1. Unboxing and Basic Understanding of the Equipment

1.1 Spesifikasi Teknis Utama

LISUN Pilih Model	ZY-3	ZY-3S
Nama Produk	Dengan perumahan	Tanpa kasus
Sudut Pembakar	Adjustable; tilted at 45° during testing; vertical during flame height calibration
Gas Pembakaran	≥95% butana (pengukur aliran gas elektronik opsional)
Rentang Pengukuran Suhu	0 – 1000 ° C
Requirements for Increasing Flame Temperature	Heated from 100°C ± 2°C to 700°C ± 3°C in 23.5 s ± 1 s
Thermocouples for Temperature Measurement	Φ0.5 mm Type K
Number of Ignition Attempts per Test	Can be set for single or multiple consecutive ignitions
Bahan tubuh	High-temperature spray-coated steel structures are heat-resistant and corrosion-resistant, making them suitable for long-term high-temperature testing environments.
Tampilan Operasi	Layar sentuh LCD ekstra besar eksklusif + lampu indikator yang jelas + pengoperasian dengan remote control.
Berat	Berat kotor 180 kg	Berat kotor 40 kg

1.2 Pemeriksaan dan Verifikasi Aksesori Saat Membuka Kemasan

1.2.1 Membuka Kemasan dan Pemeriksaan Visual

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 gauges 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 for use.

Buka pintu ruang uji dan periksa apakah ada komponen internal yang terlepas selama pengiriman atau apakah ada kelainan lain.

If you notice anything unusual, please contact us promptly.

1.2.2 Unit Utama dan Aksesoris

Needle Flame Test Main Unit: 1 unit.

Standard accessories include: ① Exhaust pipe, ② Copper block and thermocouple, ③ Silk paper, ④ Remote control, ⑤ Gauge, ⑥ Sample tray, ⑦ Igniter, ⑧ Stainless steel hose clamp (for securing the exhaust pipe), ⑨ Spare needles, spare fuses;⑩ Power cord, ⑪ Gas supply unit, ⑫ Butane gas.

Gambar 1

Note: Butane gas and batteries are classified as hazardous materials and may not be shipped with the product. Please purchase compliant gas on your own for testing purposes. If you need to use a remote control, please also purchase batteries specifically designed for the remote control.

Gambar 2

The remote control has the same functions as the touchscreen buttons; users can choose whether or not to use the remote control.

Note: Download links for the electronic user manual, warranty card, and other documents have been sent via email. Please download them promptly. If you missed the email, you may contact us directly to request the download links again.

1.3 Deskripsi Struktur Peralatan

1.3.1 Tampilan Depan Ruang Uji

① Touchscreen; ② Power controls, circuit breaker, and power on/off buttons; ③ Butane gas flow meter; ④ Test chamber door.

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1.3.2 Bagian Belakang Ruang Uji

Gambar 4

① Exhaust vent, 100 mm in diameter, securely connected to an exhaust pipe that extends to the outdoors; ② Butane inlet; ③ Power cord receptacle. 

1.3.3 Di Dalam Ruang Uji

① Needle-flame burner, with adjustable height and angle; ② Sample holder, with adjustable position to meet different testing requirements; ③ Omega Type K thermocouple connector; ④ Thermocouple compensation lead.

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Note: These are required when measuring the temperature rise in steps ③ and ④.

2. Tindakan Pencegahan Keamanan

2.1 Keamanan Listrik

2.1.1 Koneksi Daya

220V single-phase power; power outlets must comply with safety standards, provide 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 Spesifikasi Pembumian

The equipment must be reliably grounded, with a grounding resistance of ≤4 Ω. Do not use gas lines, 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 the resistance meets the requirements, to prevent electric shock, equipment malfunction, or measurement errors caused by poor grounding.

