IEC 60601-1 Winding Temperature Rise Tester
The KINGPO Winding Temperature Rise Tester is designed for determining the temperature rise of electrical windings by the resistance method. It is intended for transformers, motors, electromagnetic coils and other applicable winding components used in medical electrical equipment, supporting temperature-rise evaluation according to IEC 60601-1 and GB 9706.1.
By comparing winding resistance before and after the specified operating period, the system provides the measurement data required to determine the average winding temperature rise without relying solely on surface temperature measurement.
- Primary Use: Winding temperature rise measurement by resistance method
- Applicable Standards: IEC 60601-1; GB 9706.1-2020
- Typical Test Objects: Transformer windings, motor windings, electromagnetic coils and similar winding components
- Resistance Range: 0–10000 Ω
- Resistance Accuracy: ±0.1%
- Temperature Range: 0–125℃
- Temperature Accuracy: ±0.5℃
- Load Current Capacity: 30 A
- Software: PC software included
- Typical Users: Medical electrical equipment laboratories, certification and inspection laboratories, manufacturers and R&D departments
IEC 60601-1 Winding Temperature Rise Tester
Product Overview
Electrical windings inside transformers, motors and electromagnetic components may operate at temperatures that cannot be represented accurately by measuring only the external surface of the component.
For applicable winding measurements, IEC 60601-1 uses the change in winding resistance as a means of determining average winding temperature. The initial resistance is measured under a stabilized thermal condition, the DUT is then operated under the specified test condition, and the heated winding resistance is determined at the end of the test.
The KINGPO Winding Temperature Rise Tester is designed around this laboratory workflow. The current project configuration provides a resistance measurement range of 0–10000 Ω, resistance accuracy of ±0.1%, temperature measurement from 0–125℃ with ±0.5℃ accuracy, and a specified 30 A load current capacity. PC software is included for measurement support and data handling. These values are based on the supplied project specification.
The system is intended for winding temperature-rise evaluation rather than general surface-temperature monitoring. Final compliance depends on the applicable temperature limit, DUT construction, winding material, insulation system, operating condition and the relevant IEC 60601-1 or particular-standard requirements.
Technical Specifications
| Parameter | Specification |
|---|---|
| Resistance Measurement Range | 0–10000 Ω |
| Resistance Measurement Accuracy | ±0.1% |
| Temperature Measurement Range | 0–125℃ |
| Temperature Measurement Accuracy | ±0.5℃ |
| Load Current Capacity | 30 A |
| Measurement Principle | Winding temperature determination by resistance change |
| PC Software | Included |
| Traceability Documentation | Verification or calibration certificate required |
| Applicable Standards | IEC 60601-1; GB 9706.1-2020 |
Winding Temperature Rise Measurement Principle
The electrical resistance of a metallic conductor changes with temperature. For a winding, this relationship allows its average temperature to be determined without placing a temperature sensor inside the winding.
For a copper winding, the temperature rise can be calculated from the initial and final resistance values:
where:
- ΔT = winding temperature rise
- R₁ = winding resistance before the heating test
- R₂ = winding resistance at the end of the test
- T₁ = ambient temperature at the beginning of the test
- T₂ = ambient temperature at the end of the test
The calculation therefore depends on both resistance measurement and ambient temperature measurement.
For winding materials other than copper, the applicable temperature coefficient and calculation method should be confirmed before testing.
Typical Test Workflow
Stabilize the DUT
Allow the DUT and winding to reach the required initial thermal condition before measurement.
Measure Initial Resistance
Measure the cold winding resistance R₁ and record the initial ambient temperature T₁.
These values form the reference condition for the temperature-rise calculation.
Operate the DUT
Run the medical electrical equipment under the voltage, load, duty cycle and operating condition specified by the applicable test procedure.
Testing may continue until the required operating period or thermal stability condition has been reached.
Measure Hot Winding Resistance
At the end of the operating period, determine the heated winding resistance R₂ and record the ambient temperature T₂.
Where the resistance can only be measured after the DUT is switched off, the measurement should be performed as quickly as practicable.
Calculate Winding Temperature Rise
Use R₁, R₂, T₁ and T₂ to calculate the average winding temperature rise.
Evaluate Against the Applicable Limit
Compare the result with the temperature limit applicable to the specific winding, insulation system and medical electrical equipment.
The acceptance limit is defined by the applicable standard and DUT construction, not by the tester itself.
Important Measurement Considerations
Minimize the Delay After Power-Off
A winding begins cooling immediately after the DUT is switched off.
If resistance measurement is delayed, the measured hot resistance may be lower than the value corresponding to the actual end-of-test temperature.
For this reason, the switching and measurement sequence should be planned before the test begins.
Where required by the test procedure, several resistance readings may be taken at short intervals after switch-off to support estimation of the winding resistance closer to the instant of power removal.
Confirm the Winding Material
The resistance-to-temperature calculation depends on conductor material.
The commonly used coefficient in the IEC resistance method applies to copper windings. Aluminium or other conductor materials require confirmation of the appropriate calculation method.
Distinguish Winding Temperature from Surface Temperature
A thermocouple attached to the outside of a transformer or motor measures the temperature at the sensor location.
The resistance method instead determines the average temperature of the winding conductor.
The two values therefore serve different measurement purposes and should not automatically be treated as equivalent.
Confirm the 30 A Current Requirement
The supplied specification defines 30 A as load current capacity.
It should not be interpreted as:
- a 30 A resistance measurement current;
- a confirmed 30 A DUT operating range under every connection condition;
- confirmation of live energized resistance measurement.
The actual current path and switching architecture should be confirmed according to the final DUT configuration.
Typical Applications
The tester is suitable for temperature-rise evaluation of winding components where resistance-based measurement is applicable.
Medical Power and Isolation Transformers
Used to evaluate winding temperature rise in power transformers, isolation transformers and other magnetic components incorporated into medical electrical equipment.
Motor Windings
Applicable to motors used in pumps, fans, actuators, positioning mechanisms and other electrically driven assemblies, provided the winding can be accessed for resistance measurement.
Electromagnetic Coils
Suitable for applicable solenoid coils, actuator coils and electromagnetic assemblies where winding temperature rise needs to be evaluated.
Medical Electrical Equipment Compliance Testing
The system can be integrated into IEC 60601-1 and GB 9706.1 thermal test programs performed by:
- medical device testing laboratories;
- certification and inspection laboratories;
- manufacturer compliance laboratories;
- R&D and product verification departments.
Typical work includes type testing, design verification, pre-compliance evaluation and comparative thermal testing.
PC Software and Test Data
One set of PC software is included in the current configuration. Depending on the final system configuration, software may be used to support measurement, test-data recording and laboratory result management.
Calibration and Traceability
For laboratory and inspection applications, the Winding Temperature Rise Tester should be supplied with appropriate traceability documentation for the key measurement functions used in the test.
The current project requirement specifies that a verification certificate or calibration certificate is required for the equipment, supporting equipment acceptance, laboratory quality management and routine compliance testing.
Technical Inquiry & Expert Support
To confirm the appropriate configuration, please provide the following basic information:
| Information to Provide | Details |
|---|---|
| Applicable standard | Standard number and edition |
| DUT type | Equipment or component to be tested |
| Expected winding resistance | Approximate resistance range |
| DUT voltage and operating current | Rated electrical conditions |
| Number of windings | Number of windings to be measured |
| Winding material | Copper, aluminium or other material |
If the project has special requirements for automatic switching, software recording, calibration documentation or energized winding measurement, please indicate them when requesting a quotation.
IEC 60601-1 Winding Temperature Rise Tester
FAQ
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