Temperature Rise Tester

1. Unboxing and Basic Familiarization with the Equipment

1.1 Key Technical Specifications

LISUN Model	WS-1	WS-2	WS-3
Test Station	8
Test Current	0–50 A	0–200 A	0–300 A
Test Voltage	Less than 3V
Timer	Adjustable from 0 to 9999 seconds
Thermometer	0–1000°C (includes 8 Type K thermocouples)
In accordance with the standard	GB/T 2099.1, Clause 19 (IEC 60884-1, Clause 19)	GB/T 2099.1, Clause 19 (IEC 60884-1, Clause 19), the requirements of GB 16915.1, Clause 17 (IEC 60669-1, Clause 17), and GB/T 13140.1, Clause 15 (IEC 60998-1, Clause 15)

1.2 Unboxing and Checking the Contents

1.2.1 Unpacking and Visual Inspection

When unpacking the device, handle it gently to avoid scratching the outer casing with sharp tools. After unpacking, first inspect the exterior of the device to ensure there is no visible deformation or dents, and that the buttons are not damaged or loose.

If you notice any damage or deformation to the equipment or accessories, do not turn on the power. Please contact us immediately.

1.2.2 Main Unit and Accessories

Temperature Rise Tester: 1 unit.

The standard accessories are as follows: ① Power cord; ② Mock-up, used for testing flush-mounted electrical fixtures such as outlets; ③ Conduit; ④ 8 K-type thermocouples.

Figure 1

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1.3 Description of Equipment Structure

1.3.1 Front of the Device

① Touchscreen; ② 8-channel temperature display; ③ Test current display; ④ Power switch; ⑤ Test current adjustment.

Figure 2

1.3.2 Side and Back of the Device

① 8 Omega Type K thermocouple sockets; ② Sample terminals, capable of connecting 8 samples in series simultaneously; ③ Power cord jack.

Figure 3

2. Safety Precautions

2.1 Electrical Safety

2.1.1 Power Connection

220V single-phase power; power outlets must comply with safety standards, have proper grounding, and have a rated current that matches the equipment’s power rating and the actual load power requirements.

2.1.2 Grounding Specifications

The equipment must be reliably grounded, with a grounding resistance of ≤4 Ω. Do not use gas pipes, non-metallic water pipes, or neutral wires as substitutes for the grounding wire. After grounding is complete, use a Grounding Resistance Tester to measure the grounding resistance. Power may only be applied after confirming that it meets the requirements, to prevent electric shock, equipment malfunctions, or measurement errors caused by poor grounding.

2.2 Operational Safety

Before wiring, inspecting, or maintaining equipment, you must turn off the equipment’s power switch and the main power supply, and confirm that there is no residual voltage before proceeding;

Do not operate the equipment’s power switch, touchscreen, or instrument buttons with wet hands to avoid the risk of electric shock;

Do not place any foreign objects (such as tools or paper) inside the electrical control cabinet to prevent dust or foreign objects from causing short circuits or damaging components;

Do not plug in or unplug power cords or signal cables while the equipment is running to prevent short circuits that could damage the controller or electrical components;

The equipment is capable of outputting high currents. When connecting wires, replacing samples, or adjusting the circuitry, you must first turn off the power and set the load current control knob to the lowest setting to ensure there is no load output and to prevent electric shock;

Do not touch the sample, the thermocouple terminals, or the load output connectors during the test to avoid burns from high temperatures or electric shock;

Warning signs must be posted in the test area to prohibit unauthorized personnel from approaching, in order to prevent accidental contact with high-temperature samples or live electrical components.

2.3 Environmental Safety

The equipment must be placed in a level, dry, and well-ventilated indoor environment, away from flammable and explosive materials, corrosive gases, and strong magnetic fields.

The equipment must be installed in an air-conditioned room, with the ambient temperature maintained between 5°C and 35°C and relative humidity ≤ 85%.

The distance between the equipment and walls, as well as surrounding structures (such as other test equipment and shelving), must be at least 1000 mm to facilitate operation and maintenance; at least 2000 mm of space must be left in front of the equipment to ensure smooth operation and keep the surrounding area free of obstructions;

2.4 Other

For matters not covered in this manual, please proceed with caution or contact us.

3. Introduction to the Touchscreen Program

3.1 Test Interface

① Start timer; ② Start test power supply; ③ Reset; ④ Display of sample power-on duration; ⑤ Display of sample power-off duration; ⑥ Display of number of repetitions.

