Classification of gases
The gases are classified into three families, possibly divided into groups depending on the Wobbe number,according to the values given in EN 437.
Appliance categories
Appliances are classified into categories defined according to the gases and pressures for which they are designed.
The definition of the categories results from EN 437.
In each country, only some of the categories defined in EN 437 are marketed, in view of the local conditions of gas distribution (gas composition and supply pressures).
The marketing conditions for various appliance categories in different countries are detailed in Tables A.1 and A.2, while Table A.3 outlines the associated supply pressures For specific local and national market categories, refer to the gases and supply pressures defined in EN 437 Additionally, Table A.5 provides country-specific conditions.
Mode of supply of the combustion air and evacuation of the combustion products (appliance types
Type B
An appliance designed to connect to a flue for venting combustion byproducts outdoors, while sourcing combustion air directly from the installation room.
Type B 1 : A type B appliance fitted with a draught diverter in the combustion products circuit.
Type B 11 : A type B1 appliance without a fan in the combustion products circuit or air inlet.
Type B 11BS : A type B11 appliance factory fitted with a combustion products discharge safety device.
Type C
An appliance in which the combustion circuit is sealed with respect to the inhabitable area of the building where it is installed. Ó BSI 02-2000
A Type C appliance is linked to a horizontally mounted terminal on the wall or roof through its ducts, with the duct openings either being concentric or positioned closely enough to experience similar wind conditions.
Type C 11 : A natural draught type C1 appliance.
Type C 12 : Type C 1 appliance in which the fan is incorporated downstream of the combustion chamber/heat exchanger.
Type C 13 : Type C 1 appliance in which the fan is incorporated upstream of the combustion chamber/heat exchanger.
A type C appliance connected via its ducts to a shared duct system consisting of a single duct for both supply of the combustion air and discharge of the combustion products.
Type C 21 : A natural draught type C2 appliance.
A type C appliance connected via ducts to a vertically installed terminal The orifices of the ducts are either concentric or close enough to come under similar wind conditions.
Type C 31 : A natural draught type C3 appliance.
Type C 32 : Type C 3 appliance in which the fan is incorporated downstream of the combustion chamber/heat exchanger.
Type C 33 : Type C 3 appliance in which the fan is incorporated upstream of the combustion chamber/heat exchanger.
A type C appliance is linked to a shared duct system that includes a duct for supplying combustion air and another for discharging combustion products The openings of this shared duct system are designed to be either concentric or positioned closely enough to experience similar wind conditions.
Type C 41 : A natural draught type C4 appliance This standard does not cover this type of appliance.
Type C 42 : Type C 4 appliance in which the fan is incorporated downstream of the combustion chamber/heat exchanger.
Type C 43 : Type C 4 appliance in which the fan is incorporated upstream of the combustion chamber/heat exchanger.
A type C appliance which is connected via its separate ducts to two terminals in zones of different pressure.
Type C 51 : A natural draught type C5 appliance This standard does not cover this type of appliance.
Type C 52 : Type C 5 appliance in which the fan is incorporated downstream of the combustion chamber/heat exchanger.
Type C 53 : Type C 5 appliance in which the fan is incorporated upstream of the combustion chamber/heat exchanger.
A type C appliance which has to be connected to a separately approved and marketed system for the supply of combustion air and discharge of the combustion products.
Type C 61 : A natural draught type C6 appliance This standard does not cover this type of appliance.
Type C 62 : Type C 6 appliance in which the fan is incorporated downstream of the combustion chamber/heat exchanger.
Type C 63 : Type C 6 appliance in which the fan is incorporated upstream of the combustion chamber/heat exchanger.
Appliance marking
Data plate
Each appliance must feature a durable and securely attached data plate that remains visible upon installation, which may require the removal of a part of the casing This plate should include essential information such as the manufacturer's name or symbol, the serial number or year of manufacture, and the appliance's trade name Additionally, if applicable, it should display the CE mark, including the appliance identification number and the last two digits of the year the CE mark was issued Furthermore, it must indicate the countries of direct or indirect destination, represented by specific codes in accordance with EN 23166.
When specifying the categories for gas supply in the United Kingdom (GB) and Sweden (SE), it is essential to follow the guidelines outlined in section 4.2 Additionally, the gas supply pressures must be indicated in millibars (mbar), especially when multiple normal pressures are applicable for the same gas group.
A "Manufacturer" is defined as the individual or entity responsible for the design and production of a product intended for the Community market The product specifications must include the type of appliance as per section 4.3, whether it is a "condensing appliance," the nominal heat input in kW, nominal capacity in liters, maximum water pressure, and the degree of protection in accordance with EN 60529 Additionally, the type and voltage of the electrical supply in volts (V) and absorbed power in watts (W) must adhere to EN 60335-1 standards The appliance should be designated for installation solely on a gas supply with a governed meter, if applicable.
The indelibility of markings shall be verified by a test carried out as described in 7.14 of EN 60335-1:1988.
Supplementary markings
The appliance must feature a clear and permanent supplementary rating plate that indicates its adjustment status, including the designated country or countries of use as per the specified symbols, the gas group or range along with the corresponding gas type symbol, and the gas supply pressure or pressure couple as outlined in the relevant tables Additionally, it should detail the specific gas supply pressure or pressure couple for which the manufacturer has calibrated the appliance.
This information may, if appropriate, be given on the data plate.
The indelibility of the markings shall be verified by a test carried out as described in 7.14 of EN 60335-1:1988.
Table 1 — Symbols for indicating types of gas
Gas group or range of gases
Symbol of gas Gas pressure(s) (mbar)
Packaging
The packaging shall carry the category/categories, the type of appliance and the information given on the supplementary data plate (see 5.1.2) and the warnings as specified in 5.1.4.
Warnings on the appliance and packaging
One or more labels shall give at least the following visible and legible warnings.
The warnings on the appliance shall be visible to the user. Ó BSI 02-2000
5.1.4.1 For all appliances ắ "Read the technical instructions before installing the appliance"; ắ "read the user's instructions before lighting the appliance".
5.1.4.2 For type B 11 appliances ắ "This appliance shall only be installed outside or in a room separated from living rooms and provided with appropriate ventilation directly to the outside".
