Electrical And Thermal Stresses Test Device

1. Unboxing and Basic Understanding of the Equipment

1.1 Key Technical Specifications

Parameters	Note
Test Current	0–30 A
Setting the Number of Trials	0–9999 times

1.2 Unboxing Inspection and Verification of Accessories

1.2.1 Unpacking and Visual Inspection

When unpacking the device, handle it gently to avoid scratching the exterior casing with sharp tools. After unboxing, 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 abnormalities with the device or its accessories, do not turn it on. Please contact us immediately.

1.2.2 Main Unit and Accessories

Number	Note
①	JCY-1 Electrical and Thermal Stresses Test Device
②	Power Cord

Download links for the digital user manual, software, warranty card, and other materials have been sent via email. Please download them promptly. If you missed the email, you may contact us to request the download links again.

1.3 Scope of Application of the Equipment

This equipment is designed in accordance with Clause 12.3.11 of GB/T 2099.1 (IEC 60884-1) and Clause 12.3.11 of GB/T 16915.1 (IEC 60669-1). By applying a test current, the equipment simulates the electrical and thermal stress conditions that terminals encounter during actual use over a set cycle period and is capable of performing multiple cycle tests.

This manual refers to clause 12.3.11 of standard GB/T 16915.1 (IEC 60669-1). Please note this if you need to refer to other standards and the test requirements differ.

2. Safety Precautions

2.1 Electrical Safety

2.1.1 Power Supply Requirements

Use a single-phase AC 220 V ±10%, 50/60 Hz three-prong outlet; the ground prong must be connected to earth ground. Do not share the outlet with high-power equipment to avoid voltage fluctuations that could interfere with the test.

2.1.2 Grounding Requirements

The instrument ground wire is reliably connected to the protective ground wire, and the protective ground resistance is ≤4 Ω.

2.2 Environmental Safety

2.2.1 Temperature and Humidity Requirements

Avoid using the device in environments where humidity exceeds 70% (without condensation) or where the temperature is outside the range of 0–35°C. The optimal operating temperature is 25±2°C.

2.2.2 Environmental Contraindications

Environments with strong magnetic fields and strong electric fields;

Environments containing corrosive gases or liquids;

Areas with flammable and explosive dust, and areas containing hazardous materials;

Environments with heavy dust, high temperatures and humidity, and direct sunlight.

2.3 Operational Safety

Operators must be familiar with the instruction manual and wear insulating protective gear;

A dedicated staff member is on duty throughout the entire testing process to strictly prevent the risk of overheating and fire;

The output current can reach up to 30 A. Do not operate the device with wet hands, and do not touch the test specimen or the terminals during the test;

Do not cover the device’s cooling fan vents to ensure proper heat dissipation during operation;

Before connecting or disconnecting wires, you must stop the test, cut off the output current, turn the current knob to the minimum setting, wait until the discharge is complete (wait for at least 1 minute), then turn off the power before proceeding;

Current adjustment should only be performed after the test has been started via the touchscreen; full-scale adjustment under no-load conditions is prohibited;

During testing, do not move the wires, test specimens, or measuring equipment, to avoid affecting the test results.

2.4 Other

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

3. Equipment Overview

3.1 Front Panel

Number	Note
①	Power Switch
②	Touchscreen
③	Terminal blocks: Red—input terminal without threads; Black—output terminal; the two red and two black terminals can be short-circuited to split the current.
④	Jumper wires are intended solely for pre-shipment quality inspection; they must be replaced with test leads and non-threaded terminals before use.
⑤	The current adjustment knob may only be used after the screwless terminals have been properly connected and the “Start Test” button on the touchscreen has been tapped.
⑥	Buzzer: The buzzer will sound an alarm if the device’s output current is too high or when the test is complete.

Figure 1

3.2 Back Panel

Number	Note
①	Power Cord Jack
②	Cooling Fan

Figure 2

4. Introduction to the Program Interface

4.1 Test Interface

Number	Note
① Real-time power-on time	Current Test Power-On Duration
② Preset power-on time	Customize the power-on duration (in minutes/seconds)
③ Real-time power-outage duration	Current Test Power Outage Duration
④ Preset power-off time	Customize the power-off duration (in minutes/seconds)
⑤ Number of real-time on/off cycles	Number of cycles completed
⑥ Preset number of on/off cycles	Customize the total number of cycles
⑦ Real-time current measurement	Current output value (in A)
⑧Start/Stop	Click to start/stop the test
⑨Zero	Click to reset the current test data
⑩Reset	When the device triggers an alarm, click to clear the alarm.
⑪Home	Back to Home Page

Figure 3

4.2 Help Interface

Users may refer to the recommended testing procedures and precautions.

Figure 4

5. Preparations Before the Test

5.1 Verification of the Test Current for Test Specimen Leads

Test Specimens: 5 brand-new threaded terminals, free of damage or oxidation, rated for the same current as the socket

Select a new single-core solid copper conductor with a length of 1 m based on the rated current. Refer to the rated current of the screwless terminals to determine the test current and the conductor cross-sectional area, as shown in the table below.

