CK Insto Pvt. Ltd.

The CKINSTO Terminal Temperature Rise Test Setup is engineered to assess the thermal performance of electrical terminals, ensuring they operate safely under load conditions. This evaluation is crucial for verifying compliance with standards such as IS 1293, IS 694, and IEC 60884.

• High-Current Capability: Delivers adjustable current up to 20,000 A, simulating real-world operating conditions.

• Temperature Monitoring: Equipped with 12 K-type thermocouples (10 meters long) to measure temperature rise accurately at terminals.

• Data Logging: Real-time temperature data recording via SCADA-based PC software, with storage options including pen drive.

• User Interface: Computer-operated mechanism with PLC base, displaying voltage, current, temperature, and time.

• Safety Measures: Incorporates MCB and overload protection relay to ensure operator safety.

• Construction: Robust MS powder-coated body for durability.

• Power Plug and Socket Testing: Assessing temperature rise at terminals under rated current conditions.

• Connector Evaluation: Measuring heat generation in contact areas and connector joints.

• Wire & Cable Testing: Ensuring insulation and conductor materials withstand permissible temperature limits.

• Switchgear Components: Verifying temperature behavior in loaded electrical panels.

✅ Automated Testing – Conducts thousands of insertion and withdrawal cycles.
✅ Adjustable Force & Speed – Simulates real-world usage conditions.
✅ Electrical Load Testing – Checks contact resistance and overheating risk.
✅ High-Precision Sensors – Monitors force, wear, and electrical performance.
✅ Customizable Test Cycles – Configurable for different plug and socket types.

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The CK INSTO glow wire test chamber is widely used for testing the electrical and electronic product like lighting equipment, low-voltage apparatus and electro technical instrument.

Glow Wire Tester:
Designed for testing the flammability and heat resistance of materials, our Glow Wire Tester adheres to IEC 60695-2-10 standards, ensuring precise and reliable results for safety-critical applications.

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Alternate Keywords for Glow Wire Test apparatus

1. Glow Wire Tester

2. Glow Wire Flammability Tester

3. Glow Wire Testing Machine

4. Glow Wire Ignition Test Apparatus (GWIT)

5. Glow Wire Flammability Index Tester (GWFI)

6. Glow Wire Simulation Tester

7. Hot Wire Ignition Tester

8. IEC 60695 Glow Wire Tester

9. Plastic Flammability Tester

10. Electrical Fire Hazard Tester

11. Glow Wire Resistance Tester

12. UL 746A Glow Wire Equipment

13. High-Temperature Glow Wire Tester

14. Glow Wire Heating Element Tester

The CKINSTO Pull-out Force Test Machine for Connectors (often referred to as an Insertion & Extraction Tester or Tensile Strength Tester for Terminals) is a precision electro-mechanical apparatus used to measure the mechanical forces required to connect (insert) and disconnect (extract/pull out) various types of electrical and electronic connectors.

Its primary function is to quantify the strength and durability of the connection point, ensuring components are securely fastened but can also be serviced (disconnected) without excessive effort or damage.

This machine is highly versatile and is used for quality control (IQC/FQC), research & development (R&D), and compliance testing for a wide range of products, including:

•  Connector Sets: Measuring the combined force for inserting and extracting a mated connector pair (e.g., USB, HDMI, automotive connectors).

• Wire/Cable Pull-out Force: Measuring the tensile strength of the termination, ensuring the wire or cable remains securely held by the terminal (lugs, splices, crimp joints) under mechanical stress.

• Single-Pin/Single-Hole Force: Testing the engagement force of individual contacts within a multi-pin connector.

• Life-Cycle/Endurance Testing: Performing thousands of automated insertion and extraction cycles to measure wear and how the force profile degrades over time.

• Cord Anchorage Pull Force: For appliance cords, testing the force required to pull the cord out of the appliance housing, often combined with a torque (twist) test.

The equipment is typically an automatic, vertical force tester driven by a servo motor for precise motion control:

The Tensile test apparatus application is check tha all material strength like gland, MCB,RCCB, Plug, Cable ,etc….

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The CKINSTO Glow Wire Test Apparatus (or Glow Wire Resistant Tester) is a standardized piece of safety testing equipment used to evaluate the resistance of non-metallic materials (primarily plastics and insulating materials) to heat and fire initiated by an overheated electrical component.

This test is a core requirement for components used in electrical and electronic products to comply with international safety standards.

• Objective: To simulate the thermal stress and potential for ignition caused by a malfunctioning or overloaded electrical part (like a resistor, conductor, or joint) that reaches high temperatures and comes into contact with surrounding non-metallic materials.

• Safety Verification: It determines if the material will ignite and, if it does, whether it will self-extinguish within a specified short time, thereby preventing the spread of fire.

• Standards: The tester is designed and built to meet the requirements of the IEC 60695-2 series, specifically:

  • IEC 60695-2-10: Glow-wire apparatus and common test procedure.

