How To Test A Furnace For Safety

Transcription

1 1st February 2011 Evaluation Guideline regarding the Product Certificate GASKEUR Basic Label CV (Central Heating): 2010 for Central Heating Appliances

2 Preface This Evaluation Guideline has been adopted by the Kiwa Board of Experts of Energy Performance Label, wherein all the relevant parties in the field of supply, installation and use are represented. These Boards of Experts also supervises the certification activities and where necessary require the Evaluation Guideline to be revised. All references to Board of Experts in this Evaluation Guideline pertain to the above mentioned Boards of Experts. This Evaluation Guideline will be used by Kiwa in conjunction with the Kiwa- Regulations for Product Certification. This regulation details the method employed by Kiwa for conducting the necessary investigations prior to issuing the product certificate and the method of external control. This Evaluation Guideline is drawn up for certification purposes within the framework of GASKEUR appliance labelling. This certification is voluntary and supplementary, which implies that the label is neither obligatory for admission nor permits admission in its own right. To be admitted each appliance is required by law to bear the CE Marking. GASKEUR labels are supplementary, i.e. they provide information on a certain aspect of the appliance not clearly indicated by the CE Marking. This Evaluation Guideline states the basic requirements to be met by a central heating appliance to be eligible for GASKEUR labelling. In addition to this Evaluation Guideline, there are also Evaluation Guidelines for hot water appliances and for air heaters. As supplements to the basic labels there are labels for specific appliance properties such as efficiency, comfort and emissions for which criteria exist or which will be developed. These specific labels may only be obtained if the requirements for the basic label have been met. In order to continue harmonisation with the European standards and regulations, this Evaluation Guideline uses heat inputs and efficiencies based on the net calorific value (Hi). In order to ensure complete harmonisation with national legislation, in as far as it (still) makes use of the gross value; conversion information has been included where necessary. NOTE: This is a translation from the Dutch. In case of ambiguity or differences in interpretation between this translation and the original Dutch text, the Dutch text prevails.

3 Kiwa Nederland B.V. is a company with an international and independent reputation for testing and certification of gas and water related products for manufacturers and suppliers. These products include gas appliances, sanitary ware, measurement and control devices and installation and distribution materials. Kiwa Nederland B.V. also tests and certifies the raw materials for plastic pipe products. Furthermore, Kiwa Nederland B.V. certifies various quality, safety and environmental management systems for a wide range of customers. Kiwa Nederland B.V. also provides independent expertise in the form of consultancy in the field of installation safety. Kiwa Nederland B.V. is based in Apeldoorn and Rijswijk in the Netherlands and is accredited by the Dutch Council for Accreditation (RvA). Kiwa Nederland B.V. is appointed by the Dutch government as Notified Body in the field of the European Directives (CE Marking). All test work is carried out in Kiwa Nederland B.V. s own laboratories, which are accredited to ISO/IEC Kiwa Nederland B.V. PO Box 137, 7300 AC Apeldoorn, The Netherlands Wilmersdorf 50, 7327 AC Apeldoorn The Netherlands Telephone: +31(0) Fax: +31(0) Website: gas@kiwa.nl Kiwa N.V. All rights reserved. No part of this book may be reproduced, stored in a database or retrieval system, or published, in any form or in any way, electronically, mechanically, by print, photoprint, microfilm or any other means without prior written permission from the publisher. The use of this Evaluation Guideline by third parties, for any purpose whatsoever, is only allowed after a written agreement is made with Kiwa to this end. Validation This Evaluation Guideline has been adopted by the Boards of Experts on 1 st December This Evaluation Guideline has been declared binding by Kiwa Nederland BV on 1 st Februari Kiwa Nederland B.V st February 2011

4 Contents Preface 1 Contents 3 1 Introduction General Field of Application / Scope Acceptance of Test Reports Provided by the Supplier Certificate 6 2 Terms and Definitions General Definitions Technical Definitions 8 3 Procedure for Granting the Quality Declaration Pre Certification Tests Granting the Certificate 10 4 General and Constructional Requirements General Nuisance Appliance Category Appliance Classification Open-Flued Appliances Room-Sealed Appliances Appliance Construction General Material Selection Composition Maintenance Evacuation of Flue Gases and Supply of Combustion Air Open-Flued Appliances Room-Sealed Appliances Connection of the Gas Supply External Connections for Controls Protection Against the Risk of Freezing Temperature Classification 14 Kiwa Nederland B.V st February 2011

5 5 Operational Requirements General Efficiencies Open-Flued Appliances Room-Sealed Appliances Flue Loss from Increased Airflow and from Wind Conditions Electrical Power Consumption Heating Performance Combustion Product Evacuation for Open-Flued Appliances with Mechanical Extraction Temperature Classification Combustion Product Temperature Limiter Condensation Frost Protection 16 6 Test Methods General Gaseous Fuel Combustion Air Supply and Flue Gases Evacuation Settings for the Appliance Efficiencies Open-Flued Appliances Room-Sealed Appliances Determination of the Flue Loss at Increased Airflow and in Windy Conditions Determination of the Electrical Power Consumption Heating Performance Determination of the Counter Pressure on the Flue Stub Determination of Flue Gas Temperatures for Temperature Classification Determination of the Operating Temperature Determination of the Peak Temperature Determination of the Correct Operation of the Combustion Product Temperature Limiter (If Applicable) Condensation in the Appliance Frost Protection 20 7 Labelling Inscriptions Documentation Installation Instructions User Information 22 Kiwa Nederland B.V st February 2011

