DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS Our Ref.: NRO/PRBO 13 Jan 2014 Please find enclosed the following draft certification manual: Product manual on Room Heater as per IS 302-2-30 : 2007 Kindly examine the draft product certification manual and forward your comments on the draft manuals. Last date for comments: 28 Jan 2014. Comments, if any, may please be made in the format as given below and mailed to PRBO at the following email id: nlbo@bis.org.in. Sl. No. Name of RO / BO Clause/ Sub-clause Paragraph / Figure / Table Type of comment (General / Technical / Editorial) Comments Proposed Change Note: Separate sheets may be attached in case comments are lengthy and cannot be incorporated in the table. For BIS Use Only Doc No.: SM/IS 302-2-30-2007 Date of Issue: January 2014 PRODUCT MANUAL FOR Room Heater (First Issue) BUREAU OF INDIAN STANDARDS MANAK BHAVAN, 9, BAHADUR SHAH ZAFAR MARG, NEW DELHI – 110002 BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC- 302-2- 30-2007 ISSUE: 01 PRODUCT MANUAL DATE: NOV 2013 PREPARED BY: PAGE: 1 OF 4 APPROVED BY: AMENDMENT SHEET To ensure that each copy of the Manual contains a complete record of Amendments, this Amendment Sheet should be updated for each revised/new pages of the Manual. While issuing any amendment, an acknowledgment slip will be included for signatures and return by all Controlled Copy holders. DISCARD AMENDMENT No. Section Page Issue No. INSERT Date Section Page Issue No. SUMMARY OF CHANGE Date BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 ISSUE: 01 DATE: NOV 2013 PREPARED BY: PRODUCT MANUAL PAGE: 4 OF 4 APPROVED BY: FOREWORD Electric room heater is an household appliance usually used in winter season to make the room or space warm up to get rid of severe cold. Keeping in view the safety concern , these products has been covered under mandatory certification w.e.f Sep.2009 under IS :302-230:2007. This manual has been prepared in order to provide guidelines for processing of application & operation licences in uniform manner TABLE OF CONTENTS Sections Title Section 1 Product Description 1.1 Description of product(s) 1.2 Latest Indian Standard Number with product title and number of amendments 1.3 List of referred standards 1.4 Checklist for submission of an application for grant of licence Section 2 Raw materials/ Components 2.1 List of important raw materials/components Section 3 Manufacturing process and In-process Quality controls 3.1 Description of manufacturing process(es) 3.2 Infrastructure for production Section 4 Certification criteria 4.1 Identification of critical requirements 4.2 Scheme of testing and inspection 4.3 Marking fee rates 4.4 Grouping guidelines 4.5 Guidelines for scope of licence 4.6 Guidelines for inclusion of new varieties 4.7 Sample size and Guidelines for drawl of separate samples 4.8 Manner of sealing of sample(s) 4.9 Dealing with sample remnants 4.10 Procedure for destruction of non conforming product Section 5 Inspection and testing Page No. BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 ISSUE: 01 PREPARED BY: DATE: NOV 2013 APPROVED BY: 5.1 Packaging material requirement 5.2 List of test equipment/ facilities 5.3 Test facilities in BIS Labs/ OSLs with testing charges and approximate time 5.4 Basis of grant of licence 5.5 Details of tests to be carried out in the factory Annexes Annexure – 1 PRODUCT MANUAL PAGE: 4 OF 4 BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 PREPARED BY: ISSUE: 01 DATE: NOV 2013 PRODUCT MANUAL PAGE: 2 OF 4 APPROVED BY: SECTION 1: PRODUCT DESCRIPTION This standard recognizes the Indian accepted level of protection against hazards such as electrical, mechanical, thermal ,fire & radiation when operated as in normal use taking in to account the manufacturer’s instruction. It also covers abnormal situations that can be expected in practice. It deals with the safety of electric room heater for household & similar purposes ,rated voltage being not more than 250 V for single Phase appliances and 415 V for other appliances. Broad categories of Room Heater which are commonly used & covered under this standard are : Convector heaters:In convection heaters, heating elements either warm the air directly or heat oil or another filler, or assisted by fan which in turn transfers heat to the air in Room or Space . Radiative heaters: In Radiant Heater ,heating Element is wound on Ceramic rod or is encapsulated in heat-resistant quartz/glass tubes, mounted in front of a metal reflector in a metallic or nonmetallic body. The heating element of liquid filled radiator heat up the oil or another filler which in turn warm up the metallic fin that transfer heat . Safety Concern : The risk of fire from