Rated Current (A)	Test Current (A)	Wire Cross-Sectional Area (mm²)
≤4	9	0.75
>4 and ≤6	13.5	1
> 6 and ≤ 10	17.5	1.5
>10 and ≤16	22	2.5

5.2 Preparation of Tools and Supplies

Tools to Bring: millivoltmeter (for measuring voltage drop), insulated screwdriver, wire strippers;

Supplies: Copper wire of the appropriate specifications, jumper wires.

5.3 Specifications for Test Specimen Wiring

Connect the input wire to the red terminal and the output wire to the black terminal on the screwless terminal block;

The wire should be stripped to an appropriate length and crimped securely to ensure a good connection.

6. Test Procedure

6.1 Electrical Stress Test (Step a)

Procedure	Note
①	First, turn the current adjustment knob to the minimum setting, connect the test specimen, and verify that the connections are secure.
②	On the touchscreen, enter the test interface and set the power-on time to 60 minutes, the power-off time to 0, and the number of power cycles to 1.
③	Click “Start” to begin the test, and turn the current knob to set the current to the standard test value.
④	Keep the power on for 1 hour; current flows only through the terminals, not through the outlet; do not move the wires or the test specimen at any time during the process.
⑤	After power-up, the device triggers an alarm, and the current continues to be output.
⑥	Immediately adjust the device’s output current from the test current at the threadless terminal to the rated current.
⑦	Use a millivoltmeter to measure the voltage drop across each threadless terminal.
⑧	Acceptance Criteria: A voltage drop of ≤15 mV is considered acceptable.

6.2 Thermal Stress Cycling Test (Step b)

Instructions	Note
①	After completing the electrical stress test, click “Zero” to reset the data; do not move the specimen or the wires.
②	Parameter settings: Power on for 30 minutes, power off for 30 minutes, preset number of on/off cycles: 24. Click Start.
③	After completing the above 24 cycles, the device sounds an alarm, and the current remains at the output level.
④	Immediately adjust the device’s output current from the test current at the threadless terminal to the rated current.
⑤	Use a millivoltmeter to measure the voltage drop across the two ends of the threadless terminal and record the reading.
⑥	Repeat the above procedure to complete a total of 192 temperature cycles (measuring the pressure drop once every 24 on-off cycles).

6.3 Evaluation of Test Results

Voltage Drop Assessment: After every 24 cycles and after 192 cycles, the voltage drop must be ≤22.5 mV or ≤twice the value measured after 24 cycles (whichever is lower);

Visual Inspection: Upon visual inspection under normal lighting conditions, there are no cracks, deformations, melting, or other damage that would affect usability;

Mechanical Strength: After testing, the mechanical strength tests specified in Clause 12.3.10 of GB/T 16915.1 (IEC 60669-1) were repeated, and all test specimens met the requirements.

7. Post-Test Procedures

7.1 Termination of the Test

When the test is complete, or if you stop it manually, tap “Reset” on the touchscreen to clear the alarm messages and reset the test data.

7.2 Power Outage

First, turn the current adjustment knob to the minimum setting. After the discharge is complete (wait at least 1 minute), turn off the power. Then disconnect the millivoltmeter leads and the test specimen leads.

8. Daily Maintenance and Care of Equipment

8.1 Routine Maintenance

Before turning on the equipment, check that the exterior is clean and free of damage;

After the test is complete, wipe down the surface of the equipment and the test area of the specimen with an antistatic, dry cloth;

Check the equipment terminals for oxidation or burn marks; if any are found, wipe them with a specialized contact cleaner and replace the terminals if necessary;

Inspect jumper wires regularly; if they show no signs of overheating, aging, or damage, replace them promptly;

Check to see if the internal cooling fan is operating normally. If you hear unusual noises or if the fan is not running, please contact us immediately for repair.

8.2 Long-Term Storage

If the device will not be used for an extended period, store it in a dry, well-ventilated area, away from moisture and direct sunlight;

Disconnect all cables, store the accessories separately, and cover the device with a dust-proof cloth;

Turn the device on for 30 minutes each month to prevent the internal electronic components from deteriorating.

9. Troubleshooting and Resolving Common Problems

Fault Symptoms	Possible Causes	Procedure
The output current cannot be adjusted after the test is started.	Screwless terminals and wires are not properly connected	Please stop the test, check and confirm that the wiring is correct and secure, and then retest. The output current cannot be adjusted if the circuit is open.
A red message appears on the screen: “Excessive current!” accompanied by an alarm.	Overcurrent alarm; protection triggered due to excessive current	Immediately reduce the current and restart the test.
Touchscreen Lag	Power Supply Malfunction, System Freeze	Check the power supply to ensure it meets the requirements; restart the device and try again.