DRAFT PRODUCT MANUAL ON - Bureau of Indian … · draft product manual on electric instantaneous...

DRAFT

PRODUCT MANUAL

ON

ELECTRIC INSTANTANEOUS WATER HEATERS

As per IS 8978: 1992

BUREAU OF INDIAN STANDARDS MANAK BHAWAN,

9, B.S. ZAFAR MARG, NEW DELHI-110 002

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Doc No. : DHBO/8978/Draft Manual

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Draft Product Manual for Electrical Instantaneous Water Heaters as per IS 8978: 1992

PREPARED BY : DHBO APPROVED BY :

Amendment Sheet:

To ensure that this Product Manual contains a complete record of Amendments , this Amendment sheet shall be maintained in the Product Manual.

Sl. No. Amendment No.

Reference No.

Date of Issue

Date of Implementation Page No.


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Foreword

Electric Instantaneous Water Heater is very commonly used in domestic and similar installations for water heating purpose, popularly known as Instant Geyser. In view of its widespread use and the safety implications involved, ISI marked instant geysers are generally in demand by consumers. This product is, however, not at present covered under mandatory certification.

This product manual contains the description, manufacturing and testing of Electrical Instantaneous Water Heaters as per IS 8978: 1992. Guidelines for Grant of BIS licence for an applicant is also described in this manual. Grouping guidelines, sample size for testing, information about laboratories where the product can be got tested for the purpose of Grant of Licence etc. are described in the manual for the easiness of new applicants as well as existing licensees.


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Table of Contents

Sl. No. Contents Title Page Nos.

Description of Product 6 Latest Indian Standard Number with Product title and number of Amendments

6

List of Referred ISS for Raw Materials/Components and Test Methods

7 1

Section I (Product Description)

Check list for submission of an application for GOL

7 to 10

2

Section II

(Raw Materials/Components)

Raw Materials/Components 12

Description of manufacturing process 14 3

Section III (Manufacturing Process and In-process Quality Controls) Infrastructure for production 15

Identification of critical requirements of the ISS

17

STI 18 to 21 Marking fee rate 22 Grouping guideline 22 Guideline for writing scope of licence 22 Guideline for inclusion of new varieties 23 Sample size 23 Manner of sealing the sample 23 Whether remnants of the sample are returnable/ non-returnable

23

4

Section IV (Certification Criteria)

Procedure to be followed for destroying the product that does not meet the quality parameters during regular production

23

Packing material requirement (to be available in factory at all times) for packing/dispatch of samples

25

List of required test requirements/facilities with requirement and frequency of calibration

25

Status of test facilities in BIS labs and OSL s with testing charges

25 to 27

Approximate time required for testing by BIS labs/OSLs

28

GOL based on FT basis/IT basis/Mixed 28 Details of tests to be carried out in Factory 28

5

Section V (Inspection and testing)

List of values to be declared 29


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Section I: Product Description


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1. Description of Product

The relevant Indian Standards cover the performance and safety requirements of electric instantaneous water heaters used for domestic and similar installations.

Broad categories of electric instantaneous water heaters which are commonly used and covered in these standards are:

i) Open outlet type ii) Closed type

For electric instantaneous water heaters capacities upto 3 l are provided in the standard (see clause 1.1 of IS 8978) alongwith rated input (Wattage). However, the recommended values given in the Standard regarding input wattage are not being followed in general and the manufacture is to give declared input wattage from the preferred wattage permitted as per IS 302-1.

2. Latest Indian Standard Number with Product title and number of Amendments

8978: 1992

Specification for electric instantaneous water heaters

No. of Amendments- 2


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3. List of Referred Indian Standards for Raw Materials/Components and

Test Methods

a) 302-2-35: 1992 Safety of Household and similar electrical appliances- Part 2 Particular

requirements, Section 35 Electrical Instantaneous water heaters (upto Amendment 2)

b) IS 302-1: 2008 Safety of Household and similar electrical appliances- Part 1 General requirements (upto Amendment 1)

c) IS 694: 1990 PVC insulated cable for working voltages upto and including 1100V

d) IS 1293: 2005 Plugs and socket outlets for household and similar purposes of rated voltage upto and including 250V and rated current upto and including 16A

e) IS 1401: 2007 Protection of persons and equipments by enclosures- Probes for verification

f) IS 2071 (Part 1): 1993 High voltage test techniques- Part 1 General definitions and tests

g) IS 2071 (Part 2): 1974 High voltage test techniques- Part 2 Test procedures

4. Check-List for submission of an application for grant of licence a) Check list for application to be submitted by applicant to BIS while applying for

BIS licence


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BUREAU OF INDIAN STANDARDS




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b) List of documents to be attached with application


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Section II: Raw Materials/Components


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1. Raw Materials/Components

A typical list of raw material/ components is given below:

i) CRCA Sheet ii) Stainless steel tank/ Copper tank iii) Brass Sheet iv) Heating Element v) Thermostat vi) Flow switch/non-self resetting thermal cutout vii) Plug & Cord viii) Insulation material ix) Indicators, wires for internal connection x) Inlet/OutletValves xi) Screws & terminals xii) Packing material etc. xiii) Pressure release valve & fusible plug xiv) Powder coating/paint

Note: The compliance of Cl. 8 of STI (Doc: STI/8978/3 September 1997) shall be ensured.