  • IEC 60695-2-11: Glow-wire flammability test method for end products (GWFI).

  • IEC 60695-2-12: Glow-wire flammability index (GWFI) test method for materials.

  • IEC 60695-2-13: Glow-wire ignition temperature (GWIT) test method for materials.

The tester helps determine two main material properties:

1. Glow Wire Flammability Index (GWFI): The highest temperature at which the material, when tested, does not ignite, or if it does, the flame self-extinguishes within 30 seconds  and no material below the specimen ignites.

2. Glow Wire Ignition Temperature (GWIT): The lowest temperature that causes sustained ignition .

The CKINSTO Connector Torque and Pull Test Equipment, often referred to as a Cord Anchorage Pull Force and Torque Test Apparatus, is a specialized machine used to evaluate the mechanical strength and durability of the point where a power cord connects to an electrical appliance.

Its primary function is to simulate the mechanical stresses an appliance cord's anchorage (the point where the cord enters the product) is subjected to during normal use, ensuring it remains safe and secure.

•  Mechanical Strength Evaluation: The equipment is designed to check the quality of the cord anchorage, which is essential for relieving strain on the internal terminals.

   

• Pull Force Test: It applies a controlled tensile force (pull) along the axis of the cord. This test confirms that the cord will not detach or pull out from the appliance under the forces it might experience in real-world scenarios, such as accidentally pulling on the cord.

   

  •  Capacity: CK INSTO models are available with capacities, such as 5 kN (kilonewtons).

     

• Torque (Twist) Test: It applies a controlled twisting force (torque) to the cord. This ensures the conductors within the cord are protected from twisting strain at the terminals and that the cord anchorage prevents the cord from being twisted and potentially damaging the internal wiring or terminals.

   

• Compliance: The equipment is crucial for verifying compliance with various international electrical safety standards, such as those from IEC (International Electrotechnical Commission) like IEC 60335 and IEC 60598.

   

•  Construction: The apparatus is typically constructed of mild steel and features a digital display for precise measurement of the applied force and torque.

   

This equipment ensures that electrical appliances are robust and reliable, preventing a safety hazard that could result from the cord becoming loose or detached from the device.

The UL 486 standard covers the requirements for Wire Connectors and Soldering Lugs (UL 486A-486B) and Equipment Wiring Terminals (UL 486E). CK Insto's equipment primarily addresses the crucial mechanical and physical integrity tests required by this standard.

This is the most direct piece of equipment for testing the mechanical reliability of the wire-to-connector joint.

• Primary Function: To evaluate the secureness, or pull-out force resistance, of the electrical wire connection in lugs, terminals, splices, and wiring devices (e.g., circuit breakers, disconnect switches).

• Test Principle:

  1. A wire of the specified size is correctly terminated in the connector (terminal, lug, MCB, RCCB, etc.).

  2. The connector is secured in a rigid clamp on the test apparatus.

  3. A predetermined tensile force (pull-out load), as specified by the UL 486 standard for that wire size, is gradually applied to the wire.

  4. The equipment checks whether the wire is retained securely in the terminal for a specified duration without separating or slipping more than a specified amount.

• Key Features (Typical CKInsto Unit):

  • Capacity: Varies, but capable of applying the necessary high tensile loads  required for large conductors.

  • Automation: Automatic or Semi-Automatic operation with a controlled rate of pull.

  • Display: Digital or Touch Screen HMI for displaying the applied force, displacement, and testing time.

  • Fixtures: Interchangeable clamping fixtures to accommodate various connector types (lugs, terminals, MCBs, etc.) and a range of wire sizes (AWG/kcmil).

This equipment may be a multi-functional apparatus used for various UL 486 tests or a general term for the Securness Apparatus, and often includes the capability to perform the following:

• Conductor Damage Degree Test: This test is crucial for terminals that use a set screw.

  • Purpose: To ensure that the tightening of the binding screw on the conductor does not cause excessive damage to the wire strands, which could compromise the electrical or mechanical integrity.

     

  • Method: Involves clamping and releasing the conductor a specified number of times and then inspecting the degree of damage to the wire.

• Temperature Rise Test Setup (Often separate but related):

  • Purpose: To verify that the connector does not cause excessive heating when carrying its rated current, a fundamental requirement of UL 486.

  • Equipment: High-current power source, sensors, and data logging system to measure the temperature rise of the connector compared to a reference point.

CKINSTO offers a comprehensive range of testing equipment specially designed to meet the requirements of IS 694 – the Indian Standard for PVC insulated cables for working voltages up to and including 1100V. Our machines ensure quality, safety, and compliance with BIS guidelines, making them essential for cable manufacturers, testing labs, and electrical product developers.

The CK INSTO Flammability Test For Cables ( IEC 332 Pt 3 , BS EB 60332-3-10) is designed to evaluate the flame retardant properties of ladder materials or similar structures. It helps determine the ability of materials to resist ignition and limit flame propagation, ensuring compliance with safety and quality standards.