5.1.4.3 For type B 11BS appliances ắ "This appliance shall only be installed in a room if the room meets the appropriate ventilation requirements".
Other information
Any additional information on the appliance or its packaging that may cause confusion regarding its adjustment status, applicable categories, or intended destination countries is prohibited.
Additional marking for appliances with flue dampers
The appliance must display a permanently fixed, easily visible plate indicating that it is either equipped with a flue damper or has the capability to be fitted with one at a later date.
Instructions
Technical instructions
Every appliance must include technical instructions for installers, detailing installation, adjustment, and maintenance procedures in accordance with the regulations applicable in the country of installation.
These instructions shall comprise at least the following information :
5.2.1.1 General ắ The information on the data plate, except for the appliance number and the year of manufacture ; ắ the meaning of the symbols used on the appliance and its packaging in accordance with 5.1.1 and 5.1.2; ắ a reference to certain specific standards and/or regulations if this is necessary for correct installation and use of the appliance ; ắ if appropriate the minimum distances to be maintained between easily flammable materials ; ắ if necessary, indication that walls sensitive to heat, e.g wood, shall be protected by suitable insulation,and the distance to be observed between the wall on which the appliance is fixed and the hot external parts of the appliance ; ắ a general description of the appliance with an illustration of the main parts (subassemblies) to be removed to correct operating faults ; ắ for electrical installation : a) the need to earth appliances comprising mains-supplied electrical equipment ; b) a circuit with connection terminals (including those for external adjustment) ; ắ the method recommended for cleaning the appliance ; ắ indication of the necessary maintenance.
5.2.1.2 For installation and adjustment of the gas circuit ắ Information that the data in 5.1.2 on the state of adjustment mentioned on the data plate or supplementary plate shall be compatible with the local supply conditions ; ắ adjustment instructions for appliances that can be adjusted by the installer, comprising an adjustment table giving the volumetric rates or mass rates in cubic metres per hour (m 3 /h) or kilogrammes per hour (kg/h) or the pressure at the burner as a function of the possible adjustment data according to the category or categories The reference conditions for the volumetric rates are 15 ° C, 1 013,25 mbar, dry ; ắ if necessary, that the appliance is intended to be installed only on a gas supply with a governed meter ; ắ for appliances capable of operating on several gases, indication of the operations required to convert from one gas to another and indication that the adjustments and modifications shall only be carried out by a qualified professional or competent person When an adjustment is carried out by the installer, the adjuster shall be sealed after adjustment.
5.2.1.3 For installation of the domestic hot water ắ Installation of a check valve at the cold water inlet ; ắ incorporation of a hydraulic safety group and/or a combined temperature and pressure relief valve in accordance with the regulations in force ; ắ the maximum water pressure for which the appliance is designed indicating that even when subjected to the effect of water expansion, the water pressure in the appliance shall not exceed this value.
5.2.1.4 For installation of the combustion products evacuation circuit a) For type B1 appliances ắ the flue pipe diameter(s) as given in Table A.6 which may be used, if necessary with a duct adapter ; ắ the minimum length of the flue (1 m, or 0,5 m for certain wall-mounted appliances specified by the manufacturer) ; ắ for calculation of the flues, the combustion products mass rate in g/s and their mean temperature measured under the conditions of 8.2.2 ; b) for type B11 appliances ắ indicate clearly that type B 11 appliances shall be installed outside or in a room separated from inhabited rooms with suitable ventilation directly to the outside ; c) for type B11BS appliances ắ give a technical description of the combustion products discharge safety device ; Ó BSI 02-2000 ắ pecify that the combustion products discharge safety device shall not be put out of operation ; ắ draw attention to the seriousness of untimely interference with the combustion products discharge safety device ; ắ give instructions on the mounting of the combustion products discharge safety device and the replacement of defective parts Specify that only the manufacturer's original parts shall be used, and describe the test for the correct operation of the device which shall be carried out after servicing ; ắ draw attention to the fact that in the case of repeated shutdown of the appliance, it will be necessary to take appropriate action to remedy the discharge fault ; ắ indicate the waiting time for appliances with an automatic reset. d) for type C appliances ắ indicate the type of air supply and combustion products evacuation system to which the appliances may be connected ; ắ give the special characteristics of the terminal protection device and indications of its fitting and position relative to the terminal ; ắ indicate the maximum number of bends to be used and the maximum length of the air supply and combustion products evacuation ducts ; ắ for type C 21 appliances, the minimum dimension of the common duct on which this can be installed.
5.2.1.5 For condensing appliances ắ Specify in detail the methods adopted for the combustion products evacuation and for the removal of condensates ; in particular, attention should be drawn to the need to avoid horizontal passages ; ắ if the appliance does not meet the combustion products temperature requirements in 7.8, specify that the appliance is not intended for connection to discharge ducts likely to be adversely affected by heat (e.g plastics ducts or ducts lined with plastic) ; ắ if the appliance meets the combustion products temperature requirements in 7.8, specify : a) for these appliances, that only the materials supplied by the manufacturer may be used; b) in other cases, a list of materials capable of being used.
The installation instructions shall include all data needed for checking the appliance and the built-in flue damper for proper performance and for their maintenance.
The appliance may be delivered: a) without a flue damper; b) with a flue damper; c) with the possibility of installing a flue damper.
If there is a possibility of installing a flue damper after the installation of the appliance the instructions shall state that:
1) the only damper permitted is that tested/certificated with the appliance;
2) the damper is to be installed in accordance with the manufacturer’s instructions.
Instructions for use
Every appliance must include user instructions that provide essential information on its operation and maintenance These instructions should contain at least the following key details.
5.2.2.1 General ắ Point out that a qualified installer should be called on to install and adjust the appliance and that, in order to convert it to use other gases, a qualified installer, gas distributor, or other competent person should be called on according to the practice in the country where the appliance is installed ; ắ specify the operations for starting up and putting the appliance out of service ; ắ specify that the warnings should be observed ; ắ explain the procedures for normal operation, cleaning and day-to-day maintenance of the appliance ; ắ warn against incorrect use ; ắ explain any necessary precautions to be taken against frost ; ắ forbid any interference with a sealed component ; ắ point out that appliances should be checked and maintained periodically by a competent person on according to the practice in the country where the appliance is installed ; ắ indicate the normal capacity.