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Draft Product Manual for Electric Instantaneous Water Heater as per IS 8978:1992


Section III: Manufacturing Process and In-process Quality

Controls


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Draft Product Manual for Electric Instantaneous Water Heater as per IS 8978:1992


1. Description of manufacturing process A typical flow chart indicating manufacturing process is depicted below:


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Draft Product Manual for Electric Instantaneous Water Heaters as per IS 8978:1992


2. Infrastructure for production A Unit may need following machineries in manufacturing the electric instantaneous water heaters:

S.No. List of Tools & Machinery

1. Power Press

2. Hand Press

3. Grinder

4. Drilling Machine

5. Welding set & brazing set

6. Spot welder

7. Drying oven for paint

8. Phosphating tanks

9. Hand rolling machine

10. Gas welding set

11. Screw Drivers

12. Pliers/Nose Pliers

13. Hammers/Cutter/Files

14. Punch for marking on plate


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Section IV: Certification Criteria


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1. Identification of critical requirements of the Indi an Standard (To be identified by CMD)


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2. Scheme of Testing and Inspection:


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3. Marking fee rate : The following rate of marking fee is applicable for a licence:

i) Rate of marking fee: Unit – One Piece Rs. 1.20 per unit for all units

ii) Minimum marking fee Rs. 29000 (for Small Scale Industries) /Rs. 34000 (for Large Scale Industries) for one operative year payable in advance which will be caried to next renewals.

iii) Actual marking fee for the first nine months of the operative period calculated on unit rate basis on the production marked or the minimum marking fee whichever is higher shall be payable by the licensee.

4. Grouping Guideline (if any):

No guidelines prescribed as yet.

5. Guideline for writing scope of licence: The scope of the licence should include Rated Voltage, Rated Frequency, No. of phases, Capacity, Material of the inner tank, Protection class, type (closed/open-outlet), Pressure Class if closed type, Rated Input, Mode of control, Pollution Degree, Material Class, Class of protection against moisture. The other details may be included as per the product description. Typical description being given in the licences is as follows: Electric Instantaneous Water Heaters, 230V, ac, 50 Hz, Single Phase, 1 litre & 3 litre, Stainless Steel tank, class 1, Closed type, Pressure Class II(30 N/cm2), 3.0kW, IPX1, Pollution Degree 3, Material Group IIIa, with non-self resetting type thermal cutout

The declared parameters to be obtained from the applicant /licencee are given at page 29.


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6. Guidelines for inclusion of new varieties: For getting a new variety included in the existing licence, a licensee is required to get the sample of each variety tested from BIS recognized laboratories. In case additional manufacturing and testing facilities are required to be declared for inclusion in the scope of the licence.

7. Sample size: For Grant of Licence under Normal Procedure, the following samples to be drawn:

1. Two nos. of electric instantaneous water heaters 2. A separate inner container may also be drawn Routine sample: One no. of electric instantaneous water heaters

8. Manner of sealing the sample: Packed in a corrugated card board box. Code & sign with a permanent marker.

9. Whether remnants of the sample are returnable/non-returnable:

Returnable

10. Procedure to be followed for destroying the product that does not meet In case of sample does not meet the requirements specified in Indian Standard, such control unit shall not be marked. Since the product is not covered under Mandatory Certification, hence rejected control unit may be either destroyed or re-worked and sold as Non-ISI.


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Section V: Inspection and testing


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1. Packing material requirement (to be available in factory at all times)

for packing/dispatch of samples:

Plain corrugated card board box. Thermocol fillers for support Polythene bag of the suitable size

2. List of required test equipments/facilities with requirement and frequency of calibration: (To be decided by Central Lab, Sahibabad)

3. Status of test facilities in BIS labs and OSLs with testing charges : Technical Auditor shall ensure status of laboratory, availability of testing facilities and testing charges at the time of visit from BIS Intranet.

List of BIS Laboratories

( As on 01/03/2014)

Date :- 1/3/2014

Lab Quantity Lab Type

Testing Facility

Remarks

IS Number :- IS 8978 - 0 : 1992

CL 2 Nos. (1 inner container for pr. & mat. Test)

Elec P No TF for temp/Pr. devices + splash & drip proof test + moisture resistance test

NROL 2 Nos. Elec N

SROL 1No. Elec P Only acceptance test

IS No. Testing Charges Remarks IS 8978 : 1992 Rs.3880/- for closed type,Rs.3580/-for others

Testing Facility:: C=Complete Test facility / P=Partial Test Facility/ N=No Test

Facility


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List of Outside Recognized Laboratories

( As on 01/03/2014)

Sl No.

