GWT-200 MANUAL INDEX
Contents
1. EDAD PRODUCT SAFETY SOLUTIONS USER S MANUAL GLOW WIRE TESTER MODEL GWT 200 Serial No 35090 06 MUUUOUUOUUUUUUUN ZHUHAI KEERMAI TESTING Co LTD www keermai com Email info keermai com TEL 0756 3353658 FAX 0756 3361895 HOOOOBDEBOUOLeoOOUOODuUUg Ir D amp D PRODUCT SAFETY SOLUTIONS Topic Introduction e Warnings e Before Using e Product Purpose system Components Product Specifications e Electrical Environmental Test Parameters Fuses Symbols Labels Installation Instructions Operating Instructions Maintenance Parts Service Troubleshooting Calibration Reference Standards Warranty READ THE ENTIRE MANUAL BEFORE USING THE GWT 200 MANUAL INDEX GLOW WIRE TESTER 15 15 16 17 EDAD PRODUCT SAFETY SOLUTIONS GWT 200 GLOW WIRE TESTER IMPORTANT INSTRUCTIONS SAVE THESE INSTRUCTIONS Introduction Thank you for choosing the ED amp D GWT 200 Glow Wire Tester With proper use care and regular calibration it will provide many years of accurate and reliable service Upon receiving the unit please check for obvious physical damage to the packaging material and the instrument itself If any damage is evident please immediately notify your ED amp D representative We strongly recommend you keep all ED amp D packaging for future shipping requirements WARNING WARNING THE GLOW WIRE TEST INVOLVES A RISK OF FIRE YOU MUST PROPERLY PREPARE FOR CONDUCTING THIS2. Install and adjust foot height to level the unit Verify Sample Carriage Operation Verify that the carriage assembly is rolling smoothly If the assembly is not rolling or not rolling smoothly verify that the tensioning cord to the weight is properly seated in the pulley and not tangled with the carriage assembly e If difficulties persist remove the rear carriage cover to access the roller system Replace the cover after correcting the problem Tensioning cord should sit in groove Carriage in pulley assembly should roll smoothly Tensioning cord in out should be a straight connection Remove right side cover to correct any movement problems EDAD PRODUCT SAFETY SOLUTIONS INSTALLATION INSTRUCTIONS Continued 7 Install Flame Height Gauge Install the flame height gauge ruler on post The gauge is to be rotated such that the entire length of the ruler is facing forward entire length visible while operating the GWT 200 This gauge is used to measure the flame height during testing e DO NOT attempt to adjust the height of the ruler on the mounting bracket The zero position of the ruler is set to coincide with the top front of the glow wire e You can adjust how close the ruler is to the glow wire by changing the mounting position of the ruler bracket Position of support post can be changed to move the gauge closer farther to the glow wire 8 Main Electrical Conn
3. READ MANUAL BEFORE USING e Enclosure Panels for Qualified Service Personnel access only FUSE REPLACEMENT Fuseholders located on front panel e See fuse ratings in table above For continued protection against shock amp fire replace only with the same type amp rating of fuse Use only UL CSA BSI or VDE certified fuses Ir ID AD PRODUCT SAFETY SOLUTIONS INSTALLATION INSTRUCTIONS 1 Remove from Crate CAUTION The Glow Wire Tester is VERY heavy 72 lb 33 Kg Two people are required to remove the Glow Wire Tester from the crate Be sure to use proper lifting techniques Use care when removing the flame height gauge ruler Product Support This product is intended to be used within a fume flame hood on a tabletop capable of safely supporting the weight of the unit 72 lb 33 Kg The standard specifies conducting the Glow Wire Test in a draft free chamber with a minimum 0 5 m volume Install Feet Install each of the adjustable height feet into the integral studs on the bottom of the unit Leveling IMPORTANT To insure the correct force is applied to the test sample it is essential that the GWT 200 is level when used A bubble level is installed on the unit base to use in leveling Adjust the height of each foot until level and tighten the position nut after adjustment Use bubble level when leveling the GWT 200 Release the Sample Carriage Cut tie wraps to release the sample carriage