5.2.2.2 For type B 11BS appliances ắ State that the device interrupts the admission of gas to the burner if the evacuation of the combustion products is disturbed ; ắ describe the restart procedure ; ắ recommended that a competent person is called if there are repeated interruptions, on according to the practice in the country where the appliance is installed.
5.2.2.3 For type C appliances ắ For type C appliances with manual ignition, mention the precautions to be taken before carrying out new ignition attempts.
5.2.2.4 For condensing appliances ắ Specify that the condensate outlet(s) shall not be modified or plugged ; ắ give the instructions for cleaning and maintaining the condensate neutralization device, if fitted.
Users should ensure that a qualified individual checks the flue damper's performance during appliance maintenance, as outlined in the BSI 02-2000 guidelines.
Conversion instructions
Parts intended for conversion to another gas family, another group or gas range and/or another supply pressure shall be accompanied by conversion instructions intended for the competent person.
The instructions must detail the essential components needed for the conversion and provide a method for identifying them They should clearly outline the necessary operations for replacing these parts, including any required adjustments Additionally, it is important to note that any broken seals must be restored and preset adjusters sealed For appliances utilizing a pressure couple, it is crucial to ensure that any gas governor is either rendered inoperative within the normal pressure range or completely taken out of operation and sealed accordingly.
A self-adhesive label will be provided with the parts and conversion instructions for the appliance, indicating the supplementary markings required for the conversion as specified in section 5.1.2.
Presentation
All the information in 5.1 and 5.2 shall be given in the official language(s) of the countries in which the appliance may be installed.
Except where otherwise stated the constructional safety is verified by inspection of the appliance and its technical literature.
General
Conversion to different gases
When converting from one gas group or family to another, several operations are allowed, including adjusting the main burner's gas rate, changing injectors or restrictors, replacing the ignition burner or its components, modifying the system that regulates the gas rate, and putting an adjuster or governor out of service and sealing it.
It shall be possible to carry out these operations without having to interfere with the connections of the appliance and its ducts (water, gas, combustion products evacuation).
Materials
Proper installation of appliances, following technical instructions, ensures that the quality and thickness of their materials can endure mechanical, chemical, and thermal conditions during normal use and maintenance These materials are designed to withstand these conditions throughout their reasonable lifespan, except for any anode, which is not governed by this requirement.
Sheet metal parts, when they are not made of corrosion-resistant materials, shall be enameled or be coated with another effective protection against corrosion.
Zinc alloys can be utilized in gas applications only if they meet the quality standard ZnAl4 as per ISO 301 and are not subjected to temperatures exceeding 80 °C, as outlined in section 7.4.2 Additionally, only external threads that conform to ISO 228-1 are permissible for the main inlet and outlet connections made from zinc alloy.
The use of asbestos-based materials is forbidden.
The use of cadmium containing solder is forbidden.
Moreover, parts in contact with water shall be made of materials of quality so that the water for domestic hot water use cannot be polluted.
Condensing appliances must have all exchanger components and parts that may contact condensate made from corrosion-resistant materials or coated to ensure durability Proper installation, operation, and maintenance following the manufacturer's guidelines are essential for the appliance's longevity.
Design - Assembly - Strength
The appliance's components must be designed and assembled to ensure that its operating characteristics remain stable throughout its reasonable lifespan and under typical installation and usage conditions.
The screws of preset adjusters shall be arranged so that they cannot fall inside the pipes In addition, their threads shall not deteriorate even after several successive manipulations.
The construction of the appliance shall be such that condensate which may be produced during start up or in operation does not affect safety.
Accessibility - Ease of maintenance - Fitting and removal
It shall be possible to clean the combustion circuit by following the manufacturer's instructions.
Maintenance procedures must ensure that any removed parts are replaced in a manner that does not compromise the appliance's operational safety Specifically, the integrity of the combustion circuit must be preserved after any cleaning or maintenance activities.
Removable components, for example the burner or the heating body, shall be able to be removed with commercially available tools and with the appliance remaining in position.
It shall be easy to replace the corrosion protection anode, if any.
Gas and water pipe connections
Appliance connections must be easily accessible and clearly marked in the technical instructions and on the appliance itself Adequate space should be provided around the connections to facilitate the use of tools for assembly after enclosure removal, if required Additionally, all connections should be designed for easy installation without the need for specialized tools.
The appliance gas inlet connection shall permit rigid connection.
Appliances with a threaded inlet connection must adhere to either ISO 228-1 or ISO 7-1 standards Specifically, for ISO 228-1, the inlet connection's end must be flat enough to accommodate a sealing washer, ensuring a proper seal.
If flanges are used, they shall comply with ISO 7005 and the manufacturer shall supply the counter-flanges and sealing gaskets.
If the inlet connection consists of a plain copper tube, it shall have a straight section at least 5 cm long and shall comply with ISO 274.
For the types of gas connection commonly used in the various countries, see Table A.6.
Threaded connections shall comply with ISO 228-1 or ISO 7-1.
If copper connections are used, the end of the prepared tube shall comply with ISO 274.
If materials other than metallic materials are used, the manufacturer shall supply suitable justification of suitability for the conditions of use.
For water connection conditions in common use in the various countries, see Table A.6.
Means of achieving soundness
6.1.6.1 Soundness of the gas circuit
Screw holes and fixing studs designed for part assembly must not lead into gasways, and measures must be in place to prevent water from entering the gas circuit.
To ensure the integrity of components in the gas circuit that may be disassembled for routine maintenance, mechanical methods such as metal-to-metal joints or O-ring seals must be utilized, avoiding the use of thread sealing materials like liquids, pastes, or tapes This integrity must be preserved even after the parts are taken apart and reassembled.
However, sealing materials may be used for permanent assemblies The sealing materials shall remain effective under normal conditions of appliance use.
The soundness of unthreaded assemblies in the gas circuit shall not be achieved by means of soft soldering nor by means of adhesives.
Rubbers in contact with gas shall comply with the requirements of EN 549.
6.1.6.2 Soundness of the combustion circuit
The integrity of the combustion circuit, including the draught diverter, must be ensured solely through mechanical methods, except for components designed for routine maintenance that can be sealed with mastics or pastes to guarantee lasting soundness during normal operating conditions.
