Wire And Cable Flame Tester

1. Rozpakowanie i podstawowe zapoznanie się ze sprzętem

1.1 Kluczowe dane techniczne

LISUN Model	RSB-WC	RSB-WC1	RSB-WC2
Incinerator Cabinet Dimensions (W x H x D)	300 × 1200 × 450 mm		300 × 1300 × 450 mm
Fume Hood Dimensions (W x H x D)	N / A	930 × 1680 × 720 mm	N / A
Standardy zgodności	Complies with the GB/T 18380 series, the IEC 60332 series, and others	Complies with GB/T 5169.14 (IEC 60695-11-2); RSB-WC complies with the following standards	Complies with GB/T 20041.1 Clause 13.1.3 (IEC 61368-1 Clause 13.1.3)
Typ próbki	Single-conductor insulated wires and cables
Długość próbki	600 ± 25 mm
Specyfikacje próbek	Conductor diameter > 0.8 mm or cross-sectional area > 0.5 mm²
Moc palnika	1 kW (nominal premixed flame)
Typ gazu	High-purity industrial propane (≥95%; to be provided by the user)
Zakres przepływu gazu	0.1–1 L/min (optional electronic gas flow meter)
Zakres przepływu powietrza	3–30 L/min (optional electronic gas flow meter)
Burn Time Setting Range	0.1–999.9 s (continuously adjustable, digital display)
Materiał tubusu	High-temperature-coated steel structures are heat-resistant and corrosion-resistant, making them suitable for long-term high-temperature testing environments.
Wyświetlacz operacyjny	Proprietary extra-large LCD touchscreen + clear indicator lights

1.2 Rozpakowywanie i sprawdzanie zawartości

1.2.1 Rozpakowanie i kontrola wizualna

When unpacking the equipment, handle it gently to avoid scratching the exterior casing with sharp tools. After unpacking, first inspect the exterior of the main unit to ensure there is no visible deformation, dents, or peeling paint, and that the panel instruments and buttons are not damaged or loose. If you find any damage or deformation to the equipment or its accessories, do not power it on or use it.

Open the test chamber door and check whether any internal components have come loose during shipping or if there are any other abnormalities.

If you notice any issues, please contact us immediately.

1.2.2 Host and Accessories

Wire and cable Flame Tester fume hood (with built-in Flame Test Chamber): 1 unit.

Control cabinet for the Wire and Cable Flame Tester: 1 unit.

Standard accessories are as follows: ① Exhaust pipe; ② Compressed air pipe; ③ Propane gas pipe; ④ Power connection cable between the control cabinet and the fume hood;⑤ Connection cables between the control cabinet and the fume hood thermocouples; ⑥ Temperature-rising copper block and its thermocouple wiring; ⑦ Clamps for securing the exhaust pipe; ⑧ Power cord; ⑨ Sample tray; ⑩ Gauges.

Rysunek 1

The test requires technical-grade propane with a purity of ≥95%, which the user must provide.

The test requires an air compressor, which can be purchased from LISUN or provided by the user. If you are providing your own, please refer to the following specifications: pressure, 0.5 to 1 MPa; air storage capacity, 10 L multiplied by the number of minutes of continuous use required.

Note: Download links for the electronic user manual, warranty card, and other documents have been sent via email. Please download them as soon as possible. If you missed the email, please feel free to contact us to request the download links again.

1.3 Opis struktury sprzętu

1.3.1 Front of the Fume Hood

① Fume hood; ② Combustion chamber; ③ Sample holder; ④ Bunsen burner (angle adjustable); ⑤ Omega Type K thermocouple socket (required for calibrating the flame rise time);⑥ Test chamber door; ⑦ Exhaust vent, 100 mm in diameter, securely connected via an exhaust pipe extending to the outdoors; ⑧ Push-pull rod, used to control the position of the Bunsen burner.

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1.3.2 Front of the Control Cabinet

① Touchscreen; ② Power controls, circuit breaker, and power on/off buttons; ③ Propane gas flow meter and flow control knob, pressure gauge and pressure control knob; ④ Air compressor air flow meter and flow control knob, pressure gauge and pressure control knob.

Rysunek 3

1.3.2 Right Side of the Control Cabinet

① Propane gas inlet: Use a gas hose with an inner diameter of 10 mm; ② Compressed air inlet: Use a gas hose with an outer diameter of 8 mm; ③ Power cord socket.

Rysunek 4

1.3.3 Connection Between the Fume Hood and the Control Cabinet

Simply connect them one-to-one based on the labels and interface types.

