Abstract
Fire and flammability testing plays a critical role in ensuring the safety of electrical equipment and combustible materials, as small flames resulting from internal faults can trigger catastrophic fire hazards. The LISUN ZY-3 Needle Flame Test Apparatus is a specialized instrument designed to simulate such fault-induced small flames and evaluate ignition risks. This paper elaborates on the design principles, technical specifications, testing procedures, and application scenarios of the LISUN ZY-3, with a focus on its compliance with international standards. By analyzing its structural components and performance parameters, the paper demonstrates its significance in fire and flammability testing for lighting equipment, low-voltage electrical appliances, insulation materials, and other products. Practical test cases and data are presented to verify its reliability and accuracy, providing a reference for researchers and industry practitioners in material safety evaluation.
1. Introduction
1.1 Background of Fire and Flammability Testing
Electrical equipment and combustible materials are ubiquitous in industrial production and daily life, but their flammability poses inherent fire risks. Internal faults such as short circuits or overheating in electrical devices often generate small, localized flames that can ignite surrounding materials, leading to large-scale fires and casualties. Fire and flammability testing, as a key link in product safety certification, aims to simulate potential fire sources and assess the ignition resistance of materials and equipment, thereby preventing fire accidents from the source. Among various fire testing methods, the needle-flame test is widely recognized for its ability to replicate small fault flames, making it an essential part of safety evaluation systems for electrical and electronic products.
1.2 Overview of LISUN ZY-3 Needle Flame Test Apparatus
Developed by LISUN GROUP, the ZY-3 Needle Flame Test Apparatus is tailored to meet the rigorous requirements of fire and flammability testing for a wide range of products. It is primarily used for testing lighting equipment, low-voltage electrical appliances, household appliances, power tools, electronic instruments, and electronic meters. Additionally, it is suitable for evaluating insulation materials, engineering plastics, and solid flammable materials. The apparatus consists of three core components: a needle flame burner, a working chamber, and a temperature measuring device, which work together to simulate fault flames and accurately record test data. With compliance to international standards such as IEC 60695-2-2:2021 and IEC 62368-1:2023, the ZY-3 has been widely applied in industries worldwide for over a decade, establishing a reputation for reliability and precision.
2. Fundamental Principles of Needle Flame Test in Fire and Flammability Testing
The needle-flame test is a simulation-based fire and flammability testing method that evaluates the ignition hazard of small flames generated by equipment internal faults. The core principle involves using a needle-shaped burner of specified size to generate a stable small flame, which is applied to the test specimen at a fixed angle for a predetermined duration. The test assesses fire risk by monitoring three key indicators: whether the specimen and the underlying ignition pad ignite, the duration of combustion (including burning time and afterflame time), and the length of the flame.
For the LISUN ZY-3, the burner uses 95% butane (or propane) as fuel and has a diameter of 0.9mm, which is standardized to ensure consistency in flame size. During testing, the burner is oriented at 45° to the specimen surface, and the flame height is strictly controlled at 12mm±1mm—dimensions chosen to replicate the small, concentrated flames typical of electrical faults. The temperature measuring device, a Φ0.5mm K-type thermocouple, tracks the flame temperature, which must rise from 100℃±2℃ to 700℃±3℃ within 23.5 seconds±1s to meet standard requirements. This precise temperature profile ensures that the test flame accurately simulates real-world fault conditions, making the results of fire and flammability testing actionable for safety certification.
3. Technical Specifications and Structural Design of LISUN ZY-3
3.1 Core Structural Components
The LISUN ZY-3’s design is optimized for efficiency and accuracy in fire and flammability testing, with three integrated components:
• Needle Flame Burner: The heart of the apparatus, featuring a 0.9mm diameter needle-shaped nozzle. It can be adjusted to two angles: 45° for testing and 0° for flame height calibration, ensuring precise flame positioning relative to the specimen.
• Working Chamber: A enclosed space that isolates the test environment from external draughts, which could invalidate fire and flammability testing results. It is typically used with a ventilation system (mandatory for the compact ZY-3S model) to remove toxic fumes generated during testing, as specified in IEC 62368-1:2023 Annex S.
• Temperature Measuring Device: Equipped with a high-sensitivity K-type thermocouple (Φ0.5mm) that provides real-time temperature data with minimal error, supporting the critical temperature rise requirement for valid flame simulation.
ZY-3 Needle Flame Test
3.2 Detailed Technical Specifications
The performance parameters of the LISUN ZY-3 are aligned with international fire and flammability testing standards, ensuring consistency and comparability of test results. The following table summarizes its key specifications:
Parameter
Specification
Remarks
Burner Angle
45° (testing state); 0° (flame height adjustment)
Ensures standard flame orientation
Needle Flame Burning Time
0~999.9s±0.1s
Adjustable, 30s as default
Afterflame Time
0~999.9s±0.1s
Auto-recorded, manual pause function
Flame Height
12mm±1mm
Calibrated at 0° burner angle
Fuel
95% butane (propane optional)
Digital flow meter available as extra
Temperature Test Range
0~1000℃
Covers typical fault flame temperatures
Temperature Rise Performance
100℃±2℃ to 700℃±3℃ in 23.5s±1s
Complies with IEC 60695-11-5
Thermocouple
Φ0.5mm K-type
High sensitivity for temperature tracking
Operation Interface
Touch screen + remote control
User-friendly for complex test programs
Single Test Burns
Single or multiple (programmable)
Supports IEC 62368-1 Annex S.1 requirements
Weight (Compact ZY-3S) https://www.lisungroup.com/news/technology-news/lisun-zy-3-needle-flame-test-apparatus-a-core-tool-for-fire-and-flammability-testing-of-electrical-and-combustible-materials.html
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