4. PRODUCT SAFETY SOLUTIONS OPERATING INSTRUCTIONS Continued 5 Attach Test Samples Loosen the sample securement brackets and slide the test sample between them tighten the brackets with the sample in position e NOTE Additional holes are provided in the backing plate to allow you to move the bracket position and adjust the spacing between the brackets The backing plate is also adjustable e IMPORTANT The test sample should be positioned in the center of the sample platform e IMPORTANT The brackets must be spaced away from the backing plate by at least 9 mm to insure that the glow wire has room to penetrate the test sample without contacting the backing plate Spacer bolts between brackets amp backing plate have been provided to insure this spacing do not remove the spacer bolts 6 Adjust Stop To set the 7 mm penetration depth limit a Loosen the set screw in the adjustable stop b Move the carriage assembly forward until the sample is touching the glow wire c Slide the 7mm spacer and the stop forward until spacer is in contact with the stop bracket d Tighten the set screw in the stop this sets the maximum wire penetration depth at 7 mm as required by the standard Sample in contact with T glow wire i 4 Wr Spacer is against Ck stop bracket Adjustable stop is against spacer 7 Remove Spacer After you have tighten the set screw in the stop pull the carriage assembly back as far as it will go this wi
5. TEST THIS TEST MUST BE ATTENDED AT ALL TIMES BEFORE USING 1 DANGER The Glow Wire operates at very high temperature 1000 C Extreme caution should be observed when using the GWT 200 especially when attaching or removing the test samples 2 DANGER RISK OF HAZARDOUS ENERGY The electrical connections to the glow wire operate at low voltage high energy DO NOT wear jewelry when operating the GWT 200 DO NOT bridge the glow wire connections support rods with any metallic object 3 POTENTIAL FOR FIRE EXPLOSION amp FUMES The Glow Wire Test can ignite your test sample Fumes from burning of test samples can be toxic You must be prepared for these results by conducting this test in the proper fire test environment be sure to operate the Glow Wire Tester in an area that protects the operator from toxic fumes residues and provides for removal of any smoke and fumes after the test flame hood or other structure intended to contain flame and exhaust fumes use the Glow Wire Tester inside a suitable Fume Flame Hood available separately from ED amp D 4 ATTENDED USE Because of the risk of fire with the test sample the GWT 200 is intended to be attended at all times during use 5 USE PROPER SAFETY PRECAUTIONS when using the Glow Wire Tester properly protected test area CO fire extinguisher or other suitable fire protection prevention equipment wear safety glasses properly rated respirator if needed for fumes maintain a c
6. a modified version of the GWT 200 is available for testing to UL746A element penetration allowed to 15 mm higher VA supply source Glow Wire Detail Dimensions in mm 2 unless otherwise noted Detail Z Glow Wire Material Iron free NiCr 80 Nickel 20 Chromium Glow Wire Diameter 4 0 mm 0 04 mm before bending 16 EDAD PRODUCT SAFETY SOLUTIONS LIMITED WARRANTY Educated Design amp Development Inc ED amp D hereby warrants to the original purchaser of any new ED amp D Glow Wire Tester that the device shall be free from defect in material and or workmanship This warranty shall extend for a period of 1 year 365 days from the date of purchase Should any defect arise within the warranty period ED amp D may repair the unit at ED amp D send replacement parts or replace the defective unit with a new unit at ED amp D s discretion Under no circumstances however shall ED amp D be required to refund the purchase price of any Glow Wire Tester This warranty does not cover any failure or damage to the product resulting from accident alteration or misuse of the product or failure to follow manufacturer s operating instructions Furthermore this warranty does not cover damage caused by use of any attachment not original equipment of the product ED amp D shall not be liable for any damage caused by use of the product other than indicated in the manufacturer s instructions ED amp D DISCLAIMS ANY LIABILITY