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The CKINSTO Wire Terminal Endurance Test System is an automated, specialized apparatus designed to assess the long-term reliability and mechanical durability of electrical terminals, crimp connections, and wire harness assemblies. Its primary function is to subject the terminals to repeated mechanical stresses that simulate the operational life and wear and tear experienced in real-world applications (e.g., vibration, bending, pulling, and repeated insertions/extractions).

This testing is crucial for ensuring the connections maintain low electrical resistance and mechanical integrity over the entire service life of the product, adhering to standards like IEC, UL, and automotive industry specifications.

The system is used to test the mechanical life and fatigue resistance of various components, including:

• Crimped Terminals: Evaluating the strength and stability of the crimp joint between the wire and the terminal under repeated stress.

• Quick Connect/Disconnect Terminals: Measuring the endurance of blade or pin/socket connections through thousands of insertion and extraction cycles.

• Flexing and Bending Stress: Simulating movement in applications like appliances or automotive wiring where wires are repeatedly bent (e.g., door harnesses).

• Pull-Out Resistance: Testing the terminal's ability to maintain grip on the wire after being subjected to numerous mechanical cycles.

The CKINSTO system is typically a modular, programmable setup with the following components:

• Actuation: Uses high-precision servo motors or stepper motors to perform controlled movements (e.g., bending, rocking, twisting, or pulling).

• Fixtures: Equipped with a variety of interchangeable, self-centering grips and clamping fixtures to hold different wire gauges and terminal types securely. This ensures that the stress is applied accurately to the connection point.

• Movement Profile: Capable of executing complex, programmable motion profiles, including:

  • Oscillation/Bending: Rocking the wire back and forth over a specified angle and radius.

  • Torsion/Twisting: Applying a twisting force.

  • Linear Pull/Push: Repeatedly applying tensile and compressive forces.

While primarily mechanical, endurance testing is incomplete without electrical measurement:

• Resistance Monitoring: Measures the contact resistance or voltage drop across the terminal connection before, during, and after the endurance cycle.

• Failure Criterion: The test often concludes when the contact resistance exceeds a predefined limit (e.g., $10 \text{ m}\Omega$) or when a wire breaks (open circuit).

• Current Load: Some systems can pass a small monitoring current through the terminal during testing to simulate operational conditions.

• Control System: PLC-based or PC-controlled with a Human-Machine Interface (HMI) for setting test parameters.

• Programmable Parameters: The operator can precisely define:

  • Number of Cycles: E.g., 10,000 or 50,000 cycles.

  • Frequency/Speed: The rate at which the cycles are performed.

  • Amplitude/Angle: The degree of bending or distance of pulling.

The CKINSTO Crimp Lug Test Equipment is generally designed to perform mechanical tests on crimped cable lugs and terminals to ensure the quality, integrity, and safety of the electrical connection.

The mechanical tests typically performed by this type of equipment, often in accordance with standards like IEC 61238 and UL 486A-486B, include:

This is the most critical mechanical test for a crimp connection.

• Purpose: To measure the ultimate tensile strength of the crimp—the maximum force the connection can withstand before the conductor pulls out of the lug/terminal. This ensures the wire is held securely and will not detach under mechanical stress or vibration in service.

• Procedure:

  1. The crimped lug is securely fixed to one set of jaws on the testing machine.

  2. The free end of the cable/conductor is clamped in the opposing jaw.

  3. A controlled, increasing tensile force is applied along the axis of the cable.

  4. The force is increased until the connection fails (the wire pulls out, the wire breaks, or the crimp barrel/lug breaks).

• Measurement/Criteria: The equipment records the peak force (in Newtons or kilonewtons) at the point of failure. The measured force must meet or exceed the minimum requirement specified by the relevant standard for the conductor's cross-sectional area (e.g.,  60 ×  A mm 2​ in Newtons for copper conductors up to a maximum of 20,000 N per IEC 61238).

This test assesses the connection's ability to resist repeated mechanical stress.

• Purpose: To simulate the stress from cable movement or vibration the terminal connection may experience in real-world application. It ensures the electrical continuity is maintained.

• Procedure (Varies by Standard, often based on UL 486A/486B):

  1. The crimped connection is subjected to a specified number of flexing or bending cycles (e.g., rotation/flexing at a controlled rate).

  2. A predetermined tensile load (weight) may be applied to the cable during the test.

  3. The test monitors for any interruption in the electrical circuit.

• Measurement/Criteria: The lug must remain firmly attached with no slippage of the conductor and no interruption in electrical continuity for the duration or number of cycles specified by the standard.

For mechanical connectors, the testing may also involve verifying long-term durability, although this is more typically associated with the full type-testing standard.

• Purpose: To ensure the mechanical integrity remains stable over the product's lifespan, especially in high-vibration environments.

