
I2, I3, Ieff,
Iwinding
U1, Udc
U2, U3
P1 total
P2 total
Eta total
Temp1...4
Meaning
Rotational speed; this measure value is processed as rotational speed measure value
Torque, this measure value is processed as torque measure value
Current; this measure value is processed as current measure value
Reserved, still without relevance
Voltage; this measure value is processed as voltage measure value
Electric power; this measure value indicates the absorbed active power
Mechanic power; this measure value indicates the released power
Efficiency; this measure value indicates the efficiency
Temperatures that are monitored, whether they exceed the parameter Max. Temperature

76
Color
The definition Color indicates, in which color the curve on the screen is to be indicated.
Device
Via the definition Device it is set, which measure device is to be used for the measure value acceptance of this
measure value. The inputs at this point depend on the hardware configuration.
Channel
In the next column, the channel number of the measure value need to be entered. In most cases, a 0 is entered
here. Only at multiple-channel devices (Zimmer LMG310, HP34970) the number of the respective measure channel
needs to be entered.
Measure value
The setting Measure value determines, which value is to be read out of the respective measure device. The inputs
in the list below depend on the respective measure device. Of great importance is the Device Calculate value.
Measure values, which are allocated to this Device, are calculated on other measure values within the program.
The following settings are available:
Bedeutung
Measure
value
P1 total
The electric power is to be calculated. For this purpose either the measure values are used that
have U1 und I1 entered as function or those that have Udc and Idc .
P2
The mechanic power is to be calculated out of the measure values that have n und M.
Eta total
The efficiency is to be calculated out of the measure values that have P1 gesamt und P2
gesamt.
P1 motor,
Eta motor
Measure range
The column Measure range opens a channel selection depending on the selected measure channel and on the
measure device. At some devices, via a suitable selection of the measure range, an optimizing of the measurement
can be done. In case of doubt, AUTO for the auto range function of the device is to be entered.
Z, S
The indications Z and S indicate line and column in the excel form, where the result storage of this measure value
is to be done. The line is the one where the respective unit of the measure value is stored. The actual measure
values appear in the following lines.
Please note:
The time indications automatically take place in the first column, without an explicit indication being necessary.
...
Double clicking these three dots ... opens a window for setting the type of display of the measure value:
In the upper half of this window it is possible to define a correcting function for the measure value. This way it is
possible to calculate every measure value with a factor and an offset. In addition, it is possible to pre-set a different
basic unit. It is thus for example possible, to calculate and display a current out of the voltage drop at a measure
shunt.

77

In order to be able to use these correction factors, firs a suitable definition must be pre-set in the upper list. This
way it is possible to use this correction function in several measure configurations. In the indicated example with
the measure shunt this has the effect that upon adjusting this shunt it is only necessary to change a factor once in
order to make a change for all configurations.
In the lower part of the window you can set, which display areas are used for the measure values. The respective
basic unit needs to be entered in the line in the middle. In the displayed window, all torques up to 1000 Ncm are
calculated with the factor 1 and displayed with 1-4 decimal places before the comma and one decimal place after
the comma.
The format is identic to the formats used in Excel.
3.3.18. Command: Define cycle

At the display of a characteristic of a motor in curve-form (see below) it is possible to activate a cycle operation. It
is possible to repeat a process of individual straining types is a cycle. Various straining types and the respective
setting values and times can be entered. They are stored under a joint definition and can be selected in the test
method Characteristic of a motor in curve-form.
New
Via the button New, a new cycle can be generated.
Delete
The button Delete deletes the currently indicated cycle.
Close
The button Close closes the window.
Search for
In case of a great number of individual cycle definitions, the search for the desired cycle can be done faster by
entering several digits in Search for. In the menu shown under Selection, only those cycles appear that contain
the indicated digits.
Cycles
The cycles are processed in the table below. In the first column you can select between Switched off, Rotational
speed, Torque, Current und Power. The empty input at the first point of the list serves for deleting this
charging point.

78
3.3.19. Command: Characteristic of a motor in curve-form

For the display of the characteristic of a motor in curve-form at a motor tester, further details are necessary, which
need to be entered in the form above. This form is a supplement of the details stored under General data.
3.3.19.1.
Dynamometer
Selection of the dynamometer to be used (if several dynamometers can be connected to the tester). The respective
details are described in chapter Setup -> Setup Dynamometer.
3.3.19.2.
Voltage
Indication of the voltage that the test is to be done with. If a regulating transformer is used, this is automatically
adjusted. At devices without regulating transformer, this value is only used for internal calculations.
3.3.19.3.
Test method
The test method indicates, which charging type is to be used for the detection of the characteristics curve. At the
moment, it is possible to choose between Rotational speed, Torque, Current, Power and Cycle.
3.3.19.4.
Rotational speed
In the operating mode Rotational speed, starting with a rotational speed Rotational speed 1 in pre-settable
steps Step size, a characteristics curve is detected. The input Holding time determines, how much time the
motor has in every step for settling.
3.3.19.5.
Torque
In the operating mode Torque, starting with a starting torque Torque 1 up to a final moment Torque 2 in presettable steps Step size, a characteristics curve is detected. The input Holding time determines, how much time
the motor has in every step for settling.
3.3.19.6.
Current
In the operating mode Current, beginning with a starting current Current 1 up to a final current value Current
2 in pre-settable steps Step size, a characteristics curve is detected. The input Holding time determines, how
much time the motor has in every step for settling. Via the parameters described below (P, I und D), the
settling conditions can be optimized.
3.3.19.7.
Power
Beginning with the starting power Power 1 up to a final power value Power 2 in adjustable steps, in the
operating mode Power a characteristic curve is taken. The input Holding time determines, how much time the
motor has in every step for settling. Via the below described parameters P, I and D the settling behavior can
be optimized.
3.3.19.8.
Cycle
In the operating mode Cycle a freely adjustable load cycle can be run (see Set values -> Define cycle). It is
possible to determine cycles that consist of a row of load points of the types switched off, Rotational speed,
Torque, Current and Power, all with individual load levels (set values).
The operating mode Cycle also produces the effect that in the main window below the graphics the current
conditions of the cycle run are indicated. These are: the Cycle number, which counts the cycle runs, the Cycle

79

index, which refers to the load step within a cycle and a button End of cycle. Activating this button ends the test
as soon as the current cycle has been finished.
3.3.19.9.
P-, I-, D-regulating parameter
For the motor test, the tester has three independent PID control loops. Thus, also three independent sets of P-, Iand D-parameters exist.
The control loops are:
Rotational speed control loop n
Torque control loop M
Current and power control loop
The rotational speed control loop and the torque control loop are directly controlled by the dynamometer Magtrol
DSP6000. The respective parameters are indicated in the tool bar of the test program. This display can be switched
over between rotational speed and torque parameter display via the option buttons n and M.
The test program automatically synchronizes them with the parameters currently activated in the Magtrol
DSP6000.
In addition to these parameters, a third PID parameter set exists, which is used for the regulation of current and
power. This parameter set is also indicated in the window Manual mode, as soon as current or power control has
been selected.
3.3.19.10.
Max. current, max. torque, max. rotational speed, max. temperature
These parameters serve for initializing an automatic switch-off of the test as soon as one of these parameters is
exceeded during the test process. In order for these parameters to be effective, it is necessary that for the
respective measure value in the configuration window Setup motor test (see above) the matching allocation has
been made under Function. E.g. for the rotational speed measure value the function n must be selected or for a
temperature measure value the function Temp1.
However, the parameter Max. rotational speed has a second function. The input 0 has the effect that the
rotational speed is no longer monitored as to whether the test object is at rest. Only after this it is possible to
uncouple the test object from the brake and execute a measurement of the electrical values and the temperatures
also without it.
3.3.19.11.
Test message
Before every test, a test message can be indicated. In this case, the test will be stopped at this point and it will be
waited for a reaction of the operator.
3.3.19.12.
Picture file
In addition to the test message, a graphic display can be indicated. This photograph or drawing is read in with a
scanner at a PC and stored in the form of a file. After this, the file needs to be stored onto the hard disk of the
tester into the sub-directory C:\Schleich\Bilder\.
Here the name of the file needs to be entered. The file can have a BMP-, JPG-, or GIF-format. If no picture file name
is entered, only the test message appears.
3.3.19.13.
Starting time
The parameter Starting time determines the duration of the waiting until the test takes place.
3.3.19.14.
Total test time
This input is only relevant for cycle operation. The parameter Total test time indicates, how long the duration of
the actual measurement after the starting time is to be. After this time period, the completion message will be
given.
3.3.19.15.
Number of cycles
This input is only relevant for cycle operation. It indicates after how many runs of the loading cycle indicated under
Cycle the test is to be automatically ended. The input 0 has the effect that the cycle runs can only be ended
manually. This is done via the button End of cycle in the main window. This button is only indicated in cycle
operation.
3.3.19.16.
Completion message
This message is indicated as soon as the total test time in the cycle mode has run off. This is to inform the operator
that the requested number of load cycles has been completed and the operator can now end the test via activating
the button End of cycle (see Cycle).
3.3.19.17.
Braking speed

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The braking speed determines the rotational speed to which the test object is to be braked after switching off.
3.3.19.18.
Braking time
The braking time determines the duration of time during which the test object is to be braked to the braking
speed after switching off.
3.3.19.19.
Activate manual mode
As soon as the control box Manual mode has been activated, a setup window appears during the active motor
test, in which the load parameters can be set to the run time. There is a selection list, where you can chose
between Rotational speed, Torque, Current and Power. In relation to this, the respective load parameter is
indicated, which can also be changed via the buttons Up and Down. As further setting value, the Holding time is
indicated, which indicates the rhythm of the measure value recording. Activating the button Start has the effect
that the entered load value is approached. The currently active parameters are indicated under Current regulating
values. These inputs thus only change after activating the button Start or the return button. Activating the button
Stop ends the measure value recording.
In the lower part of the window, a table with the last 15 measure values is indicated. The latest measure values are
found in the line at the top.
3.3.19.20.
Cancel total test if the result of the test is no go
If, in a test step, a fault has been detected at the test object, it can be helpful to cancel further testing. To cancel in
case of no go, please set the check mark in the respective check box.

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3.3.20. Command: Additional programs (option)
The additional programs serve for controlling external hardware within a test process. The individual programs act
as individual test steps, which are executed during the process of the program but do not deliver a test result.
Additional programs can have the following functions:
Switch on or off any outputs
Interrogate input conditions
Indicate text messages (message window)
Enter waiting times
At the moment, 10 individual additional programs can be defined. On request, they can be inserted into a test
process several times.
The additional programs are stored under an individual definitions. It is therefore possible to generate it only once
and insert it into different test programs.

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3.3.21. Command: Define test sequence

The test sequence can be defined both, dependent on the test method and individually and independent from the
test method.
Dependent on test method
1. all earth wire test steps
2. all insulation resistance test steps
etc.
Independent on test method
1. test step: Earth wire test
2. test step: Insulation resistance test
3. test step: Current consumption test
4. test step: Earth wire test
5. test step: Visual test
6. test step: Current consumption test
etc.
firm sequence
The test step sequence is automatically defined by the PC and cannot be changed.
Test methods
The test steps of one test method are summarized to one group.
After activating the button Test methods , the test methods (for which also set values were entered) are indicated in
the left column (Available test steps).
The test method that is to be executed first is marked and taken over to the right column by activating the button
Add > .
This removes the test method from the left column and it will appear on the first position of the right column.
Activating the button < Remove would remove the method from the sequence and it would again be listed in the
"Available test steps".
For inserting a test method into an existing sequence, please mark the position in the window "Test step sequence"
where the test method is to be inserted. In the window " Available test steps", now the test method that is to be
inserted can be marked and then inserted with the button Add > .

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Test steps
The test steps can be combined individually in random order.
After activating the button Test steps , the available test steps are indicated in the left window.
The test steps are listed with the definition from the set value input.
Apart from that, the proceedings for putting together a test sequence are like at the test methods.
Additional programs
The additional programs are of special importance (see above). In the setup Test steps they can be inserted into
the test step sequence several times. As soon as one or more additional program steps have been inserted into the
test step sequence, changing to the setup Test methods and Standard is disabled. This is necessary in order to
avoid deleting these test steps out of the programmed sequence by accident.