6 8 Requirements in Respect of the Quality System Manager of the Quality System Internal Quality Control/Quality Plan Procedures and Working Instructions 23 9 Summary of Tests and Inspections Inspection Matrix Procedures for the Surveillance Programme Inspection of the Quality Management System Agreements on the Implementation of Certification General Certification Staff Qualification Requirements Qualification Report Pre Certification Tests Decision for Granting the Certificate Lay out of Certificate Nature and Frequency of External Inspections Corrections, Additions and Interpretations of Requirements Titles of Standards Standards/Normative Documents: 30 I Model Certificate 31 II Model IQC-scheme or Framework IQC Scheme 33 III GASKEUR Labels 35 IV Conversion of the Efficiency from Net Value to Gross Value 36 V Requirements for the Acceptance of Test Reports, Where Testing was Carried Out at the Laboratory of the Supplier 37 VI Flue Gas Construction at Initial Type Testing and Product Inspection 40 Kiwa Nederland B.V st February 2011

7 1 Introduction 1.1 General This Evaluation Guideline includes all relevant requirements which are adhered to by the CI as the basis for the issue and maintenance of a product certificate for the GASKEUR Basic Label. This Evaluation Guideline replaces GASKEUR CV:2002 Criteria, dated July 2002 with the accompanying corrections, additions and interpretations. The certificates issued based on those criteria lose their validity 6 months after this Evaluation Guideline has been adopted by the Board of Experts. For the performance of its certification work, the CI is bound to the requirements as included in the clause 4.6 conditions and procedures for granting, maintaining, extending, suspending and withdrawing certification of EN Field of Application / Scope This Evaluation Guideline applies to gas fired central heating appliances using water as the heat transmission medium and with a heat input of up to 900 kw (Hi). These appliances may be constructed as a complete appliance in which the burner, heat exchanger and other components are supplied as an integrated whole, or as a combination of a boiler body and an add-on burner that is part of the supply. This Evaluation Guideline also applies to central heating appliances with an integrated hot tap water facility (combination boilers and specific combinations of a boiler with an indirectly fired boiler, if this is assessed along with the boiler). 1.3 Acceptance of Test Reports Provided by the Supplier The requirements for accepting test reports from which the tests have been performed in the laboratory of the manufacturer, can be found in the normative Annex Certificate The product certificate to be issued based on this Evaluation Guideline is designated as a GASKEUR certificate. A model of the certificate to be issued on the basis of this Evaluation Guideline has been included as an Annex. Kiwa Nederland B.V st February 2011

8 2 Terms and Definitions 2.1 General Definitions In this Evaluation Guideline, the following terms and definitions are applicable: Evaluation Guideline: The agreements made by the Board of Experts regarding the subject of Certification. Board of Experts: The Board of Experts, appointed by Kiwa Nederland B.V. regarding the certification system for EPK quality marks. TI: The testing institute which carries out the approval testing programme. CI: The certification institute which carries out the certification and grants the certificates. Supplier: The party who is responsible for ensuring that the products continuously meet the requirements upon which the certification was granted. IQC Scheme: a description of the quality inspections carried out by the supplier as part of his quality system. Product Requirements: requirements made specific by means of measures or figures, focusing on (identifiable) characteristics of products and containing a limiting value to be achieved, which limiting value can be calculated or measured in an unequivocal manner. Approval Programme: The investigation to determine whether all requirements put forth in the Evaluation Guideline have been met. Surveillance Programme: the investigation which will be carried out after the issue of the certificate to determine if the certified products continue to meet the requirements set in the Evaluation Guideline, whereby it is also indicated which frequency the Surveillance Programme will be carried out by Kiwa. Remark: In the Inspection Matrix there is a summary of which programme will be carried out by Kiwa in the initial type testing and in the maintenance stage, and with which frequency the Surveillance Programme will be carried out. Product Certificate: A document in which the CI declares that a product at the time of delivery is considered to fulfil the product specifications as specified in the certificate. Kiwa Nederland B.V st February 2011