Figure 4

3.2 Parameter Settings Page

① Setting the duration of power application to the sample; ② Setting the duration of power disconnection from the sample; ③ Setting the number of repetitions; ④ Setting the duration of the alarm.

Figure 5

4. Preparations Before the Test

4.1 Preparing the Environment

In accordance with the standard requirements, the test assembly should be placed in a draft-free environment during testing to prevent airflow from affecting the accuracy of temperature measurements.

When testing flush-mounted electrical accessories, a test environment that complies with the standards must be set up in advance (see the model in the “General Accessories” section): Place the mounting box into the pine trough and fill the space between the mounting box and the trough with plaster, ensuring that the front edge of the mounting box is flush with the front surface of the pine trough (with a deviation of no more than ±5 mm). The plaster should be 10 mm to 15 mm thick, and the pine trough must have at least 25 mm of wood surrounding the plaster; After the test assembly is constructed, it must be allowed to dry for at least 7 days.

Note: If you need models in other sizes, please contact us or manufacture them yourself according to the specifications.

4.2 Confirmation of Standards Used

4.2.1 Determination of Test Parameters

Depending on the type of sample being tested, consult the corresponding standard to determine the key parameters:

Sample Type	Reference Standards	Test Current	Test Duration	Temperature Rise Limit
Outlets/Plugs	GB/T 2099.1-2021	As specified in Table 20 (e.g., for multi-outlet receptacles, use the corresponding rated current)	60 ± 5 min	Terminals, connectors, and clamping components ≤ 45K
Switch	GB 16915.1-2024	As specified in Table 17 (e.g., 20 A test current for a 16A circuit breaker)	1h	Terminals ≤ 45K; non-metallic knobs/handles ≤ 5K; other non-metallic external components ≤ 55K; metallic knobs/handles ≤ 35K; other metallic external components ≤ 45K
Connectors	GB/T 13140.1-2008	As specified in Table 2 (e.g., 24 A test current for a 2.5 mm² connection capacity)	Reach thermal equilibrium (temperature rise ≤ 1 K within 1 hour)	Current-carrying components of the clamped part ≤ 45K
Note: For switches with indicator lights, if the circuit current is ≤3 mA (neon lamp/LED), temperature rise tests related to the indicator light may be omitted; when testing protective devices (such as fuses), use low-impedance wire to short-circuit the circuit.

4.2.2 Validation of the Test Mode

Determine whether load/no-load cycle testing is required (refer to the relevant standard requirements); if cycle testing is required, specify the number of cycles, the duration of each power-on period, and the duration of each power-off period;

Verify the temperature measurement method (this device uses a thermocouple for measurement) and ensure that the thermocouple is positioned so as not to affect measurement accuracy (e.g., near critical areas such as clamping components or terminals).

4.3 Sample Preparation

4.3.1 Sample Selection and Preparation

Select representative samples (such as plugs, receptacles, switches, terminal blocks, etc.) based on the test requirements, ensuring that the samples are in good condition, free of damage, and consistent with the product’s condition upon shipment;

Electrical accessories with detachable wiring must be connected to polyvinyl chloride (PVC)-insulated wires with the corresponding rated cross-sectional area as required by the standard (see the table below); accessories with non-detachable wiring shall be tested as delivered;

Nominal cross-sectional area of copper conductors used in temperature rise tests (refer to GB/T 2099.1-2021):

Rated Current (A)	Fixed Electrical Accessories	Portable Electrical Accessories
≤10	Solid/Stranded Wire 1 mm²	Flexible wire, 1.5 mm²
>10 and ≤16	Solid/Stranded Wire 1.5 mm²	Flexible wire, 2.5 mm²
>16	Solid/Stranded Wire, 4 mm²	Flexible wire, 6 mm²

Terminal screws or nuts must be tightened to 2/3 of the specified torque (see requirement 12.2.8 of standard GB/T 2099.1-2021).

4.3.2 Sample Installation

Flush-mounted outlet: Installed in a flush-mounted box, which is placed in a pine groove and filled with plaster as required. The cable enters through the top of the box, and the entry point is sealed to prevent air circulation. The length of each conductor inside the box is (80±10) mm;

Surface-mount outlets/switches: Mounted at the center of a pine block, which must be at least 20 mm (thick) × 500 mm (wide) × 500 mm (high);

Plug: Place it in the center of a pine block (block specifications as above); if the plug has a side grounding prong or a spring-loaded grounding prong, it must be inserted into a standard fixed outlet for testing;

Multiple fixed outlets (shared terminals): Insert the test plug under the most unfavorable conditions to ensure that the test current distribution meets the requirements;

Connectors: Single-pole terminals connect wires according to a predetermined method, while multi-pole terminals connect up to three adjacent terminals. Wire lengths must comply with standard requirements (1 m for wires ≤ 10 mm², 2 m for wires > 10 mm²; lengths may be shortened in accordance with the manufacturer’s specifications).

