Glow Wire Tester – QualiFlame™ GWT
Glow Wire Test Apparatus for Electrical Insulation and Plastics
The QualiFlame™ GWT Glow Wire Tester is designed for fire hazard testing of electrotechnical products, plastics, and electrical insulation materials. The system uses an electrically heated nickel-chromium loop as the ignition source to evaluate how finished products, molded components, and insulation materials respond when exposed to a glowing element.
The glow wire test apparatus operates from 500°C to 1000°C with temperature stability of ±2°C. During testing, the heated wire contacts the specimen under a calibrated force of 0.97 N. The instrument is suitable for appliance manufacturers, electrical component suppliers, polymer testing laboratories, and certification organizations conducting glow wire flammability and fire resistance evaluations.
Available Configurations
The QualiFlame™ GWT is available in two configurations: a version with an integrated test chamber and a configuration without the chamber. The chambered model provides an enclosed testing area exceeding 0.5 m³, featuring a dark interior and black test background to improve flame visibility through the large viewing window.
An included exhaust pipe helps direct combustion products away from the testing area during operation. A touchscreen control system manages the test sequence, while a separate remote control box provides convenient operation near the specimen.
Temperature and Ignition Time Measurement
A digital timer controls the standard 30-second contact period with an accuracy of ±0.1 seconds. Separate timing channels measure ignition time and flame extinction time over a range of 0 to 999.9 seconds. Test timing data is recorded automatically, while manual timeout control is also available when required.
The system uses an armored Type K thermocouple rated from -40°C to 1100°C to measure the glow wire tip temperature. Temperature data is displayed through a digital indicator for clear monitoring during the test.
Glow Wire Heating and Safety Features
The QualiFlame™ GWT provides continuously variable current adjustment for precise control of glow wire heating. A built-in ammeter allows operators to monitor the heating current directly during testing.
For electrical protection, the control system incorporates fuses and a miniature circuit breaker. These safety components help protect the electrical control circuit during operation.
The QualiFlame™ GWT provides a controlled setup for glow wire testing, fire hazard evaluation, ignition behavior analysis, and flame extinction measurement of electrical insulation, plastics, and electrotechnical components.
Glow Wire Tester – QualiFlame™ GWT Applications
The QualiFlame™ GWT Glow Wire Tester supports fire hazard evaluation for electrical products, plastics, polymer materials, and electrical insulation. It is suitable for product development, quality assessment, material evaluation, and third-party testing.
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Household Appliance Manufacturing: Evaluates housings, terminal blocks, and internal plastic components used in refrigerators, washing machines, and small kitchen appliances for resistance to ignition caused by overheated components.
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Electrical Connectors and Terminal Blocks: Tests insulating housings and components positioned near current-carrying conductors and screw terminals to assess ignition behavior under glowing wire contact.
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Switches, Sockets, and Wiring Accessories: Evaluates finished wiring devices to determine their response to contact with a heated glow wire and assess the potential for localized ignition to spread.
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Plastics and Polymer Compounding: Supports evaluation of flame-retardant polymer formulations by analyzing ignition temperature and burning behavior during material development and grade qualification.
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Wire and Cable Insulation: Assesses insulation and jacketing compounds for resistance to ignition when exposed to glowing contact points, overheated connections, or similar thermal conditions.
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Lighting Fixtures and Luminaires: Tests lamp holders, drivers, diffusers, and other polymer components positioned near sustained heat sources.
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Automotive Electrical Components: Evaluates fuse boxes, relay housings, connector bodies, and other electrical components used in automotive wiring systems.
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IT and Audio-Video Equipment: Tests enclosure materials and internal polymer components used in power supplies, adapters, and electronic equipment for their response to glowing wire contact.
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Certification and Third-Party Laboratories: Supports glow wire testing for product evaluation, including the determination of glow wire flammability and ignition temperature characteristics for certification and approval processes.
Glow Wire Tester Standards
The QualiFlame™ GWT is designed around internationally recognized glow wire test methods covering apparatus configuration, glow wire temperature control, specimen contact, and testing procedures.
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IEC 60695-2-10: Fire hazard testing – Part 2-10: Glowing/hot-wire based test methods – Glow-wire apparatus and common test procedure.
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UL 746A: Standard for Polymeric Materials – Short Term Property Evaluations.
These standards provide test procedures and requirements used to evaluate the fire-related behavior of polymeric and electrical insulating materials under controlled glow wire conditions.
Glow Wire Tester – QualiFlame™ GWT Key Features
The QualiFlame™ GWT Glow Wire Tester combines precise temperature control, automated timing, and adjustable electrical current to provide consistent and controlled glow wire testing for plastics, electrical insulation, and electrotechnical components.
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Touchscreen Program Control: Controls the approach, contact, dwell, and withdrawal sequence according to preset parameters, reducing operator-dependent timing variations during glow wire testing.
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Remote Control Box: Allows operators to start and stop the test sequence from a convenient position while maintaining direct visibility of the specimen.
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Optional Integrated Test Chamber: Available with or without an integrated enclosure, providing flexibility for laboratories with existing extraction or testing enclosures.