9 2.2 Technical Definitions Heat input The amount of energy which is supplied per unit of time in the form of gas to the gas appliance based on the calorific net value 1 of the gas. Symbol: Q Unit: kilowatt (kw). Nominal heat input Heat input under reference conditions according to the manufacturer. For appliances with an input range this will be considered to be the minimum and the maximum setting. Symbol: Q n Unit: kilowatt (kw). Input range The range, defined by a minimum and a maximum value within which the heat input may be set by way of a pre-setting. Output The amount of energy which is transferred per unit of time by the appliance to the heat-transporting medium (central heating water). Symbol: P Unit: kilowatt (kw). Nominal output The output under nominal conditions according to the manufacturer. Symbol: P n Unit: kilowatt (kw). Efficiency Relationship between the output and the heat input expressed as a percentage. Symbol: η Full load efficiency Relationship between the output at full load and the heat input. Symbol: η n Part load efficiency Relationship between the output at part load and the heat input. Symbol: η d Toxicity index Relationship between the measured CO and CO 2 percentage times 100; in formula form (%CO / %CO 2) x 100. Set-up area An area which is not designated as a boiler room in which an appliance is set up (for example a kitchen, attic, cupboard, workshop, production area, sports hall etc.). Boiler room Area intended for the setting up of a boiler with a (joint) nominal heat input equal to or greater than 130 kw. Combustion product temperature limiter A protective device that switches off the appliance if the flue gases exceed the maximum permitted operating temperature (EN 677:1998 "device for limiting the flue gases temperature"). 1 Heat inputs and efficiencies can be based on the calorific net value (H i ) or the calorific gross value (H S) of the gas. All heat inputs given in this Evaluation Guideline are based on the net calorific value (H i) of the gas. Kiwa Nederland B.V st February 2011

10 CLV system (combination air supply and combustion product evacuation system) System which works with the natural airflow and which consists of a combination of a pipe or duct for the common supply of combustion air and a pipe or duct for the common evacuation of flue gases. This system is only intended for type C appliances fitted with a fan. Common flue gases evacuation system System which works with the natural airflow and which consists of a pipe or duct for the common evacuation of flue gases. This system is only intended for type C appliances fitted with a fan and with an individual air supply system. Technically Identical Series With technically identical series it is meant that the appliances within such a series shall be built from main components with the same construction principle (e.g. the construction of the heat exchanger(s), pump, fan, burner, etc.). Example: appliances with heat exchangers or burners with different construction principles will therefore not be considered as one series. Appliances with heat exchangers or burners with the same construction principles, but where the heat exchangers or burners have different capacities, are considered as belonging to one series. Kiwa Nederland B.V st February 2011

11 3 Procedure for Granting the Quality Declaration 3.1 Pre Certification Tests The pre certification-tests to be performed are based on the (product) requirements as included in this Evaluation Guideline including the test methods and contain, de pending on the nature of the product to be certified: (sample) testing to determine whether the products comply with the product and/or functional requirements, Production Process Assessment Assessment of the quality system and the IQC-scheme, Assessment on the presence and functioning of the remaining procedure 3.2 Granting the Certificate After finishing the pre-certification tests the results are presented to the person deciding on granting of certificate. This person evaluates the results and decides whether the certificate can be granted or additional data and/or tests are necessary. Examples of certificates are given in Annex I. If a combination of labels is mentioned on the certificate, as well as the requirements of the Evaluation Guideline GASKEUR Basic Label CV (Central Heating): 2010 for Central Heating Appliances, the requirements of the Evaluation Guideline concerned also need satisfying, such as: Evaluation Guideline GASKEUR HR (High Efficiency, Heating): 2010 for Central Heating Appliances; Evaluation Guideline GASKEUR SV (Clean Combustion): 2010 for Central Heating Appliances; Evaluation Guideline GASKEUR CW-HRww (Comfort Hot Water-High Efficiency, Hot Water): 2010 for Central Heating Appliances, Instantaneous Water Heaters and Storage Water Heaters; Evaluation Guideline GASKEUR NZ (Reheating Solar boiler): 2010 for Central Heating Appliances, Instantaneous Water Heaters and Storage Water Heaters; Evaluation Guideline GASKEUR HRe (High Efficiency electricity): 2010 for Central Heating Appliances; Kiwa Nederland B.V st February 2011

12 4 General and Constructional Requirements 4.1 General The appliance should have a valid CE mark under the European Directive for Gas Appliances of 16 December 2009 (2009/142/EC). This marking should be based on at least a type inspection on the basis of the "Essential Requirements" as specified in Annex I to the above-mentioned Directive and the European standards and the associated supplements which are applicable to the appliance. 4.2 Nuisance The appliance must function without producing a nuisance level of noise in any operational phase. Any limited amount of gas that is released upon start up or upon extinguishing may not cause any nuisance (e.g. a gas smell). No condensation may be formed which is a nuisance during operation, or which pollutes the appliance or its environment. 4.3 Appliance Category Appliances should be in categories I2L, I3P, I3B, I3B/P, II2L3P, II2L3B or II2L3B/P. Appliances which are set up for natural gas should be suitable for a nominal inlet pressure of 2.5 or 10 kpa (= 25 or 100 mbar). Appliances which are set up for liquid gas should be suitable for a nominal inlet pressure of 3 or 5 kpa (= 30 or 50 mbar). 4.4 Appliance Classification Open-Flued Appliances Central heating appliances of type A are not eligible for the GASKEUR label. Open-flued central heating appliances with a natural flue gases evacuation duct (type B11) which can be placed in a set-up area should be type B11bs, which means that they should be fitted with an exhaust protection device ("ttb"). This flue gases evacuation protection device should comply with the requirements of EN This obligation does not apply to appliances which may only be located in boiler rooms. Open-flued central heating appliances with mechanical evacuation should be type B22 or B23. Appliances of types B12(bs), B13(bs), B21, B31, B32 and B33 are not eligible for the GASKEUR label. Type B14 is considered to be B11; all B4 type appliances are considered to be B1 appliances. 1 EN 297 applies up to a heat input of 70 kw, but under the GASKEUR label this requirement applies to all appliances that can be located in a set-up area. Kiwa Nederland B.V st February 2011