To ensure the proper functionality of the appliance and its ducts in relation to the installation room and the areas the ducts traverse, mechanical means must be utilized Additionally, replacing the seal after cleaning or servicing, as recommended by the manufacturer, is allowed.
Certain components of the assembly, designed for continuous service under normal operating conditions, may be joined in a manner that ensures lasting integrity and reliability, even if they are not meant to be disassembled for regular maintenance.
The components of the combustion circuit, including ducts, bends, and terminal or duct adapters, must be properly aligned to create a stable assembly Additionally, parts meant for periodic servicing should be designed to maintain their integrity and soundness after reassembly.
Supply of combustion air and evacuation of the combustion products
Adjustments to the air intake cross-section leading to the combustion chamber, as well as the cross-section of the combustion products evacuation flue, are not permitted for appliances that do not utilize fans.
Fan-assisted appliances typically include an adjustment feature in the combustion air intake or exhaust system to accommodate specific installation conditions This adjustment is achieved through the calibration of orifices or by following the manufacturer's precise positioning guidelines.
Any appliances shall be designed so that the combustion air supply is ensured under normal conditions of use and maintenance.
Type B1 appliances shall be fitted with a draught diverter, fixed rigidly to the appliance by the manufacturer or installer in compliance with the instructions supplied by the manufacturer.
The draught diverter's outlet connection must be female, and manufacturers may provide an adaptor for connecting the diverter outlet to the appliance's flue For reference, Table A.7 lists the flue diameters currently used in different countries.
The flue must be inserted at least 15 mm vertically or 30 mm horizontally to ensure optimal performance Proper insertion depth is crucial to prevent any obstruction in the evacuation of combustion products.
During installation, it may be necessary to adjust the length of the air supply and combustion product evacuation ducts by cutting them to fit the wall thickness; however, these modifications must not compromise the proper functioning of the appliance.
It shall be possible, if necessary, to connect these ducts to the appliance using a commercially available tool; the accessories and fitting instructions shall be supplied by the manufacturer.
Terminal outlets for combustion air supply and exhaust of combustion products must be positioned within a square measuring 50 cm on each side, ensuring they are located in areas of equal pressure.
No opening in the external surfaces of the terminal shall permit the entry of a 16 mm diameter ball, applied with a force of 5 N.
When properly installed according to the manufacturer's guidelines, the terminal guard must maintain a distance of more than 50 mm between any part of the guard and the terminal, excluding the wall plate.
The design of the horizontal terminal must ensure that any condensate is expelled away from the wall Additionally, if the manufacturer specifies a protective guard for the terminal in the installation instructions—specifically for situations where combustion product outlets open onto a walkway—this device must be provided to the laboratory for testing.
The terminal shall be supplied with the appliance for test.
Appliances must be designed to achieve the manufacturer's specified distances for the projection of combustion air and discharge ducts into the common duct, regardless of the total thickness of the flue and cladding.
6.1.7.5 Requirements for fan-assisted appliances
To ensure safety, access to the rotating components of fans must be restricted Components exposed to combustion products should be protected against corrosion unless constructed from corrosion-resistant materials, and they must also be able to endure the temperatures associated with combustion products.
6.1.7.5.2 Device for monitoring air supply
Before starting the appliance, it is essential to ensure there is no air flow simulation Continuous monitoring of combustion air supply is required, which can be done by checking the pressure of combustion air or products, applicable only for appliances with a constant-speed fan and fully enclosed combustion circuits Key requirements include: duct lengths not exceeding 3 meters, absence of movable or adjustable blocking devices in the ducts, and a heat exchanger pressure loss not exceeding 0.05 mbar Alternatively, the flow rate of combustion air or products can also be checked.
Confirming the state of operation
The installer must ensure proper ignition and operation of the burner(s), including monitoring the flame length of any ignition burner It is permissible to open a door or remove a case, as long as the integrity of the combustion circuit, as outlined in section 7.2.2, is preserved upon closure or replacement.
Visibility must be maintained and should not degrade due to heat exposure, especially in areas with viewing windows Furthermore, optical elements such as mirrors and sight glasses must preserve their clarity and functionality.
Users should be able to verify the operation of the appliance after opening a door, either by visually observing the flame or through an indirect method, such as an indicator light if the main burner has a flame detector The flame indication system must be distinct from other fault indicators, except in cases where the flame-checking mechanism itself fails, leading to a signal that no flame is present.
Drainage
It shall be possible to drain the appliance easily without the aid of any tools other than a screwdriver or a spanner.
NOTE It is assumed that an appliance supplied with an hydraulic safety group defined in 3.8.1 fulfills this requirement.
Electrical equipment
The electrical equipment of the appliance shall comply with the relevant requirements of EN 50165, except where reference is made to another electrical standard in 6.2 of this standard.
Electric shock protection is unnecessary for ignition devices at high voltages as long as the energy content of each pulse, the number of pulses, and the delay between them adhere to specified limits (refer to Annex G).
Appliances equipped with electronic components or systems that ensure safety must adhere to the relevant EN 298 standards for electromagnetic compatibility and immunity levels.
According to EN 60529, if a manufacturer indicates the electrical protection type on an appliance's data plate, it must specify the level of personal protection against contact with hazardous electrical components within the appliance and the degree of protection against water penetration that could cause harmful effects inside the appliance.
Operational safety in the event of failure or restoration of the auxiliary energy
If the appliance uses auxiliary energy, its design shall be such that no risk can occur in the event of failure of the auxiliary energy or following its restoration.
Adjusting, control and safety devices
General
The operation of safety devices shall not be overridden by adjusting and control devices.
There shall be no shaft or lever capable of being operated outside the body that could prevent correct closure of the gas shut-off valve.
For the servicing of the device, any screwed fastenings that require removal must feature a metric thread in accordance with ISO 262, unless an alternative thread is necessary for the proper operation and adjustment of the device.
Thread-forming screws that create a thread without generating filings can be utilized and can be substituted with metric machine screws that adhere to the specified ISO standard.
Self-tapping screws that cut a thread and produce filings shall not be used for the assembly of gas-carrying parts or of parts that may be removed for servicing.