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3.3.22. Command: Label print-out

In this window, the settings for the label printer are done. For being able to use the label print-out, it is necessary
to use a special label printer (thermo transfer printer). It is not possible to print via a standard printer. After calling
the command "Edit label", the following picture will appear:
If a label is to be printed, it first needs to be generated with the program Create-A-Label. This program is part of
the delivery extent. It was not made by Messrs. Schleich; it was made by the supplier of the thermo transfer
printer. For the exact operation of the program, please see the attached operating manual.
After a label has been graphically generated with Create-A-Label, it is stored on the hard disk.
We recommend the storage in the following directory: c:\caltools\...
The file name of the stored label is entered in the tester program. For this input, please use the field Label File.
As soon as a test program is loaded out of the database later on, it will automatically be recognized that there is a
label print-out for this test program. In this case, the tester will automatically search for the name of the label file in
the respective directory and then transmit the label directly to the printer.
The printer will not print the label right away, because some inputs (variables) are still missing on the label. These
variables can be for example: type, date, name of operator, etc. The variables will not be transmitted to the printer
before the end of the test. As soon as the printer has received these variables, it enters them into the label, which it
has received before. Now the printout starts.
This technique has the advantage that it is not necessary to transmit the complete graphic label for every printout; this would take too much time. The graphic format of the label is only transmitted to the printer at the
beginning. After this, only the variables are transmitted to the printer and entered at the respective points of the
label.
The altogether up to 10 print variables are entered in the tester program. The number of the print variables must
exactly match the number of variables intended for the label. The tester program will only enable as many print
variables in the input (white background in the input field) as reserved on the label.
Attention: The number of the print variables and the number of the variables intended for the label
must absolutely be the same. It is also necessary that every field where an input can be made (white
background) contains a value.

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If one print variable is missing, the data will be transmitted to the printer after a test, however, the printer doesn't
print.
Explanation of the various buttons for the label input

OK
This button serves for ending the input for the label print-out.
Cancel
Activating this button interrupts the input without data acceptance.
Test print
This button enables the trial print-out of a label. As soon as the test print is activated, the tester
transmits the label file and the respective print variables to the printer and starts the test print.
Delete
Activating this button deletes all inputs for this label in the input window.
Create
After activating this button, the program Create-A-Label starts automatically. Now you can
generate the label graphically and store it. After ending the Create-A-Label program, you will be
back at the input of label data. Please note: in order that calling the Create-A-Label program works
correctly, the correct input must exist for the program call. You will find the input by clicking on the
following commands with the mouse:
Setup
Parameter (followed by password input "123")
Data bases
Path names
Additional
>> Label program
In the input field Label program the program call for the label program needs to be entered. This is
the standard input:
C:\Caltools\Caltools.exe.
If the path input for the program is not correct, there will be an error message and the Create-ALabel program will not be initiated.
Import
This is a solution made for customer's specification and should not be used.
Print invers
The label is turned by 180 degrees (so to say: printed head over)
Correction X
With this correction it is possible to move the label print-out within the label to the right. As
standard, "0" is entered here.
Correction Y
With this correction it is possible to move the label print-out within the label down. As standard, "0"
is entered here.

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For entering an input in an input field, you click on the desired field with the mouse.
Now a list opens, from which you select the input.
Some further information for generating a label:

As already mentioned above, a labeld created with the Create-A-Label program must have the input possibility for
print
variables. Later on, these print variables are filled with the respective information by the tester. After this, the
print-out
takes place.
After initiating Create-A-Label, you will see the following picture:
Attention: Please do not activate this button. Activating this button seems to end the program, however it is still
active in the background (task bar). This leads to an error.
In case the error appears again, the tester program needs to be ended first. After this, the Create-A-Label program
is clicked on in the Task bar and then closed properly.

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Below please find the example of a label. The fields marked with xx... are the print variables. At these points, the
tester will later on enter the actual value that is to be printed.
Text which is not entered

1. print variable
2. print variable
At the label, the print variables are counted continuously from the bottom to the top.
In order to define a print variable, the print variable needs to be clicked on with the right mouse button. Now select
the command Edit.
Then you will see the following picture:
For one print variable, now "Datenquelle" needs to be set to "Vor Ausdruck". Otherwise it will not be recognized as
a print variable.

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Attention: After the label has been generated and stored, it is absolutely necessary to generate a socalled command file of the label. Otherwise the tester cannot find this file and thus it cannot print it out
either.
Initiate the command Generate Command File.
The command file should be stored in the following directory: C:\Schleich\Label\....

Please note: the name of the file (of the label) is also the name that needs to be entered in the tester program at
the input Label file.
3.3.23. Command: New test program

The command New test program deletes all currently loaded test steps and set value inputs. After this a completely
new test program can be generated.
Test programs stored in the database will not be changed.

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3.4.
Main command: Setup
With sub-commands of the main command Setup, the person who does the setting-up has the possibility to
configure various features of the tester.
3.4.1.
Command: Manual mode
Some testing devices have a "Manual mode". If the testing device has for example automatic contact devices, it is
possible to do certain maintenance work via the "Manual mode".
3.4.2.
Command: On/Off display
With the function "On/Off display" it is possible to read-in and display the digital 24V inputs of the tester. The digital
outputs can additionally be set manually in order to check their functions.
The option "On/Off display" shows all on and off conditions of the tester in a compressed display.
End display
Show data of measuring board
also
The upper half of the screen shows all inputs; the lower half of the screen shows all outputs.
Inputs:
The inputs are listed exactly like in the connection diagram from E00 to E37. In case the input is in "0-condition",
the respective input is displayed in a gray field. In case of "1-condition", the respective input is displayed in a red
field.
Outputs:
Like the inputs, all outputs are listed in accordance to the connection diagram. Here too, the "0-condition" is
marked by a gray field and the "1-condition" is marked by a red field.
Attention: With the four arrow buttons, a rectangular colored cursor can be moved to an output. By activating the
Enter button, the output can be switched on and off.

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Attention
Caution: Via this option it is also possible to switch on relays that switch on voltages or measuring devices at the
test station.
The possibility to set outputs is very helpful in case of service. The service person should, however, always inform
himself about the according consequences by means of the connection diagram before switching on an output.
Measuring board:
Exactly like the digital inputs and outputs, the analog inputs and measuring channels can be displayed.

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3.4.3.
Command: Options
Via a great variety of parameters, the tester is configured. This refers to the databases, the hardware and various
basic settings.
The parameters should only be changed if absolutely necessary, because faulty inputs can lead to
malfunctions and, in the worst case, to faulty measurings.
In case of wrong inputs, faulty measurements can have the consequence that bad test objects are
indicated as go.
For the adjustment of the parameters, Schleich GmbH assumes no responsibility. In case of unsureness regarding
the adjustment, it is always better to ask a manufacturers technician .
With "Select options" the person who does the setting-up has the possibility to determine certain behaviors and
certain features of the test station.
Most inputs have been done in the factory and should only be changed by Schleich GmbH. Changes that
have been made carelessly can lead to major malfunctions of the tester.
The options should be changed very carefully, because faulty inputs can lead to malfunctions (e.g. data
storage has been switched off).
Since the input is very extensive, a window with various index cards opens up.
By clicking on the desired index card you can see its contents.

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3.4.3.1.
Command: Options - General information
When are the test messages to be indicated?

Here you can determine, when the messages described in chapter Set values Test messages are to appear.
In principle, it is possible to indicate no test messages. In this case, none of the options is activated. It is, of
course, also possible to indicate the test messages under certain conditions. Up to 3 options can be activated.
after switching on the tester
Explanation: the test message appears directly after switching on the tester. This draws the operators
attention to the test messages.
before starting a test
Explanation: the test message appears before a new test is started. In this case it appears every time at
the beginning of a test.
after loading a test program out of the database
Explanation: the test message appears directly after loading a new test program out of the database.
This is the standard application for the indication of the test messages. As soon as the operator changes
the test program, the respective messages appear to prepare the tester respectively for the new test.
Further settings
The display can be adapted via various options:
Enable programming mode via password
Explanation: Normally, the programming mode is activated via the key switch. If you desire, on top of
that, the possibility to enable the programming mode via a password, this option needs to be activated.
The password management can be found in the chapter User Management, where you can enter an
individual password for every user.
Switch off PC automatically after leaving the program
Explanation: as soon as the program is left, the PC switches of automatically (or shows a message that
the PC can be switched off).
In order to avoid undesired usage of the PC, this option should, if possible, always be activated.
Text messages
With this option it is possible to delete the pre-defined answers on text messages. The test program contains
several text messages with a switch Dont show message again. If this switch is activated, this message will not
be indicated at this point the next time. Instead, the question will always be answered as it was upon activating the
switch. If you have activated this switch by accident, these pre-defined answers can be deleted in the window
below via the button Delete. Now the respective messages are again indicated the next time.

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3.4.3.2.
Command Options - Display
Display options
The display can be adapted via various options:
Position the mouse pointer automatically
Explanation: after a button on the screen has been activated via the mouse, the mouse pointer normally
stays at this position after changing to a new screen. It could sometimes be helpful that the mouse
pointer directly jumps to a new button. This makes the working process a little bit faster. If you desire
this function, please activate this option. It takes a while to get used to this function.
Indicate all texts with text numbers
Explanation: the tester indicates all texts with a number. The number comes from the text file. This
display can be helpful in case of service.
Indicate measuring results after all tests have been completed
Explanation: If, in a time-critical process, the last 1/10 second is to be gained, the display of the
measuring values can be delayed until the end of all test steps. Only after this, the colored result points
per test step are indicated.
Show large result box (with option to repeat on 'no go')
Explanation: This option activates the large display of the result at the end of a test .
Automatic mode without error messages for 'no go' results
Explanation: Testers that are being used in automatic production lines are normally remote-controlled
by the control unit of the production line. In this case it would be unfavorable, if messages appeared on
the screen, which must be acknowledged. This option allows to disable error messages completely. The
operator doesnt need to acknowledge error messages and the automatic processes are not interrupted.

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Indicate order data in the status line

Explanation: in the status line on the screen, the loaded test program is indicated. It could also be
helpful that in addition to the loaded test program the name of the order is indicated also. If this is
desired, please activate this option. Now the status line contains both inputs together.
Symbol bar
Here you can determine the symbols that are to be indicated in the symbol bar upon testing.
The display of the symbol in the

symbol bar can be activated or
deactivated with the a check
mark
Double-clicking on the symbol that is to be changed opens the window for selecting the file. All symbols that are in
the sub-directory Graphic are listed.
Here you can select a symbol.
On the screen, two symbols per task are indicated. The reason for this:
The symbols on the left are indicated when the key switch [Test/Setup] is set to "Setup". The symbols on the right
are indicated when the switch is set to "Test".
Please note: where no check mark is set, no symbols will be indicated!

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3.4.3.3.
Command: Options - Tests
How is the test to be started?

Start test with start button at service cabinet
Explanation: the start button, e.g. on the front panel of the GLP3-2000 is activated.
Start test with start button on screen
Explanation: In the tool bar on the very left you will find the start symbol (triangle inside button)
Start test with button on coil probe
Explanation: this option is customer-specified.
Start test with button on heater probe
Explanation: this option is customer-specified
Start test with protection cover
Explanation: the test starts as soon as the safety contact at the protection hood is closed. Opposite to
the other starting methods, the test is interrupted immediately if the safety contact opens again.
Start test with dual-hand start
Explanation: the test starts as soon as the dual-hand start is activated. Opposite to the other starting
methods, the test is interrupted immediately if the dual-hand start opens again.
Start test with foot switch
Explanation: the test starts as soon as the foot switch is activated. Opposite to the other starting
methods, the test is interrupted immediately if the foot switch opens again.
Test methods
Repeat test, in case a protection device has triggered
Explanation: this option is activated, if e.g. after the protection cover has opened and then closed again,
the test process is to be continued.

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3.4.3.4.
Command: Options... - Tests - Set test methods
Most settings are made at the factory and should only be changed by Messrs Schleich. Uncareful
changes can lead to major malfunctions of the tester.
The adjustment and configuration of the test methods is done at the factory. This is the reason why the
configuration and setting is not described in detail. Below please find only some additional information
for some test methods, in order to adapt the test method respectively. Detailed information on the
configuration of the complete test program are not intended in this operating manual.
Test methods
Setting check marks in front of the individual test methods, activates or deactivates the software for the individual
tests. It doesnt make sense to activate test methods that are not included in the tester. If those test methods are
activated, this could even lead to malfunctions at the tester, because the program tries to activate certain
measuring devices (which do not exist).
General data
Here, the general data for the tester are configured. At this point, no further information are intended for this
operating manual.
Visual check
No further information are intended for this operating manual.
Mechanics
No further information are intended for this operating manual.