electric heaters may be mitigated by low surface temperatures (as found on oil-filled convective/Radiant heaters), or by switches that cut power in the event of the device being knocked over (often found in the bases of Room heaters), or by thermal cut-out switches /Thermostat . In addition to the these Safety devices ,Room Heater having non metallic enclosure are equipped with thermal fuse also . The values of parameter to be declared by manufacturer : I)Type : convection heater/fan heater/heater for use in green houses/Liquid filled radiators/panel heater/Radiant heaters/tubular heaters. Rating : Rated voltage in volts, Nature of Supply Voltage , Rated Frequency/Rated power input. II)Classification : Class I/II/III .& Degree of protection against harmful ingress of water. III) pollution Degree IV) Material group if Pollution degree is other than 1. . BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 ISSUE: 01 DATE: NOV 2013 PREPARED BY: PRODUCT MANUAL PAGE: 2 OF 4 APPROVED BY: 1.2. Latest Indian Standard Number with product title and number of amendments Indian Standard Number: IS 302-2-30:2007 Product title: Safety of Household And Similar Electrical Appliances –Room Heater No. of amendments: 1 1.3 List of referred standards The following IS Standards are necessary adjuncts to this standard: IS No. Title 302-1:2008 SAFETY OF HOUSEHOLD AND SIMILAR ELECTRICAL APPLIANCRES PART-1 GENERAL REQUIREMENTS. 1060 (part1):1966 revised) 1401:2007 Method of sampling and test for paper and allied products: part1( Protection of persons & equipment by probes for verification(second revision) 11000(part2)/Sec2:1984 : Fire Hazards Testing :Part2 Test methods Sec.2 Needle flame Test 12766 :1997 paper ,computer- Specification ( Ist Revision) OTHER RELEVANT STANDARDS 9968(Part-1)1988 Elastomer insulated cables:part-1 for working voltages up to & including 1100V ( 1st revision) 694 :1988 PVC insulated Cables for working voltage up to & including 1100 v ( 3rd revision) 1293:2005 Plug& socket rated voltage & current up to & including 250V & 16A. (Third revisionThe following IS Standards are necessary adjuncts to this standard: BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 PREPARED BY: ISSUE: 01 DATE: NOV 2013 PRODUCT MANUAL PAGE: 3 OF 4 APPROVED BY: 1.4. Check-list for submission of an application for grant of licence: As per Annexure 1 BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PRODUCT MANUAL PAGE: 2 OF 2 APPROVED BY: SECTION 2: RAW MATERIALS/ COMPONENTS 2.1. List of important components List of Major Component of Room Heater ( Fan Heater / Radiant Heater) Sr. Name of Component No Check List 1 Visual Exam No loose bobbin ,Al Bracket fitting ,sign of rust DoM Measurement Weight Cross sectional area of wire harness Fan Motor HVT/Flash ,LVS & Functional Test 1500 V/5Sec 2 Thermostat / Self Resettable Thermal Cut Out LVS RPM on no load /On Load Cold Resistance of Coil Input on no load/ load Visual Exam Color of Zn plating,Rating & marking, Requirements As per Ref Sample & DoM in mmyy format As per the wt model Ref. Sample No flash over/breakdown shall occur 120 V Max. As per Ref Sample As per Ref Sample As per Ref Sample Color of Chasis & Rating shall match with that of Ref . Sample& Marking in MMYY format be Checked Measurement Dimensional Check of Shaft & Chasis put the thermostat in condition of assembly & ensure. As per Ref Sample HVT/Flash Test 1500 V/5Sec 3 Switch Visual Exam Color , Moulding Defect, Rating & printing No flash over/breakdown shall occur as per Ref. sample. BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 ISSUE: 01 PREPARED BY: 4 Heating Element DATE: NOV 2013 Main Suppy Cord with moulded plug PAGE: 2 OF 2 APPROVED BY: Visual Exam Ensure proper assembly & loose Terminals Measurement Cold Resistance 5 PRODUCT MANUAL As per Ref Sample 51 Ω - 55ΩΩ for IKW & 26 Ω - 28Ω for 1Kw Visual Exam Colour ( PVC Cable) ,cotton Braiding defects in rubber cable Marking & Rating of Plug & PVC Cable As per Ref Sample Measurement Length of Cord & area of X-sec of Copper Conductor As per Ref Sample. HVT / Flash Over & continuity Test 1500 V/5 Sec Continuity ( Plug Pin L-with Red Core , BBlack Core & E- Green/Yellow Core ) 6 Reflector Visual Exam Electroplating Defect, Scratches , dents & burrs Measurement Weight 7 Metallic or Non metallic Enclosure Shall with Stand Shall Comply As per Ref Sample Visual Exam Scratches ,Powder coating /Screen Printing dents/sharp edges , Deep Spot welding marks Colour Variation, Moulding As per ref Sample BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PRODUCT MANUAL PAGE: 2 OF 2 APPROVED BY: Defects, Measurement Weight As per ref Sample IS Standards exist for the following component/ Raw Material 1. Main supply cord : IS 9968part-1(1988) & IS:694:1988 2. Three pin top : IS:1293:2005 SECTION 3: MANUFACTURING PROCESS AND IN-PROCESS QUALITY CONTROLS 3.1. Description of manufacturing process MANUFACTURING PROCESS AND IN-PROCESS QUALITY CONTROLS i)Description of manufacturing Process(es) with quality Checks MANUFACTURING PROCESS & IN PROCESS CONTROLS ( FAN HEATER) Stage No Stage Check points 1 Bottom Assembly No Color deviation,scratches,moulding defect,powder coating defect ,loose connectioning of supply cords & loose assembly of componenets i.e heating element, motor, fan line connector switch ,thermostat. 