• Procedure: Subjecting the connection to vibration, impact, or other cyclical stress to see if the clamping force degrades.

In summary, the CKINSTO test equipment specializes in quantifying the strength of a crimp connection primarily through the Pull-Out Force Test, ensuring the joint is mechanically robust enough to meet stringent industry safety and reliability standards.

The CKINSTO UL 486 Connector Test Apparatus is a sophisticated, multi-functional system designed to rigorously evaluate the mechanical and electrical integrity of wire connectors, soldering lugs, and equipment wiring terminals in accordance with the UL 486A-B (Wire Connectors and Soldering Lugs) and UL 486E (Equipment Wiring Terminals) standards.

The equipment is crucial for ensuring that electrical connections can withstand the stresses of installation and prolonged real-world use without failing, which could lead to fire or shock hazards.

The apparatus combines several distinct testing capabilities required by the UL 486 standard into a single, comprehensive system:

• Purpose: To simulate the real-world mechanical stress, vibration, and cable movement that a connected terminal may experience in service. It verifies that the connection remains secure and maintains electrical continuity.

• Functionality: A conductor of the specified size is terminated in the connector under test. The connector is rigidly clamped, and the wire is passed through a bushing (sized according to the wire gauge). A motorized mechanism then subjects the wire to a specified number of flexing or bending cycles (e.g., at a rate of 9 \pm 2 revolutions per minute) while under a calibrated tensile load (weight).

• Measurement/Criteria: An integrated electrical continuity monitoring circuit detects any interruption in the connection.The test automatically stops if the circuit opens (failure), recording the precise number of cycles at the point of failure.

• Purpose: To measure the connection's ultimate tensile strength—the force required to pull the conductor out of the connector.This is the primary verification of the quality of the crimp or screw connection.

• Functionality: The system uses a high-accuracy load cell to apply a precisely controlled, increasing tensile force (pull-out load) to the conductor at a specified, constant rate until the connection fails (the wire separates or breaks).

• Measurement/Criteria: The system records the peak force at the moment the conductor disengages. This value must meet or exceed the minimum pull-out force specified by the UL 486 standards table for that specific wire size (AWG/kcmil).

• Purpose: To ensure that the connector's clamping mechanism (like a set screw) does not excessively damage the wire strands upon tightening, which could compromise the mechanical strength or electrical performance.

• Standards Compliance: Fully compliant with UL 486A-B and often other relevant standards like IEC 60947-7-1.

• Control System: Typically features an Automatic/Microcontroller-based operation with a Touch Screen HMI (Human-Machine Interface) for easy input of test parameters (e.g., wire size, pull force, number of cycles).

• Fixtures: Includes a comprehensive set of interchangeable clamping jaws, bushings, and calibrated weights to accommodate a wide variety of connector types (lugs, terminals, MCBs, RCCBs) and conductor sizes .

• Construction: The main frame is built from heavy-duty, powder-coated Mild Steel (MS) for stability and long-term industrial durability.

• Safety: Includes features like an emergency stop button and over-force protection.

The CKINSTO Stability Cooling Chambers is a state-of-the-art, temperature-controlled testing environment designed to simulate low-temperature conditions. It is ideal for testing the durability, performance, and reliability of materials, components, and products under extreme cold temperatures.

This chamber is widely utilized across industries such as automotive, aerospace, electronics, pharmaceuticals, and research laboratories to ensure products meet stringent quality and safety standards.

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The CKINSTO Glow Wire Test Apparatus is a premium, high-precision fire hazard testing instrument designed to evaluate the flammability and fire resistance of plastic materials and electrical components. Fully compliant with IEC 60695-2-10, this PLC-controlled system eliminates manual error, ensuring repeatable and reliable results for safety certification.

•  Temperature Range: Room Temperature to 960°C (Adjustable & Highly Stable).

   

• Control System: Advanced PLC-based architecture.

• Interface: Intuitive Touch Screen HMI for real-time monitoring and data entry.

• Test Force: Standardized 1.0N ± 0.2N (Constant force application).

• Glow Wire: Standard Ni/Cr (80/20) wire, 4mm diameter.

   

• Timer Range: 0–999.9s (Resolution: 0.1s) for Ti, Te, and Ts.

• Operation: Fully Automatic motorized carriage movement.

• User-Friendly HMI: No complex knobs. Set your temperature and time parameters directly on the digital screen.

• High Accuracy: Equipped with high-precision thermocouples to ensure the glow wire tip stays within the strict tolerances required by international standards.

• Fully Automatic: The motorized specimen carriage ensures a smooth, constant speed approach and withdrawal, removing operator bias.

• Safety First: Built-in ventilation and a reinforced tempered glass observation window for safe monitoring.

• Durable Build: Finished with anti-corrosive coatings to withstand high-heat environments.

Ideal for quality control and R&D in:

• Electrical & Electronics Manufacturing.

• Plastic & Polymer Testing Labs.