13 4.4.2 Room-Sealed Appliances Room-sealed appliances should be type C11, C12, C13, C31, C32, C33, C42, C43, C52, C53, C62, C63, C82 or C83 1. Appliances of types C21, C22, C23, C41, C51, C61, C71, C72, C73 and C81 are not eligible for the GASKEUR label. 4.5 Appliance Construction General The quality and the wall thickness of the materials from which the appliance is constructed, and also the way in which the various components are put together, should be such that the appliance will not undergo any major changes with respect to its constructional and operational characteristics during a reasonable life expectancy under normal circumstances with respect to installation and use. A reasonable life expectancy is considered to be a period of at least 10 years following installation and circumstances of use which are considered to be normal in the Netherlands Material Selection All appliance components should be able to withstand the mechanical, chemical and thermal conditions to which they will be exposed in normal use during the life expectancy of the appliance. Components of the appliance on which condensation can form such as during a cold start, low temperature operation, etc., should be made from corrosion-resistant material or from a material which is sufficiently protected against corrosion, unless the wall thickness is such that early failure may be considered to have been excluded Composition Connections at places where condensation may occur may not experience excessive corrosion. For this reason, seams and gaps should be avoided as much as possible. Appliances in which condensation can occur in the flue gases evacuation duct (on the basis of EN 297:1994/A5 "Criteria for Condensation in the Flue") should either be fitted with a condensation drain for the condensation which occurs in the flue gases evacuation system or it should be clearly stated in the installation instructions that this device should be fitted. In appliances that are not specifically intended for setting up in a boiler room, this facility should be constructed in accordance with NPR 3378 part 42. Appliances in which condensation can also occur in a balanced state, should comply with the applicable Evaluation Guideline for the GASKEUR HR label with respect to the evacuation of condensation and the construction and material choice for the parts in contact with condensation. 1 Appliances of types C42 and C43 are only admitted for use on a CLV system and appliances of types C82 and C83 are only admitted for use on a common exhaust system. 2 With respect to the distribution gas it may be assumed that the total sulphur content will not amount to more than 50 mg/m 3 Kiwa Nederland B.V st February 2011

14 4.5.4 Maintenance It must be possible to carry out periodic cleaning and maintenance work with tools which are normally available without having to disconnect the connections to the appliance, with the exception of the electrical connection (plug), the gas supply (appliance valve), combustion product evacuation duct and any condensation outlet. The combustion product side seal of the appliance should only be achieved through mechanical means. For components that have to be disassembled during normal maintenance no pastes or sealants may be used as a sealing agent unless it is not necessary to replace them during maintenance. The seal of the appliance should also be guaranteed after repeated cleaning and maintenance work. 4.6 Evacuation of Flue Gases and Supply of Combustion Air Open-Flued Appliances Open-flued central heating appliances that are supplied without a flue construction should be fitted with a flue connection with an internal diameter so that flue material with diameters in accordance with Table 1 can be directly applied. Use of an adapter is only permitted if this is part of the delivery of the appliance and is to be assessed as an integral component during inspection. For open-flued central heating appliances with mechanical extraction this flue connection should be at least suitable for the minimum pipe diameter which is required for a flue system resistance length of at least 6m and for opening out into the area for "free outflow", area I, of NPR 3378 part 61:1999, or in accordance with NEN 2757 the area where Δp out = 0 Pa applies. Generally obtainable flue diameters (mm) in the Netherlands Table Room-Sealed Appliances Room-sealed central heating appliances which are supplied without a flue gases evacuation construction should be fitted with a combustion air supply and combustion product flue connection with an internal diameter such that the supply and flue material with diameters in accordance with Table 1 can be directly connected. If a diameter modification or a crossover from concentric to parallel (or vice versa) is desired, then an adapter may be used which is also delivered if it is also to be tested as part of the appliance during the inspection of the appliance in the seal testing examination. The connections should be gas-tight after installation. For appliances which may be located in a set-up area this should be achieved without the use of extra devices. This means that the connecting stubs should be fitted with, for example, a suitable rubber lip ring. Kiwa Nederland B.V st February 2011