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Resistance
With ambient temperature sensor for resistance compensation
Activate this option, if the tester has an ambient temperature sensor, which measures the ambient air. On
the basis of the detected temperature, a measured copper resistance is converted to how it would be at 20
degrees Celsius.
With pyrometer for resistance compensation
Activate this option, if the tester has a pyrometer, that measures the temperature of the test object
contact-free. On the basis of the detected temperature, a measured copper resistance is converted to how
it would be at 20 degrees Celsius.
No resistance compensation
Activate this option, if the tester is to do no automatic temperature compensation.
with spread at the resistance test absolute instead of in percentage

Activate this option if the spread at the resistance test is to be calculated not in percentage but as an
absolute numerical value.
Disable functional test in case one coil resistance is too small
Explanation: this option is customer-specified.
The other settings at the resistance test are not to be adjusted.
Thermo element
At this point, no further information are intended for this operating manual.
Continuity
At this point, no further information are intended for this operating manual.
Function
Show continuous measurements
Explanation: if this option is activated, during a test that lasts over an extended time period, the measure
result will be indicated continuously. The display will take place at the actual value of the test step.
This can for example be used at a current measurement test step for being able to see the current already
at the starting time of a motor. The evaluation would not take place before the end of the starting phase.
Please note: the continuous display might slow the tester down a little bit.
Enable graphic display
Explanation: this is a customer-specified solution.
Compensation at voltage error switching
Explanation: this option serves for the compensation of a measure error at the voltage measuring. This
setting is done at the factory and must not be changed.
Current correction
Explanation: with the current correction it is possible, at fluctuating voltages, to correct the current to the
set voltage. This can be used especially well at ohmic consumers. This is explained by the following
example: If, for example, at a heating resistance the current consumption is measured at a voltage that is
somewhat to low, the current will be respectively to low. Via the current correction it is possible, via a
comparison between the set voltage and the actual voltage, to calculate the voltage deviation. With this
voltage deviation, it is possible to correct the current proportionally. That means, in case of a voltage that
is too small, the current is respectively calculated up or in case of a current that is too high, the current is
calculated down. This function can either be switched on or activated. At the activation it is possible to
choose between a proportional or an anti-proportional correction. The anti-proportional correction works in
a way that in case of a voltage that is too small it is not calculated up but also down and vice versa. This
function could possibly be used for lamps with electronic ballasts.
The other settings at the function test are not to be adjusted.

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High voltage
Explanation: At this point, no further information are intended for this operating manual.
The settings of the high voltage test should not be changed.
Insulation
Explanation: At this point, no further information are intended for this operating manual.
The settings of the high insulation test should not be changed.
Rotary field
Sense of rotation test with statistical signals
Explanation: For the sense of rotation test, normally a hall element probe is used. For some applications, a
rotating rotor is used. This rotating rotor turns as far as a left or right stop and activates a limit switch.
Under these circumstances, this option needs to be activated.
Disable sense of rotation test, if other test results are no go
Explanation: if any other test was already no go, the sense of rotation test can be deactivated. This can
make sense, if e.g. the high voltage test was no go. In this case it is often of no use, to connect a rotary
field voltage to the test object.
Limit voltage set value in relation to the resistance set values
Explanation: at the rotary field test, a rotary field (three-phase mains normally between 0-150V
steplessly adjustable or fixed voltage of 30V) is connected to the test object. At a rotary field test with a
regulating transformer adjusted via software, it is possible (if there is too high a voltage) that upon
adjusting a new type there is an extremely high current. This should be avoided. Via the software it is, in
addition, possible to install a plausibility check, so that in case of small resistance values only small voltage
values are pre-settable for the rotary field test. Thus the tester automatically changes, in relation to the
resistance set values, the voltage set values in a way that no currents are flowing that are too high. (This
function is, of course, only interesting, if also the rotary field test is executed with a regulating variable
transformer. However, the test is often executed with a fixed-ratio transformer, where no over currents can
occur.)
Surge voltage
Explanation: The settings of the insulation test should not be changed.
3.4.3.5.
Command: Options... - Tests - Compile test programs
The complete tester is internally controlled with special macro programs. We can adapt these macro programs
customer-specified to the testing task. In some cases, this is done by the customer. (This would apply to 1 out of
100 users.) This is the reason why the macro programs are not explained in this operating manual, because they
would exceed the normal operating features of the tester. For the test process, the macro programs are required in
a compiled version. Therefore it is necessary to activate this command, if changes have been made at the macro
programs. The tester will search all changes of the macro programs and compile them.

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3.4.3.6.
Command: Options - Test results
Which test results are to be stored?

Only 'no go' actual values
Only 'go' actual values
Store all (acknowledge if 'no go')
Store all (without acknowledgement)
Don't store
Input order data
At start of test
Via main menu
After loading a test sequence
No order numbers
With shift numbers
Explanation: as soon as this option is activated, the shift number will additionally be automatically be
requested upon the order input. This shift number will also be stored in the database. Upon a statistical
evaluation, it is also possible to do an evaluation on the shift number.

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Activate customer administration

Explanation: as soon as this option is activated, the customer number will also be automatically be
requested upon the order input. Thus the order will be allocated to a customer. At a later print-out, the
customer incl. address etc. will also be printed out.
As soon as this option is activated, there will be two further commands activated in the main menu
Database.
In order to be able to enter customers during the input of an order, they first need to be entered into
the customer database.

101
Define order data

All order data can be defined as desired. The order data are usually interrogated after loading a new test program.
In case you do not wish to use an order data administration, this can be de-activated without problems. For this
purpose it is the best, to make no inputs at the order data. In this case the tester recognizes automatically that no
order data inquiry is desired. The following picture shows the window for the input of order data. Here you can
enter up to 10 individual order data inquiries. As soon as one or more inquiries have been defined, the respective
window for the order inquiry appears upon changing the test program.
Via the order input you configure, which inputs the operator has to do upon generating an order.
Altogether, up to 10 inputs can be made. If you configure only one or two inputs, the operator will only be
requested to enter one or two inputs.
The possible inputs are numbered from 1 - 10. An input consists of the following components:
Identification
Upon entering the order, the identification text later appears left of the input window.
Help text
This help text will appear when the mouse pointer is held over the input field.
Index
As soon as an order input is to take place, it is necessary to enter a j at the index.
Barcode
If this order input value is to be done via barcode, here a 1 needs to be entered, otherwise a 0 needs to
be entered.
from
If the barcode also includes other information, here you can enter, from where the first digit in the barcode
is to be read in.
to
If the barcode also includes other information, here you can enter, where the last digit in the barcode is
that is to be read in.
Input format
If desired, it is possible to influence the input format of the input. It is defined via a random combination of
the following signs:
*
random sequence of signs
?
individual sign
#
individual number
Example: the input ###??? determines that the order input at this point is to consist of 3 numbers and 3
further signs.
After you have received the tester, it is very important to do the configuration of the order input first.
Not before doing this, you should start with the normal operation of the tester. Should the order input be
re-configured later on, this could result in partial data losses of the results and orders already stored.

102
Below please find a screenshot of the order input and the respective inquiry.
Depending on the number of order inputs, the respective number of inquiries will appear upon the order input 1, 2
... 10.

103
In addition to the order data, it is here also possible to select the customer. In this example, the option
With shift number is activated, also (see above). Therefore, the shift number is requested to be entered at
this point.
In order to print an order, the statistics need to be opened. Here you select "Which order is to be searched
for?" and enter the order.
Now the button Print order must be activated.

104
The order is now printed with the name of the customer and with your company name. If the name of your
company is to appear, it must have been entered.
Further options storage of actual values?

Auto serial no.
Explanation: the serial number is to be generated automatically. Beginning at a starting value, the
number is continuously counted upward.
See Setup Parameter main command Additional
command Serial numbers.
Inquire serial number before every test
Explanation: the serial number is inquired from the operator before the test. The serial number is
entered via keyboard or via barcode.
With barcode scan.
Explanation: the serial number is read in via barcode. Opposite to the previous option, the reading-in
takes place in the "background". That means that no input window opens up on the screen and the
barcode can always be read in. As soon as the tester receives a barcode from the barcode scanner, it
will be evaluated. In automatic lines it is thus for example possible to read in the barcode from devices
that are passing by.
Clear counter on every new order
Explanation: as soon as a new order is generated, the counter contents that have been reached until
then ('go' and 'no go' counter will be re-set to "0")
Delete error counter at type change
Explanation: as soon as a new test program is read in, the counter contents that have been reached
until then ('go' and 'no go' counter will be re-set to "0")
Explanation: the serial number is the number, that the test object is individually marked with (e.g. a number that
is continuously counting up).

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Define device number
With this command it is possible to configure the generator for serial numbers in a very flexible way.
The serial number is an individual number that is found on every test object. There are 2 possibilities to allocate
this serial number:
1.
The serial number is allocated from a central place in your factory. In this case the device is, for example as
barcode, already on your label. In order to be able to clearly allocate the test results later on to this device
(test object), it is sensible to read in the device number from your label and store it together with the test
results in the database.
2.
The device number is allocated by the tester. It is possible to equip the tester with a label printer. As soon as
the test result is OK, a label is printed. In order to be able to allocate the test results individually to this
device, it is possible to print the serial number onto the label. The kind of generating the continuous serial
number is determined with this command.
The following description refers to this facility of allocating the serial number.
Start
The serial number begins with a start number, which is usually "1". From here, the serial number starts to
count up. The continuous counting can be done infinitely, or, e.g. after completing an order, start again with
"1".
Reset
The continuous serial number can, e.g. before starting a new order, be reset to the starting value.
Alignment
The serial number can consist of various particulars (see below - "Format"). If, for example, 6 digits are
reserved for the number, but the present serial number has only 2 digits, you can determine, how the
present serial number is to be inserted into the 6-digit space. You can choose between right-aligned or leftaligned.

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Fill characters
With the above described alignment of the serial number, there might be blanks. These blanks are filled
with the fill characters.
Example: 6-digit reservation - 2-digit serial number (e.g. 13) - right-aligned - Fill sign = 0
-> result: 000013
Example: 6-digit reservation - 2-digit serial number (e.g. 13) - left-aligned - Fill sign = 0
-> result: 130000
This would surely be bad, because it would lead to an incorrect numbering!
Example: 6-digit reservation - 2-digit serial number (e.g. 13) - left-aligned - Fill sign = -> result: 13--- count GO results only
The device number counter only goes to the next number in case of a go result.
Tester number
Here you enter the number of the testing device that is also to appear in the serial number on the label.
This can for example be the number of the location.
By entering something completely different here (e.g. a factory code), this input can of course also be used
for another purpose.
Date back-to-front (coded)
If the number printed on the label is supposed to include the date of the test, you can here determine,
whether the date is to be printed back-to-front. That means, the date would not be printed Day-Month-Year
but Year-Month-Day. The 4 digits within the year would also be printed back-to-front. 1999 would be 9991.
Format
Here you can enter the combination of the serial number. The above screenshot shows an input of
DDMMYYSSSSSSPPPP.
This would mean that for the continuous serial number counter 6 digits are reserved. The date is in front of
the serial number, which is followed by the tester number.
Present serial number
Here you can see the present serial number.

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Determine barcode structure

The type of the test object and the device number are more and more often scanned in via barcode. The barcode
often consists of many specific criteria. It is possible that the barcode itself contains further information. In this case
it makes sense that it is possible to define the barcode into various parts. This input window serves for defining the
barcode. The minimum and maximum length serve to determine, how many digits the barcode has. This input
serves to check the plausibility of the barcode. Barcodes which are too long or too short, will be eliminated
automatically. The input Start serial number determines the position in the barcode, from where the serial number
starts. The input Length device number determines, how long the device number in the barcode is. The input
Start test type determines at which point in the barcode the type of the test object is defined. The input Length
test type determines, how long the indication of the test object is.

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3.4.3.7.
Command: Options - Language
The test station can be operated with different languages. Choosing the according flag activates the language, if
existing. After a different language has been chosen it is necessary, however, to leave the programme and restart
it; only by doing this a complete change-over is possible.
Only the languages that are installed are activated.

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3.4.3.8.
Command: Options - Print
Print test results

Print all 'go' test results
Explanation: either a test document is printed out or the latest test in an overview
Print all 'no go' test results
Explanation: print-out only in case of "no go"
Print error report on standard printer
Explanation: this is a report of the occurred no gos of the latest production.
Printer selection
Print-out of all test results on built-in panel printer DATAMEGA
Explanation: print-out on strip printer with serial interface
Print-out of all test results on roll printer
Explanation: print-out of test results on roll printer.
Print-out of all test results on standard printer
Explanation: the standard printer is the standard printer defined under Windows. In order to be able to
print
it is therefore necessary that a printer is installed and defined as standard under Windows. Otherwise
there
will be an error message.
In case the printer has not yet been defined, please activate the command Printer set-up... .
Print-out of all test results with external program
Explanation: the external program can be for example Word. With this function the data are transmitted
to Word.
Command line
Here you enter the command that is executed upon the print-out via an external program, in order to start
the exernal program.
No print-out of test results on the standard printer

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Printer set-up...
Now, it is possible to configure the printer accordingly. The diplay depends on the printer installed. For the
description, please refer to the manual of the printer.

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3.4.3.9.
Command: Options - Label Printing
The indicated data are just global standard. Via the menu point Set values / label printing you can define the
details of label printing for the respective test program.
Print label if results are 'go'

Explanation: in case of 'go' there will be a print-out on the activated printer.
Print label if results are 'no go'
Explanation: in case of 'no go' there will be a print-out on the activated printer. This sticker might help the
person who does the repair in finding the error.
Eltron/Zebra & Create-A-Label
Explanation: this option needs to be activated, in case an Eltron printer (now Zebra) with Create-A-Lable
software is used.
Zebra & BarTender/BarOne
Explanation: this option needs to be activated, if a zebra printer with the program BarTender or BarOne is
used.
Sato
Explanation: this option is applied, if a Sato label printer is used.
CAB
Explanation: this option is applied, if a CAB printer is used.
Number of labels
Explanation: here you determine, how many labels are to be printed automatically. The standard is 1. If 2
lables are needed (e.g. one label for the test object and one label for the shipping carton), a 2 needs to be
entered).
Printer port
Explanation: here you determine, via which PC-interface the printer is controlled. This is a configuration,
which is usually done at the factory and should, if possible, not be changed.