7. FOR ANY DAMAGES RESULTING FROM DELAY OR LOSS OF USE AND SERVICE OR REPAIR OR FOR LOSS OR DAMAGED DEVICES OR FOR ANY INCIDENTAL OR CONSEQUENTIAL NEGLIGENCE OR OTHER FAULT ON THE PART OF THE MANUFACTURER OR OTHERS THE IMPLIED WARRANTIES ON THIS PRODUCT SHALL BE IN EFFECT ONLY FOR THE DURATION OF THE EXPRESSED WARRANTY PERIOD AS SET FORTH ABOVE AND THEREAFTER THERE SHALL BE NO WARRANTIES EITHER EXPRESSED OR IMPLIED INCLUDING WARRANTIES OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE ON AN ED amp D GLOW WIRE TESTER ee J UUUUOUUUUUUUL ZHUHAI KEERMAI TESTING Co LTD www keermai com Email info keermai com TEL 0756 3353658 FAX 0756 3361895 HOOOEBEBOUOLeOOUOODuUOUg 17
8. ayer of tissue paper ED amp D model ATP 01 or equivalent and secure tissue paper by tape under the board e Place the board under the glow wire be sure board tissue paper is under the area where the glow wire will contact the test sample e IMPORTANT Only use tissue paper which has not been previously burnt or discolored Use new tissue paper any time dripping flaming particles have touched the tissue paper Notch in board aligns with support post for flame gauge Space between glow wire Support posts and board Wrap board with tissue paper and tape under board 11 EDAD PRODUCT SAFETY SOLUTIONS OPERATING INSTRUCTIONS Continued 11 Set Temperature a Current Control Knob should be in the zero position rotate counterclockwise b Turn on the mains switch mains indicator light will illuminate green and the temperature meter will operate c Press the green WIRE ON switch WIRE ON light will illuminate amber d Rotate the current control knob clockwise to the position that results in the specified test temperature See the chart below for typical test temperatures and the approximate test current for each e Turn the knob to the appropriate test current using the ammeter for reference e After glow wire fully warms make additional adjustments using the knob until the temperature meters shows your desired test temperature e IMPORTANT Allow temperature to stabilize for 60 seconds befor
9. e proceeding Test Temperature Approximate Wire Current See your test standard for test temperature tolerance Typical tolerance is 10K 12 EDAD PRODUCT SAFETY SOLUTIONS OPERATING INSTRUCTIONS Continued 12 Move Sample to Glow Wire a While holding the carriage assembly move the locking bar to release the assembly b Guide the carriage assembly forward as the sample approaches the glow wire release the carriage assembly allowing the sample to come in contact with the glow wire the carriage assembly will maintain a 1 N force between the sample and the glow wire e IMPORTANT Per the standard DO NOT adjust the test current temperature after the glow wire contacts the test sample c During testing using a stop watch or other suitable timing device to record The start time when the glow wire and test sample initiate contact The time elapsed to ignition The time for an ignited sample to extinguish after removal of the glow wire The maximum flame height see your test standard for further details Any ignition of the tissue paper any charring burning discoloring etc 13 Withdraw the Test Sample After the test time of 30 sec 1 sec slowly retract the sample platform assembly and lock into the retracted position using the locking bar 14 Turn Off Glow Wire Press the red WIRE OFF Switch the WIRE indicator light will extinguish The ammeter should immediately go to zero The tempe
10. ection Connect the Glow Wire Tester to a properly rated electrical source using the integral power cord e Be sure to observe all regulations contained in your local electrical code e Verify that the source voltage is rated to match the unit rating plate e Verify that the input plug is the proper plug configuration If you need to change the plug please utilize a licensed electrician knowledgeable with your local electrical codes Use only a Safety Certified plug The inlet coupler is a type CEE 22 rated 10 Amps EDAD PRODUCT SAFETY SOLUTIONS OPERATING INSTRUCTIONS Be sure to consider the instructions in your Safety Standard 1 Prepare Test Samples Prepare your test samples and conduct any pre conditioning per the requirements in your test standard i e IEC60695 2 11 IEC60695 2 12 IEC60695 2 13 e WARNING Do not use samples larger than necessary to minimize the potential for spreading of fire 2 Mains Switch OFF Turn the main switch to the off position 3 Turn Current Control to Zero Rotate the current control knob to the zero position rotate counterclockwise Rotate Current Control Knob to zero turn counterclockwise 4 Retract Carriage Assembly Pull the carriage assembly all the way back away from the glow wire and use the locking bar to hold the assembly in the retracted position Pull here to retract Flip up locking bar to hold carriage assembly in the retracted position EDAD