15 4.7 Connection of the Gas Supply The central heating appliance should be fitted with a good connection facility for the gas supply. This connection must be manufactured from materials which are generally available in the Netherlands for making detachable gas-tight connections, such as right-handed sealing pipe thread in accordance with ISO 7-1 (conical outside thread and cylindrical inside thread) or compression fittings in accordance with KE 35 or BRL K 623/01. For connection sizes larger than 1¼" use may also be made of a flanged joint in accordance with ISO 7005, as long as the counter flange and packing material is also supplied. A flange joint is mandatory for connection sizes greater than 2". 4.8 External Connections for Controls The appliance should be properly accessible and located in a circuit with a safe, very low voltage connection point for the connection of the wiring for the room thermostat and other external controls. 4.9 Protection Against the Risk of Freezing Appliances to which combustion air is supplied from the outside air should be fitted with a safeguard against the risk of freezing. Exceptions to this are appliances with a built-in fan in which the combustion air and the flue gases are supplied or removed respectively through a concentric duct and terminal system Temperature Classification If the manufacturer indicates that the appliance is suitable for connection to a plastic combustion product evacuation system, then the temperature class should be indicated in accordance with Table 2: Temperature class Operating temperature ( C) Peak temperature ( C) T T T T T T T T Table 2 Kiwa Nederland B.V st February 2011

16 5 Operational Requirements 5.1 General The operational requirements are based on the test conditions in article. 6.1 unless otherwise indicated. 5.2 Efficiencies The water-side (= direct) efficiencies for the heating function of the appliance must at least comply with the following values: for appliances with a heat input of not more than 100 kw: full load at least 88.5% part load at least 86.5% for appliances with a heat input greater than or equal to 100 kw but not more than 400 kw: full load at least 88% % points per 10 kw heat input part load at least 86% % points per 10 kw heat input for appliances with a heat input greater than or equal to 400 kw: full load at least 90 % part load at least 88 % These requirements apply for both the minimum and the maximum adjustable heat input for appliances with an input range within which the heat input can be adjusted in advance Open-Flued Appliances In open-flued appliances the efficiencies should be measured in accordance with article Room-Sealed Appliances In room-sealed appliances the efficiencies should be measured in accordance with article Flue Loss from Increased Airflow and from Wind Conditions For open-flued appliances the flue loss may not be more than 2% greater than the flue loss for a normal airflow at a static airflow which is 10 Pa higher than the normal airflow. For room-sealed appliances, in the event of wind gusts of 12 m/s, the flue loss may not rise by more than 5% compared to the flue loss with no wind Electrical Power Consumption From the electrical power consumption, with the exception of that of the circulation pump for the central heating function, for appliances with a nominal heat input up to and including 25 kw, a maximum of 50 W and, for appliances with a nominal heat input greater than 25 kw, a maximum of 2 W/kW heat input will be left out of consideration for the determination of efficiency. The remaining electrical power consumption will be deducted from the efficiency on the basis of primary energy (see Annex IV). Kiwa Nederland B.V st February 2011

17 5.3 Heating Performance Under the conditions in accordance with Article 6.3 and set up in accordance with the manufacturer s instructions, the appliance must be capable of: 1. providing a supply water temperature of 90 C at a return water temperature of 70 C, or 2. providing a supply water temperature of 90 C at a higher return temperature than 70 C if this is the result of adjustment by any heat input control (modulation on the basis of water temperature. There must then be an indication in the instructions at which supply water temperature this regulator acts. This may not, however, be before 80 C. There must also be an indication at which relative heat input the maximum temperature of 90 C will be reached), or 3. providing a supply water temperature of 80 C at a return water temperature of 60 C. In this case the instructions must expressly indicate that the appliance is designed for heating systems which are intended for a temperature regime of C as a maximum. 5.4 Combustion Product Evacuation for Open-Flued Appliances with Mechanical Extraction For open-flued appliances which are fitted with a fan for the transportation of the flue gases, the following data should be determined and supplied: a) the counter pressure on the flue stub whereby the appliance operates during a cold start; b) the counter pressure on the flue stub whereby the appliance just remains in operation; c) a summary of the calculated possibilities for the flue gases evacuation system on the basis of the counter pressures in a) and b) determined in accordance with article 6.4, and in relation to the outflow area in accordance with NPR At the counter pressures occurring in a) and b) the toxicity index may not exceed the value 2 during testing in accordance with article Temperature Classification The temperature class of the appliance must correspond to the class in which according to Table 2 both the operating temperature and the peak temperature fall. If the operating temperature and the peak temperature fall in different classes then the higher of the two applies as the temperature class of the appliance. 5.6 Combustion Product Temperature Limiter If the appliance is fitted with a combustion product temperature limiter then it may not activate under normal circumstances, including during a cold start. 5.7 Condensation Under the applicable conditions according to EN 297/A5:1998 no condensation may occur in the appliance or the flue gases evacuation system unless the component in question is designed and constructed as such in accordance with article Frost Protection If in accordance with article 4.9 a protective device against the risk of freezing is required then this should engage the appliance when the temperature of the outgoing boiler water is less than 5 C. Kiwa Nederland B.V st February 2011