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3.4.3.10.
Command: Options - Data
Storage of files
The tester uses a great variety of databases. The tester needs the information at which point of the hard disk the
databases are. The tester also needs name of the respective database. Since a lot of databases are being used,
they are grouped together on various index cards.
For every database that is being used, the respective complete path name is necessary. It is also indicated,
whether the database is activated.
Since the tester can also be operated in a network, it needs to be determined (in case of network operation), what
the name of the database in the network is. Therefore there is also a network database path name for every
database pathname.
On principle, the databases are all stored in the directory C:\Schleich\Dblib\ . The only exception are the result
databases, which are stored in the directory C:\Schleich\Archiv\ .
The same structure should be used for the network. The only difference will be a different letter for the drive.

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Process filing
Set values
The set value database contains the test programs.
Set value database

The set value database contains all test programs.
Resistance database
The resistance database contains the resistance values for special test programs. These resistance values
are not determined in the test program, but every time transmitted externally via network. This is a
customer-specified solution.
With a test program, where the resistances are pre-set externally, it is thus possible to test a great number
of different stators.
Resistance table
The resistance database contains the resistance values for special test programs. These resistance values
are not determined in the test program, but every time transmitted externally via network. This is a
customer-specified solution.
In an intermediate step, the tester generates the resistance database out of the resistance table that exists
in text form.
If the local name of the database is different than the name in the network, the following
process takes place: Directly after switching on the tester, the tester copies the database from
the network into the tester. The tester now continues to work with the database where the
check mark for "Active" is set.
Network synchronization
Dies die Sollwertdatenbank gilt allerdings nicht, wenn die Funktion Automatischer Datenabgleich aktiviert ist. In
this case, only those data records from the network database that are newer than the respective local data records
are copied into the local database.
Database connection string
The connection to an SQL server is defined via the database connection string. For this purpose, the SQL server
needs to be prepared accordingly. In SQL mode, all data (test programs, order data, test results) are stored in a
database.

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Actual values
Since large quantities of data slow the tester down, the actual values are stored in a daily or monthly file. Upon
change of day or month, the tester automatically generates a new empty database. As empty database, the tester
uses the empty source database.
It is re-copied to become the new target database. It receives a clearly allocated name.
Actual value database (Source)

Upon generating a new actual value database, this source database is used as origin for the new target
database.
Actual value database (Target)
This database contains the test results of the individual tests.
The name for the actual value database is determined as follows:

Iyymmdd.mdb
Definition:
yy
mm
dd
year (2 digits)
month (2 digits)
days (2 digits)
If the local path of the database differs from the network definition, the following process
takes place: Directly after starting the test program, the tester copies the new test result
data, which are stored locally, into the network database. The tester now continues to work
with the database where the check mark for "Active" is set.
It is, therefore, recommended to store all data on the network right away. A time-consuming synchronization of the
result data when starting the program can thus be avoided. If the network should break down, the data would be
stored in the local path mentioned above. When restarting the program (if the network has stabilized), the data will
be synchronized with the network database.
Save test results in separate files
If the test results are to be managed not only in the database of the tester, but also in an external quality
management system (RQM system), please use the function Save test results in separate files. In addition to the
path for storing these data, it is necessary to define a batch file, which serves for transmitting the data to the RQM
system.

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Structure of the result databases
Stempel.mdb
I020902.mdb
I021001.mdb
I021103.mdb

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Orders
The tests that have been done can be allocated to certain orders. This not absolutely necessary. If you don't work
with an order input, the test results will only be stored in the daily or monthly database.
However, if later on evaluations are to be done related to an order, e.g. for a certain customer in the statistics, it
will be necessary to add a certain search criterion (the order) to the test results. The data entered for the orders
are stored in the order data base.
Address data of the customers can be stored in the customer database. They can be used when printing the test
results. This function is only available, if customer administration has been activated in the options of the test
results.

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Additional
User database
The user database contains the various users and passwords of the tester.
Label database
The label database contains the stored labels, which can for example be printed out via a thermo transfer
printer.
External program
An external program is a program generated by the user. After the test, with this program the user has the
possibility to do various tasks himself. This variant is suitable for users who can write their own programs
(XX.exe).
As additional information, the program initiation contains also the results. This way, the user can e.g.
release a print-out himself.
Label program
For the graphical generation of a label, a special program is necessary. This program is also installed on the
hard disk of the tester. In order to initiate the label program directly from the tester, here the path name
and the program name for initiating the program must be entered.
Label files
Defines the path, where the label forms are stored. The label forms are created with the label program (see
above).
Path for BVP files
For lamp testers, here the wiring information is indicated (Basisverdrahtungsplan = BVP = basic wiring
diagram).
Database Frequ.Drive Parameters
If the tester has a frequency converter, this input defines, in which database the data of the frequency
converter are to be stored.

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Documents
Database service programs

The tester uses the Access database structure. Access databases have the tendency to become quite large after
they have been used for a certain time. This can also happen if only a small quantity of data is stored. Only using
the database makes it grow larger. Databases of large size need more time for loading for example test programs.
It is therefore sensible to compress databases from time to time. At this point you can enter the time interval in
days between the automatically initiated compressing of data. After starting the tester, when a new compressing is
necessary, the tester will do the compressing automatically. The operator will see a message that the databases
are being compresses and that he has to wait a moment. In case of very large databases the compressing might
take several minutes.
Compress set value database ..
After a certain time, the databases in the tester increase in size. Access databases sometimes get larger
than necessary. It is therefore helpful to compress the databases in regular time intervalls. During the
compressing process also a repair process takes place automatically.

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Repair database ..
The compressing of the database normally only refers to the set value database. The tester consists of
various individual databases, which are all used during the test process. In case one of these databases is
defective, it is possible to selected, repaired and compressed the database with this command.

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Delete old set value data ..
Explanation: with this function it is possible to delete set values out of the set value database up to a
certain point in time. Attention! This function should only be used with utmost care, because the statistics
will be incorrect if set values are missing. In order to be able to draw the graphics related to a set value,
set values are necessary for the statistical calculation.
Therefore, this function should, if possible, not be used!
Further settings
Automatic compressing of the databases every ... X days
Explanation: as mentioned above it makes sense to compress and repair the set value databases in regular
time intervals. This can also be done automatically. In this case it is necessary to set the respective time
frame at the automatic compressing. It is for example possible to determine that all databases are
automatically checked, repaired and compressed every 100 days. Of course, the time frame can be much
shorter. However, some users prefer a longer time period, because the compressing process can take
several minutes.

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Set-up backup jobs

We strongly recommend to do backup jobs of the tester in regular intervals. Should the hard disk be defective, it
will later on be possible to read in this backup job. If no data backup exists in such cases all test programs will be
lost and need to be re-generated completely new. It would also be necessary to calibrate the tester completely
new, because the calibration values for the measure technique are also stored on the hard disk.
We therefore strongly recommend to do the data backup carefully and in regular intervals.
In order to facilitate the proceedings of data backups, the setter can determine, when data backups are to be done.
As soon as this date is reached, a message will appear on the screen, which informs you that a data backup needs
to be done.
In the tester there are databases that change permanently, databases that don't change often and there are also
calibration values that are only changed once a year. In order to save time, it is therefore not absolutely necessary
to save all data upon every data backup. For this reason it is possible to generate individual data back-up jobs that
only include certain files into a back-up job.
Number of back-up job

It is possible to generate up to 10 different data back-up jobs. By clicking on the respective button (1...10),
you can choose the back-up job.
Name of back-up job
The selected data back-up job (1...10) is given a name. It is thus for example possible to group only set
values, only actual values or only machine parameters together to one data back-up job.
Execution on (date)
It is also necessary to enter at which day the next data back-up is to take place. On this day the operator
will receive a message to inform him that a data back-up needs to be done.
Repeat after ... days
If the data back-up is to be repeated in regular intervals (this applies especially set value databases), you
can here enter after how many days after the latest back-up the next back-up is to take place.
Which files are to be saved?
To every data back-up job it is necessary to include the files that are to be saved.
You can either indicate a certain file or complete directories. In order to save the SETUP directory you
would need to enter C:\SCHLEICH\SETUP\*.*
Target drive for data back-up
The data back-up can be stored on various target drives. With the standard Windows help (at the lower left
of the screen) you can choose the respective drive. This can be e.g. the floppy drive, a ZIP drive or the

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hard disk. However, if you do a data back-up on the same hard disk that contains the original data, this
would be of no use.
Name of back-up file
After selecting the drive, the name of the back-up file needs to be entered, too.
Compress data
In case of large files, compressing the data makes sure that you don't need too many diskettes for the
back-up job. Especially in case of large databases, compressing is very effective. The size of the data can
be reduced from the original size to 5%.
Target drive exchangeable data carrier
Here you can determine, whether the data are to be stored onto an exchangeable data carrier, e.g. diskette
or a special ZIP diskette. An exchangeable data carrier is standard.
Format data carrier before saving
In case data carriers are used for the back-up, that have been used before, it is advisable to format the
data carrier before doing the back-up job automatically.
Also save all sub-directories
If this option is activated, it is also possible to save all sub-directories of the selected directory.
Files after Backup to Paper-Bin
It is possible that a data back-up is done, because there is not enough room on the hard disk. In this case
it can be sensible to delete for example result data bases that are already several years old from the hard
disk. In order to have the data available for possible future usage it is advisable to save theses result
databases before. If this option is activated, the saved files are automatically moved into the Paper-Bin,
which equals deleting the files. Please note: the files are, however, not deleted completely, because
Windows keeps them in the Paper-Bin. In order to create new space on the hard disk it is therefore
necessary to empty the Paper-Bin. (This is a standard Windows function - the operation is a pre-condition).
In case the data back-up has failed, it is possible to read the files out of the Paper-Bin and re-activate
them.

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3.4.3.11.
Command: Options - Test programs
Test plan configuration

Double station
Explanation: This option is activated, if the test station is a double test station. In this case it is possible to
load either individual or the same test programs for each test station.
with assignment plan (lot size)
Explanation: this option is activated, if within one test process various test objects of the same kind arre to
be tested one after the other. It is thus possible to test e.g. 4 motors of the same type one after the other
in one process, without having to load 4 individual test programs.
with head database (compounded test programs)
Explanation: with the head database it is possible to compound test programs to groups. This makes for
example sense, if there are lamps of individual mechanical designs, but they are to be tested with the same
test program.
In this case, the test program is only generated once and allocated to various articles.

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3.4.3.12.
Command: Options - Hardware
Hardware settings
with key switch Test / Program
Activate this option, if the tester has the key switch "Test / Program". This key switch disables input and
changing of test programs and set values.
with key switch Enable / Disable
Activate this option, if the tester has the key switch "Enable / Disable". This key switch disables the
complete tester.
Protection cover opens automatically
Activate this option, if the protection cover is to open automatically after the test.
Switch 'Open cover' stops the test process
Activate this option, if the tester has a protection cover that opens automatically. As soon as this switch is
activated during the test, the test process will be interrupted.

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Extended hardware configuration
I/O Definitionen ..
The tester avails of various digital outputs and inputs. Every output and every input has a number, which can also
be found in the schematics.
Since the tester has a very flexible structure, the individual outputs and inputs can be assigned to an activity
(function).
It is therefore possible that at one tester the 'go' lamp is assigned to output 100 and at another model to output
101.
In this table it is determined, at which connections the individual relays, valves etc. are connected.
Changes should only be made if absolutely necessary (in accordance with the manufacturer), because
faulty inputs can lead to malfunctions and, in the worst case, to damaging the tester.
Explanation:
This input determines, which hardware connections are connected to the respective software function. If, for
example, the go lamp is to be switched on, output 100 needs to be set. The settings of this clamp table are done
by the manufacturer and must under no circumstances be changed.

