Screwless Terminal Deflection/Bending Test Device

1. Unboxing and Basic Familiarization with the Equipment

1.1 Key Technical Specifications

Parameters	Note
Bend Angle	0–360°, increment: 10°
Test Bending Direction	In each of the 12 directions, each spaced 30° ± 3° apart
Force Calibration Weights	0.25 N, 0.5 N, 1.0 N
Direction of Force	Perpendicular to the unbent wire
Number of workstations	Single-station

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 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 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-2 Threadless Terminal Bending Tester
②	Weights: 1 each of 0.25 N, 0.5 N, and 1.0 N
③	Power Cord

Download links for the digital user manual, software, warranty card, and other materials have been sent via email. Please download them as soon as possible. If you missed the email, please feel free to contact us to receive the download links again.

1.3 Scope of Application of the Equipment

This equipment is designed in accordance with Clause 12.3.12 of GB/T 2099.1 (IEC 60884-1) and Clause 12.3.12 of GB/T 16915.1 (IEC 60669-1). The equipment simulates the bending stress that terminals may experience during actual wiring by applying bending forces of specific directions and magnitudes to the connected wires, thereby evaluating the terminals’ clamping ability and contact stability.

This manual refers to clause 12.3.12 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 this product 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;

Do not reach into the area of moving parts with your hands or tools while the equipment is in operation;

Do not touch the wires, test specimens, or terminals while the test power supply is energized;

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 View

Number	Note
①	Power Switch
②	Buzzer: The buzzer will sound an alarm when the test is complete.
③	Touchscreen
④	Fixture used to secure test specimens with threadless terminals, ensuring no displacement or loosening during testing
⑤	Weights
⑥	Weight slide rod, used to ensure that the force is applied perpendicular to the wire

Figure 1

3.2 Rear View

Number	Note
①	Power Cord Jack
②	Stepper Motor, Control Terminal Rotation Angle

Figure 2

4. Introduction to the Program Interface

4.1 Test Interface

Number	Note
① Current number of bends	Real-time display of the number of bends completed
② Preset number of bends	Customize the total number of bends
③ Current wait time	Countdown to the Interval Between Two Bends
④ Preset wait time	Customize the interval duration
⑤ Single-bend angle	Customize the angle of each bend
⑥ Current Location	Display the current angle in real time
⑦Start/Stop	Start/Stop Test
⑧Reset	Reset Test Data, Clear Alarms
⑨CW	Motor (Fixture) Manual Forward Rotation
⑩CCW	Manual Reversal of the Motor (Fixture)
⑪Back	Motor (Fixture) Returns to Home Position
⑫Zero	Set the current position of the motor (fixture) to 0° (reference position)
⑬Home	Return to the Home Page

Figure 3

4.2 Help Screen

Users may refer to the suggested testing process and precautions.

Figure 4

5. Preparations Before the Test

5.1 Preparation of Specimens and Consumables

5.1.1 Specimen Requirements

Three switch specimens that had not been tested were used.

Remove any parts that interfere with bending, while retaining the wire-guiding components.

5.1.2 Preparation of Test Leads

Use solid single-strand copper wire and test it immediately after stripping the insulation to prevent oxidation.

Select the cross-sectional area based on the switch’s rated current:

Rated Current of the Outlet	First Order (Minimum Cross-Section)	Order 2 (Largest Cross-Section)
<6A	1.0 mm²	1.5 mm²
6–16 A	1.5 mm²	2.5 mm²

5.2 Preparation of Auxiliary Equipment

Test power supply (the LISUN JCY-1 is an option), providing a continuous current with a fluctuation of ≤±5%.

Millivoltmeter (provided by the user), used to measure the voltage drop across the terminals.

5.3 Confirmation of Standard Test Parameters and Wiring Diagrams

5.3.1 Matching Wire Cross-Sectional Area to Force

Nominal Cross-Sectional Area of the Wire	Bending Force Value	Corresponding weights
1.0 mm²	0.25 N	0.25N weight
1.5 mm²	0.5 N	0.5 N weight
2.5 mm²	1.0 N	1.0 N weight

5.3.2 Setting Parameters for the Bending Test

Set the angle for each bend to: 30.0°;

Bending direction: 12 directions, full coverage; that is, set the total number of bends to 12;

Wait time: Set according to test requirements (recommended: 5.0 s);

5.3.3 Power Supply and Millivoltmeter Wiring

Please also refer to the standard diagram below for the connection between the power supply (JCY-1) and the millivoltmeter.