11. ill only attract contamination The brass rollers within the carriage assembly housing can be lubricated with light machine oil PARTS SERVICE e Contact ED amp D for all parts service o Replacement glow wire is ED amp D model P GWT 200 E Replacement thermocouple is ED amp D model P GWT 200 T Silver foil min 99 8 pure approx 0 06 mm thick is ED amp D model GWT SVR Tissue paper is ED amp D model ATP 01 O O 14 EDAD PRODUCT SAFETY SOLUTIONS TROUBLESHOOTING WARNING Risk of Shock The electrical enclosure panels should be removed by Qualified Service Personnel only 1 Unit Is Not Operating Mains Indicator Light Not Lighting e Verify that the on off Switch is ON front panel e Verify that the power cord is plugged in and your power source is turned on and operating properly e Disconnect power and verify that the main fuse is intact front panel 2 Unit Is Not Operating Mains Indicator Light Is Lighting but Temperature Does Not Rise e Verify that the Circuit Breaker is reset push to reset e Verify that you have pushed the WIRE ON switch to energize the glow wire e Rotate the Current Control Knob in a clockwise direction to increase glow wire current temperature The ammeter needle should rise shows the current increase o If the current does not rise when turning the control knob disconnect power and verify that the control fuse is intact front panel o If the current does rise when turn
12. ing the control knob push the WIRE OFF switch Allow the glow wire to cool to room temperature Then verify that the thermocouple is properly inserted into the hole on the back of the glow wire If the thermocouple is properly inserted the thermocouple may need to be replaced conduct silver foil melt calibration process 3 Temperature Rise Inconsistent o Perform silver foil melt calibration process to insure proper temperature display o Verify glow wire see calibration instructions Replace as needed o Replace thermocouple CALIBRATION The Glow Wire Tester was completely calibrated prior to shipment by ED amp D and a certificate of calibration was included with the unit NOTE removal of the electrical enclosure panel is to be done by Qualified Service Personnel Only Re calibration points are as follows e WARNING Do not leave the GWT 200 with the element energized for long periods of time Warm up the unit allow temperature to stabilize conduct the calibration and then shut the unit off e Glow Wire The glow wire was calibrated to the dimensions shown in the diagram on page 16 You will only need to measure the diameter of the glow wire tip periodically Note that the 4 0 wire diameter specification is prior to bending The glow wire tip diameter should be measured when new the standard specifies that when the glow wire tip diameter is reduced by 10 from its original bent diameter it should be replaced e Temperatu
13. lean work area with no exposed hazards in the area etc It is your responsibility to insure a safe test environment 6 CAUTION The Glow Wire Tester is VERY heavy 72 Ib 33 Kg Two people are required to remove the Glow Wire Tester from the crate Be sure to use proper lifting techniques EDAD PRODUCT SAFETY SOLUTIONS PRODUCT PURPOSE The Glow Wire Tester model GWT 200 is designed to carry out fire hazard testing on solid insulating materials and other solid combustible materials This test is intended to determine the potential for the test material to be ignited by an external heat source simulates heating of combustible materials used in products should they be subjected to high heat from adjacent parts such as glowing elements overloaded resistors hot coils and windings etc For the glow wire test a loop of resistance wire is electrically heated to a specific temperature and the specimen being tested is brought into contact with this heated wire for 30 seconds The amount of force between the glow wire and the test sample is held constant at 1 N Observations and measurements are made to evaluate the fire hazard presented by the test sample while exposed to elevated temperatures The objective of the test is to record the behavior of the material when subjected to the high temperature glow wire time to ignition time to extinguish maximum flame height and whether dripping particles ignited the tissue paper The test tempe