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Clamp assignment ...
A GLP3 testing device normally only puts 3 connection clamps for the test object at disposal: L, N and PE.
In this case, the clamp assignment is not so important.
However, there are testers that put 12 and more connections at disposal. In order to be able to indicate the
connection of the leads to the operator as clearly as possible, it is possible to define in form of a clamp assignment,
which clamp is to be connected to which connection lead of the test object.
This clamp assignment thus explains the function of the leads of the tester to the test object.
Especially the clamp assignment can vary to a great extent at stator testers. To ensure that the user can connect
the individual leads as easy as possible without the danger of mixing them up, this clamp assignment is very
flexible.
The clamps of a tester are always numbered beginning with 1. A tester with 6 winding connection clamps thus has
the clamp numbers: 1, 2, 3, 4, 5 and 6.
The easiest way to explain this is to use an example:
Task
A stator with 3 connection leads is to be connected.
The leads are marked U, V and W.
Lead U is to be connected to clamp 1, lead V is to be connected to clamp 2 and lead W is to be connected to
clamp 3.
Solution
In the table, the letter U can now be assigned to clamp No. 1, etc. The advantage is that later, upon the input of
the set values for the test step, the operator enters a U instead of clamp 1 at the test connection. Another major
advantage is that the operator directly sees on the screen which lead (namely U) is to be connected to the 1.
clamp.
This assignment 1 = U etc. drastically reduces connection errors by the operator.
Since, in practice, clamp 1 is at one stator type for example connected to lead U, at another stator type, however,
for example to lead W1, different names can be assigned to the same connection clamp (e.g. see picture: U, MAIN,
W1) etc.
Explanation: The clamp assignment determines, which outputs are assigned to which clamp of a stator tester. In
order to activate one clamp, it can become necessary to switch on various outputs. This is exactly determined in
this clamp table. The settings of this clamp table are done by the manufacturer and must under no circumstances
be changed.

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For assigning the clamp colors, the following picture appears:
Meaning of clamp at the respective

clamp number
Clamp numbers (e.g. of the spring
terminal clamps at the MTC3 tester)
Lead 1 of connection clamp 1 is e.g. red
Lead 2 of connection clamp 2 is e.g.

green
Double-clicking on the color opens a

color selection window. From this
selection, you choose a color.
If you double-click on the field "text

white", the text in the clamp will appear
in white on the screen.
If you double-click on the field "no text",

no text will appear in the clamp on the
screen.
Here, the individual connection leads that have, in the assignment table, been assigned to the connection clamps,
are given individual cable colors.
Please note: should the color of the cable be very dark and the connection cable also have a bright text printed in,
it is possible, for a better display of the text on the screen, to make the text white.

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Measuring devices, measuring boards ..
Explanation: This setting is done by the manufacturer and must under no circumstances be changed.
Explanation: This setting is done by the manufacturer and must under no circumstances be changed.

129
Serial interface ..
Explanation: in case a serial interface is used with the tester, here it is configured. This configuration should
under not circumstances be changed and is done at the factory.

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Inputs for special functions ..
Type inputs
Via the type inputs, it is possible to pre-select a test program digitally (e.g. via an SPS).
The tester has individual inputs. Here, the used inputs are determined.
103,104,105 means that the inputs 103, 104 and 105 are used for the selection. Thus there are 8 choices
(binary pattern) from 0 ... 7. This digit is the first digit in the name of the test program. This digit can be
followed by clear text. Example: 6Motor3KW here, upon generating the binary pattern 110 the test
program with number 6 is loaded.
Assignment inputs
In case of a multiple occupying in a test cover, the assignment
inputs determine, how which nest is occupied.
This input determines the used inputs.

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3.4.3.13.
Command: Options - Signals
Acoustical signals
if test result is go
Explanation:
If the test result is OK, there is to be an acoustical signal.
if test result is no go
Explanation:
If the test result is not OK, there is to be an acoustical signal.
if an error has occurred
Explanation:
If an error has occurred at the tester, there is to be an acoustical signal.
Horn
Signaling horn on, if test result is no go
Explanation:
If the test result is not OK, there is to be a special, very loud signal.

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3.4.3.14.
Command: Options - Blackbox Test
The blackbox test is an extremely important examination of the complete tester. Upon switching-on, the tester
executes a self-test. During this self-test, all integrated relays and measuring paths are checked. Via the blackbox
test also all connection paths incl. clamps up to the test object are checked. It is therefore absolutely necessary to
execute this blackbox test in regular time intervals. In order to be able to use the blackbox test, it is necessary to
generate a test program called Blackbox in the database. In this test program, the individual test steps are
defined with the respective tolerance pre-setting.
The blackbox can either be ordered by Messrs Schleich or made by the customer. The blackbox should correspond
to the test object that is to be tested. Often, the test object is simulated in the blackbox via the respective
resistances. Especially at earth wire resistances, insulation resistances and resistances between the currentcarrying leads this is easily possible. If you have a surge generator, this surge voltage should be tested accordingly.
For this purpose it is necessary to use a prepared stator that provides a stable result without affecting its insulation
ability over many test cycles.
automatic BLACKBOX test after switching on

Activate this option, if, after switching on, the tester is to test the functioning of the tester via a selftest,
first. This blackbox test should be activated! With this test you can check, whether the tester works
correctly.
start BLACKBOX test automatically
Explanation: if the tester has an integrated blackbox (firmly installed), the blackbox test can begin
automatically after starting the test program. Although, at a normal process, the blackbox program is
loaded automatically, the blackbox test is not started automatically. This makes sense, because the
blackbox needs to be connected first.
time-controlled BLACKBOX test
Explanation: in case the blackbox test is to be activated in regular time intervals, this option needs to be
activated. In addition, it is of course necessary to determine the respective time intervals, which should not
be too long.
counter-related BLACKBOX-Test
Explanation: if the blackbox test is to be activated after a certain number of test object, this option needs
to be activated.

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3.4.3.15.
Command: Options - Additional
Calibration date
Here, the calibration date of the latest calibration and of the next calibration is indicated. Approximately 4 weeks
before the next calibration is due, the tester will automatically give out a calibration message. Despite this
message, the tester can still be used. In any case, the calibration service at your factory or at Messrs. Schleich
should be informed.
The calibration message can be acknowledged by the operator. This enables the tester again. However, the
operator should know that he needs to inform the respective person that a calibration needs to be done.
New calibration date
After the calibration, the next calibration date is entered. This calibration date is usually only entered by your
companys calibration service or by Schleich. The calibration date can only be changed with a special password.
This password is either the password of the administrator or the password of the calibration personnel (see user
management).

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User management
The tester is equipped with an extensive user management. That means that the individual persons working with
the tester (users) need to be entered into a database. Within this database (user database), individual passwords
and rights are allocated to the users. As soon as the user wants to undertake certain changes, e.g. of the set
values, he will after the change be asked for the users name and the respective password. If the input is wrong,
the change will not be executed.
Via the allocation of individual rights to individual users, it is thus for example possible, to enable the person who
does the set-up to change set values, but enable the person responsible for the calibration only to do the
calibration. All rights are allocated by the administrator.
PASSWORD
tester is updated.
Set up user ..
It is possible to enter various users at the tester. For every user, it is also possible to configure the individual
rights. In addition, it is possible to allocate an individual password to every user.
It is possible to allocate one right or various rights to one user. Therefore, e.g. both the right Test and the right
Change set values can be allocated to the user. Activating the button Options... enables the input of additional
configurations for the user management.
Test
With this right, the user is only able to test.
PLEASE NOTE: If a user is to log on at the tester, a selection of the allowed users appears in a list. In order
for the name to appear in the selection list, it is necessary that Check user rights in the user management
is switched on.
Change set values (only nominal values)
With this right your can change the set value, but not the tolerances.
Change set values (only tolerances)
This right allows additionally, to change the tolerances.

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Change set values (only system parameters)
This right allows additionally the input and changing of system parameters, like test times etc.
Configurations in general
Configurations extended
Set-up operation
This right enables the possibility to activate the set-up operation. A standard tester usually has no set-up
operation. The set-up operation is only integrated at testers, at which a lot of mechanical movements are
activated. In this case the set-up operation offers the possibility, to activate mechanical movements.
Set-up operation I/O-level
With this right you have the possibility to indicate the input / output display of the testers, or also activate
outputs.
I/O definitions, measure boards
This right gives you extensive possibilities for the configuration of the tester. Definitions and determination
of measure boards are usually a setting which is done at the factory and should only be changed in
accordance with the manufacturer.
Calibration
This right should only be allocated to the calibration personnel.
Administrator
The administrator right includes all right mentioned above. If a user is determined as administrator, he
automatically obtains all rights.
PLEASE NOTE: If the administrator is also to log in at he tester as user, the check mark before Test must
be set additionally.
Options ..
Passwords become invalid, if ...
After a password has been entered, the tester checks automatically, whether the password is enabled in the user
management. If user name and password match, for a pre-settable time, the user has the possibility to use the
rights that were allocated to him. The following 4 options automatically deactivate the rights.
... the key switch is set from Program to Measure.

If this option is activated, the rights are deactivated as soon as the key switch is re-set from the position
Program to Measure.
... the test program is ended.

As soon as the test program is ended, all rights are automatically deactivated.
... a new test is started.

If this option is activated, the user rights are automatically deactivated by starting a new test process.
... the pre-set time period is exceeded.

The above-mentioned possibilities to deactivate the user rights can be restricting. Especially if a rest
program is newly generated and developed, it is unfavorable to lose the rights, e.g. when starting the test
process. Normally it is better, to have the rights deactivated after a pre-settable time. We recommend a
time period of 10 minutes. As soon as, within 10 minutes, no input is made at the tester (only tests are
done), the user automatically loses the rights. If, within these 10 minutes, further changes are made at a
test program etc., from this point the time period of 10 minutes starts again.
PLEASE NOTE: For a favorable working with the tester, we recommend to activate the right Key switch from
Program to Measure, The test program is ended and The pre-set time period is exceeded.

136
Further settings ..
In addition, further settings can be configured in the user management.
Indicate list with user names in the main menu and force selection
With this option it is possible to have a test process not started before an operator has logged in at the
tester. If this right is activated, the name of the operator automatically appears in the main testing window.
It is important to know, that only those users, that have been allocated he right Test, appear in the selection list.
Change operator only after password has been entered
In case an operator has to log in at the tester, it might be helpful that the operator logs in at the tester not
only with his name but also with his password. This way you can be sure that no one can log in at the tester
under a different name. The tester will only accept the operator if the password is entered correctly.
Process test programs only after password has been entered
In principle, upon changing set values, the right should be interrogated, whether the respective person is
allowed to change these set values (allocation of rights user management). For this standard case, the
option should be switched on. However, there are applications, where the input of a password upon
changing set values is too time-consuming. For this reason, you can switch off the inquiry for the password
with this option.

137
Password of the day:

If, for any reasons, the password of a user is lost, it might become necessary to log in at the tester with a
special password. Otherwise it would no longer be possible to change data. For this reason, here the
password of the day is indicated. This password changes automatically every day. As soon as this password
of the day is used, it is possible to enter the passwords in the user management correctly, matching the
user.
Before going to the user management, it is, however, necessary to enter the correct password of the day.
Since this password is not visible upon making the input, it is necessary to call the supplier in order to ask
for the current password of the day. You will be given the password of the day, so that you can use the
tester again.
Change password ..
For changing a password it is necessary, as customary for Windows, to enter the correct user password first. If this
user password correct, the password can now be changed. As a confirmation of the new password, it needs to be
repeated. This is to avoid that the password is entered with a spelling error and thus no longer useable.
PASSWORD
tester is updated.

138
3.4.4.
Command: Setup data storage
In the window Setup data storage, the type of storing the test results in the Excel form can be influenced.
At the top of this window you will find the list Setup. A new setup is generated by allocating a new name for the
current configuration. All current settings are doubled and stored under a new name. At the same time, a new clear
KonfigNo is generated, which is indicated on second position at the top.
The third information Basis determines the Excel file that is used as a copying basis for the generation of the
result protocol. Double clicking this text field opens a file-selection dialog, where this file can be selected. The
button Processing opens this basis for processing under Excel.
The measure channel table in the middle part of the window has already been described under Setup motor
measurement (see above).
The lower part of the configuration window contains allocations for the used Excel form. Here, as customary in
Excel, positions in the table are either indicated via line and column (e.g. E6) or as via a definition (e.g. Test
voltage). The definitions must correspond to the field names used in the Excel form.
In general, the excel form contains a drawsheet and the result pages. In the result protocl, the drawsheet only
exists once and describes the general ratings of the motor.
The result pages contain a continuous number for every test that is executed at this motor. If the number of lines
(see input Number of lines in the table) is not sufficient for all measure points, a test can also consist of several
pages. As standard, a test also contains an additional page with the test data.

139
3.4.5.
Command: Setup dynamometer
Here you determine, which dynamometers exist. They appear in the main window under the definition indicated
here as selection list Dynamometer.
The individual parameters have the following meaning:
Number of dynamometer:
Clear continuous number that indicates the position in the list of the main window. This parameter should not be
changed.
Definition:
The dynamometer defined here is indicated in the main window. This definition can also be exported into an Excel
form as Aufnehmername (see window Setup).
Max. torque:
Maximum torque according to the ratings of the dynamometer. This value is indicated on the type plate of the
dynamometer.
Unit dynamometer:
Unit according to the ratings of the dynamometer.
Factor torque:
Correction factor for the torque of this dynamometer. The standard value is 1. This standard value should only be
changed in special cases.
Offset torque:
Additive value for the torque. The standard value is 0. This standard value should only be changed, if for example
the dynamometer is installed in a vertical position.
Divisor rotational speed:
Dynamometer have various encoder for the rotational speed. As standard, the encoder has 60 impulse per
revolution. There are, however, dynamometers with 600 and 6000 impulses per revolution. Respectively a different
value needs to be entered here.
Output:
In case of automatic switch-over at the dynamometers, here the respective switching output needs to be entered.
With the Arrows at the bottom of the window, you can chose between the dynamometers.
After activating the button New
a new dynamometer can be defined. The button Delete deletes the
currently selected dynamometer out of the configuration. The button Close closes the setup window
and transmits the changes into the dynamometer list in the main window.