• Household Appliance Safety Certification.

• Automotive Component Testing.

Designed and manufactured in accordance with:

• IEC 60695-2-10 / 11 / 12 / 13

• ASTM D6194

• UL 746A

The CKINSTO Glow Wire Test Apparatus is a premium, high-precision fire hazard testing instrument designed to evaluate the flammability and fire resistance of plastic materials and electrical components. Fully compliant with IEC 60695-2-10, this PLC-controlled system eliminates manual error, ensuring repeatable and reliable results for safety certification.

•  Temperature Range: Room Temperature to 960°C (Adjustable & Highly Stable).

   

• Control System: Advanced PLC-based architecture.

• Interface: Intuitive Touch Screen HMI for real-time monitoring and data entry.

• Test Force: Standardized 1.0N ± 0.2N (Constant force application).

• Glow Wire: Standard Ni/Cr (80/20) wire, 4mm diameter.

   

• Timer Range: 0–999.9s (Resolution: 0.1s) for Ti, Te, and Ts.

• Operation: Fully Automatic motorized carriage movement.

• User-Friendly HMI: No complex knobs. Set your temperature and time parameters directly on the digital screen.

• High Accuracy: Equipped with high-precision thermocouples to ensure the glow wire tip stays within the strict tolerances required by international standards.

• Fully Automatic: The motorized specimen carriage ensures a smooth, constant speed approach and withdrawal, removing operator bias.

• Safety First: Built-in ventilation and a reinforced tempered glass observation window for safe monitoring.

• Durable Build: Finished with anti-corrosive coatings to withstand high-heat environments.

Ideal for quality control and R&D in:

• Electrical & Electronics Manufacturing.

• Plastic & Polymer Testing Labs.

• Household Appliance Safety Certification.

• Automotive Component Testing.

Designed and manufactured in accordance with:

• IEC 60695-2-10 / 11 / 12 / 13

• ASTM D6194

• UL 746A

The CKINSTO Glow Wire Test Apparatus is a premium, high-precision fire hazard testing instrument designed to evaluate the flammability and fire resistance of plastic materials and electrical components. Fully compliant with IEC 60695-2-10, this PLC-controlled system eliminates manual error, ensuring repeatable and reliable results for safety certification.

•  Temperature Range: Room Temperature to 960°C (Adjustable & Highly Stable).

   

• Control System: Advanced PLC-based architecture.

• Interface: Intuitive Touch Screen HMI for real-time monitoring and data entry.

• Test Force: Standardized 1.0N ± 0.2N (Constant force application).

• Glow Wire: Standard Ni/Cr (80/20) wire, 4mm diameter.

   

• Timer Range: 0–999.9s (Resolution: 0.1s) for Ti, Te, and Ts.

• Operation: Fully Automatic motorized carriage movement.

• User-Friendly HMI: No complex knobs. Set your temperature and time parameters directly on the digital screen.

• High Accuracy: Equipped with high-precision thermocouples to ensure the glow wire tip stays within the strict tolerances required by international standards.

• Fully Automatic: The motorized specimen carriage ensures a smooth, constant speed approach and withdrawal, removing operator bias.

• Safety First: Built-in ventilation and a reinforced tempered glass observation window for safe monitoring.

• Durable Build: Finished with anti-corrosive coatings to withstand high-heat environments.

Ideal for quality control and R&D in:

• Electrical & Electronics Manufacturing.

• Plastic & Polymer Testing Labs.

• Household Appliance Safety Certification.

• Automotive Component Testing.

Designed and manufactured in accordance with:

• IEC 60695-2-10 / 11 / 12 / 13

• ASTM D6194

• UL 746A

The CKINSTO Glow Wire Test Apparatus is a premium, high-precision fire hazard testing instrument designed to evaluate the flammability and fire resistance of plastic materials and electrical components. Fully compliant with IEC 60695-2-10, this PLC-controlled system eliminates manual error, ensuring repeatable and reliable results for safety certification.

•  Temperature Range: Room Temperature to 960°C (Adjustable & Highly Stable).

   

• Control System: Advanced PLC-based architecture.

• Interface: Intuitive Touch Screen HMI for real-time monitoring and data entry.

• Test Force: Standardized 1.0N ± 0.2N (Constant force application).

• Glow Wire: Standard Ni/Cr (80/20) wire, 4mm diameter.

   

• Timer Range: 0–999.9s (Resolution: 0.1s) for Ti, Te, and Ts.

• Operation: Fully Automatic motorized carriage movement.

• User-Friendly HMI: No complex knobs. Set your temperature and time parameters directly on the digital screen.

• High Accuracy: Equipped with high-precision thermocouples to ensure the glow wire tip stays within the strict tolerances required by international standards.

• Fully Automatic: The motorized specimen carriage ensures a smooth, constant speed approach and withdrawal, removing operator bias.