14. ll allow enough distance at the end of the stop rod for you to slide off the spacer After removing spacer use the locking bar to hold the carriage assembly in the retracted position Store the spacer in a safe place Remove spacer from end of stop rod 10 EDAD PRODUCT SAFETY SOLUTIONS OPERATING INSTRUCTIONS Continued 8 Set Flame Gauge Install and rotate the flame gauge such that the entire length of the ruler is facing forward entire length visible while operating the GWT 200 This gauge is used to measure the flame height during testing See installation instructions if you wish to further adjust the position of the ruler with respect to the glow wire e DO NOT attempt to adjust the height of the ruler on the mounting bracket The zero position of the ruler must coincide with the top front of the glow wire to allow you to measure the flame height e You can adjust how close the ruler is to the glow wire by changing the mounting position of the ruler bracket Position of support post can be changed to Zero on ruler Ir move the gauge aligns with top iu g closer farther to edge of glow iil N the glow wire wire 9 Withdraw Sample Pull the carriage assembly all the way back away from the glow wire and use the locking bar to hold the assembly in the retracted position Use locking bar to keep carriage assembly retracted 10 Prepare Tissue Paper Board e Wrap the wood board approx 10 mm thick with 1 l
15. nge their shape and may necessitate replacement Do not use tools to scrape off residue and do not use abrasive cleaners or materials on the glow wires The glow wire is very expensive to replace due to the precision dimensions and low tolerance e Periodically measure the tip diameter of the glow wire WARNING Only measure the glow wire when the glow wire has cooled to room temperature Per the requirements in the standard the glow wire should be replaced when the diameter has been reduced by 10 from its original bent diameter must measure glow wire when new e Contact ED amp D for replacement glow wires ED amp D model P GWT 200 E C Thermocouple e Due to the extremely high test temperatures the thermocouple will occasionally need to be replaced For this reason you may wish to retain an extra thermocouple so you are prepared when the thermocouple burns open e Insure that the thermocouple is inserted fully into the hole in the back of the glow wire tip The thermocouple is intended to be in contact with the inside surface of the glow wire tip The thermocouple can be gently bent to reposition as needed e Contact ED amp D for replacement thermocouples ED amp D model P GWT 200 T D Carriage Assembly Rods Rollers e Be sure that the rods remain free of contamination Use a soft cloth to wipe the rollers clean as needed Any contamination of the rods can affect the force applied to the test sample DO NOT lubricate the rods as this w
16. rature and resulting behavior of the material are used to identify the suitability of the material for specific application it can also be used to develop a flame rating for the material This product complies with IEC60695 2 10 2001 and other standards requiring Glow Wire Tests See page 16 for more details S EDAD PRODUCT SAFETY SOLUTIONS stem Components Control Panel A OVOZI A LTOMMOO W Temperature Meter displays glow wire temperature Mains Indicator Light Green illuminates when mains switch is on Current Control Knob to increase decrease test current through the glow wire Mains Fuse see page 6 for ratings Circuit Breaker manual reset push to reset Mains On Off Switch 0 1 controls mains power to the unit Current Meter Ammeter displays test current through glow wire WIRE OFF Switch Red push to stop test current through the glow wire WIRE ON Switch Green push to start test current through the glow wire Control Fuse see page 6 for ratings Tissue Paper Wood Surface one package of tissue paper and one 10 mm thick wood board included Bubble Level for use in leveling the GWT 200 Sample Platform includes brackets to hold test sample Depth Limiting Spacer Stop limits penetration depth of glow wire into test sample to 7 mm Glow Wire Thermocouple thermocouple measures temperature at inside tip of glow wire Flame Height Gauge allows for measuring the flame heigh