140

3.4.6.
Command: System information
This command serves to indicate the version number and the registered user of the software.
3.4.7.
Command: Event log
If the testing device internally detects errors, or the operator calls certain commands, an automatic storage of a
note in an event log on the hard disc takes place. The note is stored with date and time. In case of service there is
thus the possibility for a better analyzing.
Filter function
The event log offers various possibilities of filtering. For filtering, symbol buttons A Z or Z A are used. In the
event log, it is further possible to search for certain events and print out the event log. The deletion of the event
log is not intended. It thus stores all information, that has occurred during the complete operation time.
Event log / Filtering: In case you want to search for a special event in the event log, please call the command
View in the event log. Under View you can now enter the desired event in the field Definition. By activating the
button OK, only the events that match this definition are indicated on the screen. In addition, it is possible to
limit the events to a certain time period.

141

3.4.8.
Command: Exit
The command "Exit" ends the program of the testing device.

Attention
Before switching off the tester, this command should always be called. For the Windows operating
system it is better, to end the program correctly.
Afterward doing this, please switch off the mains switch.

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4.
4.1.
Calibration
Calibration
The tester must be calibrated in regular intervals; we recommend once a year. The software of the tester informs
the operator approximately one month before the next calibration date that the calibration is coming up soon.
Despite this message and also in case the calibration date is exceeded, the tester can still be used. In
this case, however, Messrs. Schleich GmbH assume no liability.

143
5. Miscellaneous
5.1.
Directory tree of the tester
All programs and files are found on hard disc c:. The Windows and the System directory are essential directories. In
addition to the actual Windows operating system, these directories contain important files of the tester. Depending
on the operating system, the Windows directory can also be defined as WinNT or the like. Under Windows2000
and WindowsXP, the most important system files are, furthermore, not to be found under System but under
System32.
All further programs of the tester are in the Schleich directory.
c: -+- Windows -+- System ...

.
!
.
..
!
+- Schleich -+- Dblib --- Init
!
+- Setup
!
+- Texte
!
+- Archiv
!
+- Grafik
!
+- Progs
!
+- Kalibrie --- IOKarten
!
+- Gage --- 95driver
!
+- gagescop
!
+- Bilder

144
5.2.
Explanations of directories
Below please find a list of the various sub-directories with the respective explanations.
Dblib
contains the set value database, the order database and various other databases
Sollwerte.mdb This file contains all set values (test programs).
Stempel.mdb This file contains the order data.
StammGlp.mdb This file contains the data for the customer management.
Init
contains an installation file for deleting and re-generating all databases
Kalibrie
contains the calibration program for calibrating and adjusting the measure board and for
the determination of the applied hardware configuration
Kalibrie.ini
configuration file for hardware definitions
Setup
contains the configuration files for the tester

Backup.reg
essential file with a copy of the input of the WIN-registry-Information
Schleich.reg
contains the same information as Backup.reg, but from the state when the tester
was delivered
Config.mdb
contains the configuration of the input masks of the individual test methods
Klemmen.mdb contains hardware configuration data
Texte
contains the text files for the various languages
Archiv
contains the result databases (actual value databases)

I021003.mdb The databases are organized monthly. The tester automatically generates a new
database for every month. In order to be able to distinguish the databases, the
name begins with the month. The underscore is followed by the year.
Grafik
contains the graphic symbols like Icons etc.
Progs
contains the sequence programs of the tester

Every test method has a macro-like file, which determine the interaction of hardware and software
to a great extent.
Gage
contains, at testers with surge test, the drivers for this task
Gagescop
contains, at testers with surge test, the drivers for this task
Bilder
contains pictures that can be displayed as graphics in some test steps

145
5.3.
Re-generate databases
By calling a special command, it is possible to delete all databases and put them into the empty initial status.
This should, however, never be done or only in exceptional cases, because this
command deletes all test programs and all results that have so far been generated
and stored completely.
For the execution of the re-generation of the databases, you only need to copy an empty database into the dblib
directory. Empty sample databases can be found in the packed file initdb.zip in the Init directory. With the
respective program (e.g. WinZip) the ZIP file can be opened. The desired database is selected and extracted into
the respective directory.
c: -+- Windows -+- System ...

.
!
.
..
!
+- Schleich -+- Dblib --- Init
5.4.
Working with limited user rights
The standard design of Schleich testers allows the operating system to be operated only with administrator rights.
If necessary, the test program can also be operated with limited user rights. For this purpose, it is necessary the
rights and, if necessary, change them as described below.
We recommend to grant full access to the directory C:\Schleich and all subdirectories for the respective user. In
the most simple case, the rights should be set as follows:
Under Windows2000 and WindowsXP it is also necessary to adapt the access rights for the WindowsRegistry. In the program Regedt32.exe, the key HKEY_LOCAL_MACHINE\Software\Schleich is used
for this purpose. The rights of this key also need to be adapted, so that the respective Windows user can
fully access this key and all subkeys.

146
5.5.
Protocol of I/O-interfaces
There are two ways, the tester can contact another control:
1. possibility: I/O-interface
2. possibility: serial interface
5.5.1.
Communication via I/O-interface
The communication with another control (e.g. a PLC) takes place via digital inputs and outputs. They are realized in
a way that they are operated directly on the voltage level, e.g. of a PLC. The voltage level is 24V DC. The voltage of
24V is supplied for the communication by the control that is to be controlled. Therefore the tester operates
potential-free from the control that the data transfer is done with.
The following diagram shows the individual signal conditions between the control and the tester. These signals must
be in a firm time-wise relation, so that there is no communication conflict.
Basically, it is distinguished between 2 different versions. Both versions can be used for both, a single station and a
dual station.
The essential difference between both versions is that at version 1 the PLC takes the starting signal back after the
start of the test and at version 2 the starting signal remains at the tester until the end of the test. Even when the
test is still in process at the other station (in case of a dual station), with version 2 it is, in addition, possible to
apply the starting signal at the other station.

147
PLC
Signals
Tester
Tester is okay
Start-Version I
Start Station 1
Start Station 2
Type-Code1
...
Type-Code x
signal may be inverted
Testing
signals may be inverted
Fault 1
...
Fault x
result go
result no go
Start-Version II
Start Station 1
Start Station 2
Type-Code1
...
Type-Code x
signal may be inverted
Testing
Fault 1
...
Fault x
result go
result no go
Error-Condition
Tester is okay
Error
ENTER

finish test sequence
Tester has booted
Tester power supply on
Error message is shown

on the screen
GLP3-2000 Protokoll.vsd
148

Description of the signals
Tester is OK
After switching on and starting the tester, the tester gives a signal, which informs you that
the tester is ready for operation. The tester can not be started before this signal is active.
In case there is an error at the tester, which is for example indicated via a screen message,
the signal will be taken back. Only after the screen message has been acknowledged by the
operator, the signal will be re-activated.
Start version 1
Start Station 1
From the control the tester receives the command to start the test at station 1. As soon as
the signal has been recognized by the tester, the PC sends an acknowledge message to the
testing connection.
Start Station 2
From the control, the tester receives the command to start the test at station 2. As soon as
the tester has recognized the signal, the PC sends an acknowledge message to the testing
connection.
There are 2 possibilities to trigger a type change (change of test program) at the tester.
1. Possibility: via the keyboard, the operator manually searches the desired test program in the database.
2. Possibility: on control leads, the external control puts an input code at disposal, which is read in by the tester.
Then the tester automatically loads the respective test program (matching the control code). With 8 coded leads it
is, for example, possible, to select and load automatically up to 256 different test programs.
Type code 1 ... (X)
The respective code must, of course, be generated by the external control before the
beginning of the starting signal. As soon as the starting signal is on, the tester reads in the
code and automatically loads the test program. After this, the tester starts the test also
automatically and sets the testing signal.
Testing
Das Testing-Signal is set at the beginning of a test. After the test is completed, the signal is
taken back.
Fault 1 ... (X)
If the external control also needs the information, in which test step an error has occurred,
the tester can set an error signal via the respective outputs. It is possible to define one error
output per test step. It is also possible to group test steps together, e.g. by defining one
error output for all high-voltage steps. For safety reasons, these signals should, if possible,
be low-active. That means, in case of an error, the output will be switched off. The
advantage is that in case of a faulty connection between the tester and the control or a
defective output, the control will always receive the Low-Signal from the tester. From this,
the control would derive that there is an error. In case of a great number of errors in the
test step it would be recognized that it is not an error at the test object, but an error in the
wiring or at the output of the tester.
Result go / Result no go
At the end of a test either the Result go or the Result no go signal is set. After
the Testing-Signal has been switched off again, the control can read in and evaluate
the fault outputs and the result outputs.

149
5.5.2.
Communication via the serial RS232 interface
The communication with an external control (e.g. a PLC) can take place via the serial interface. The following
functions of the remote control are possible:
1. The external control informs the tester which test program is to be loaded.
You can configure, how the test is to be started:
a. Directly after receiving the control command for the test program, the test is started automatically.
b. The test process continues to be started via external hardware starting inputs.
2. Before, during and after the test, the tester transmits the latest test results to the external control.
Below please find a description of the individual control commands and data-transmission strings.
1. Control command from the external control for loading a new test program.
<STX> P test program definition <CR> <LF>
(in Hex: 02 50 test program definition 0D 0A)
Explanation: The command starts with the code <STX>, followed by the letter P. This serves to inform the tester
that a test program is to be loaded. The P is followed by the test program definition. The test program definition
must be exactly the same as stored in the database of the tester. It is not important whether capital letters are
used. The control command is ended with the code <CR>.
After the tester has received the control command, it is first checked, whether the test program has already been
loaded by the tester. If the test program has not been loaded, the tester loads the test program automatically out
of the database afterwards. If the test program does not exist in the database, the respective message will be sent
to the external control.
Basically, after receiving the control commands, the tester always sends an answer to the external control.
If there is no answer, the external control can recognize that the tester is, for example, not switched on.
The answers to the external control are as follows:
Answer, if the test program is existent in the database:
<STX> P 1 <CR> <LF>
(in Hex: 02 50 01 0D 0A)
Answer, if the test program is not existent in the database:
<STX> P 0 <CR> <LF>
(in Hex: 02 50 00 0D 0A)
If the test program can be loaded, the test is started immediately. I.e. in the standard settings, no special
command for starting is necessary.

150
2. Control command from the external control for starting a test

<STX> S <CR> <LF>
(in Hex: 02 53 0D 0A)
Explanation: The command structure is identical to the P-command described above. The S-command starts the
latest loaded test program, as soon as the tester is ready.
3. Control command from the external control for defining a device number
<STX> G GNr1,GNr2 <CR> <LF>
Example:
<STX> G555555,666666 <CR> <LF>
(in Hex: 02 47 35 35 35 35 35 35 2C 36 36 36 36 36 36 0D 0A)
GNr1 and GNr2 may be any two alphanumerical values with max. 20 characters. In this example for GNr1 the
555555 has been entered and for GNr2 the 666666. The comma , and the equals sign = have a special
function in this command and must, therefore, not be part of the device number.
Explanation: The command structure corresponds to the commands described above. The G-command is followed
by a list (separated by commas) with the device numbers of the individual test stations. The length of the list
depends on the number of available test stations.
Before starting the test, this parameter must be transmitted to the respective stations. Otherwise, these device
numbers would be used for the tests to follow in the respective stations.
If only the device number of a single test station is to be entered, you can also use the following syntax of this
command:
<STX> G Station=Idx <CR> <LF>
Example:
<STX> G2=44444 <CR> <LF>
(in Hex: 02 47 32 3D 34 34 34 34 34 0D 0A)
In this example, the device number 44444 is allocated to the test object in the second test station.
4. Control command from the external control for defining a station index
<STX> I Idx1,Idx2 <CR> <LF>
Example:
<STX> I5,6 <CR> <LF>
(in Hex: 02 49 35 2C 36 0D 0A)
Idx1 and Idx2 may be any two numerical values between 1 and 32767. In this example, for Idx1 the 5 and for
Idx2 the 6 was entered.
Explanation: The command structure corresponds to the commands described above. The I-command is followed
by a list (separated by commas) with the index values of the individual test stations. The length of the list depends
on the number of available test stations. This command must be sent, before the test is started.
If this command is not used, the test stations are numbered, starting with 1 for the first test station.
When inquiring the test results, the indices allocated via this command are indicated or printed as station numbers.
If only the index of a single test stations is to be entered, you can also use the following syntax of this command:
<STX> I station=Idx <CR> <LF>
Example:
<STX> I2=4 <CR> <LF>

