DRAFT ÖNORM EN 303-5 Edition: 2010-09-01

Central-Heating boilers Part 5: Heating boilers for solid fuels, hand and automatically stoked, nominal heat output of up to 500 kW ― Terminology requirements, testing and marking Zentral-Heizkessel ― Teil 5: Heizkessel für feste Brennstoffe, hand- und automatisch beschickte Feuerungen, Nenn-Wärmeleistung bis 500 kW ― Begriffe, Anforderungen, Prüfungen und Kennzeichnung Chaudières de chauffage centrale ― Partie 5: Chaudières spéciales pour combustibles solides, à chargement manuel et automatique, puissance utile inférieure ou égale à 500 kW ― Définitions, exigences, essais et marquage

ICS 01.040.91; 91.140.10 Identical (IDT) with prEN 303-5:2010-08 Supersedes ÖNORM EN 303-5:1999-07 responsible Committee 058 Heating systems and components

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Note: Because of possible comments, the final version of this ÖNORM can differ from the present Draft. Please send your comments (in writing) by 2010-10-15 to Austrian Standards Institute.

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Explanations concerning Draft

The present Draft European Standard EN 303-5 has been submitted to CEN members for voting. In case of a positive result of the voting as required by CEN/CENELEC regulations, this Draft will be published as EN.

Like all member organizations of CEN, Austrian Standards Institute is basically obliged to implement Euro-pean Standards in Austria and to withdraw conflicting standards.

Austrian Standards Institute herewith submits this Draft of a European Standard as Draft ÖNORM to public enquiry and information.

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EUROPEAN STANDARD

NORME EUROPÉENNE

EUROPÄISCHE NORM

DRAFT prEN 303-5

August 2010

ICS 01.040.91; 91.140.10 Will supersede EN 303-5:1999

English Version

Central-Heating boilers - Part 5: Heating boilers for solid fuels, hand and automatically stoked, nominal heat output of up to 500

kW - Terminology requirements, testing and marking

Chaudières de chauffage centrale - Partie 5 : Chaudières spéciales pour combustibles solides, à chargement manuel

et automatique, puissance utile inférieure ou égale à 500 kW - Définitions, exigences, essais et marquage

Zentral-Heizkessel - Teil 5: Heizkessel für feste Brennstoffe, hand- und automatisch beschickte

Feuerungen, Nenn-Wärmeleistung bis 500 kW - Begriffe, Anforderungen, Prüfungen und Kennzeichnung

This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee CEN/TC 57. If this draft becomes a European Standard, CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European Standard the status of a national standard without any alteration. This draft European Standard was established by CEN in three official versions (English, French, German). A version in any other language made by translation under the responsibility of a CEN member into its own language and notified to the CEN Management Centre has the same status as the official versions. CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom. Recipients of this draft are invited to submit, with their comments, notification of any relevant patent rights of which they are aware and to provide supporting documentation. Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and shall not be referred to as a European Standard.

EUROPEAN COMMITTEE FOR STANDARDIZATION C O M I T É E U R O P É E N D E N O R M A LI S A T I O N EUR OP ÄIS C HES KOM ITEE FÜR NOR M UNG

Management Centre: Avenue Marnix 17, B-1000 Brussels

© 2010 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members.

Ref. No. prEN 303-5:2010: E

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Contents Page

Foreword ..............................................................................................................................................................5

1 Scope ......................................................................................................................................................61.1 General ....................................................................................................................................................61.2 Biogenic fuels ........................................................................................................................................61.3 Fossil fuels .............................................................................................................................................61.4 Other solid fuels (e.g. peat) ..................................................................................................................6

2 Normative references ............................................................................................................................7

3 Definitions ........................................................................................................................................... 10

4 Requirements ...................................................................................................................................... 144.1 General requirements ......................................................................................................................... 144.2 Construction requirements ................................................................................................................ 154.2.1 Production documentation ................................................................................................................ 154.2.2 Heating boilers made of steel and non-ferrous materials .............................................................. 154.2.3 Boilers made of cast materials .......................................................................................................... 224.2.4 Safety and design requirements ....................................................................................................... 234.3 Safety requirements ........................................................................................................................... 254.3.1 General ................................................................................................................................................. 254.3.2 Manual stoking .................................................................................................................................... 264.3.3 Automatic stoking............................................................................................................................... 264.3.4 Safety against back burning for automatic stoked boilers ............................................................ 264.3.5 Safety against fuel overload of the boiler or interruption in fuel supply ...................................... 294.3.6 Surface temperatures ......................................................................................................................... 294.3.7 Leakage of the combustion system .................................................................................................. 304.3.8 Temperature control and limiting devices ....................................................................................... 304.3.9 Heating boiler accessories ................................................................................................................ 314.4 Boiler performance requirements ..................................................................................................... 324.4.1 General ................................................................................................................................................. 324.4.2 Boiler efficiency .................................................................................................................................. 324.4.3 Flue gas temperature ......................................................................................................................... 334.4.4 Draught ................................................................................................................................................ 334.4.5 Combustion period ............................................................................................................................. 344.4.6 Minimum heat output ......................................................................................................................... 344.4.7 Emission limits .................................................................................................................................... 34