2 Top Cover assembly No Color Deviation,scratches,moulding defect,powder coating defect ,loose connection & loose assembly of component assembled ,effectiveness of screen printing. 3 Stage No (1+ 2) No Visual Defects ,loose fitting misalignment missing of component. 4 Visual Inspection No moulding ,Printing , Visual Defects & Loose Fitment. BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PRODUCT MANUAL PAGE: 2 OF 2 APPROVED BY: 5 Fixing of Rating Label & inspecting tag No gap/Bending & Printing/Marking be legible& durable 6 Safety & Functional Test 7 Cleaning H.V test-1.5kV/5sec, LC=210Um max,ECR-0.1Ohm max,IR-10MOhm Min & Motor LVS, Element Glow & functional test. No Visual Defect /Missing. Cleaned Properly. 8 Packing Unit carton 9 Packaging Master Carton 10 Storage/Dispatch Print Colour, Pasting/Stappling ,CM/L No.,Ensure GCard, Manual , Polybag & Pulp /Thermocol packing & Correct Marking of MRP&Date of Manufacture Print Colour,Pasting/Stappling /rust on stapples, CM/L No,Consolidated MRP& Date of Manufacture Nos of unit/Master & Taping & Strapping. Storage Area – Cleaned,moisture proof,Stacking on pallets MANUFACTURING PROCESS & IN PROCESS CONTROLS ( RADIANT HEATER) Stage No Stage Check points 1 Main Assembly 4 Visual Inspection 5 Fixing of Rating Label & inspecting tag No Color deviation,scratches,moulding defect,powder coating defect ,loose connectioning of supply cords & loose assembly of componenets i.e heating element, line connector, switch , Loosefitting ,misalignment of component. No moulding ,Printing , Visual Defects, Scratches , dents , deep lines & Loose Fitment. No gap/Bending & Printing/Marking be legible& durable BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PRODUCT MANUAL PAGE: 2 OF 2 APPROVED BY: 6 Safety & Functional Test 7 Cleaning 8 Packing Unit Carton 9 Packing Master Carton 10 Storage /Dispatch 14 Storage /Dispatch H.V test-1.5kV/5sec, LC=210Um max,ECR0.1Ohm max,IR-10MOhm Min & functional test. No Visual Defect /Missing. Cleaned Properly. Print colour , Pasting/Stappling ,CM/L No, MRP 'Ensure G-Card, Manual , Polybag & Pulp /Thermocol packing & Correct Marking of MRP&Date of manufacture Print Colour of Sheet, Pasting/Stappling,Consolidated MRP & Date of Manufacture & Tape & Strapping Storage area -clean,moisture proof,with pallets & proper stacking Storage area shall be clean , moisture proof & Proper Stacking on Pallets 3.2. Infrastructure for production Following basic manufacturing facilities shall be available at applicant unit for the production ii) Infrastructure for production Sl. No. 1 2 3 4 5 6 7 8 List of Machinery Electric/Pnuematic Screw Driver along with Bits& nut runners of different Sizes Sr No Punching Machine/Laser printing machine Digital Weighing Machine Hand Press Hand Drill/Threading Machine Conventional Hand Tools ( NosePliers, Thimble Crimping Tools,Mallets,Hammers,Scissors,) Pad Printing Machine Motorised Conveyor System BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 ISSUE: 01 PREPARED BY: 9 10 11 DATE: NOV 2013 PRODUCT MANUAL PAGE: 2 OF 2 APPROVED BY: Electric Generator Set Compressor Electric Strapping Machine The capacity and number of manufacturing machines or testing machines may vary as per production needs and applicability. The process quality controls shall be followed as per STI for the product. 12 Tape Dispanser BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PRODUCT MANUAL PAGE: 1 OF 2 APPROVED BY: SECTION 4: CERTIFICATION CRITERIA 4.1. Identification of critical requirements All requirements documented in standard shall be considered critical unless mentioned otherwise. 4.2. Scheme of testing and inspection The STI for IS 302-2-30:2007 as in force shall be applicable i.e. Doc: STI /302-2-30/2 September2009. The implementation of STI shall be verified during surveillance inspection. 4.3. Marking fee rates The details of rate of marking fee are available on BIS intranet/website. 