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Precision Contact Timer: Controls the standard 30-second contact period with ±0.1 s accuracy and provides a timer range from 0 to 9999 seconds.
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Separate Ignition and Extinction Timing Channels: Records ignition and flame extinction times independently over a range of 0 to 999.9 seconds, with automatic data recording and manual timeout functionality.
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Continuously Variable Current Adjustment: Provides smooth control of glow wire heating current, allowing operators to achieve the required tip temperature without changing fixed current ranges.
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Built-In Ammeter Monitoring: Displays glow wire current in real time, providing an additional reference during temperature setup and test operation.
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Digital Temperature Indicator: Displays the measured glow wire tip temperature directly for convenient monitoring during calibration and testing.
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Armored Type K Thermocouple: Covers a temperature range of -40°C to 1100°C and is designed for repeated glow wire testing cycles.
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Nickel-Chromium 80/20 Glow Wire: Uses a Ø4 mm ±0.04 mm nickel-chromium glow wire to maintain the specified geometry and consistent heat transfer during testing.
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Calibrated Application Force: Applies the specified contact force to help maintain consistent specimen contact and improve test repeatability between laboratories.
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Controlled 7 mm Penetration Limit: Limits glow wire travel to the specified penetration depth, helping prevent excessive penetration through thin test specimens.
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Dark Interior and Black Background: Improves visibility of brief or low-intensity flames, supporting accurate observation and timing during the test.
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Supplied Exhaust Pipe and Buckle: Provides a dedicated route for combustion products to exit the test area without requiring a custom extraction connection.
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Consumables Kit Included: Includes a spare glow wire loop, thermocouple, silver foil, metal brush, pine board, tissue paper, and specimen disc for testing and maintenance requirements.
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Fuse and Miniature Circuit Breaker Protection: Provides electrical protection for the control circuit against overload during extended testing and high-temperature operation.
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Customizable Power Supply and Interface Language: Supports different local power supply configurations and operator interface language requirements for international laboratory use.
Theory and Method
The QualiFlame™ GWT Glow Wire Tester reproduces a localized thermal failure that can occur in electrical and electronic products. An overheated component, damaged connection, overloaded resistor, or heating element can reach high temperatures and come into contact with nearby plastic or electrical insulation. Glow wire testing evaluates whether the material ignites under this contact and measures how long any resulting flame continues after the heat source is removed.
The test uses a 4 mm diameter nickel-chromium 80/20 glow wire as the standardized heat source. Its electrical resistance and thermal characteristics provide a controlled heating element for repeatable testing cycles.
Resistive Heating and Temperature Control
Electrical current passes through the nickel-chromium wire, generating heat through electrical resistance. The glow wire reaches an equilibrium temperature when the electrical heat input balances heat losses through radiation and convection.
An armored Type K thermocouple positioned at the glow wire tip measures the actual temperature directly. This provides a more reliable temperature measurement than estimating temperature from electrical current alone. The control panel includes adjustable current control and an ammeter, allowing operators to fine-tune the heating conditions before and during testing.
Specimen Contact and Mechanical Control
Mechanical test parameters are also critical for consistent glow wire testing. The specimen carriage advances at 18 mm/s, applies a calibrated contact force of 0.97 N, and limits penetration to 7 mm. These controlled parameters help prevent excessive penetration through thin-wall specimens and maintain consistent contact conditions throughout the test.
During the test, operators monitor and record key observations, including ignition time, flame extinction time after glow wire withdrawal, and whether burning particles ignite the tissue paper positioned on the pine board beneath the specimen.
The resulting observations can be used to determine the applicable flammability index, ignition temperature characteristics, or pass/fail assessment, depending on the test method and product requirements.
Glow Wire Tester - QualiFlame™ GWT Technical Specifications
| Parameter |
Specification |
| Model |
QualiFlame™ GWT |
| Configuration |
With or without integrated test chamber |
| Glow Wire Element |
Ø4 mm ±0.04 mm, nickel-chromium 80/20 |
| Temperature Range |
500°C to 1000°C, continuously adjustable |
| Temperature Accuracy |
±2°C |
| Thermocouple |
Ø1.0 mm Type K (Ni/Cr-Ni/Al), armored sheath rated -40°C to 1100°C |
| Searing Time |
30 s ±0.1 s (OMRON H5CN-XAN-Z digital timer, 0 s to 9999 s, preset table) |
| Ignition Timing |
0 s to 999.9 s ±0.1 s, automatic recording, manual timeout |
| Flame Extinction Timing |
0 s to 999.9 s ±0.1 s, automatic recording, manual timeout |
| Penetration Depth |
7 mm ±0.5 mm |
| Application Force |
0.97 N ±0.1 N |
| Approach Speed |
18 ±3 mm/s |
| Test Background |
Black |
| Test Process |
Automatic control, independent test cycle |
| Test Chamber Volume |
≥0.5 m³ (chambered configuration) |
| Control System |
Microcontroller with touch screen program |
| Reference Standards |
IEC 60695-2-10, UL 746A |
| Voltage |
220 V, 48 Hz to 60 Hz, 800 VA (110V is also available) |
| Display Panel Language |
English (other languages available on request) |