Rysunek 4.1

Rysunek 4.2

2. Środki ostrożności

2.1 Bezpieczeństwo elektryczne

2.1.1 Podłączenie zasilania

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 (it is recommended to install a dedicated circuit breaker).

2.1.2 Specyfikacje uziemienia

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

2.1.3 Contraindications for the Procedure

Przed przystąpieniem do podłączania, kontroli lub konserwacji sprzętu należy odłączyć główne zasilanie sprzętu i upewnić się, że nie ma napięcia resztkowego;

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.

2.2 Bezpieczeństwo operacyjne

2.2.1 Bezpieczeństwo operacyjne

While the equipment is in operation, non-professionals are prohibited from disassembling or repairing it. In the event of a malfunction, contact after-sales service personnel or operate the equipment only under the guidance of a technician;

The High Temperature Chamber door must be closed during testing. Observe the test process through the chamber viewing window to avoid burns from high-temperature radiation or sparks from burning materials;

In the event of a malfunction or abnormality, immediately stop the test, shut off the power and gas supply, and troubleshoot the problem (see “Chapter 9: Troubleshooting and Handling Common Malfunctions”). Do not force the equipment to start up; operating the equipment before the malfunction has been resolved may cause further damage to the equipment.

2.2.2 Zabronione zachowanie

Do not use propane gas with a purity lower than 95% to avoid affecting flame stability and test accuracy;

Do not open the control cabinet door while the equipment is running to avoid touching internal high-voltage components and causing an electric shock;

Do not disassemble core components without authorization; modifying the equipment will void the warranty and may result in safety incidents;

Do not place heavy objects (such as tools or accessories) on top of the equipment to avoid damaging the equipment panel or impairing heat dissipation;

Do not stack flammable items (such as cardboard boxes, plastic wrap, etc.) around the equipment.

2.3 Bezpieczeństwo środowiskowe

2.3.1 Wymagania instalacyjne

The equipment must be installed in an air-conditioned room where the ambient temperature is maintained between 5°C and 25°C and the relative humidity is ≤85%. If the ambient humidity is high, condensation may form near the equipment door and test ports; in such cases, improve room ventilation or use a dehumidifier;

The installation site must be free of high concentrations of dust, corrosive gases (such as sulfur dioxide and chlorine), and flammable or explosive atmospheres. Direct sunlight must not be allowed to shine on the equipment to prevent corrosion of the equipment housing and aging of electrical components;

The storage of flammable and explosive materials (such as alcohol, gasoline, etc.) is strictly prohibited in the test area to prevent the risk of fire or explosion;

Propane gas is highly flammable. Store it at a temperature of 40°C or lower, and avoid direct sunlight, violent impacts, or proximity to sources of ignition;

The work area is equipped with fire extinguishers (dry powder or carbon dioxide), and operators are familiar with how to use them;

Keep the device away from locations with significant fluctuations in ambient temperature, such as near vents or indoor entrances, to prevent the device’s temperature control accuracy from being affected;

Stay away from sources of strong magnetic and electric field interference (such as large electric motors and high-voltage equipment).

2.3.2 Wymagania przestrzenne

The distance between the equipment enclosure and walls, as well as surrounding fixtures (such as other testing equipment and shelving), must be at least 1000 mm to facilitate maintenance;

At least 2000 mm of space must be left at the equipment door opening to ensure that the door can be opened in any direction, facilitating the placement and removal of samples.

2.3.3 Horizontal Placement

The device must be placed on a flat surface. Use a level to ensure the device is level: Place the level on the top surface of the device and make sure the bubble is centered. Note: The device has four adjustable legs that can be used to level it. Once leveled, ensure that all four legs are firmly in contact with the surface.

If the equipment is tilted, the angle of the Bunsen burner will be inaccurate, and this may cause the sample, Bunsen burner, and temperature-rising copper block to shift out of position, affecting the test results.

2.4 Inne

W sprawach nieujętych w niniejszym podręczniku prosimy zachować ostrożność lub skontaktować się z nami.

3. Wprowadzenie do programu Touchscreen

Interfejs użytkownika 3.1

① Burn time; ② Afterglow time; ③ PV is the current value; ④ SV is the set value; ⑤ Lighting: Used to turn on the lighting inside the test chamber for easier observation; ⑥ Fan: Used to exhaust smoke generated inside the test chamber after the test is complete;⑦ Ignition; ⑧ Air supply on; ⑨ Propane gas supply on; ⑩ Start test;⑪ Reset: Click after the test is complete or before the next test begins to clear the test data; ⑫ Afterglow Pause: Used to record the time it takes for the sample’s afterglow to extinguish; ⑬ Parameter Settings; ⑭ Temperature Calibration: Performs a temperature rise test.