2.1.3 Kontraindikasi untuk Prosedur

Before wiring, inspecting, or maintaining equipment, the main power supply to the equipment must be disconnected, and operation may only begin after confirming that there is no residual voltage;

Jangan mengoperasikan sakelar daya peralatan, layar sentuh, atau tombol instrumen dengan tangan basah untuk menghindari risiko sengatan listrik;

Jangan meletakkan benda asing apa pun (seperti perkakas atau kertas) di dalam kabinet kontrol listrik untuk mencegah debu atau benda asing menyebabkan korsleting atau merusak komponen;

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 Keselamatan Operasional

2.2.1 Keselamatan Operasional

Saat peralatan sedang beroperasi, orang awam dilarang membongkar atau memperbaikinya. Jika terjadi kerusakan, hubungi petugas layanan purna jual atau operasikan peralatan di bawah bimbingan teknisi;

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 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 problem is resolved may cause further damage to the equipment.

2.2.2 Perilaku yang Dilarang

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

Jangan membuka pintu kabinet kontrol saat peralatan sedang beroperasi untuk menghindari menyentuh komponen tegangan tinggi di dalamnya dan menyebabkan sengatan listrik;

Jangan membongkar komponen inti tanpa izin; memodifikasi peralatan akan membatalkan garansi dan dapat mengakibatkan insiden keselamatan;

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

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

2.3 Keselamatan Lingkungan

2.3.1 Persyaratan Instalasi

Peralatan harus dipasang di ruangan ber-AC di mana suhu lingkungan dijaga antara 5°C dan 25°C dan kelembaban relatif ≤85%. Jika kelembaban lingkungan tinggi, kondensasi dapat terbentuk di dekat pintu peralatan dan port pengujian; dalam kasus seperti itu, tingkatkan ventilasi ruangan atau gunakan alat pengering udara (dehumidifier);

Lokasi pemasangan harus bebas dari konsentrasi debu yang tinggi, gas korosif (seperti sulfur dioksida dan klorin), dan atmosfer yang mudah terbakar atau meledak. Sinar matahari langsung tidak boleh mengenai peralatan untuk mencegah korosi pada wadah peralatan dan kerusakan komponen listrik;

Penyimpanan bahan yang mudah terbakar dan meledak (seperti alkohol, bensin, dll.) dilarang keras di area pengujian untuk mencegah risiko kebakaran atau ledakan;

Butane gas is a highly flammable substance. Store it at a temperature of ≤40°C, and keep it away from direct sunlight, violent impacts, and sources of fire;

Area kerja dilengkapi dengan alat pemadam kebakaran (jenis bubuk kering atau karbon dioksida), dan operator sudah familiar dengan cara menggunakannya;

Keep the equipment away from areas with significant fluctuations in ambient temperature, such as near ventilation ducts and room entrances, to prevent these fluctuations from affecting the equipment’s temperature control accuracy;

Jauhi sumber gangguan medan magnet dan listrik yang kuat (seperti motor listrik besar dan peralatan tegangan tinggi).

2.3.2 Persyaratan Ruang

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

Setidaknya harus ada ruang selebar 2000 mm pada bukaan pintu peralatan untuk memastikan pintu dapat dibuka ke segala arah, sehingga memudahkan penempatan dan pengambilan sampel.

2.3.3 Penempatan Horizontal

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, it will cause the needle flame burner to be misaligned and may result in the displacement of the sample, burner, temperature-rising copper block, and other components, thereby affecting the test results.

2.4 Lainnya

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

3. Pengantar Program Layar Sentuh

3.1 Antarmuka Pengguna

① Burn time; ② Afterglow time; ③ Number of burns; ④ PV is the current value; ⑤ SV is the set value; ⑥ Lighting: Turns on the lighting inside the test chamber to facilitate observation; ⑦ Fan: Expels smoke generated inside the test chamber after the test is complete; ⑧ Start (A): Starts the test;⑨ Reset (B)—click after the test is complete or before the next test begins to clear the test data; ⑩ Afterglow Pause (C)—used to record the time it takes for the sample’s afterglow to extinguish;⑪ Gas On (D), controls the opening and closing of the gas solenoid valve; ⑫ Parameter Settings, enters the parameter settings interface; ⑬ Test Records, views historical test data; ⑭ Temperature Calibration, performs a temperature rise test. Note: The four buttons (A, B, C, D) can also be controlled using a remote control.

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3.2 Antarmuka Pengaturan Parameter

① Burn time setting; ② Afterglow time setting; ③ Number of burns setting.