4.4 Equipment Preparation

4.4.1 Sample Connection

Connect the components in series in the direction indicated by the black lines in the figure below. When the load current is high, use sufficiently thick connecting wires to ensure that the wires’ current-carrying capacity matches the test current and to prevent the wires from overheating.

If connecting only one sample, connect terminals ① and ⑨; if connecting two samples in series, connect the first sample to terminals ① and ②, and the second sample to terminals ② and ⑨; If you need to connect three samples in series, connect the first sample to terminals ① and ②, the second sample to terminals ② and ③, and the third sample to terminals ③ and ⑨. And so on.

Figure 6

Taking a flush-mounted outlet as an example, once all the wires are connected, it will look like the image below. You need to short-circuit the terminals to generate a test current for the circuit.

Figure 7

Note: Sample installation and wiring must comply with standard requirements to prevent loose wire connections that could cause poor contact or arcing.

Select the key points where temperature measurements are required (such as terminals, connectors, clamping components, and housings). Securely attach the other end of the thermocouple (the sensing end) to the measurement point using high-temperature-resistant tape or adhesive (such as Loctite 7452), ensuring tight contact with the sample surface and that it does not come loose.

4.4.2 Equipment Warm-up

To ensure safety, first turn the front-panel test current adjustment knob counterclockwise to the lowest setting. Then turn on the device’s power switch and let it warm up for 15 minutes. Proceed with the next steps only after the touchscreen display has stabilized and the temperature display shows no abnormal fluctuations.

5. Operating Procedures for the Temperature Rise Test

5.1 Parameter Settings

Access the touchscreen parameter settings interface and set the following: ① sample power-on time, ② sample power-off time, ③ number of cycles, and ④ alarm duration (the device will sound an alarm when the test is complete). Note: Please refer to the relevant standard requirements to determine whether the test requires a power-on/power-off cycle and how long the test should last. After completing the settings, click “Test” to return to the test interface.

Figure 8

5.2 Commissioning: Current Testing and Startup Testing

① Tap “Test Power-On” on the touchscreen, ② turn the load current adjustment knob, and ③ adjust the real-time current displayed here to meet the test requirements (please refer to the applicable standard to determine the specific current required).

Figure 9

Note: Adjust the current gradually to avoid sudden spikes or drops that could damage the equipment or the sample.

Once the test current has stabilized (fluctuation range ≤ ±0.5%), click “Start Timer” to begin the test. During the test, monitor the displayed temperature to determine whether the sample has passed the test.

Figure 10

Temperature data must be closely monitored during the test. If an abnormal spike in temperature or an alarm occurs, the test should be stopped immediately to investigate any issues with the sample or equipment.

5.3 Monitoring the Test Process

Monitor the temperature data on the display in real time, and record the initial temperature (when the power is off) and temperature changes during the test;

Monitor the load current display to ensure that the current remains stable within the test current range at all times. If abnormal fluctuations in the current occur, promptly investigate the cause (such as loose connections or poor contact with the sample);

If there is an abnormal spike in temperature or an alarm is triggered, the test should be stopped immediately to investigate any issues with the sample or equipment.

During the test, do not alter parameters, touch the wiring, or move the sample without authorization to ensure stable test conditions.

6. Post-Test Procedures

6.1 Equipment Operation

6.1.1 Test Termination

After the test is complete, wait for the device to automatically cut off the test current, or manually click “Start Test Power” again to cut off the test current;

Tap the “Reset” button on the touchscreen to clear the data from this test and restore the device to its initial state;

Slowly turn the test current adjustment knob counterclockwise to the lowest position, then turn off the device’s power switch.

6.2 Data Processing

6.2.1 Data Recording

Record the temperature data before and after the test (initial temperature, final temperature, and maximum temperature rise), and calculate the temperature rise using the following formula: Temperature rise (K) = Final temperature (°C) – Initial temperature (°C);

Record the test current, test duration, number of cycles (if applicable), sample model, serial number, and test environment parameters (temperature, humidity), and compile this information into a test record form.