18 6 Test Methods 6.1 General Gaseous Fuel The measurements, unless otherwise specified, are taken with the reference gas or gasses at the nominal supply pressure for the appliance category in question as stated in EN 437, EN 438 and EN 677 and on the basis of the following conditions: - Ambient temperature: 20 C ± 2 C (hourly average with setpoint 20 C) - Humidity: 70 % ± 5% - Barometric pressure: kpa - Wobbe and calorific value: net value (H i) - Air velocity: < 0.5 m/s Combustion Air Supply and Flue Gases Evacuation The diameter of the flue gases evacuation duct and of any air supply pipe should be in accordance with the installation instructions or should correspond to the diameter of the connection stub of the appliance. Open-flued appliances with a natural airflow are fitted with a vertical flue gases evacuation duct with a length of 1m. In open-flued appliances which are fitted with a fan for the transportation of the combustion air or gasses the tests are carried out at the lowest value of the counter pressure on the flue stub at which the appliance can become operational. Room-sealed appliances should be fitted with an air supply duct and a flue gases evacuation duct of the shortest length specified in the manufacturer's specification. The inlet and outlet shall lie in zones of equal pressure Settings for the Appliance An appliance that has heat input modification by way of a pre-setting should be set at the highest nominal heat input. An appliance that has a facility for the preparation of hot tap water (combination appliance) should be assessed with the tap water preparation function switched on. If there is also a heat retention switch then this must be set at the highest position. If this is not done for particular reasons then this will be recorded in the inspection dossier for verification of the basic assumptions for the testing for the underlying GASKEUR labels. Where it is not otherwise stated in this Evaluation Guideline the other settings will be in accordance with the manufacturer s specifications and recorded in the inspection dossier. 6.2 Efficiencies Open-Flued Appliances Both the water-side full load efficiency and the part load efficiency will be determined in accordance with the direct method as in EN 297:1994/A2:1996/A2- C1:2006, art and art Kiwa Nederland B.V st February 2011

19 6.2.2 Room-Sealed Appliances Both the water-side full load efficiency and the part load efficiency will be determined in accordance with the direct method as in EN 483:1999/A2:2001/AC:2006, art and art Determination of the Flue Loss at Increased Airflow and in Windy Conditions Open-flued appliances are made operational at nominal heat input as in article 6.1. When temperature balance has been reached, the flue loss is determined at normal airflow. The measurement is then repeated with an increased static airflow at the flue gases evacuation duct, which is 10 Pa higher than the normal airflow in the first measurement. Room-sealed appliances are made operational at nominal heat input as in article 7.1, without wind gusts on the supply and evacuation terminal of the appliance. When temperature balance has been reached, the flue loss is determined. The measurement is then repeated at a horizontal wind of 12 m/s in direction of the axis of the terminal. If the capacity of the fan is dependent on the load on the appliance then the measurement should also be carried out at the lowest capacity of the fan and the associated highest and lowest heat input values of the appliance, as far as applicable Determination of the Electrical Power Consumption The electrical power consumed by the appliance is determined in such a manner that the power consumed by the circulation pump is measured separately and specified in the inspection dossier. For the assessment of compliance with the requirement in articl the electrical consumption of the pump is not, however, taken into consideration. 6.3 Heating Performance The appliance is made operational at nominal heat input as in article 6.1, while the water circulation is continued with the built-in circulation pump or set in accordance with the installation instructions with the aid of an external pump. When a return water temperature of 60 C has been achieved the supply water is checked to see if it is at a temperature of 80 C. If it is not expressly stated that the appliance is only suitable for installations which are laid out for C then the testing will be continued by regulating the cooling load in such a manner that the return water temperature only rises by a maximum of 2 K/minute until the supply water temperature reaches 90 C. During this measurement a check will be made on whether and, if so, at which supply temperature the appliance begins to modulate back and at which heat input the supply temperature reaches 90 C. Compliance with the requirements of article 5.3 are subsequently checked. 6.4 Determination of the Counter Pressure on the Flue Stub The appliance is fitted with a flue gases evacuation duct with a nominal diameter corresponding to that of the flue stub of the appliance and with a length of 10 times this diameter. The pressure measurement point is located in the pipe at a height of 5 times the diameter. a) The appliance is calibrated on the reference gas at the nominal heat input or at the maximum heat input if the appliance has an input range. The values in question are determined as follows: for the determination of the maximum duty pressure the appliance is started cold with a fully closed flue gases evacuation duct. The terminal is then gradually opened until the appliance Kiwa Nederland B.V st February 2011