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Note: If only one burn cycle is required, set the number of burn cycles to 1. If a continuous burn test is required in accordance with a specific standard (such as IEC 62368-1:2023 Annex S S.1), set the number of burn cycles according to the standard; you must also set the burn time and afterglow time separately for each burn cycle.

3.3 Test Record Interface

① Recorded burn time; ② Recorded afterglow time; ③ Reset—tap to clear the data on this page.

Gambar 8

Note: Whether conducting a single-burn test or a continuous-burn test, the system automatically records the burn time and afterglow time for each burn. It can store data for up to 5 burns; once the limit is reached, you must press the reset button to clear the data before continuing to record.

3.4 Temperature Calibration Interface

① Tampilan suhu saat ini; ② Tampilan waktu kenaikan suhu; ③ Mulai pengaturan suhu; ④ Akhiri pengaturan suhu; ⑤ Koreksi suhu (tidak perlu perubahan); ⑥ Atur ulang: Ketuk untuk menghapus data saat ini dan uji ulang waktu kenaikan suhu.

Gambar 9

Note: Common standards (IEC 60695-11-5, IEC 60695-2-2, GB/T 5169.5, etc.) require that the starting temperature for temperature rise tests be 100°C and the ending temperature be 700°C. Users may also set other starting and ending temperatures in accordance with specific standards.

4. Persiapan Sebelum Ujian

4.1 External Environment

Atur suhu lingkungan sekitar menjadi 23±2°C dan kelembapan relatif menjadi 50±5% untuk mencegah faktor lingkungan memengaruhi hasil pengujian. Catatan: Persyaratan suhu dan kelembapan untuk lingkungan penyimpanan peralatan berbeda dengan persyaratan untuk lingkungan pengoperasiannya.

4.2 Flame Adjustment

4.2.1 Connecting the Butane Gas Supply

If you are using our standard gas supply unit, you will need to purchase a butane cylinder of the appropriate size and then connect it using the gas hose provided. ① Gas outlet on the supply unit; ② Gas inlet on the pin-flame device.

Gambar 10

① Lock the butane cylinder; ② Turn the knob to the maximum setting.

Gambar 11

You may also use any other air supply device; simply connect it to the device’s air inlet using a 6mm-diameter air tube.

4.2.2 Flame Adjustment

Adjust the burner nozzle to a vertical position.

Access the touchscreen program interface and tap the “Gas On (D)” button.

Adjust the gas flow meter knob and use the igniter to light the wick. If the gas flow is too high or too low, the wick may not ignite; in this case, continue adjusting the gas flow while attempting to ignite the wick until the flame ignites normally. Special Note: Minimize the time interval between turning on the gas and successful ignition (less than 5 seconds); otherwise, excess gas may accumulate inside the test chamber, creating a hazard during ignition.

Gambar 12

Continue adjusting the flow meter knob and use a gauge to verify that the flame height meets the standard requirements. According to the standards (IEC 60695-11-5, IEC 60695-2-2, GB/T 5169.5, etc.), the flame height should be 12 mm.

Gambar 13

Once the flame is adjusted, there is no need to adjust the flowmeter; simply tap the “Gas On” D button on the touchscreen to shut off the gas.

4.3 Sample Pretreatment and Sample Mounting

4.3.1 Perlakuan Awal Sampel

Test specimens must be complete equipment, assemblies, or components; if a portion of the specimen must be cut off, avoid exposing the cut edge to a flame.

The samples, pine boards, and silk paper should be left at 23±2°C and 50±5% relative humidity for at least 24 hours to ensure they are in a stable condition.

Remove oil, dust, and other contaminants from the sample surface to ensure that the test conditions match those of normal use.

4.3.2 Contoh Instalasi

Adjust the needle to the test angle (45°) according to the standard and secure it in place.

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Go to the work page. Click the “Start (A)” button. The burner will automatically move to the limit stop position. At this point, secure the sample based on the position of the needle.

Gambar 15

According to standard IEC 60695-11-5, the flame application positions are as follows:

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Once the sample is securely in place, click the “Reset (B)” button to return the burner to its initial position. The burner will also automatically return to its initial position once the set combustion time has elapsed. Note: You must click the “Reset (B)” button once before you can click the “Start (A)” button again.