• Safety First: Built-in ventilation and a reinforced tempered glass observation window for safe monitoring.

• Durable Build: Finished with anti-corrosive coatings to withstand high-heat environments.

Ideal for quality control and R&D in:

• Electrical & Electronics Manufacturing.

• Plastic & Polymer Testing Labs.

• Household Appliance Safety Certification.

• Automotive Component Testing.

Designed and manufactured in accordance with:

• IEC 60695-2-10 / 11 / 12 / 13

• ASTM D6194

• UL 746A

The CKINSTO Ignitability Tester is a fully-equipped flammability testing system designed for evaluating the burning characteristics of plastic materials used in electrical devices and appliances.
It supports both Horizontal (HB) and Vertical (V-0 / V-1 / V-2) flammability test methods under the UL 94 standard.
This system features a large combustion chamber, precision burner assembly, and PLC-based control for accurate, safe, and repeatable testing.
Purpose

This apparatus is used to determine:

·       Flame propagation rate in horizontal test mode.

·       After-flame time, after-glow time, and dripping behavior in vertical mode.

·       Material classification as HB, V-0, V-1, or V-2 according to UL 94.

·       Safety compliance for plastics used in electronics, appliances, automotive, lighting and consumer goods.

It provides manufacturers, QC labs, and certification bodies with a reliable solution to validate flame-retardant material performance.

·       Chamber Volume: 0.75 cubic meter

·       Material: Heavy-duty M.S. body, powder-coated

·       Front Glass Door for safe observation

·       Built-in Exhaust Fan

·       Burner Diameter: 9.5 mm

·       Adjustable Stainless Steel (S.S.) Burner Stand

·       Motorized Burner Movement for precise positioning

·       Regulator, Manometer & Flow Rotameter included

·       Thermocouple: 0.5 mm dia with copper tip

·       Gas cylinder & gas regulator arranged by user

·       Horizontal & Vertical positioning

·       300 mm Steel Scale for flame measurement

·       Sample Mounting Stand: Height adjustable

·       PLC-based automatic operation with timer control 

This test is often referred to as a Thermal Cycling Test or Temperature Cycling Test.

• Objective: To simulate the repeated heating and cooling cycles that electrical connections experience in service due to changes in electrical load (current) and ambient temperature. This exposes the connection to stresses caused by the differential thermal expansion and contraction between the conductor (cable) and the terminal material (lug).

• Failure Mechanism: Failure is typically indicated by an increase in contact resistance at the crimp or joint, leading to excessive heat generation, material degradation, and ultimately, system failure.

• Standards: The system is typically designed to comply with thermal cycling requirements in major industry standards, such as:

  • IEC 61238-1: Compression and mechanical connectors for power cables.

  • UL 486A-B: Standard for Wire Connectors and Soldering Lugs.

  • IEEE 837: Standard for Qualifying Permanent Connections Used in Substation Grounding.

• 1. Current Injection and Cycling Unit

•  High-Current Source: A powerful, regulated AC or DC current source (often a current transformer/injector) capable of delivering the required heating current.

• Capacity: Ranges from hundreds to thousands of amperes , depending on the size of the lugs being tested.

• Automated Cycling: A programmable switchgear system to automatically turn the current ON and OFF according to the test protocol's specified heating and cooling periods.

• Test Bench/Busbars: Robust, high-conductivity copper busbars are used to connect the lugs and cables, minimizing the busbar's own heating.

• Reference Conductor: The standard requires one or more reference conductors of the same material and size as the cable under test to be included. The temperature rise of the lug connection is measured relative to this reference conductor.

• Fixtures: Specialized clamping and mounting fixtures ensure the lugs and cables are secured without adding extraneous mechanical stress.

• Temperature Measurement: High-accuracy, multi-channel temperature monitoring using K-type Thermocouples or non-contact Infrared Cameras. Thermocouples are attached to the lug/connector and the reference conductor.

• Voltage Drop Measurement: High-precision instruments  are used to measure the voltage drop across the crimp joint. This drop is directly related to the contact resistance .

•  Control System: PLC-based control with a PC interface (SCADA) for fully automated operation.It allows the operator to set:

• Data Logging: Automatically records temperature rise, voltage drop, and cycle count for continuous monitoring and final reporting.

The CKINSTO UL 486 Thermal & Mechanical Test System is a sophisticated apparatus specifically designed to evaluate the safety, integrity, and performance of wire connectors, soldering lugs, and terminals according to the comprehensive requirements of the Underwriters Laboratories (UL) 486 standard.

The UL 486 standard covers four main sections (A, B, C, D) which specify both thermal (electrical) and mechanical tests that wire connectors must pass to ensure they provide a reliable, low-resistance connection that can withstand physical stress and environmental factors.

The CKINSTO system integrates multiple test capabilities into a modular or unified setup to perform these critical verifications:

This section ensures the connector does not overheat in service.