4.4. Grouping guidelines No grouping guidelines are available for IS 302-2-30:2007 4.5. Guidelines for scope of licence Licence shall be granted with scope specifying the type(s) of the product. Licence shall not be granted with “open scope”. The grant of licence letter and the Licence Document shall clearly indicate the following: Safety of household and similar appliances – Electric Room heater (Fan Heater), 2000W, 230V, 50 Hz, ac, Class I, single phase, ordinary, IPXO, Pollution Degree 3, Material group III-a, portable type, Insulation Class ‘E’ of fan motor winding, fitted with thermostat and self resetting thermal cutout as per IS 302-2-30:2007. 4.6. Guidelines for inclusion of new varieties Inclusion of other varieties shall e considered for the type of product for which confirming test report as per guidelines submitted . 4.7. Sample size and Guidelines for drawl of separate samples Sample sizes - 2 BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 ISSUE: 01 PREPARED BY: DATE: NOV 2013 PRODUCT MANUAL PAGE: 6 OF 7 APPROVED BY: 4.8. Manner of sealing of sample(s) Effort shall be made, as far as possible, to send samples without the manufacturer’s identification and/or markings. Any label and/or manufacturer's identification shall be removed or defaced. Test request shall clearly indicate the following: a) Date of manufacture; b) Quantity, c) Lot No. 4.9. Dealing with sample remnants The remnants of samples may be disposed off after testing. 4.10. Procedure for destruction of non conforming product The non conforming product shall be disposed off . SECTION 5: INSPECTION AND TESTING 5.1. Packaging material requirement : CorrugatedUnit/Master Carton , Thermocol/Pulp packing/Foam Sheet/Front Impact Strip /Poly/Bubble bag/Manual&Guarantee card/Bopp Tape/Straps/Sealing Wax. 5.2. List of test equipment/ facilities and Chaemicals To be provided by CL 5.3. Test facilities in BIS Labs/ OSLs with testing charges and approximate time The list of BIS laboratories and laboratories recognized by BIS, where sample of Electric Iron can be sent for independent testing, are available on BIS intranet/website. The inspecting officer/agent shall collect latest status in respect of any laboratory before proceeding for inspection. BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 ISSUE: 01 PREPARED BY: PRODUCT MANUAL DATE: NOV 2013 PAGE: 6 OF 7 APPROVED BY: 5.4. Basis of grant of licence The basis of grant of licence shall be based on independent testing. 5.5. Details of tests to be carried out in the factory Following tests may be carried out in factory: S.No Tests 1 Protection against electric shock 2. Electrical Insulation&Leakage current at Ref to Cl. 8 of IS:302-2-30:2007 Operating Temperature 13 3. Earthing connection 27 4. Input 10 5. Temperature Rise 11 6. Stability & Mechanical Hazards 20 7. Mechanical Strength 21 8. Screw & connection 28 9. Resistance to heat & fire 30 BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 ISSUE: 01 PRODUCT MANUAL DATE: NOV 2013 PREPARED BY: PAGE: 1 OF 1 APPROVED BY: ANNEX-I CHECK-LIST FOR APPLICATION TO BE SUBMITTED BY APPLICANT TO BIS WHILE APPLYING FOR BIS LICENCE UNDER PRODUCT CERTIFICATION SCHEME OF BIS The following check-list is required to be submitted with all the applications for grant of BIS licence under the Product Certification Scheme of BIS. Please tick (√) in the relevant box. Whether applied under: Simplified Procedure □ Normal Procedure □ Note: Refer BIS website or details of “Simplified Procedure” and “Normal Procedure” for grant of licence. No. Check-point General 1. Name & Address 2. Status of Applicant (Manufacturi ng Unit) 3 IS No. & Varieties 4. History 5. Signature 6. Machinery Requirement Is the application form completely filled? Is the name and address of applicant (manufacturing unit applying for licence) same in the application as given in the attached document of Central/State Government a. Has it been indicated whether the applicant is a large scale or small scale unit? b. In case the applicant is a small scale unit, does the applicant hold valid Registration Certificate from the Local / State authority or from a Chartered Accountant, and is the certificate attached. c. Has it been indicated whether the applicant is a Public Sector or a Private Sector company? a. Has applicant recorded the applicable Indian Standard with correct title of the Standard? b. Where applicable, has applicant mentioned designation, grade, type, variety, size, etc., of the product for which the BIS licence is sought? a. Where applicable, has the applicant provided information regarding earlier BIS licence(s) held by them and / or cancelled in the past? b. Where applicable, has the applicant provided information regarding BIS licences currently held by them? a. Is the application signed by the CEO of the applicant? b. In case