5 Test ....................................................................................................................................................... 355.1 Test base ............................................................................................................................................. 355.1.1 General ................................................................................................................................................. 355.1.2 Choice of boiler and fittings to be tested ......................................................................................... 365.1.3 Condition of the boiler ....................................................................................................................... 365.1.4 Type test .............................................................................................................................................. 365.2 Measuring instruments and methods ............................................................................................... 365.3 Test fuel ............................................................................................................................................... 375.4 Pressure test for boilers of sheet or sheet metal of non-ferrous metal ........................................ 395.4.1 Tests to be carried out before production ....................................................................................... 395.4.2 Test during production ...................................................................................................................... 395.5 Pressure test for boilers of cast iron or non-ferrous metals ......................................................... 395.5.1 Test to be carried out before production ......................................................................................... 395.5.2 Test during production ...................................................................................................................... 405.6 Test for gas side soundness ............................................................................................................. 405.7 Conducting the boiler performance test .......................................................................................... 41

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5.7.1 General ................................................................................................................................................. 415.7.2 Setting up the test rig .......................................................................................................................... 425.7.3 Measured quantities ............................................................................................................................ 425.7.4 Test duration ........................................................................................................................................ 435.8 Determination of the heat output and the efficiency of the boiler.................................................. 435.8.1 Method for the measurement of the heat output ............................................................................. 435.8.2 Determining the nominal heat output ................................................................................................ 445.8.3 Determining the minimum heat output ............................................................................................. 445.8.4 Determination of the boiler efficiency (direct method) .................................................................... 445.8.5 Electrical consumption ....................................................................................................................... 455.9 Determination of the emission values ............................................................................................... 455.9.1 Determination of the emissions at nominal heat output ................................................................. 455.9.2 Determination of the emissions at minimum heat output ............................................................... 455.10 Calculation ........................................................................................................................................... 455.10.1 Boiler heat output ................................................................................................................................ 455.10.2 The heat input ...................................................................................................................................... 455.10.3 Boiler efficiency ................................................................................................................................... 465.10.4 Emissions ............................................................................................................................................. 465.11 Determination of the waterside resistance ....................................................................................... 475.12 Surface temperature ............................................................................................................................ 475.13 Function check of the temperature controller and safety temperature limiter (automatic

reset and/or manual reset).................................................................................................................. 475.14 Function test for the rapidly disconnect able firing system ........................................................... 475.15 Function test on the device for dissipating excess heat (partly or non disconnectable

firing system) ....................................................................................................................................... 485.16 Check of the safety and risk assessment ......................................................................................... 485.16.1 General ................................................................................................................................................. 485.16.2 Safety test of consequences of fuel overload and effect of a blockage of the fuel supply ......... 495.16.3 Loss of combustion air supply .......................................................................................................... 495.16.4 Resistance to thermal conductance .................................................................................................. 49

6 Test report and other documents ...................................................................................................... 49

7 Designation .......................................................................................................................................... 507.1 General ................................................................................................................................................. 507.2 Information on the boiler plate ........................................................................................................... 507.3 Data plate requirements ...................................................................................................................... 51

8 Technical documentation, supplied with boiler ............................................................................... 518.1 General ................................................................................................................................................. 518.2 Technical information and installation instructions ........................................................................ 518.3 Operating instructions ........................................................................................................................ 53

Annex A (informative) Manual measurement of particles in the gas flow, gravimetric determination of particle load with filter systems ........................................................................... 54

Annex B (informative) Vocabulary................................................................................................................... 59

Annex C (informative) Design criteria for solutions to prevent back burning ........................................... 61

Annex ZA (informative) Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC Machinery Directive .................................................... 66

Annex ZB (informative) A-deviations .............................................................................................................. 69ZB.1 General ................................................................................................................................................. 69ZB.2 Deviations from Austria: ..................................................................................................................... 69ZB.2.1 General ................................................................................................................................................. 69ZB.2.2 Boiler efficiency for nominal heat output and minimum heat output ............................................ 70ZB.2.3 Emission limits .................................................................................................................................... 70ZB.3 Deviations from DENMARK ................................................................................................................ 71ZB.3.1 Subclause 4.4.2 Boiler Efficiency ...................................................................................................... 71ZB.3.2 Subclause 4.4.7 Emission Limits ....................................................................................................... 71ZB.3.3 Subclause 5.1 Test Base..................................................................................................................... 72

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ZB.4 Deviations from Germany .................................................................................................................. 72ZB.4.1 Clause 4.4.7 Emission limits .............................................................................................................. 72ZB.4.2 Clause 5.9 ............................................................................................................................................ 74ZB.5 Deviations from Switzerland .............................................................................................................. 74ZB.6 Deviations from United Kingdom ...................................................................................................... 75

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Foreword

This document (prEN 303-5:2010) has been prepared by Technical Committee CEN/TC 57 “Central heating boilers”, the secretariat of which is held by DIN.