Rysunek 5

3.2 Parameter Settings Interface

① Burn time setting; ② Afterglow time setting.

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3.3 Temperature Calibration Interface

① Current temperature display; ② Temperature rise time display; ③ Start temperature setting; ④ End temperature setting; ⑤ Temperature correction—no changes needed; ⑥ Reset—tap to clear the current data and retest the temperature rise time.

Rysunek 7

Note: Common standards (such as GB/T 5169.14 and IEC 60695-11-2) require that the temperature rise test begin at 100°C and end at 700°C. Users may also set different start and end temperatures in accordance with specific standards.

4. Przygotowania przed testem

4.1 Environmental and Equipment Inspection

4.1.1 Test Environment Requirements

Set the ambient temperature to 23±2°C and the relative humidity to 50±5% to prevent environmental factors from affecting the test results. Note: The temperature and humidity requirements for the equipment’s storage environment differ from those for its operating environment.

4.1.2 Equipment Piping Connections and Inspections

Verify that the exhaust pipe is securely connected to the equipment’s exhaust outlet and extends to the outside.

After connecting the propane cylinder to the equipment, set the cylinder pressure regulator to slightly above 0.1 MPa. Connect the air compressor, which delivers compressed air at a pressure between 0.5 and 1 MPa, to the equipment.

Check that the propane gas lines and compressed air lines are properly connected and free of leaks, and that the clamps are securely fastened. You can apply soapy water to the joints and watch for bubbles to determine if there are any leaks.

4.2 Adjusting the Flame

Adjust the Ben Sheng lamp to a vertical angle.

On the touchscreen program interface, press the “Propane Gas On” button, roughly adjust the propane pressure knob and the flow meter knob, then press and hold the “Ignition” button to successfully ignite the flame. Then adjust the propane settings to the specified standard values (propane pressure: 0.1 MPa; flow rate: 650 ± 30 mL/min). Important Note: Minimize the time between pressing the “Propane On” button and ignition (less than 5 seconds) to prevent excessive propane buildup in the combustion chamber, which could pose a hazard.

Press the “Air On” button, then adjust the air pressure control knob and the flow meter knob to the specified standard values (air pressure: 0.1 MPa; air flow rate: 10 ± 0.5 L/min).

Use a gauge to measure the flame height, and fine-tune the air and propane flow rates separately until the flame meets the test requirements. The flame heights required by the IEC 60695-11-2 (GB/T 5169.14) standard are as follows:

Rysunek 8

The gauge is used as follows; all dimensions marked on it conform to the standard:

Rysunek 9

Once the flame is adjusted, press the “Propane On” button to make it pop out, cutting off the propane gas supply; the flame will automatically go out. Then press the “Air On” button again to shut off the compressed air supply.

No changes need to be made to the propane gas cylinders, air compressors, or any of the adjustment knobs on the front panel of the RSB-WC equipment for the time being, so that combustion tests or temperature calibration can be performed directly later on.

4.3 Sample Pretreatment and Mounting

4.3.1 Wstępne przygotowanie próbki

Sample Cutting: Cut wire and cable test specimens to a sufficient length in accordance with the standard, and remove any oil or impurities from the surface. Requirements for sample length in the IEC 60695-11-2 (GB/T 5169.14) standard: The test specimen shall be a single length of wire or cable measuring (600 ± 25) mm.

Conditioning: Allow the sample to stand in the test environment (23±2°C, 50±5% humidity) for at least 24 hours.

4.3.2 Sample Installation and Bunsen Burner Adjustment

Round cable: The distance between the flame contact point and the lower edge of the horizontal bracket is 475 ± 5 mm;

Flat cable: The flame contact point is located in the center of the flat section, 475 ± 5 mm from the lower edge of the upper support;

Adjust the angle of the Bunsen burner to 45°, use the push-pull rod to push the Bunsen burner all the way down, and secure the pretreated sample to the sample holder in reference to the Bunsen burner’s position, ensuring the sample is vertical and does not wobble. Use a gauge to confirm the distance between the Bunsen burner and the sample so that the tip of the inner blue cone of the flame just touches the sample surface, as shown in the standard diagram below:

Rysunek 11

Place the collection tray directly beneath the sample to collect the combustion droplets.

5. Cable Combustion Test Procedure

5.1 Ustawianie parametrów testu

Burn Time Setting: Set the burn time based on the equivalent diameter of the sample cable:

Rysunek 12

Equivalent Diameter Conversion: For non-circular cables (such as flat cables), measure the circumference and convert it to an equivalent diameter (calculated as if it were a circular cable).