151

(in Hex: 02 49 32 3D 34 0D 0A)
In this example, the index 4 is allocated to the second test station.
5. Control command from the external control for the direct selection of stations
<STX> N station <CR> <LF>
Example:
<STX> N1 <CR> <LF>
(in Hex: 02 4E 31 0D 0A)
The active test stations is changed as soon as the present test is ended.
6. Control command from the external control for the selection of stations
<STX> A station <CR> <LF>
Example:
<STX> A1 <CR> <LF>
(in Hex: 02 41 31 0D 0A)
The test station is only pre-selected, the following commands for loading or starting refer to the indicated test
station.
The active test stations is not changed before the starting command for the respective station has been received.
7. Control commands from the tester to the external control

The control commands from the tester to the external control serve for transmitting all information during a test
process to the external control. This way, the external control can, for example, display all test data on an
additional monitor the same way as the tester. In addition, the external control can evaluate data and, e.g. in case
of a conveyor system with pallets, execute the respective pallet control. The test results received from the external
control can, for example, also be stored in an additional database or transmitted into a pallet.
The control commands from the tester to the external control are divided into four groups:
header
test step
device number
footer
The header is always transmitted at the beginning of a new test. The Header contains the information that are
known at the beginning of a new test; e.g. the device number of the test object. For the external control, receiving
the header signals the beginning of a new test.
The test step is always transmitted to the external control directly after a test step has been performed. The
transmission contains exactly the same information as indicated on the monitor of the tester in the test step. The
information are the test step definition, the set value, the actual value, the latest error counter and the result of the
test step.
The device number is transmitted at the end following the data of the latest test step. This device number is also
indicated in the status bar of the test program. The number serves for identifying the test object, therefore it is
stored in the result database.
The footer is always transmitted after finishing a complete test. The Footer contains the information that is not
known before the test is completed, e.g. the total test result.
The control commands to the external control are as follows:
Header:
<STX> H test program definition <TAB> test station <TAB> date <TAB> starting time ....
.... <TAB> name of operator <TAB> order data <CRLF>

152

The name of the operator and the order data are only indicated if the program has the respective configuration, i.e.
only if the list of the current operator or the order management is configured.
Test step:
<STX> T <TAB> test step definition <TAB> set value <TAB> actual value ....
.... <TAB> counter content no go <TAB> test result <CRLF>
Meaning of the code for the test result:
0 = test of the test step not OK (no go)
1 = test of the test step OK (go)
The above control command for the test step is an example. The transmission corresponds exactly to the display of
a test step on the monitor of the tester. Since the display on the monitor has been configured, however, the control
command can only be indicated as an example. At the end of the control commands, always the test result (0 or 1)
is transmitted.
Optionaly, it is possible to give out the respective sequence number for every test step. This number always
corresponds to the present position of the test step in the current process. Disabled test steps are considered for
the allocation of numbers. A sequence of the test steps 1,4,8, as listed as in the example data set, if the other test
steps (2,3,5,6,7) are disabled, is, therefore, possible.
test step:
<STX> T <TAB> sequence number <TAB> test step definition <TAB> set value <TAB> actual value ....
Dataset example:
<STX>HSampleTestProgram<TAB>1<TAB>07/19/2005<TAB>09:20:22<TAB><TAB><CRLF>
<STX>T<TAB>1<TAB>resistance U<TAB>
13.740 mOhm <TAB>
13.769 mOhm <TAB>0<TAB>1<CRLF>
<STX>T<TAB>4<TAB>resisatnce V<TAB>
13.740 mOhm <TAB>
<STX>T<TAB>8<TAB>surge U<TAB>
5.00%, 10.0%<TAB>
0.4%, 0.1%<TAB>0<TAB>1<CRLF>
If the data of the curve are to be indicated during a surge test, as well, this needs to be activated optionally in the
software. The transmission is enabled with the help of an additional data line. Transmitted are the Y-values of the
respective curve.
test step:
<STX> T <TAB> test step definition <TAB> set value <TAB> actual value <TAB> count<TAB> test result
<CRLF> <STX> TD <TAB> test step definition <TAB> value1, value2, value3, value4, value5, value6
<CRLF>
device number:
<STX> N device number <CRLF>
The device number of the test object is transmitted.
footer:
<STX> F total test result <TAB> test time <TAB> counter GO <TAB> counter NO GO <CRLF>
Please note:
The individual information between the <TAB> signs can be of varying length. The <TAB> signs were used in order
not to have to define the length firmly. In the external control, it is therefore necessary to search for the <TAB>
sign and for the <CR>-<LF> sign in order to find the beginning and the end of the individual information. With this
technique, the transmission is very flexible. At the external control, however, more software is necessary for the
evaluation of the control commands.
Meaning of the abbreviations:
<STX>
start of text
<CR>
carriage return
<LF>
line feed
<CRLF>
carriage return & line feed
<TAB>
tabulator
P
test program
H
header
T
test step
N
device number
code:
code:
code:
code:
code:
code:
code:
code:
code:
Dec
Dec
Dec
Dec
Dec
Dec
Dec
Dec
Dez
02
13
10
13 10
09
80
72
84
78

(=
(=
(=
(=
(=
(=
(=
(=
(=
HEX
HEX
HEX
HEX
HEX
HEX
HEX
HEX
HEX
02)
0D)
0A)
0D 0A)
09)
50)
48)
54)
4E)
153

F
footer
code: Dec 70
(= HEX 46)
Dataset example:
<STX>HSampleTestProgram<TAB>1<TAB>07/19/2005<TAB>09:20:22<TAB><TAB><CRLF>
<STX>T<TAB>resistance U<TAB>
13.740 mOhm <TAB>
<STX>T<TAB>resistance V<TAB>
13.740 mOhm <TAB>
<STX>T<TAB>resistance W<TAB>
13.740 mOhm <TAB>
<STX>T<TAB>resistance spread <TAB>
2.0 %
<TAB>
0.235 %
<TAB>0<TAB>1<CRLF>
<STX>T<TAB>surge U<TAB>
5.00%, 10.0%<TAB>
0.4%, 0.1%<TAB>0<TAB>1<CRLF>
<STX>T<TAB>surge V<TAB>
5.00%, 10.0%<TAB>
0.3%, 1.7%<TAB>0<TAB>1<CRLF>
<STX>T<TAB>surge W<TAB>
5.00%, 10.0%<TAB>
0.2%, 2.4%<TAB>0<TAB>1<CRLF>
<STX>T<TAB>insulation resistance test <TAB>
100.000 MOhm <TAB>
> 5.0 GOhm <TAB>2<TAB>1<CRLF>
<STX>N123456<CRLF>
<STX>F1<TAB>00:15,81s<TAB>10<TAB>2<CRLF>
The example dataset contains the following information:

The definition of the test program is SampleTestProgram
The test was started on 19 July 2005 at 9:20:22.
In the first three test steps, the resistance of the three windings (U, V and W) is detected. The default values
(set values) were 13.74 mOhm. The measured values were 13.769 mOhm in the U winding, 13.74 mOhm in the
V winding and 13.737 mOhm in the W winding. The error counter of the three test steps was 0 and the test
result was GO (=1).
In the following test step the spread was determined. The limit value was 2%; 0.235% were detected. Here,
the error counter was also set to 0 and the test result was GO.
In the next three test steps, the windings were tested with the surge test. The default values were 5% tolerance
at the evaluation of the correlation and 10% tolerance at the evaluation of the attenuation. For the U winding a
0.4% deviation of the correlation was detected and for the attenuation a deviation of 0.1%. For the V winding,
0.3% respectively 1.7% were detected. For the W winding 0.2% respectively 2.4%. Here, the error counter was
also 0 and all results were GO.
In the last test step, the insulation resistance test was performed. The limit value was set to 100 MOhm; an
insulation resistance above the measuring limit of the applied devices was detected (>5.0 GOhm).
In the following line, the device number of the test object is transmitted, in this case 123456.
The bottom line, the footer, shows the test result 1, i.e. GO and a test time of 15.81s. The total counter GO
was set to 10 and the total counter NO GO was set to 2. The latest test is not contained in this counter and
is thus the 11th GO result.
8. Control commands from the tester for editing test programs

This control command serves for editing already defined test programs externally.
test step:
<STX>E<TAB>methode<TAB>step<TAB>set value=value1<TAB>set value=value2<TAB><CRLF>
Explanation: the command starts with the code <STX> followed by the letter E, which serves to inform the tester
that a certain test step of the present test program is to be edited. The E is followed by the clear identification of
the test step.
It consists of the method number and the respective test-step number. Every test method has special method
number, which can be found in the attached file (Pruefmethoden.xls). Here, you can enter either the number or
the short term, as shown in the below example data set:
Example data set:
<STX>E<TAB> R_W <TAB>1<TAB>1=resistanceP1<TAB><CRLF>
<STX>E<TAB> 2
<TAB>1<TAB>1=resistanceP1<TAB><CRLF>
The test step results from the sequence within a test program; so every single test method consists of a random
number of test steps starting with 1. The below data set is an example, where the definitions of the first 5
resistance test steps are changed.
+++weiter+++Beispieldatensatz:
<STX>E<TAB>R_W<TAB> 1 <TAB>1=Widerstand Schritt 1<TAB><CRLF>

154

So entspricht der Teil <TAB>R_W<TAB>1<TAB> der Identifikation des ersten Widerstandsprfschrittes.
Im Folgenden werden nun die Parameter mit ihren zu editierenden Werten aufgelistet. Die Bezeichnung dieser
Parameter findet hnlich wie bei den Prfschritten ber die eindeutige SollwertID statt, welche anhand einer
seperaten Liste nachvollzogen werden kann. Hierbei ist einer einzelnen Prfmethode immer eine genaue Anzahl von
vordefinierten Parametern zugeordnet, ber die der jeweilige Sollwert editiert werden kann. Die zu jeweiligen
Sollwerte werden ber ein = mit ihrem zu setzenden Wert verknpft und untereinander durch ein <TAB>
voneinander abgetrennt.
Dies ist anhand des nachfolgenden Beispiels zu erkennen:
Beispieldatensatz:
<STX>E<TAB>R_W<TAB>1<TAB> 1=WiderstandsP1 <TAB> 2=13.740 <TAB> 14=100 <TAB> 20=23 <CRLF>
Folgende Parameter wurden in dem obigen Beispiel verndert:

1
2
14
20
(=WiderstandsP1 )
(=13.740)
(=100)
(=23)
=>
=>
=>
=>
Bezeichnung des Prfschrittes

Nennwiderstand
Oberer Grenzwert
Fehlerausgang 2
Bei der bertragung der Parameter knnen verschiedene Arten von Fehlern auftreten. Um die Ursache des Fehlers
erkennen zu knnen, wird hier zwischen vier verschiedenen Fllen unterschieden. So kann zunchst einmal die
angesprochene Methode in dem Prfstand gesperrt sein (1) oder aber der bergebene Prfschritt ist in dem Prfplan
nicht definiert (2). Ferner kann der bestimmte Sollwert fr die angesprochene Methode entweder nicht vorhanden
(3) oder aber gesperrt also nicht freigegeben sein(4).
Bei jeder bertragung wird ber die RS232 Schnittstelle eine Antwort zurckgegeben. In dem Fall einer fehlerfreien
Kommunikation und einem erfolgreichen Editieren des Prfschritts wird die folgende Meldung bertragen:
Bei erfolgreicher Datenbertragung:
<STX> E 1 <CR> <LF>
(in Hex: 02 45 01 0D 0A)
Sofern bei der Datenbertragung ein Fehler aufgetreten sein sollte wird dies ber zwei getrennten Antworten
zurckgegeben. Die erste Antwort beinhaltet die einfache Meldung dass ein Fehler aufgetreten ist, in der zweiten
Meldung wird der aufgetretene Fehler genauer beschrieben.
Erster Teil der Antwort bei einem Fehler:
<STX> E 0 <CR> <LF>
(in Hex: 02 45 00 0D 0A)
Zweiter Teil der Antwort bei einem Fehler:

(1) Wenn die Prfmethode nicht freigegeben ist:
<STX> METH LOCKED(MethID) <CR> <LF>
155
(2)Wenn der Prfschritt nicht existiert:

<STX> STEP NOT FOUND (MethID->Schritt) <CR> <LF>
(3)Wenn der Sollwert nicht definiert ist:
<STX> METH LOCKED(MethID->SW) <CR> <LF>
(4)Wenn der Sollwert nicht freigegeben ist:
<STX> METH LOCKED(MethID ->SW) <CR> <LF>
Innerhalb der Klammern wird die betroffene Stelle ber die oben erluterten IDs genau beschrieben.