Place the silk paper on the sample holder and position the sample holder directly below the combustion point.

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5. Needle Flame Test Procedure

5.1 Pengaturan Parameter Uji

Set the combustion time, afterglow time, and number of combustion cycles based on the sample properties and standard requirements.

5.2 Prosedur Uji

Press the “Gas On (D)” button on the touchscreen. Use the igniter to light the burner needle. Then close the test chamber door.

Click “Reset (B),” then click the “Start (A)” button to begin the test. The burner moves to the ignition position, and the burn time begins to be timed.

For a single combustion test: When the set combustion time ends, the afterglow time begins to be measured, the gas supply is automatically shut off, and the burner returns to its initial position. If the test specimen catches fire during the test, press the “Afterglow Pause (C)” button when the flame on the test specimen goes out to record the afterglow time.

For multiple combustion tests: At the end of the set first combustion time, the burner returns to its initial position, but the flame does not extinguish. If the sample’s flame does not extinguish within the set first afterglow time, the sample fails the test, and the gas supply is automatically shut off. If the sample’s flame extinguishes within the set first afterglow time, click “Afterglow Pause (C)” to end and record the data for the first ignition, and the burner will automatically return to the sample to start the timer for the second ignition. The third, fourth, and fifth flame application tests are conducted automatically using the same method.

6. Prosedur Pasca-Ujian

6.1 Pengoperasian Peralatan Setelah Pengujian

6.1.1 Penanganan Aman

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.

Close the valve on the gas supply unit, unlock the gas cylinder, remove it, and store it as required (avoid direct sunlight and high temperatures, etc.).

6.1.2 Pembersihan Peralatan

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

If the silk paper or pine board has been damaged by fire, replace it immediately.

Check to see if the burner nozzle is clogged; if there are any impurities, clean it with a fine needle (taking care not to damage the nozzle orifice).

6.2 Pencatatan dan Pengorganisasian Data Eksperimental

The test report must include the following:

Jenis sampel, spesifikasi, metode persiapan, dan kondisi pra-perlakuan;

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

Test parameters: burning time, afterglow time, number of tests;

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

Test Results: Does it meet the flammability requirements (no ignition or afterglow ≤ 30 seconds, and the tissue paper does not ignite)?

6.3 Persiapan Sampel

If samples are not completely incinerated 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.

Simpan sebagian sampel pasca-uji untuk ditinjau kembali atau diverifikasi hasilnya di kemudian hari.

6.4 Penyimpanan Peralatan

6.4.1 Persyaratan Penyimpanan Jangka Pendek

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

6.4.2 Persyaratan untuk Penyimpanan Jangka Panjang

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.

Perangkat ini sebaiknya dinyalakan sekali sebulan selama setengah jam saja untuk mencegah penuaan komponen listrik (seperti kapasitor dan kontaktor).

7. Kalibrasi Suhu

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 and weighs 0.58 g ± 0.01 g.

7.1.2 Basis for Calibration

According to the requirements of Annex A of IEC 60695-11-5 (GB/T 5169.5), the time required for the temperature of a copper block to rise from 100 °C ± 5 °C to 700 °C ± 3 °C is 23.5 s ± 1.0 s.

Prosedur 7.2

Adjust the flame to 12 mm ± 1 mm using the method described in Section 4.2, then extinguish the flame.

Insert the thermocouple plug into the Omega Type K thermocouple socket provided inside the test chamber. Secure it using the standard copper block so that it is positioned 6 mm directly above the burner nozzle, ensuring that the flame fully impinges on the copper block.

Gambar 18

Gambar 19

Go to the temperature calibration screen 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 work interface, click “Gas On (D),” use the igniter to light the burner, and slowly close the test chamber door.

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.

Ulangi kalibrasi sebanyak tiga kali, biarkan blok tembaga mendingin secara alami hingga di bawah 50°C setelah setiap pengukuran.

Calculate the average time to temperature rise based on the three measurements; if it is within 23.5 s ± 1.0 s, the flame meets the requirements.

7.3 Handling Temperature Deviations During Calibration

The temperature rise time is used to determine whether the butane 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 a problem with the equipment itself.