the application is signed by a person other than the CEO, is the application signed by the authorized signatory of the applicant and his authorization is attached by the authorized signatory? a. Does applicant possess requisite manufacturing infrastructure to manufacture the product as per the Indian Standard? b. Is installed capacity of production indicated in the application? Observations Page No. BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 PREPARED BY: 7. Test Equipment & Calibration 8. QC personnel 9. Raw Materials and Components 10. Plant Layout 11. Test Report(s) ISSUE: 01 DATE: NOV 2013 APPROVED BY: c. Does applicant have all machineries installed as per manufacturing process at the applicant’s manufacturing premises? d. If answer to ‘c’ above is no, does the applicant outsource any of its manufacturing processes and possesses valid agreement(s) with other manufacturing units for the outsourced processes and traceability of material, thus produced, etc.? e. If answer to ‘d’ above is yes, does the applicant has any control over such outsourced activity? Are these outsourced process will ensure testing the quality of final product for all requirements at the applicant's manufacturing premises? a. Does applicant possesses requisite test facilities in-house as per the relevant Indian Standard at its factory address? b. Are valid calibration certificates for relevant test equipment attached are complete and valid at least 3 months after the date of recording? c. If reply to ‘a’ above is no, does applicant have arrangement with a BIS recognized outside lab for testing of the requirements for which it does not possess test facilities inhouse? Is the consent letter as attached by applicant in this regard in order? Note: Relaxation in in-house test facilities may be allowed on submission of proper justification for requirements which are obligatory to get tested and for which frequency of testing, as prescribed in the relevant scheme of testing and inspection (STI), is, normally, one month or more. Does the applicant employ qualified & experienced Quality Control (QC) personnel on permanent basis and possess documentary evidence to establish the same? Are the copies of the qualification certificates and appointment letters of the QC personnel are in order. Where ever requirements for raw materials/ components used in the manufacturing of the product are specified in the standard, do test reports/suppliers’ test certificates, as submitted by the applicant show that these requirements are met as per the standard? Does copy of the plant (applicant manufacturing premises) layout clearly indicates locations of manufacturing machinery, laboratory, office, workshop, amenities, storage area, etc.? a. Is the attached test report of in-house or from independent laboratory cover all requirements of the Indian Standard and ispassing in such requirements? PRODUCT MANUAL PAGE: 1 OF 1 BUREAU OF INDIAN STANDARDS PRODUCT CERTIFICATION TITLE: GENERAL DOC: PC-302-2-30- 2007 PREPARED BY: 12. Undertaking ISSUE: 01 DATE: NOV 2013 APPROVED BY: b. In case the application is filed under “simplified Procedure” is the test report(s), in original, as submitted a) from BIS or its recognized laboratories? b) the test report is not older than one month from the date of submission of application, c) covers all the requirements of the standard, and d) passes in all such requirements In case application is under simplified procedure, an undertaking shall be obtained from the applicant on his letter-head that the licence if granted against his application shall be put under Stop Marking by BIS if the verification sample(s) (any sample including the long duration test samples) drawn during visit of the BIS officer prior to grant of licence fail to conform to the requirements of relevant Indian Standards. The licensee shall take necessary corrective actions and inform the same to BIS along with fresh samples (of rating/size/variety which facilitates verification of corrective actions on the reported failures) manufactured after taking the corrective actions. The resumption of marking in such cases shall be allowed only on the basis of independent satisfactory Test Reports of the fresh samples offered (including long duration tests where failures were in long duration tests). In case the fresh sample drawn by BIS for independent testing fails, or the licensee does not inform corrective actions taken and does not offer improved samples within 1 month of the date of Stop Marking, the licence shall be processed for cancellation and no further chance would be given to the licensee PRODUCT MANUAL PAGE: 1 OF 1
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