156

Externe Ergebnisdatei
Sobald entsprechend Fehler! Verweisquelle konnte nicht gefunden werden. die Ergebnisspeicherung in
einzelne Dateien aktiv ist, werden die Prfergebnisse in dem eingestellten Verzeichnis in Form von Textdateien
abgelegt. Diese Textdateien haben standardmig folgendes Format:
/*B
TTD:03:11:07
TTS:11:27:03
BDT:Muster
SNR:0001
OPT:
nOK Hochspannung Wicklung - Tisch: Prfspannung=2048.4 Vac, Strom=9.2 mA, Zeit=1.1 s, Prfzeit=1.0
TTE:11:27:09
FAILED
TAR:
TMA:2554
##
/*B
TTD:03:11:07
TTS:15:30:09
BDT:Muster
SNR:0002
OPT:
OK Hochspannung Wicklung - Tisch: Prfspannung=2012.1 Vac, Strom=8.1 mA, Zeit=1.1 s, Prfzeit=1.0
OK Hochspannung Wicklung - Tisch: Prfspannung=2095.5 Vac, Strom=8.8 mA, Zeit=1.1 s, Prfzeit=1.0
OK Widerstand L - N: R (20C)=41.168 Ohm, R (mess)=41.168 Ohm, Temperatur=0,00 C
OK Leistungsaufnahme: Leistung=1249.46 W, U-L1=230.1 V
TTE:15:30:41
PASSED
TAR:
TMA:2554
##
Dargestellt sind zwei aufeinanderfolgende Ergebnisse des gleichen Prfplans, wobei im zweiten Datensatz
zustzliche Prfungen durchgefhrt wurden.
Die Datenstze enthalten im Einzelnen folgende Informationen:
/*B Startzeile, leitet einen neunen Datensatz ein
TTD: Datum der Prfung im Format TAG:MONAT:JAHR
TTS: Uhrzeit des Starts der Prfung im Format STUNDE:MINUTE:SEKUNDE
BDT: Name des Prfplans, ist i.A. die Bezeichnung des Prflings
SNR: Seriennummer bzw. Gertenummer des Prflings
OPT: Prfername, wenn im Gert konfiguriert
OK oder nOK
Ergebnis eines Prfschritts, darauf folgen Details zu dem jeweiligen Prfschritt
Der erste Teil ist immer die Bezeichnung des Prfschritts, die weiteren Details hngen von der
Art der jeweiligen Prfung und der Konfiguration des Gertes ab, beispielsweise die eingestellte
Sprachversion.
TTE: Uhrzeit des Endes der Prfung im Format STUNDE:MINUTE:SEKUNDE
PASSED oder FAILED: Gesamtergebnis der Prfung
TAR: Zusatzangabe, wenn im Prfplan konfiguriert; ist blicherweise ohne Inhalt
TMA: Projektnummer des Prfgertes
Der Dateiname der Ergebnisdatei setzt sich standardmig wie folgt zusammen:
Pmmddyy.DAT
Dabei ist:
mm der aktuelle Monat
dd
der aktuelle Tag
yy
das aktuelle Jahr
Beispiel:
P031107.dat
Diese Datei ist somit vom 11. Mrz 2007.
Nach jedem Schreiben in eine Ergebnisdatei wird ein externes Programm aufgerufen. Dies kann dazu genutzt
werden, diese Datei ins Netzwerk zu verschieben oder z.B. eine Datenkonvertierung auszulsen.
Im oben genannten Konfigurationsfenster lassen sich auch andere Dateiformate aktivieren, diese sind jedoch nur in
speziellen Systemkonfigurationen sinnvoll nutzbar.

157
5.6.
Shortcuts
The following shortcuts are available with the standard configuration in the main window of the test program:
Key
F1
F2
F3
F4
F5
F6
F7
F8
F7
F8
F9
F10
F11
F12
Shift+F2
Shift+F3
Strg+1
Strg+2...
Strg+F8
Strg+P
Function
Help, opens this manual
Reset error
Start test
Load test program
Station 1 (if two or more test stations, e.g. for dual test stations)
Station 3 (if more than 2 stations)
Station 4 (if more than 3 stations)
Test step generator (if existing)
Teach-In-Mode on/off
Manual surge test (if existing)
Activates the menu bar
Indicate test message window, in programming mode with enabling for processing
Input of order data
View orders and statistics
Indicate error list (if existing)
Further test stations, if existing
Activate single-step mode
Print test results, opens the printing dialog
Other inputs are interpreted as barcodes.

158
5.7.
Definitions and explanations
Double click
Index card
Button
Symbol bar
Main menu
Sub-command
Check box -
Option -
Scrolling horizontally, vertically
Drag and drop
With the left mouse button you activate the button below the mouse pointer.
Via the display of index cards it is possible to show various inputs on the screen in a more
organized manner. The data is summarized in groups per index card. (see option
selection)
A button is a switch that is graphically displayed on the screen. Activating this button via
the keyboard (if the button is framed) or clicking on it with the left mouse button, starts
the function related to it.
The symbol bar is line in the upper area of the screen in which you find buttons with
graphic symbols. Via activating one of these graphic symbols, the respective command is
executed. These commands can also be activated via main menu and sub-command.
Using the symbol bar is a lot faster, though.
The main menus are listed in the upper area of the screen. These main menus are for
example "Database" or "Set values". As soon as you click on one of the main menus with
the mouse, you will see a list of sub-commands.
After activating a main menu, you will see a list of sub-commands. The respective subcommand is activated via the keyboard or via the mouse.
A check box is a small square box. If the ckeck box is empty, the function is not
activated. An activated check box has a check mark - the function is activated. For deactivating the check box, you need to click on it with the mouse.
An option box is round. When it is activated, it has a black dot inside. Options are always
grouped together. Within one group, only one option can be activated. Therefore this
group is framed and within the frame you will find a headline.
It is possible that sometimes there is not enough room on the screen for indicating all
data. In this case, the tester automatically generates a vertical and / or a horizontal
scrolling bar. There is a small button inside the scrolling bar; at the ends it has arrows.
Via the button or the arrows, the contents of the window can be moved and thus all
information can be indicated.
Drag and drop is a very easy possibility to move individual lines within a list. To do so,
you click on the line that is to be moved with the right mouse button and keep it pressed.
Now you move the mouse pointer to the desired line and then let go of the button, which
will move the line to the desired point.

159
6. Subject index
+/- %-tolerance 66, 67, 69

+/- %-Tolerance 58
+/- Tolerance 73
Earth wire test 50, 83

Einstellungen 24
Error code 59, 64
Evaluation 66, 73, 74
Event log 141
Export data 34
A
AC/DC 63, 67
Activation of the programming mode 16
Active power 67
additional input line 49
Additional outputs 52, 54, 59, 64, 66, 68
Analog test 73, 75
Annex 163
Apparent power 67
B
F
Feedback control 63
Filter 32, 33
Function test 67
G
General information 13
General parameters 45
Backup 30, 123

H
C
Calibration 143
Calliper 69
Capacity 64
Changing set values 20, 45
Connection for test probe 50
Continuity resistance 66
Continuity test 66
Copyright 13
Correction 68, 86
CosPhi 67
Current consumption 67, 83
High voltage test 10, 60

Hinweistext 80
HV-adjustment 26
I
Identification 102
Indication of statistics results 36
individual commands 21
Input of order data 22, 32
Input of set values 18
Insulation resistacne test 72
Insulation resistance test 52, 83
D
database 22, 26, 28, 29, 34, 35, 36, 45, 47, 85, 89,
93, 101, 106, 113, 114, 115, 117, 118, 119, 145
Database 26, 27, 29, 101, 159
Databases 30, 119
Definitions and explanations 159
Delete go / no go counter 24
Delete test program 29
directories 31, 122, 123, 144, 145
Directory tree 144
Disable test methods 25
Display 35, 47, 48, 93
Display of individual results 35
Distribution indication 42
L
Label print-out 85
Language 100, 109
leakage current 53
Leakage current test 53
Lenght of lead 50
Liability 13
Load set values 27, 28, 42, 44
Lower limit value 52
M
Manual mode 90

160

Max. current 64
Measure channel 73
Measure delay 63
Measure time 74
Measuring time 53
Mechanical tests 69
Min. current 64
Miscellaneous 144
N
New test program 89
Nominal resistance 58
Norm 53
O
On/Off display 90
Optionenauswahl - Anzeige 97, 99
Order input 22, 24, 102
Outputs 90
P
Parameter 30, 80, 86, 105
Parameters 22
Path names 86
Picture file 45, 46, 49, 50, 52, 54, 59, 65, 66, 68, 74
Print 15, 35, 36, 86, 104, 110, 112, 113
Programming mode 15
Prfung 94
R
Ramp time 63
Reaction time 51
Re-generate databases 146, 147
Regulations for safety 9
Release of the tester 14
Repair message 52, 53, 59, 68, 69
Resistance table 114
Resistance test 55, 59
Restore 31
Results and statistics 32
Rotary field 70
Rotary field test 70
Rotational speed 68
S
Safety 8
Save set values 29
Search criteria 32

Select Options 24, 92, 93, 96, 100, 109, 110, 112,
113, 124, 125, 132, 133, 134, 141
Selftest 26
Sense of rotation 68, 70
Serial number 32
Serial numbers 105
Setup 22, 24, 27, 30, 32, 47, 86, 90, 95, 105
Single step (on/off) 23
Sollwerte 145
Spot check 63, 69
Stabilization time 58
Start test 21, 96
Start type 51
Starting time 53, 67
Starting voltage 67
Storage 22, 24, 27, 32
Surge test 72
surge tester 72
Switch off 53
Symbol bar 125, 132, 133, 134, 159
T
Test connection 50, 52, 58, 63, 66
Test current 50
Test message 50, 52, 54, 58, 64, 66, 68, 69, 74, 79,
80, 81
Test methods 22, 24, 83
test probe 50, 51, 52, 53
Test probe 53
test sequence 76, 78, 79, 82, 83, 84, 100
Test time 50, 52, 63, 66
Test type 52, 53, 58, 67
Test voltage 52, 67
Text field 48
Transformer 63
Trend indication 37, 41
U
Upper / lower limit 58, 67
Upper / lower limit value 58
Upper limit value 50
User messages 47
V
Variation range 58
VDE 0104 10, 12
Visual check 48
W
Waiting time 67, 73
With repair 50, 52, 53, 59, 68, 69
161

Notes:
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________
_________________________________________________________________________________

162
7. Annex
Written confirmation that the operating manual has been read carefully and understood.
Person (Name)
Department

Date
Signature
163

Pawin 32 E

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Programming manual

Copyright by Schleich GmbH

Programming manual for WIN32

Programming mode ........................................................................................ 15

Selection of the set value that is to be changed .................................................................... 18

Explanation of the individual commands ........................................................ 21

Main command: database ...............................................................................26

Load set values ................................................................................................ 27

Search criteria ............................................................................................................................32

3.2.7. Command: Detect reference curve ...................................................................................... 42

Main command: set values ..............................................................................45

Command: General parameters .......................................................................................... 45

Never touch test objects or test leads during the test!!!

Programming manual for WIN32

Command: Leakage current test ......................................................................................... 53

Command: Insulation resistance test................................................................................... 52

Command: Earth wire test ................................................................................................. 50

Further inputs for the motor tester ................................................................................................46

Command: User messages ................................................................................................. 47

Command: Resistance test................................................................................................. 55

Never touch test objects or test leads during the test!!!

Programming manual for WIN32

Command: High voltage test .............................................................................................. 60

Command: Continuity test ................................................................................................. 66

Command: Mechanical tests.............................................................................................. 69

Command: Function test .................................................................................................. 67

Command: Rotary field test .............................................................................................. 70

Never touch test objects or test leads during the test!!!

Programming manual for WIN32

Command: Insulation resistance test with the surge tester ................................................... 72

Define motor parameters ................................................................................. 75

Additional programs (option) ............................................................................ 82

Main command: Setup ....................................................................................90

Command: Manual mode ................................................................................................... 90

Command: Options - General information ....................................................................................93

Setup data storage ......................................................................................... 139

Never touch test objects or test leads during the test!!!

Programming manual for WIN32

Miscellaneous ............................................................................................... 144

Communication via I/O-interface....................................................................................... 147

Shortcuts .................................................................................................... 158

Subject index ............................................................................................... 160

Annex ........................................................................................................... 163

Never touch test objects or test leads during the test!!!

Programming manual for WIN32

Never touch test objects or test leads during the test!!!

Programming manual for WIN32

Never touch test objects or test leads during the test!!!

Programming manual for WIN32

Regulations for safety at work

Never touch test objects or test leads during the test!!!

Programming manual for WIN32

Important information for users of high voltage testing equipment

Caution! High voltage!

Never touch test objects or test leads during the test!!!

Programming manual for WIN32

Never touch test objects or test leads during the test!!!

Programming manual for WIN32

Notes for the operation of testing devices according to VDE 0104

Never touch test objects or test leads during the test!!!

Programming manual for WIN32

Never touch test objects or test leads during the test!!!

Programming manual for WIN32