• Standard Compliance: Addresses the Temperature Rise Test and Heat Cycling Test requirements (central to UL 486A/B).

• High-Current Source: Includes a regulated AC or DC power source capable of delivering the connector's rated current (or test current) and maintaining stability for the duration of the test.

• Temperature Monitoring: Employs high-accuracy thermocouples (e.g., K-type) and a multi-channel data acquisition system to measure the temperature rise of the connector and a nearby reference conductor.

• Heat Cycling: Automates the repetitive application and removal of the test current (cycling) over a specified number of cycles (e.g., 500 cycles) to simulate long-term operational stress.

• Failure Criterion: The primary failure mode is an excessive temperature rise or a significant increase in the connector-to-reference conductor temperature difference over the course of the cycling test.

This section verifies the mechanical strength of the termination, ensuring the wire remains securely gripped by the connector.

• Standard Compliance: Addresses the Wire Pull-out Force Test (central to UL 486A/B/C/D).

• Tensile Tester: Integrates a precision motorized tensile tester (Pull-out Force Test Machine) equipped with a high-accuracy load cell and adjustable grips.

• Force Application: Capable of applying a precisely controlled, continuously increasing tensile force to the wire while the connector is securely held.

• Measurement: Records the maximum force (peak load) required to pull the conductor completely out of the connector.

• Failure Criterion: The connector fails if the wire separates from the terminal at a force less than the minimum value specified in the UL 486 standard for that wire size/gauge.

Advanced CKINSTO systems may also include apparatus for other UL 486 requirements:

• Insulation Resistance/Dielectric Voltage Withstand Test: To verify the electrical properties and safety of insulated connectors (UL 486C).

• Corrosion/Environmental Chamber: A humidity or salt spray chamber to test performance after exposure to harsh environmental conditions (UL 486D).

• Torque Testing: A digital torque meter for testing the secureness of screw-type terminal connections.

In summary, the CKINSTO UL 486 Test System provides a comprehensive, automated platform for manufacturers to ensure their wire connectors meet the stringent safety and reliability requirements mandated by UL, covering both their ability to handle electrical load without overheating and their ability to withstand mechanical forces.

The CKINSTO Glow Wire Test Apparatus (or Glow Wire Testing Machine) is a specialized piece of automated equipment designed to assess the fire hazard resistance and flammability of insulating materials and non-metallic components used in electrical and electronic products. This is done by simulating the short-term thermal stress caused by an overheating component or an electrical fault.

• Primary Use: To evaluate the fire risk of plastic and other non-metallic materials, particularly those near current-carrying parts in electrical appliances, lighting equipment, and low-voltage apparatus.

• Simulates: The effect of heat from potential ignition sources like overloaded connections or searing elements.

• Standards: The equipment is designed to comply with a range of international safety standards, including:

  • UL 746A: Standard for Polymeric Materials – Short Term Property Evaluations (The standard specifically referenced in your query).

  • IEC 60695-2-10 (Glow-wire apparatus and common test procedure).

  • IEC 60695-2-11, -12, -13 (covering End Product Testing, Flammability Index - GWFI, and Ignition Temperature - GWIT).

  • Other standards like IEC 60335-1 (Safety of Household Appliances).

Modern CKINSTO models are often fully automated and feature advanced control systems:

• Glow Wire: A 4 mm diameter wire loop made of Nickel-Chromium (80:20 Ni/Cr alloy), which is electrically heated.

• Temperature Control: Uses a PID Digital Temperature Controller to regulate the temperature of the glow wire, typically up to $1000^{\circ}\text{C}$ or $1100^{\circ}\text{C}$, ensuring high temperature stability and precise results.

• Current Source: An auto current source with a CT-operated ammeter capable of delivering up to 150A heating current.

• Specimen Holder: A motorized or preloaded specimen holder trolley that applies a specified force (typically $1.0 \text{ N}$) to press the test sample against the heated glow wire for a set time (usually 30 seconds).

• Control System: Often uses a PLC-controlled system with a Touchscreen Interface for intuitive operation, monitoring, and automated data recording of parameters like:

  • Application Time

  • Ignition Time ($t_{i}$)

  • Flame Duration ($t_{a}$)

  • Extinguishing Time ($t_{e}$)

• Chamber: Enclosed test chamber, sometimes with an exhaust fan, to ensure controlled testing conditions and safe smoke removal.

This apparatus allows manufacturers to determine the material's Glow Wire Flammability Index (GWFI)—the highest temperature at which the material self-extinguishes within 30 seconds—and the Glow Wire Ignition Temperature (GWIT)—the lowest temperature causing sustained ignition.

Glow-wire Test Apparatus According to UL746A, IEC829, DIN695 and VDE0471 for Flammability Index Test provides a visual example of a similar glow-wire test setup and its application in flammability testing.