20 commences operation. The counter pressure in the flue gases evacuation duct is then measured at that moment. b) For the determination of the shutdown pressure the supply water temperature is set to 80 C. Once temperature balance has been reached the terminal from the flue gases evacuation duct is gradually closed. The pressure in the flue gases evacuation duct is measured at the moment when the combustion air safety device cuts in. For the counter pressures in a) and b) the toxicity index is determined under the following conditions: In a state of heating up where the water temperature is approx. 20 C and after a delay of about 10 seconds beginning from the moment the burner is ignited In a balance state where the boiler water has an ingoing temperature of 40 C and an outgoing temperature of 60 C In a balance state where the boiler water has an ingoing temperature of 60 C and an outgoing temperature of 80 C. 6.5 Determination of Flue Gas Temperatures for Temperature Classification Determination of the Operating Temperature The control thermostat of the appliance is set to its highest position. The flue gases evacuation duct is fitted at a maximum height of 0.5m from the flue stub with a spider-shaped measurement probe including a temperature sensor to determine the temperature of the flue gases. The appliance is made operational as specified in 7.1 at a heat input that is 5% higher than the nominal heat input respectively the highest heat input in the input range. The volume flow of the water is set at a temperature increase for the water (difference between supply and return) of 20 K and the heat emission is set at a temperature increase for the supply water of a maximum of 2 K/min. The pressure in the evacuation duct is regulated in such a manner that the highest flue gases temperature occurs. The highest flue gases temperature is then determined before, during and after the moment when the control thermostat engages. This is the operating temperature Determination of the Peak Temperature The control thermostat of the appliance is bridged. If the thermostat maximum can be adjusted then it is set to the highest position and then the appliance is put into operation and calibrated in the same way as in article The highest temperature is then determined before, during and after the moment of locking out. This is the peak temperature. 6.6 Determination of the Correct Operation of the Combustion Product Temperature Limiter (If Applicable) The appliance is put into operation and adjusted in the same way as in article The control thermostat is then set to the highest value. The appliance is then operated at around the switching point of the control thermostat until no rise in temperature has been observed for some time. Then check for compliance with the first requirement of article 5.6. Kiwa Nederland B.V st February 2011

21 6.7 Condensation in the Appliance The appliance is subjected to a test in accordance with EN297/A5:1998 article 4.11 under the associated conditions. A check is made for compliance with article Frost Protection For the assessment of the switching value prescribed in Article 5.8 a separate test of the protection device is sufficient. Kiwa Nederland B.V st February 2011

22 7 Labelling 7.1 Inscriptions If the appliance is certified on the basis of the GASKEUR Regulations and also meets the requirements set out in this Evaluation Guideline, the manufacturer may obtain the right to apply the GASKEUR Basic label. The label shall be as indicated in Annex 3. If a combination of labels are mentioned on the certificate, as well as the requirements of the Evaluation Guideline GASKEUR Basic Label CV (Central Heating): 2010 for Central Heating Appliances, the requirements of the Evaluation Guideline concerned also need satisfying, such as: Evaluation Guideline GASKEUR HR (High Efficiency, Heating): 2010 for Central Heating Appliances; Evaluation Guideline GASKEUR SV (Clean Combustion): 2010 for Central Heating Appliances; Evaluation Guideline GASKEUR CW-HRww (Comfort Hot Water-High Efficiency, Hot Water): 2010 for Central Heating Appliances, Hot Water Appliances and Hot Water Storage Appliances; Evaluation Guideline GASKEUR NZ (Reheating Solar boiler): 2010 for Central Heating Appliances, Hot Water Appliances and Hot Water Storage Appliances; Evaluation Guideline GASKEUR HRe (High Efficiency electricity): 2010 for Central Heating Appliances; 7.2 Documentation The appliance should be accompanied by a documentation package with instructions for the installer and for the user Installation Instructions In addition to that which is stated in the European Directive on Gas Appliances the installation instructions should also contain: (if applicable) The instruction that the appliance is designed for installations which are laid out for a supply temperature of 80 C and a return temperature of 60 C, and that it is therefore not suitable for installations which work on a regime. The counter pressure value on the flue stub at which the appliance operates during a cold start (see article 5.4) The counter pressure value on the flue stub at which the appliance just remains in operation (see article 5.4) The electrical power consumption during full load, part load and stand-by An instruction and a summary of the possibilities for constructing a combustion gas evacuation system based on the data specified above (if applicable) An instruction for the correct installation and connection of the combustion product temperature limiter (if applicable) The temperature classification Kiwa Nederland B.V st February 2011

23 7.2.2 User Information In addition to that which is stated in the European Directive on Gas Appliances the user instructions should also contain: (if applicable) an explanation of the operation of the frost protection (if applicable) an explanation of the operation of the combustion gas temperature limiter Kiwa Nederland B.V st February 2011

24 8 Requirements in Respect of the Quality System This chapter contains the requirements which have to be met by the supplier s quality system. 8.1 Manager of the Quality System Within the supplier s organizational structure an employee must have been appointed who is in charge of managing the supplier s quality system. 8.2 Internal Quality Control/Quality Plan The supplier shall have an internal quality control scheme (IQC scheme) which is applied by him. The following must have been demonstrably recorded in this IQC scheme: what aspects are checked by the producer; according to what methods such inspections are carried out; how often these inspections are carried out; in what way the inspection results are recorded and kept. This IQC scheme should at least be an equivalent derivative of the model IQC scheme included in the addendum. 8.3 Procedures and Working Instructions The supplier shall be able to submit the following: procedures for: dealing with products showing deviations; corrective actions to be taken if non-conformities are found; dealing with complaints about products and/or services delivered; the working instructions and inspection forms used. Kiwa Nederland B.V st February 2011