To ensure optimal functionality, the operation of moving parts, such as diaphragms, must remain unobstructed by surrounding components Factory-adjusted and sealed packing glands are recommended for effectively sealing these moving parts.
Manually adjustable packing glands shall not be used.
To ensure effective dust protection, a device must be installed before the primary control or shut-off device at the gas inlet The strainer's mesh size should not exceed 1.5 mm, and it must prevent the passage of a 1 mm pin gauge For class D' automatic valves, the mesh size is further restricted to a maximum of 0.2 mm.
All devices mentioned in section 6.2, along with any multifunctional controls, must be designed to be removable or exchangeable to facilitate cleaning or replacement as needed.
The control knobs shall be designed and located so that they can neither be fitted in an incorrect position nor be capable of moving of their own accord.
When there are several control knobs, they shall not be interchangeable if this could prejudice safety.
All appliances must include a manual shut-off valve that enables users to easily turn off the gas supply to both the main burner and the ignition burner, if applicable This valve should be designed for straightforward operation and secure installation.
User controls
Every appliance shall be provided with at least one device enabling the user to control the admission of gas to the burner and to the ignition burner.
Shut-off shall be effected without delay, for example it shall not be subject to the delay time of the thermoelectric flame supervision device.
Markings are unnecessary when incorrect operation is not possible, such as when a single button operates both the flame supervision device and the ignition burner However, when markings are required, the following symbols should be used: a full disc ( ắ off ) for the off position, a stylized spark ( ắ ignition ) for ignition, and a large stylized flame ( ắ full rate of the burner ) to indicate the full rate of the burner.
To ensure safety, boilers equipped with separate gas rate controls for the burner and ignition burner must have an interlock system This system prevents the main burner from receiving gas before the ignition burner is activated, thereby minimizing the risk of hazardous situations.
When a single gas rate control serves both the burner and ignition burner, the ignition position must include a distinct stop or notch for user clarity Additionally, the unlatching operation, if required, should be manageable with one hand.
If the only gas shut-off device operates by turning, it shall turn off in a clockwise direction as seen by an observer facing the knob.
Preset gas rate adjusters
Preset gas rate adjusters shall be designed so that they are protected against accidental incorrect adjustment by the user once the appliance has been put into service.
To ensure safety, any components of the appliance that should not be handled by installers or users must be adequately protected Lacquer can be applied for this protection, as long as it withstands the heat generated during the appliance's normal operation.
A preset gas rate adjuster is mandatory for appliances using more than one group of the first gas family, and optional for other appliances.
The preset adjusters shall : ắ be sealed if the adjustment is only made by the manufacturer ; ắ be able to be sealed if an adjustment is carried out by the installer.
The preset gas rate adjuster shall be locked and sealed when a gas of a family or group carrying a "+" suffix is used.
The adjustment may be continuous (adjusting screw) or discrete (change of restrictors).
The adjuster of an adjustable gas governor is regarded as a preset adjuster.
The action of adjusting these devices is called "adjusting the gas rate".
These devices shall be designed so that they can be moved easily with commercially available tools, even after prolonged use.
Gas governor
Gas governors shall meet the applicable requirements of EN 88.
Appliances intended to operate with first family gases shall have a gas governor A gas governor is optional for other appliances.
A governor designed for operation with a pressure couple must be adjusted to ensure it does not function between the two normal pressures Nonetheless, in the context of a pressure couple, the use of a non-adjustable gas governor is allowed for the ignition burner.
The gas governor must be designed for easy adjustment and serviceability, allowing for straightforward modifications or replacements when converting to a different gas type However, it is essential to implement measures that prevent unauthorized access to the preset adjustments.
Pressure test points
All appliances shall be provided a gas pressure test point which allows the pressure at the appliance inlet to be measured.
For appliances that necessitate burner pressure measurement, it is essential to include a second pressure test point downstream of any preset adjuster, following the installation or conversion guidelines.
For type C appliances, the measurement shall be able to be carried out at these points without opening the combustion circuit.
The pressure test points shall have an external diameter of 9 , 0 - 0 0 , 5 mm and a length of at least 10 mm to enable a rubber tube to be fitted.
The diameter of the bore of the pressure test point shall not exceed 1 mm at the narrowest place.
Ignition devices
6.2.6.1 Ignition of the ignition burner
It shall be possible to light, in a simple manner, ignition burners that are directly ignited by hand.
Ignition devices for ignition burners must be accurately positioned in relation to the burner components Additionally, these devices should be easily installable and removable using standard tools, ensuring convenience in maintenance and operation.
Special ignition devices shall be provided (e.g electric igniters) for type C appliances Ignition of these appliances shall always be possible with the combustion chamber closed.
6.2.6.2 Ignition device for the main burner
The main burner shall be fitted with an ignition burner or a device for direct ignition Direct ignition shall not cause deterioration of the burner.
The cross section of the flame ports and the terminal area of the injectors shall not be adjustable.
Ignition burners must be accurately positioned in relation to the components and the burners they ignite When ignition burners vary based on the type of gas, they should be clearly marked for easy substitution and installation This requirement also extends to injectors, which only need to be replaced as necessary.
For appliances using first family gases, a rate adjuster is essential if the ignition burner rate is not controlled, while for second and third family gases, it is optional However, the use of a rate adjuster is prohibited for second and third family Ó BSI 02-2000 gases when a pressure couple is employed If ignition burners or injectors can be easily modified to match the gas characteristics, the adjuster may be excluded.
Primary air inlet control devices are not permitted.
Devices for direct ignition must guarantee safe ignition with voltage variations between 85% and 110% of the nominal value The activation of these ignition devices should occur simultaneously or before the automatic valve opens to release the gas for ignition Additionally, the ignition device must be de-energized independently from the flame detection system and must be turned off by the conclusion of the ignition safety period.
Flame supervision device
The presence of a flame shall be detected : ắ either by a thermoelectric flame supervision device ; ắ or by the flame detection device of an automatic burner control system.
At least one flame detector is required.
Before releasing gas to the main burner, it is essential to detect the presence of a flame at the ignition burner, which ignites the main burner.
Separately marketed thermoelectric flame supervision devices shall meet the applicable requirements of
EN 125 or EN 126 in the case of devices integrated in multifunctional valves.