Name of the Recognized Laboratory Lab Code Testing Charges

Remarks

IS Number :- IS 8978 - ELECTRIC

INSTANTANEOUS WATER HEATERS

1 Hi Physix Laboratory, L-83, Sector 1, DSIDC Indl. Area, Bawana, Delhi-110039 Delhi Contact : Sh. D.P.Bahuguna, CEO [09899552976] Tel : 011-27750231 Fax : 011-27750231

8120126 Rs.17100/- and Rs.1000/- for Transient Over Voltage test, if applicable. [ 25% discount to BIS]

2 HI PHYSIX LABORATORY INDIA PVT. LTD. A-79,MIDC Ranjangaon Pune-412220 Maharashtra Contact : Shri Pankaj Rai (CEO) Tel : 09811177231 Fax : 02138-232903

7126926 Rs.20000/- and Extra Rs.5000/- for upto 1000 switching cycles & Rs.20000/- for upto 10000 switching cycles of control devices. ( 25% discount to BIS)

Including safety tests as per IS 302-2-35

3 Bharat Test House Pvt Ltd 781, HSIIDC Industrial Estate Rai Sonepat-131001 Haryana Contact : Shri Rajeev Gupta, CMD Tel : 9810314585 Fax : 0130-2297675

9126826 Rs.7450/- [55% discount for BIS]

4 Central Electrical Testing Laboratory, Kakkalur Thiruvallur, (District). Kakkalur-602003 Tamilnadu Contact : Shri C.Selvam, Deputy Director (E&E) Tel : 044-27660384 Fax : 044-27660302

6104524 Routine test - Rs. 3700/-, Acceptance test - Rs.8500/-, Type test - Rs.11300/- , All test- Rs. 12900/-

Alongwith IS 302-2-35:1993


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STANDARDS Draft Product Manual for Electric Instantaneous Water Heaters as per IS 8978:1992

PREPARED BY : DHBO

APPROVED BY :

List of Outside Recognized Laboratories

( As on 01/03/2014)

5 National Test House (NR) Kamla Nehru Nagar Ghaziabad-201001 Uttar Pradesh Contact : The Director Tel : 0120-2789493 Fax : 0120-2789883, 13

8101304 Rs.10000/- (inclusive of safety testing charges as per IS 302-2-35 @ Rs.5,000/-)

6 MSME Testing Centre, (Deptt. of Industrial Development) Shaheed Capt. Gaur Marg, Phase-III, Okhla New Delhi-110020 Delhi Contact : Sh. A.K.Mukherjee, Quality Manager Tel : Mobile:9810331625 Fax : 011-26847973

8101204 Rs.7000/- (25% concession for BIS)

7 Electrical Research & Development Association P.B. No. 760, ERDA Road, Makarpura Industrial Estate Vadodara-390010 Gujarat Contact : Dr. M.K. Shah, JD&Quality Manager -Mob:09978940911 Tel : 0265-2642942,964,377 Fax : 0265-2648382

7101125 Rs.16800/- [25% discount for BIS]

8 Delhi Test House Plot No.50, Phase-IV, Sector-57, HSIDC Industrial Area, Kundli, Sonepat-131028 Haryana Contact : Shri M.C.Goel, Director Tel : 0130-2116529 Fax :

9127026 BIS testing charges


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4. Approximate time required for testing by BIS labs/OSLs : (To be decided by Central Lab, Sahibabad)

5. Whether grant of licence will be based on : Factory testing basis × Independent testing basis √ Mixed (Factory testing basis plus Independent testing basis) ×

6. Details of tests to be carried out in the factory in case of :

� Applicant sample/verification sample- All possible Routine tests like Protection against electric shock, High Voltage test, Earthing Connection, Pressure test and Acceptance tests like Input, Insulation Resistance and Electric Strength at operating temperature etc.

� Surveillance samples All possible Routine tests like Protection against electric shock, High Voltage test, Earthing Connection, Pressure test and Acceptance tests like Input, Insulation Resistance and Electric Strength at operating temperature etc.

� Market sample- The laboratory shall conduct maximum possible tests in order to assess quality of the product.

� Raw material- Compliance of Cl. 8.0 of STI (Ref: Doc. STI/8978/3 September 1997) and Cl.24 & 25 of IS IS 302-1 shall be ensured.


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ANNEXURE of CLAUSE 5 OF SECTION 4

DECLARED VALUES TO BE OBTAINED FOR INSTANTANEOUS WA TER HEATERS AS PER IS 8978: 1992

i) Rated capacity in litres ii) Rated voltage in volts, nature of supply & frequency iii) Rated input in Watts iv) Type of water heater (open-outlet/closed type) and pressure class where applicable v) Classification according to protection against electric shock vi) Classification according to degree of protection against moisture vii) Material of inner tank and grade of material viii) Fitted with flow switch/non-self resetting thermal cutout etc.

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