25 9 Summary of Tests and Inspections In this chapter a summary is given of the following items, which form part of the certification process: Approval Programme; Inspection of general, constructive and functional requirements; Procedure for the surveillance programme; Inspection of the quality management system; Furthermore, it is also indicated with which frequency the Surveillance Programme will be carried out by the CI. 9.1 Inspection Matrix Description of Requirements Article in Investigation in relation to: Guideline Approval Programme Surveillance by Kiwa after issue of the certificate Inspection Frequency General and Constructional Requirements Basic requirements 4.1 x x 1 x per 24 mths Nuisance 4.2 x x 1 x per 24 mths Appliance category 4.3 x x 1 x per 24 mths Appliance classification 4.4 x x 1 x per 24 mths Appliance construction 4.5 x 1 x per 24 mths Evacuation of Combustion Gases and 4.6 x 1 x per 24 mths Supply of Combustion Air Connection of the gas supply 4.7 x 1 x per 24 mths External connections for controls 4.8 x 1 x per 24 mths Protection against the risk of freezing 4.9 x 1 x per 24 mths Temperature classification 4.10 x 1 x per 24 mths Operational Requirements General 5.1 x x 1 x per 24 mths Efficiencies 5.2 x x 1 x per 24 mths Heating performance 5.3 x x 1 x per 24 mths Evacuation of flue gases for open flued 5.4 x 1 x per 24 mths appliances with mechanical extraction Temperature classification 5.5 x 1 x per 24 mths Combustion gas temperature limiter 5.6 x 1 x per 24 mths Condensation 5.7 x 1 x per 24 mths Frost protection 5.8 x 1 x per 24 mths 1) With significant changes of the product or production process, compliance with the (product) requirements shall be reconfirmed. 2) The given inspections shall be carried out by Kiwa at their premises 3) Procedures for the surveillance programme are given in 9.2 4) The inspections given for the surveillance programme shall be carried out on one appliance per technically identical series. Kiwa Nederland B.V st February 2011

26 9.2 Procedures for the Surveillance Programme Description for the procedure of settings input during the surveillance programme. The appliance for the surveillance programme will be selected by Kiwa from the running production line or stock of the manufacturer or importer. The selected appliance is removed from its box by the TI at their premises and is connected and adjusted in the test environment conforming to the included installation manual. Subsequently, it will be determined whether the appliance is functioning correctly and to what extent the corrected heat input (Q c, conform to Article of the EN 483:1999) and/or the actual heat input (Q i, conform to Article of the EN 483:1999) deviates from the nominal heat input as indicated on the identification plate of the appliance (Q n, conform to EN 483:1999). The following three situations can occur: Situation 1: (Q c < 0,95Q n) or (Q c > 1,05Q n) In case the appliance has been set and the corrected heat input deviates by more than 5% from the nominal heat input according to the identification plate, then the measurements will be stopped. This is designated as a failure. Situation 2: (Q c 0,95Q n and Q i 0,98Q n) or (Q i 1,02Q n and Q c 1,05Q n) In the case that the appliance has been set and the actual heat input deviates by more than 2% and the corrected heat input deviates by more than 5% from the nominal heat input according to the identification plate, then: 1. The TI will discuss with the manufacturer whether the measurements regarding the surveillance programme can be started, or whether the appliance needs to be adjusted to fall within the 2% heat input deviation from the nominal heat input according to the identification plate. 1.1 In the case that the manufacturer indicates that the measurements regarding the surveillance programme can be started, these measurements will be begun; 1.2 In the case that the manufacturer indicates that the appliance needs to be adjusted to fall within the 2% heat input deviation from the nominal heat input according to the identification plate, the TI will assess whether the adjustments needed are marginal. Marginal means here that the adjustments are within the limits of the usual production tolerances which can occur In the case that the adjustments, as assessed by the TI are marginal, then the manufacturer or the TI, on assignment and after written permission of the manufacturer has been received, will apply these adjustments 1 and the actual heat input will be re-measured In the case that the actual heat input deviates by less than 2% from the nominal heat input as indicated on the identification plate, then the measurements in regards to the surveillance programme will be started. 1 For example, if relevant set points have not yet been incorporated in the GASKEUR test report, this still needs to be carried out. Kiwa Nederland B.V st February 2011

27 Situation 3: (0,98Q n < Q i < 1,02Q n) In the case that the actual heat input deviates more than 2% from the nominal heat input as indicated on the identification plate, then, after discussion with the manufacturer, step 1.2 may be repeated or this will be designated as a failure. In the case that the actual heat input deviates by less than 2% of the nominal heat input as indicated on the identification plate, then the measurements in regards to the surveillance programme will be started. 9.3 Inspection of the Quality Management System The quality management system of the supplier will be inspected by the CI once per year. This assessment will comprise at least the aspects as indicated in the Kiwa Regulations for Product Certification. Kiwa Nederland B.V st February 2011