Afterglow Time Setting: The standard does not specify a value for afterglow time. If you are conducting tests in accordance with other standards and need to use the afterglow time to calculate the burning rate, please set a reasonable afterglow time.

5.2 Procedura testowa

First, use the push-pull rod to move the Bunsen burner away from the sample;

Tap “Propane On,” press and hold the “Ignition” button to light the flame, then tap “Air On”; the unit will automatically maintain the flame;

Once the flame has stabilized, use the push-pull rod to slowly move the Bunsen burner to the test position. At the same time, tap “Start Test” on the touchscreen, and the burn time countdown will begin,

During the test, monitor the combustion status of the sample through the observation window and record whether the fire spreads, if there are any dripping materials, and other such phenomena;

Once the burn time has elapsed, the equipment automatically shuts off the propane and air supplies, the flame goes out, and the “afterglow time” begins;

When the sample’s afterglow has completely extinguished, immediately click “Afterglow Pause” and record the afterglow duration.

6. Procedury po teście

6.1 Equipment Operation After Testing

6.1.1 Bezpieczne postępowanie

After the test is complete, click the “Fan” button to activate the exhaust system and remove smoke and toxic gases from the chamber. Wait at least 5 minutes for the chamber to ventilate before opening the door.

If testing is not to be continued that day, turn off the equipment, the propane tank, and the air compressor.

6.1.2 Equipment Cleaning

After the equipment has cooled, wipe the inner walls of the test chamber, the Bunsen burner, and the sample holders with a dry cloth to remove any combustion residues.

If any burning droplets fall, please clean the drip tray and dispose of the droplets in accordance with environmental protection requirements.

6.2 Recording and Organizing Experimental Data

The test report must include the following:

Sample type, specifications, preparation methods, and pretreatment conditions;

Number of test specimens, installation locations, and flame application points;

Test parameters: burn time, afterglow time;

Test Observations: Whether the sample ignites, the duration of the afterglow, and whether the sample is completely burned;

Test Results: Passed—the distance between the lower edge of the upper support and the starting point of the charred area is >50 mm; Criteria for Failure: The fire extends downward to a distance greater than 540 mm from the lower edge of the upper support; Re-testing Rules: If the initial test fails, new samples must be prepared for two re-tests. If both re-tests pass, the batch of samples is deemed to have passed.

6.3 Przygotowanie próbki

If samples are not completely burned after testing, they should be classified and disposed of as waste. If they contain toxic or flammable residues, they must be sealed and handed over to a specialized agency for disposal.

Retain a portion of the samples after testing for subsequent review or to verify the results.

6.4 Equipment Storage

6.4.1 Short-Term Storage Requirements

If the equipment is for everyday use, no special handling is required.

6.4.2 Requirements for Long-Term Storage

If the device will not be used for an extended period (more than one month), please unplug the power cord 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 electrical components (such as capacitors and contactors) from deteriorating.

7. Kalibracja temperatury

7.1 Calibration Preparation

7.1.1 Calibration Conditions

Ambient temperature: 23 ± 2 °C; relative humidity: 50 ± 5%; no airflow disturbances;

The calibration copper block and thermocouple are in good condition; the copper block is made of Cu-ETP UNS C11000.

7.1.2 Basis for Calibration

Requirements regarding the temperature rise time in the IEC 60695-11-2 (GB/T 5169.14) standard: The time required for a copper block to heat up from 100°C ± 5°C to 700°C ± 3°C shall be 46 s ± 6 s.

Procedura 7.2

Adjust the flame according to the procedure in Section 4.2, then extinguish the flame.

Insert the thermocouple plug into the Omega Type K thermocouple socket provided in the test chamber, and secure it using the standard copper block 95 mm directly above the burner nozzle, ensuring that the flame fully contacts the copper block.

Rysunek 14

Rysunek 15

Close the test chamber door, enter the temperature calibration interface, and set the following: start temperature to 100°C, end temperature to 700°C, and leave the temperature correction at the default value. Click “Reset” to clear the historical data.

Return to the operating screen, tap “Air On” and “Propane On,” then press and hold “Ignition.”

Rysunek 16

Return to the temperature calibration screen and observe the current temperature and heating time displayed on the touchscreen. The timer starts automatically when the copper block reaches 100°C and stops automatically when it reaches 700°C.

Repeat the calibration three times, allowing the copper block to cool naturally to below 50°C after each measurement.