In the event of a flame failure or damage to the sensing element or its connection to the actuator, the device will initiate a non-volatile lockout of the appliance.
If a safety device acts on the thermoelectric flame supervision device, closure shall be immediate.
In addition, for type C appliances, this device shall comprise either an ignition lockout, or a restart lockout.
Automatic burner control systems shall meet the applicable requirements of EN 298.
In case of flame failure, the system shall result in, at least: ắ spark restoration; ắ or recycling; ắ or volatile lockout.
For spark restoration or recycling processes, if no flame is detected at the conclusion of the ignition safety time (T SA), a volatile lockout must be implemented to ensure safety.
Combustion products discharge safety device
Appliances shall be so constructed that in abnormal draught conditions there is no release of combustion products in a dangerous quantity into the room concerned.
This can be achieved with a combustion products discharge safety device; in this case the appliance is designated as a type B11BS appliance.
Appliances designed for outdoor installation or in well-ventilated rooms separate from living areas may not require specific devices; however, packaging and instructions must clearly warn users about usage limitations These appliances are classified as type B11.
Any adjustable component forming part of the safety device shall be sealed by the manufacturer.
The safety device shall be designed so that it cannot be dismantled without a tool.
Incorrect refitting, after servicing, shall be made difficult.
The safety device shall be designed so that the electrical insulation withstands the thermal stresses resulting from spillage of the combustion products.
If the connection between the sensor and the responding device is interrupted, or if the sensor is damaged, a safety shutdown will be initiated, potentially after a designated waiting period.
Protection against accidental overheating
Closed appliances shall be fitted with overheating protection which cuts off the gas supply before the water temperature reaches 100 °C.
If the appliance is fitted with an electric overheating safety limiter, it shall meet the requirements of
The action of the overheating safety device shall result in a non-volatile lock-out.
The sensor of the overheating safety device shall be independent of that of the control thermostat.
The gas supply valve must be distinct from the thermostat-controlled valve, ensuring independent operation Additionally, the overheating safety device should be fixed and non-adjustable, maintaining its functionality without interference from the cold water supply or mineral deposits.
Any malfunction in the sensor, its connections to the actuator, or any disruption in the external power supply can lead to impaired device performance, necessitating an automatic safety shutdown.
Control thermostat
All appliances shall be fitted with a thermostat which makes it possible to keep the water temperature in the storage vessel within specific temperature limits.
The water temperature thermostat shall meet the requirements of EN 60730-2-9 for type 1.
This thermostat can be categorized into three types: a) user-adjustable, featuring a clearly marked position and an easy-to-use adjustment method like a knob; b) installer-adjustable, equipped with a mechanism for installers to make adjustments and seal the settings; or c) non-adjustable.
Automatic shut-off valves
Automatic shut-off valves shall meet the relevant requirements of EN 161.
For gas circuits involving the main burner and ignition burner with a heat input exceeding 0.250 kW, it is essential to include at least two valves in series This setup must consist of either a class C valve or a thermoelectric flame supervision device, along with a second class D valve that does not have a mandated closing time for appliances with a heat input not exceeding specified limits.
70 kW, and with a closing time not exceeding 5 s for appliances with a heat input greater than 70 kW.
For ignition burners with a heat input of 0.250 kW or less, it is essential to equip the gas circuit with at least one class C valve or a thermoelectric flame supervision device to ensure safety and compliance.
Safety devices designed for non-volatile lockout must ensure that both valves close simultaneously In instances involving a thermoelectric supervision device, these safety devices may only operate on that specific device.
If the main burner is ignited directly and the order for control closure is not given simultaneously to the two valves, they may be class C valves.
If the period between the orders for control closure of the valves is less than or equal to 5 s, the orders are regarded as being simultaneous.
A class C valve may be replaced by a class B or class A valve; a class D valve may be replaced by a class
Diagrams of the composition of the gas circuit are given in Annex D.
Combustion products temperature limiter
When connecting an appliance to a flue that may be negatively impacted by high combustion product temperatures, such as plastic or plastic-lined flues, it is essential that the appliance is equipped with a safety device This device must ensure that the temperature of the combustion products does not surpass the maximum allowable temperature specified by the manufacturer for these materials.
The temperature-limiting device for combustion products must be fixed and require a tool for access, ensuring it cannot be adjusted easily This mechanism will lead to a non-volatile lockout of the appliance, enhancing safety and preventing unauthorized modifications.
Combined temperature and pressure relief valve
If the manufacturer's installation guidelines require a combined temperature and pressure relief valve, it is essential for the manufacturer to either install this valve on the appliance or provide it as part of the appliance package, ensuring compliance with prEN 1490 standards.
When specifying a combined temperature and pressure relief valve, it is essential to install a connector at a designated location that is adequately sized to ensure the valve fully opens before the water temperature reaches 100 °C.
Flue damper
When marketing the appliance and flue damper separately, they must be designed to prevent incorrect assembly Installation instructions should clearly address this assembly method.
If auxiliary energy is disrupted or a critical component of the flue damper malfunctions, the main burner cannot continue to operate while the flue damper is closed.
The gas supply to the main burner of the appliance shall not be released before the closure member has gone through 90 % of its total passage to the open position.
The connections between the damper and the shaft of the electric motor shall be rigid.
The closure member must be securely connected to the switch that controls the gas supply to the main burner to prevent it from loosening The switch should be directly activated by the valve position, or alternatively, protected by an equivalent safeguard Additionally, limit switches must be designed and connected to ensure that a false "open position" signal is not generated.
The position of the flue damper switch shall be proved prior to the operation of the burner.
An indication of the position of the flue damper shall be readily visible to the user.
The flue damper shall actuate an automatic shut-off valve of class A, B or C.
For appliances equipped with permanent or semi-permanent ignition burners, it is essential that the flue damper's minimum passage in the closed position guarantees optimal pilot performance while preventing condensation from combustion byproducts.
Main burner
The cross section of the flame ports and the terminal area of the injectors of the burners and ignition burners shall not be adjustable.
All removable injectors and/or restrictors shall have an indelible identification mark to prevent any confusion.
In the case of non-removable injectors and/or restrictors, the marking may be on the tank.
Injectors and restrictors must be easily replaceable without disconnecting the appliance Their design should ensure that their positions are clearly defined and secured to prevent incorrect installation.