8. Perawatan Rutin

Siklus Pemeliharaan	Proyek Pemeliharaan	Operasi Pemeliharaan
Setelah setiap tes	Pembersihan Peralatan	1. Wipe down the interior and exterior of the test chamber, the observation window, and the fixtures; 2. Clean up any drips and soot from the sample tray.
Seminggu sekali	Pemeliharaan bantalan	Wipe down the linear bearing rail with a cloth dampened with mineral oil to ensure the moving parts operate smoothly.
Sekali sebulan	Inspeksi Sistem Gas	1. Check the gas connection for leaks (using soapy water); 2. Inspect the hoses for signs of aging and replace them if necessary;
Setiap 3 bulan sekali	Kalibrasi Nyala Api	Flame temperature rise test to verify whether the temperature rise time complies with 23.5 ± 1 s
Setiap 6 bulan sekali	Pemeriksaan Sistem Kelistrikan	1. Periksa apakah saluran daya dan terminal pembumian terpasang dengan aman; 2. Ganti sekering yang sudah aus; 3. Uji kinerja sistem pengapian.
Sekali setahun	Perawatan Komprehensif	1. Replace the gas hoses and gaskets; 2. Calibrate the touchscreen’s timing accuracy; 3. Inspect the needles for wear and replace them if necessary; 4. Contact the supplier to arrange for professional testing and calibration

9. Pemecahan Masalah dan Penyelesaian Masalah Umum

9.1 The flame won’t ignite

Gejala Kesalahan	Kemungkinan penyebab	Prosedur
No flame during ignition	1. The valve on the gas supply unit is not open; 2. There is a leak in the gas line; 3. The needle is clogged; 4. The igniter is malfunctioning	1. Open the gas supply valve and make sure there is sufficient gas; 2. Check the pipe connections, tighten any loose parts, and use soapy water to check for leaks; 3. Use a fine needle to remove debris from the needle tip, or replace it with a spare needle; 4. Replace the igniter battery, or replace the igniter with a spare one
Gas is escaping, but it won’t ignite	1. Insufficient gas purity; 2. Excessive gas buildup inside the test chamber; 3. The igniter is too far from the needle	1. Replace the butane/propane gas with a purity of ≥95%; 2. Open the chamber door to ventilate for 5–10 minutes before igniting; 3. Adjust the position of the igniter so that it is close to the tip of the needle when igniting.

9.2 Temperature Calibration Failed

Gejala Kesalahan	Kemungkinan penyebab	Prosedur
The warm-up time is too long	1. Insufficient flame height; 2. Gas flow rate too low; 3. Copper block misaligned	1. Readjust the flame height to 12 mm ± 1 mm; 2. Turn the gas flow meter knob clockwise to increase the gas flow rate; 3. Adjust the position of the copper block to ensure it is 6 mm directly above the needle tip.
The warm-up time is too short	1. Flame height exceeds the limit; 2. Gas flow rate is too high	1. Reduce the gas flow rate and use a gauge to calibrate the flame height; 2. Fine-tune the flow meter knob to reduce the gas supply intensity.
No temperature display	1. The thermocouple is not connected properly; 2. The thermocouple is damaged	1. Unplug and replug the thermocouple connector to ensure a secure connection; 2. Replace the thermocouple with a new one.

9.3 Afterglow duration cannot be recorded

Gejala Kesalahan	Kemungkinan penyebab	Prosedur
After the sample flame goes out, clicking “Afterglow Pause” produces no response.	1. The “Start” button was not pressed first; 2. The “Afterglow Pause” button was not reset; 3. Touchscreen malfunction	1. Verify that the test has started and the burn time has elapsed; 2. Press the “Afterglow Pause” button to reset the system before proceeding; 3. Restart the device; if the problem persists, contact customer service.

9.4 The Device Will Not Start

Gejala Kesalahan	Kemungkinan penyebab	Prosedur
The touchscreen does not respond after the power is turned on	1. The power cord is not properly connected; 2. The power supply voltage is abnormal; 3. The fuse has blown	1. Check the power cord connection and make sure the plug is securely inserted; 2. Verify that the power supply voltage is 220V ± 10%; 3. Replace the fuse with one of the same specification (included in the packing list).