The CKINSTO Terminal Mechanical Integrity Test Equipment is a comprehensive, multi-station test system designed to evaluate the physical and electrical durability of wire connectors, lugs, and terminals. Engineered to meet and exceed the requirements of national and international standards like UL 486A-B, IEC 60947-7-1, and others, this apparatus is a cornerstone for quality assurance in the electrical components industry.

This single, integrated system consolidates multiple critical tests to provide a full evaluation of a terminal's integrity, ensuring long-term safety and performance.

Key Features and Test Capabilities:

1. Secureness Test (Flexing & Bending Endurance)

• Purpose: Simulates the repeated mechanical stress a terminal may face in service, such as vibration or cable movement.

• Functionality: The apparatus automatically subjects the wire-terminal connection to a specified number of flexing cycles at a controlled rate (e.g., 10 RPM), all while under a specific tensile load.

• Pass/Fail Criteria: An integrated continuity monitoring circuit detects any interruption in the electrical connection. The test automatically stops if a failure occurs, providing a precise cycle count.

2. Pull-Out Force Test (Tensile Strength)

• Purpose: Measures the ultimate tensile strength of the connection to ensure the wire is held securely and will not pull out under expected or unexpected forces.

• Functionality: A high-precision load cell applies a controlled, increasing pull-out force to the conductor at a specified rate until the connection fails.

• Data Capture: The system records the peak force at which the conductor disengages, providing a critical metric for connection quality.

3. Temperature Rise Test (Thermal Performance)

• Purpose: Evaluates the thermal performance of the terminal under load to ensure it does not overheat and compromise the integrity of the connection or surrounding components.

• Functionality: The apparatus can be integrated with a current source to pass a specified current through the terminal. Thermocouples measure the temperature rise of the terminal and its conductor under this electrical load, verifying compliance with temperature limits.

• Compliance: This test is essential for compliance with standards like IS 1293 and IEC 60884, which are vital for terminal and connector certification.

Integrated System Design:

•  Robust Construction: Built with a heavy-duty, powder-coated Mild Steel (MS) or stainless steel frame to ensure stability and durability for continuous testing.

   

• Versatile Fixtures: The system includes a comprehensive set of interchangeable clamping jaws, weights, and fixtures to test a wide range of conductor sizes and terminal designs.

• Advanced Control: A single PLC-based HMI touchscreen provides an intuitive interface for controlling all test parameters, including cycle count, force application, temperature monitoring, and test duration.

• Safety Features: Equipped with essential safety features such as an emergency stop button, over-force protection, and safety interlocks on all moving parts.

The term CKINSTO Electrical Fire Hazard Tester is a collective category covering several specialized pieces of equipment designed to evaluate the flammability and fire-risk potential of electrical and electronic components and materials, particularly plastics and insulation. The tests are crucial for meeting international safety standards and preventing electrical fires.

CKINSTO provides individual apparatuses for specific tests as defined by standards like IEC 60695 and UL 94.

The main testers that fall under the "Fire Hazard Tester" category include:

• Purpose: To simulate the thermal stress produced by a hot, failed, or overloaded component (like a resistor or conductor) coming into contact with insulating material.

• Principle: A Nickel-Chromium (Ni/Cr) wire loop is heated to a specified temperature (e.g., $550^{\circ}\text{C}$ to $960^{\circ}\text{C}$) and pressed against the test sample (often a non-metallic part or a finished product) with a defined force ($1.0 \text{ N}$) for a set time (typically 30 seconds).

• Measurement: Measures the time it takes for the material to ignite and/or self-extinguish (Afterflame Time, Afterglow Time).

• Standards: Adheres to IEC 60695-2-10, -11, -12 (GWFI and GWIT).

• Purpose: To determine the burning characteristics of plastic materials used in devices and appliances.

• Principle: A specimen is subjected to an open flame from a Bunsen burner in a draft-free chamber, either vertically (V-0, V-1, V-2 ratings) or horizontally (HB rating).

• Measurement: Measures the time the sample continues to burn after the flame is removed (Afterflame Time), the afterglow time, and whether flaming drips ignite cotton placed below the sample.

• Standards: Complies with UL 94 and related IEC 60695-11-10 standards.

• Purpose: To simulate the effect of a small flame that might result from a component fault on nearby parts of an electrical product.

• Principle: A small, defined flame (produced by a needle burner using Butane/Propane) is applied to the specimen for a set duration.

• Measurement: Measures the sample's flaming time, glowing time, and whether ignition occurs.

• Standards: Complies with IEC 60695-11-5.

• Purpose: To measure the resistance of solid insulating materials to the formation of a carbonized, conductive path (tracking) on their surface when exposed to an electric field and contaminated by an electrolyte (simulating moisture and impurities).

• Principle: Uses a precisely controlled voltage applied between two electrodes on the material's surface while drops of electrolyte solution are automatically dispensed.

• Measurement: Determines the CTI value—the maximum voltage at which the material does not fail by tracking after 50 drops.

• Standards: Complies with IEC 660112 (ASTM-60112).