17. rature meter will continue to display the glow wire temperature e DANGER Extreme burn hazard Although the wire current is off it will take several minutes for the glow wire to cool Allow the glow wire to cool to room temperature before proceeding 15 Remove Sample AFTER THE GLOW WIRE HAS COOLED TO ROOM TEMPERATURE remove the test sample 16 Repeating Test AFTER THE GLOW WIRE HAS COOLED TO ROOM TEMPERATURE if you will be conducting another test return to step 2 17 Test Conclusion At the conclusion of testing e Turn the current control Knob to the zero position rotate counterclockwise e Turn the Mains switch off e Clean glow wire with a non abrasive cloth or brush do not alter the glow wire shape size e Protect the GWT 200 from dust dirt and other contamination when not in use especially important to keep the rods rollers that are part of the moving carriage assembly from contamination 13 EDAD PRODUCT SAFETY SOLUTIONS MAINTENANCE Replacement of the glow wire and thermocouple are to be conducted by Qualified Service Personnel Only A Overall Unit e WARNING Do not leave the GWT 200 with the element energized for long periods of time Warm up the unit allow temperature to stabilize conduct the calibration and then shut the unit off B Glow Wire e After Each Use Insure that the glow wire is clean of any residue DO NOT use any abrasive objects on the glow wire using abrasive objects will cha
18. re Measurement The temperature meter and the thermocouple should be annually calibrated NOTE the silver melt calibration method described in the next item is the method of calibration described in the standard e Silver Melt Per the standard IEC60695 2 10 the system should also be calibrated to verify that a Strip of pure silver foil starts to melt on the upper surface of glow wire tip at 960 C 15 C o Silver foil min 99 8 pure measuring approx 2 mm x 0 06 mm thick available from ED amp D model GWT SVR o Be sure that all silver foil is removed from the element after calibration e Ammeter The ammeter is for reference only and is therefore not required to be calibrated e Force If the system is level and the carriage assembly weight cord rods rollers are not subject to damage or contamination the force should remain constant and not require re calibration 15 EDAD PRODUCT SAFETY SOLUTIONS REFERENCE STANDARDS This product complies with the International Standard for Fire Hazard Testing Glowing hot wire based test methods Glow wire apparatus and common test procedures IEC60695 2 10 2001 It is intended to be used by glow wire application standards IEC60695 2 11 IEC60695 2 12 and IEC60695 2 13 This product also complies with most end product standards requiring Glow Wire Tester compliance such as IEC60335 1 IEC60950 1 and other standards with the following Glow Wire Test specifications Note that
19. t when ignition occurs WIRE ON Indicator Light Amber illuminates when test current is on EDAD PRODUCT SAFETY SOLUTIONS PRODUCT SPECIFICATIONS 2 unless otherwise indicated Mains Electrical Ratings Mains Electrical Configuration Power Connection Environmental Ratings Overall Dimensions Overall Weight Glow Wire Element Contact Force Glow Wire Penetration Wooden Board Distance to Board Tissue Paper Ammeter Temperature Meter Thermocouple 120 or 230 VAC 10 50 60 Hz 5 0 2 5 A see markings on GWT 200 for voltage current rating of your GWT 200 2 Wire Ground Earth Detachable power supply cord with integral plug 10 40 C indoor use only 12 in D x 35 in W x 25 in H 30 5 x 88 9 x 63 5 cm 72 Ibs 32 6 Kg see diagram on page 16 1 N 0 2N between the test sample and the glow wire 7 mm 0 5 mm Approx 10 mm thick 200 mm 5 mm ED amp D model ATP 01 weighs 12 g m 30 g m 0 200 A 2 FS 0 999 C 1 FS Type K 0 5 mm diameter Fuse Rating for Units Fuse Rating for Units rated 110 120 VAC rated 220 240 VAC Mains T5A 250 VAC T3A 250 VAC Control T1A 250 VAC T1A 250 VAC 1 Cc D Symbols Location DANGER SHOCK HAZARD POTENTIAL e Electrical Enclosure Panels for Qualified Service Personnel access only e DO NOT bridge the glow wire connections support rods Risk of Hazardous Energy 3 V 200 A WARNING
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