Burners must be easily accessible without requiring significant disassembly of the appliance If any components of the burners are removable, their placement should be clearly defined, and the securing mechanism must ensure they are difficult to misalign.
Primary air inlet control devices are not permitted.
NOTE Primary air adjusters are authorized for adjustments made and sealed at the factory In this case they are regarded as being non-existent.
Discharge of condensate
Non-condensing appliances must manage condensate by either evacuating it or re-evaporating it, ensuring that no condensate escapes the appliance, except under specific conditions through the combustion products flue of type C11 appliances.
For condensing appliances, it is essential to ensure that condensate generated during operation, including that formed in the discharge pipes for combustion products, is effectively removed through appropriate discharge pipes.
The inside diameter of the condensate discharge pipe shall be at least 13 mm.
The discharge system of the appliance must be designed for easy inspection and cleaning as per the manufacturer's guidelines, ensuring it is not prone to obstruction Additionally, it should prevent the transmission of combustion products into the installation room, which can be achieved by incorporating a water trap This water trap must feature a seal of at least 25 mm, maintaining its effectiveness at the maximum pressure within the combustion chamber and the maximum flue length specified by the manufacturer.
Surfaces in contact with condensates (except purpose-provided drains and water traps) shall be designed to prevent condensate retention.
Carrying out the tests
Characteristics of the test gases
Storage water heaters are designed to operate efficiently with various gas types These specifications ensure that the appliances function satisfactorily across different gas families and pressure levels, utilizing preset adjusters as needed.
The compositions and principal characteristics of the different test gases corresponding to the families or gas groups are given in EN 437.
Requirements for preparation of the test gases
The test gases are prepared in accordance with EN 437.
Choice of test gases
Appliances that can utilize gases from multiple groups undergo testing with reference and limit gases aligned with their specific categories, as outlined in EN 437.
For the efficiency tests (see 8.1.2.2), if several reference gases are specified, one of the 2nd family gases is used, preferably G 20.
Test pressures
The selection of test pressures for appliances must adhere to EN 437 standards, taking into account the specific appliance categories and the test gases used, while ensuring compliance with the relevant requirements of the standard.
The test pressures, i.e the static pressures to be applied at the gas inlet connection with the appliance in operation, are given in EN 437.
These pressures and corresponding injectors shall be used in accordance with the requirements specified inAnnex A depending on the country in which the appliance is to be installed.
General test conditions
The appliances are tested under the following conditions except where otherwise stated.
The appliance should be installed in a well-ventilated area with minimal air movement (less than 0.5 m/s) and an ambient temperature of 20 ± 7 °C, unless stated otherwise Additionally, it must be shielded from direct sunlight.
For all tests, except where otherwise stated in the particular clauses, the appliance is installed, used and put into operation under the conditions specified in the manufacturer’s instructions.
Wall-mounted appliances should be installed on a vertical test panel made of plywood or a material with similar thermal properties, following the guidelines provided in the technical instructions.
A type B1 appliance is tested under a draught generated by a 1-meter high flue, featuring an internal diameter that matches the smallest specification provided by the manufacturer in the technical instructions, in accordance with the guidelines outlined in Table A.7.
The thickness of the flue pipe is less than 1 mm.
To ensure proper compatibility, if the diameter of the appliance flue socket does not match the external diameter specified in Table A.7, a 1 mm thick linking piece should be utilized to adjust the flue socket diameter.
The height of the flue is determined based on the orientation of the flue socket; for appliances with a horizontal flue socket, measurement is taken from this axis, while for those with a vertical flue socket, it is measured from the plane of the flue socket outlet.
Type C appliances undergo testing with their ducts and terminals assembled according to the manufacturer's specifications Typically, when the installation instructions indicate that a special terminal guard must be used, tests are conducted without this guard unless otherwise specified in the relevant test documentation.
A type C2 appliance is tested with the connecting ducts assembled in accordance with the manufacturer's instructions but not connected to a common test duct.
The appliance is designed to connect to a water supply that can be regulated to maintain required pressure levels within ± 4% This specification refers to the pressure differences between the appliance's inlet and outlet, including the provided valves.
The water inlet temperature must not exceed 25 °C, and during testing, the inlet temperature should remain stable, varying by no more than ± 0.5 °C when measuring the water outlet temperature.
The inlet temperatures are measured immediately upstream of the water inlet connection Unless otherwise specified, the outlet temperatures immediately downstream of the outlet connection.
The hot water temperature is measured with a low inertia thermometer 3)
Unless otherwise specified in particular clauses, measurements shall be made with the maximum uncertainties stated below:
A "low inertia thermometer" is defined as a measuring device that achieves 90% of the final temperature rise within 5 seconds when immersed in still water, specifically in the temperature range of 15 °C to 100 °C, according to BSI 02-2000 standards.
The laboratory assesses uncertainties within two standard deviations, accounting for various factors such as instrument contribution, repeatability, calibration, and ambient conditions Specific uncertainties include atmospheric pressure at 5 mbar, combustion chamber and test flue pressure at ±5% or 0.05 mbar, gas pressure at ±2%, and water-side pressure loss at ±5% Additionally, the water and gas rates are measured with a precision of ±1%, while time is recorded with an accuracy of ±0.2 seconds up to 1 hour and ±0.1% beyond that Auxiliary electrical energy is evaluated at ±2%, and temperature measurements include ambient temperature at ±1 K, water temperature at ±2 K, combustion products at ±5 K, gas temperature at ±0.5 K, and surface temperature at ±5 K Furthermore, the uncertainties for CO, CO2, and O2 are ±6%, gas calorific value is ±1%, gas density is ±0.5%, mass is ±0.05%, and both couple and force are measured with a tolerance of ±10%.
To accurately determine the leakage rate during soundness tests, a volumetric method is employed, providing a direct reading with an error margin not exceeding 0.01 dm³/h This method utilizes specialized apparatus, as illustrated in Figure 1, or other equivalent devices to achieve reliable results.
The stated measurement uncertainties relate to individual measurements.
For measurements that combine a number of individual measurements (for example: efficiency measurements), smaller uncertainties may be necessary on the individual measurements to ensure the required total uncertainty.