Calculate the average time for the temperature rise based on the three measurements; if it falls within 46 s ± 6 s, the flame meets the requirements. A single temperature calibration is sufficient for each tank of propane gas.

7.3 Handling Calibration Temperature Deviations

The temperature rise time is used to determine whether the propane gas you are using, the flame being calibrated, and the test conditions meet the standard test requirements. If the temperature rise time is incorrect, it means your test does not meet the standard requirements; it does not indicate that there is a problem with the equipment itself.

8. Rutynowa konserwacja

Cykl konserwacji	Projekty konserwacyjne	Operacje konserwacyjne
Po każdym teście	Czyszczenie sprzętu	1. Wipe down the interior and exterior of the test chamber, the viewing window, and the fixtures; 2. Clean up any drips and soot from the drip tray
Raz w tygodniu	Konserwacja łożysk	Wipe down the linear bearing rail with a cloth dipped in organic oil to ensure that the moving parts operate smoothly.
Raz w miesiącu	Gas System Inspection	1. Check the gas connection for leaks (using soapy water); 2. Inspect the hoses for signs of aging and replace them if necessary; 3. Clean the flow meter and differential pressure gauge
Raz na 3 miesiące	Kalibracja płomienia	The time required to heat the copper block from 100°C ± 5°C to 700°C ± 3°C should be 46 s ± 6 s.
Raz na 6 miesiące	Inspekcja instalacji elektrycznej	1. Check that the power lines and ground terminals are secure; 2. Replace worn-out fuses; 3. Test the ignition system’s performance
Raz w roku	Kompleksowa konserwacja	1. Replace the gas hose and gaskets; 2. Calibrate the touchscreen’s timing accuracy; 3. Inspect the Bunsen burner for wear and replace it if necessary; 4. Contact the supplier to arrange for professional testing and calibration

9. Rozwiązywanie problemów i rozwiązywanie typowych problemów

9.1 Ignition Failure

Objawy usterki	Możliwe przyczyny	Podejście
No flame when the ignition button is held down	Propane cylinder not opened / pressure regulator not adjusted	Open the main valve on the gas cylinder and adjust the pressure regulator to approximately 0.1 MPa.
	Propane Flow Too Low/Pipe Blockage	Flush the tubing and adjust the flow rate to 650 ± 30 mL/min.
	Ignition Electrode Misalignment	Adjust the ignition needle so that it is 3–5 mm from the flame outlet.
	Igniter Malfunction	Contact customer service to have the igniter replaced

9.2 Flame Height Does Not Meet Standards

Objawy usterki	Możliwe przyczyny	Podejście
The total flame height is too low	Insufficient propane flow / Excessive air flow	Increase the propane flow rate, decrease the air flow rate, and take the measurement again.
The total flame height is too high	Excessive propane flow / Insufficient air flow	Reduce the propane flow rate, increase the air flow rate, and take the measurement again.
No Blue Flame Heart	Niewystarczający przepływ powietrza	Increase the airflow and adjust until a blue flame core appears.

9.3 Temperature Rise Time Does Not Meet Requirements

Objawy usterki	Możliwe przyczyny	Podejście
Time to reach temperature > 52 seconds	Insufficient flame power / Poor contact with the copper block	Readjust the flame height and flow rate, and check that the copper block is securely installed.
Warm-up time < 40 seconds	Excessive flame power / Temperature measurement error in the copper block	Reduce the propane flow rate, calibrate the temperature sensor, and contact the manufacturer for calibration.

9.4 Awarie elektryczne

Objawy awarii	Możliwe przyczyny	Podejście
No display on the touchscreen	Power Not Connected/Fuse Blown	Check the power connection and replace the fuse with one of the same rating.
Przycisk nie odpowiada	Touchscreen Malfunction/Poor Circuit Connection	Restart the device, check the internal wiring, and contact customer service for repairs.
The device automatically shuts down	Overload Protection / Unstable Power Supply Voltage	Check the power supply voltage, avoid operating the device under overload conditions, and restart the device.

9.5 Other Faults

Objawy usterki	Możliwe przyczyny	Podejście
Combustion fumes cannot be vented	Clogged exhaust duct / Fan malfunction	Clean the exhaust duct, check the fan’s operating condition, and replace the fan if it malfunctions.
The sample is not secured properly	Loose Bracket Clamps	Adjust the fixture to ensure the sample is vertical and does not wobble.
Significant Deviations in Test Data	The equipment is not level / Ambient temperature and humidity are outside the specified range	Recalibrate the equipment’s level and adjust the ambient temperature and humidity to the standard range.