6.2.2 Interpretation of Results

Comparison of Temperature Rise Data from Comparative Tests with Standard Limits:

① If the temperature rise is ≤ the standard limit, the sample is deemed to meet the temperature rise requirement;

② If the temperature rise exceeds the standard limit, the sample is deemed nonconforming, and the cause of the nonconformity must be analyzed (e.g., the connector sleeve is too thin, poor contact, insufficient wire cross-sectional area, etc.).

6.3 Sample and Equipment Preparation

6.3.1 Sample Removal

After the sample has cooled to room temperature, remove the load wires and thermocouples one by one. When removing them, avoid pulling on the wires with force to prevent damage to the sample or the thermocouples;

Inspect the condition of the sample after the test (e.g., whether it is deformed, scorched, or has loose connections) and record the relevant details.

6.3.2 Equipment Organization

Organize accessories such as thermocouples and lead wires, and store them neatly to prevent the wires from becoming tangled or damaged;

Clean the surface of the equipment (wipe with a dry cloth; do not get it wet), remove any debris from the test area, and keep the environment tidy.

7. Daily Maintenance and Care

7.1 Short-Term Storage Requirements

If the equipment is used on a daily basis, no further action is required after cleaning is completed following each test.

7.2 Long-Term Storage Requirements

If the device will not be used for an extended period (more than one month), please disconnect all cables and cover the device with a dust cover to prevent dust buildup.

The device should be powered on once a month for just half an hour to prevent the aging of electrical components (such as capacitors and contactors).

8. Troubleshooting and Resolving Common Problems

8.1 The device won’t turn on

8.1.1 Causes of Failure

The power cord is not properly connected or is damaged; there is no power or the voltage is abnormal; the device’s fuse has blown; the power switch is malfunctioning.

8.1.2 Treatment Methods

Check that the power cord is securely connected, the plug is firmly inserted, and the power cord is not damaged; if damaged, replace it. Use a multimeter to verify that the supply voltage is AC 220 V ± 10%; if there is no power, troubleshoot the power circuit; Check whether the fuse has blown; if so, replace it with a fuse of the same specification (never substitute with other conductors). If none of the above issues are found, the power switch may be faulty; contact the manufacturer for repair.

8.2 The current cannot be adjusted or is unstable

8.2.1 Causes of Failure

The load current adjustment knob is damaged; the sample lead connection is loose or has poor contact; the Voltage Transformer is faulty; the sample is wired incorrectly or the sample itself is faulty (e.g., an open circuit).

8.2.2 Treatment Methods

Check whether the knob rotates smoothly without any sticking; if damaged, replace it. Re-inspect the sample wiring, tighten any loose connections, check for short circuits, and replace any damaged sample wires; Disconnect the sample wiring and directly short-circuit the device’s sample terminals. If the current still cannot be adjusted or remains unstable, the Voltage Transformer may be faulty; contact the manufacturer for repair. Check whether the sample wiring meets the requirements and whether the sample is functioning properly (e.g., no open circuits). Replace any faulty samples and try again.

8.3 Inaccurate temperature measurement or no display

8.3.1 Causes of Failure

The thermocouple is not connected properly or is damaged; there is poor contact between the thermocouple and the sample surface; the temperature measurement module is malfunctioning; the display shows an error.

8.3.2 Treatment Methods

Check whether the thermocouple is securely connected to the device interface; try unplugging and replugging it. If the thermocouple is broken or the insulation is damaged, replace it; Check whether the thermocouple’s sensing tip is in close contact with the sample; reattach it securely to ensure it is not loose; compare the measurement with a standard thermometer. If the deviation is too large, the temperature measurement module may be faulty; contact a calibration or repair service. If a single temperature channel shows no display, the interface for that channel may be faulty; try testing by switching to a different thermocouple interface.

8.4 Equipment Alarm Anomalies

8.4.1 Causes of Malfunctions

Temperature rise exceeds the preset limit; test time has elapsed; abnormal current (overload).

8.4.2 Treatment Methods

If a temperature rise exceeds the limit and triggers an alarm: Immediately stop the test, check whether the sample is in good condition, whether the thermocouple is positioned correctly, and whether the test parameters comply with the standard; after troubleshooting, repeat the test. If a time-out alarm is triggered: This is a normal occurrence; proceed according to the test completion procedure. If an abnormal current alarm is triggered: Check whether the current setting exceeds the rated value; after troubleshooting, reset the equipment;