The appliance shall be fitted successively with the appropriate components for each of the reference gases used, for the corresponding normal test pressure.
The gas governor and the preset gas rate adjusters are put out of service if they are not permitted for the gas concerned.
The appliance is adjusted, if necessary, in accordance with the technical instructions.
Except for tests having different conditions, the appliance is supplied with the reference gas(es) at normal pressure, in accordance with 7.1.4, and operated at its nominal heat input.
Before conducting tests with a reference gas at the nominal heat input, necessary adjustments are made to achieve a precision of ± 2% in the nominal heat input This can be done by modifying the gas rate adjuster settings, disabling the gas governor if present, and adjusting the appliance supply pressure accordingly If the appliance lacks both a gas rate adjuster and a governor, or if these devices are out of service, the appliance supply pressure must be adjusted to ensure optimal performance.
The tests with the limit gases shall be carried out with the injector and adjustment corresponding to the reference gas of the group to which the limit gas belongs.
The test pressures shall be maintained constant to within ± 0,2 mbar.
For all the tests at the minimum and maximum pressures, the pressures in 7.1.4 shall be used without the above correction.
The appliance is supplied with nominal electric voltage or a voltage within the nominal voltage range, unless otherwise indicated in the specific clauses.
Unless otherwise specified in the relevant subclauses, the tests are carried out in the steady state condition.
To achieve a steady state, the thermostat should be set to an average value, allowing for a consistent flow of water that supports the burner operating continuously at either full or reduced capacity This process should begin only after a 10-minute period during which the burner reaches its maximum output.
The thermostat is adjusted to the specified setting for the test Temperature equilibrium is achieved when the appliance, initially cold, is heated, drained, and then heated again until the burner turns off.
Soundness
Soundness of the gas circuit
The gas circuit shall be sound.
Soundness is assured if the leakage of air does not exceed : ắ test no 1: 0,06 dm 3 /h ; ắ test no 2: 0,06 dm 3 /h, per shut-off device ; ắ test no 3: 0,14 dm 3 /h. Ó BSI 02-2000
The appliance gas inlet is connected to an air supply delivering an appropriate and constant pressure. The appliance is at room temperature which shall remain constant throughout the tests.
Initial tests are conducted upon delivery of the appliances, followed by additional assessments as per the standard After completing these tests, gas-tight joints specified as removable in the manufacturer's instructions are taken out and reinstalled five times.
An example of a device using the volumetric method is given in Annex E and Figure 1.
The soundness of the first closure member is checked, with all other downstream closure members in the open position.
The pressure upstream of the appliance is 150 mbar.
If the closure members have not been verified in accordance with the requirements of EN 161, the test is carried out with the appliance returned to its original state.
The test is conducted in the direction of gas flow, with the first closure member open and the second closure member closed, while the ignition burner gas circuit remains blocked.
The pressure upstream of the appliance is 50 mbar for appliances not using third family gases and 150 mbar for appliances using third family gases.
Any closure members in the ignition burner gas circuit are subjected to the same test.
This test is carried out at a test pressure of 6 mbar.
To assess total leakage, all valves must be opened as if the appliance is in operation, while the gas outlet is securely blocked using solid injectors or appropriate components provided by the manufacturer.
The pressure upstream of the appliance is 50 mbar for appliances not using third family gases, and 150 mbar for appliances using third family gases.
Soundness of the combustion circuit and evacuation of the combustion products
Combustion products shall only escape from the outlet of the flue to which the appliance is connected.
The appliance, as outlined in section 7.1.5, is connected to a 1 m test flue, or a 0.5 m flue for wall-mounted models, unless the manufacturer specifies a 1 m flue for testing The testing is conducted using one of the designated reference gases or a gas typically distributed for the relevant category, at nominal heat input in still air and under normal draught conditions at steady state, as referenced in section 7.1.5.7.
Spillages are detected using a dewpoint plate, which is kept at a temperature slightly above the ambient air's dewpoint This plate is strategically moved near areas where spills are suspected to ensure accurate detection.
In uncertain situations, utilize a sampling probe linked to a rapid-response CO2 analyzer to detect spillages at levels around 0.1% Ensure that the sampling process does not disrupt the appliance's operation or cause any release of combustion products.
The requirement is satisfied if the amount of CO2 does not exceed the amount in the test room by more than 0,20%.
The leakage rate is adjusted to reference conditions without considering the air's relative humidity Soundness is guaranteed when the leakage rates remain within the limits specified in Table 2.
Table 2 — Soundness of combustion circuit
Combustion products circuit completely surrounded by the combustion air circuit a
Combustion products circuit not completely surrounded by the combustion air circuit a
When manufacturers choose to test appliances and ducts separately, the relevant requirements are derived from the applicable column Additionally, separate ducts are classified as completely surrounded if the leakage rates of the combustion products discharge duct do not exceed 0.03 dm³/h per mm diameter per joint.
Tests are conducted to ensure that the assembly has the maximum number of seals recommended by the manufacturer, including those between the appliance and its ducts, the connection ducts, the ducts and bends if applicable, as well as between the ducts and the duct adapter or terminal when necessary.
If necessary, the wall mounting or the seal with the duct adapter may be sealed in compliance with manufacturer's instructions.
Testing can be conducted either on the appliance body and ducts separately or on the appliance when connected to its ducts, depending on the manufacturer's choice.
The test pressure for appliances varies based on their design: for appliances without fans or those with fans located downstream of the combustion chamber, the required test pressure is 0.5 mbar In contrast, for appliances where the fan is positioned upstream of the combustion chamber, the test pressure is 0.5 mbar plus the pressure measured in the combustion chamber casing (p br), with the appliance in thermal equilibrium at the nominal heat flow rate and utilizing the longest ducts specified by the manufacturer.
The combustion circuit of the appliance must include connections to the body and ducts, incorporating air intake and flue systems One end of this circuit should be connected to a pressure source, while the other end must be sealed off.
Hydraulic test and soundness of the water circuit
No water leakage shall appear during the test, nor any permanent visible deformation after the test.
The test pressure for the water circuit is 1,5 times the maximum service pressure declared by the manufacturer.
The water circuit is kept at the test pressure for at least 10 min, with the hydraulic safety group, if fitted, being put out of service.