Figure 5

6. Test Procedure

6.1 Sample Clamping

6.1.1 Wire Installation and Positioning

Prepare a solid single-core wire in the order specified in 5.1.2, insert it correctly into the threadless terminal, and tighten it according to normal operating requirements.

6.1.2 Terminal Clamping and Securing

Use the CW/CCW controls to manually adjust the fixture to the correct reference position, then click “Zero” to set it to 0°.

Securely clamp the threadless terminal in the equipment’s dedicated fixture to ensure there is no wobbling or displacement.

Position the wire horizontally so that it extends straight forward, passing through the weight slide rod, and ensure that the distance from the end of the terminal to the slide rod (the point of application of force) is 100 mm.

6.2 Loading Weights

6.2.1 Selection of Force Values

Select the appropriate weights in accordance with Section 5.3.1; mixing or misusing weights is prohibited.

6.2.2 Confirmation of Loading Location

Slowly slide the weight down the slide rod until it touches the wire.

6.3 Formal Testing Begins

6.3.1 Test Power Supply

Turn on the test power supply (JCY-1). Refer to the JCY-1 manual to ensure that the parameters on the JCY-1 touchscreen are set to provide a continuous current output. Click “Start,” then adjust the output current to the specimen’s rated current. Verify that the current is stable, with fluctuations of ≤±5%.

6.3.2 Startup Test

Tap “Start” on the touchscreen, and the device will automatically perform the bending test according to the set angle, number of cycles, and interval.

6.3.3 Process Monitoring

Monitor the voltage drop reading on the millivoltmeter in real time and determine whether it meets the standard (the voltage drop should be ≤25 mV).

Monitored the angle, frequency, and wait time; the equipment is operating normally.

6.4 Other Steps

6.4.1 The voltage drop during the test met the requirements

If all tests in the first sequence are passed, select the wires for the second sequence in accordance with the standard (see 5.1.2) and continue with the testing.

After completing Test Specimen 1, when testing Specimens 2 and 3, manually adjust the fixture using the CW/CCW controls to the appropriate reference position. Ensure that the reference position angles for each specimen differ by 10°, then click “Zero” to set the angle to 0°.

6.4.2 Voltage Drop Did Not Meet Requirements During Testing

If the voltage drop in any of the 12 test directions exceeds 25 mV, continue applying force in that direction (i.e., click Start/Stop to halt the test, and the fixture will stop rotating) until the voltage drop falls below 25 mV; however, the force application time must not exceed 1 minute. After the voltage drop falls below 25 mV, continue applying force in that direction for 30 s; during this 30-second period, the voltage drop should not increase (then click Start/Stop to resume the test).

If a test specimen fails the test in any direction in which the test force is applied, the test shall be repeated on another set of specimens; during the retest, all specimens must pass.

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

Refer to the JCY-1 instruction manual to turn off the power and disconnect the wires. If you are not continuing with the test, shut down the JCY-2, then remove the millivoltmeter leads, weights, test specimen, and wires.

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, the fixtures, and the test area of the specimen with an antistatic, dry cloth;

Keep the jaws of the fixture clean and free of wire debris and dust.

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;

Apply a layer of rust-preventive oil to the surfaces of the fixtures and weights to prevent rust;

Disconnect all cables, store the accessories separately, protect the weights from impact, and cover the equipment with a dust-proof cloth;

Turn on the device for 30 minutes each month with no load to prevent the internal electronic components from deteriorating.

9. Troubleshooting and Resolving Common Problems

Fault Symptoms	Possible Causes	Procedure
The touchscreen is unresponsive	Power Supply Malfunction, System Freeze	Check the power supply to ensure it meets the requirements; restart the device and try again.
The motor does not rotate during the test.	Parameter Configuration Error	Check that the parameter settings are correct; make sure the angle and number of repetitions are not set to 0.