This document is currently submitted to the CEN Enquiry.

This document will supersede EN 303-5:1999.

According to EN 303-5:1999 the following fundamental changes are given:

the scope was extended to a nominal heat output of the heating boilers for ≤ 500 kW;

usable fuel to non-wood biomass and further solid fuels extended;

requirements for materials, weld joints and wall thicknesses revised;

mandatory risk analysis implemented;

general and electrical safety requirements revised;

emission class 1 and 2 deleted and new emission class 4 and 5 added;

tests revised and new tests for safety requirements added:

annexes new structured;

consideration of the essential requirements of the Machinery Directive 2006/42/EC.

The following structure is intended for the European Standards for heating boilers:

EN 303-1, Heating boilers ― Part 1: Heating boilers with forced draught burners ― Terminology, general requirements, testing and marking

EN 303-2, Heating boilers ― Part 2: Heating boilers with forced draught burners ― Special requirements for boilers with atomizing oil burners

EN 303-3, Heating boilers ― Part 3: Gas-fired central heating boilers ― Assembly comprising a boiler body and a forced draught burner

EN 303-4, Heating boilers ― Part 4: Heating boilers with forced draught burners ― Special requirements for boilers with forced draught oil burners with outputs up to 70 kW and a maximum operating pressure of 3 bar - Terminology, special requirements, testing and marking

EN 303-5, Heating boilers ― Part 5: Heating boilers for solid fuels, hand and automatically stoked, nominal heat output of up to 500 kW ― Terminology, requirements, testing and marking

EN 304, Heating boilers ― Test code for heating boilers for atomizing oil burners

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1 Scope

1.1 General

This draft European Standard applies to heating boilers up to a nominal heat output of 500 kW which are designed for the burning of solid fuels only and are operated according to the instructions of the boiler manufacturer.

Solid fuels in this standard are:

1.2 Biogenic fuels

Biomass in natural state in form of:

a) A log wood with water content w ≤ 25 %;

b) B1 chipped wood (wood chipped by machine with and without bark, usually up to a maximum length of 15 cm) water content from w 15 % to w 35 %;

c) B2 chipped wood as under B1, except w > 35 % moisture;

d) C1 compressed wood (pellets without binding agents, made of wood and/or bark particles; permitted are natural binding agents such as molasses, vegetable paraffins and starch); Pellets according to EN 14961-2 (under development);

e) C2 compressed wood (briquettes without binding agents, made of wood and/or bark particles; permitted are natural binding agents such as molasses, vegetable paraffins and starch); Briquettes according to EN 14961-3 (under development);

f) D sawdust up to w 50 % moisture;

g) E non woody biomass such as straws, reeds, kernels and grains.

1.3 Fossil fuels

a) bituminous coal;

b) brown coal;

c) coke;

d) anthracite.

1.4 Other solid fuels (e.g. peat)

The boilers can be used with natural draught or forced draught. The stoking can be manual or automatic.

This standard contains requirements and test methods for safety, combustion quality, operating characteristics and maintenance of heating boilers and covers also all external equipment that influences the safety systems (e.g. backburn safety device, integral fuel hopper).

This standard covers only boilers including burners as a unit. A matching of a boiler body with a burner according to EN 15270 is only possible if the whole unit is tested to this standard.

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The regulations of this standard apply to heating boilers which are to be tested on a boiler test stand by a third party meeting the EN ISO/IEC 17025 requirements.

Heating boilers in accordance with this standard are designed for central heating installations where heat carrier is water and whose maximum allowable temperature is 110 °C (safety temperature limiter) and which can operate at a maximum allowable operating pressure of 6 bar. For heating boilers with a built-in or attached water heater (storage or continuous flow heater) this standard only applies to those parts of the water heater which are necessarily subject to the operating conditions of the heating boiler (heating part).

The standard does not apply to:

central heating boilers and other heating appliances which are also designed for the direct heating of the place of installation;

cooking appliances;

the design and construction of external fuel storage and transportation devices prior to the safety devices of the boiler;

room sealed applications;

condensing boilers.

The purpose of this standard is to specify the necessary terminology for solid fuel heating boilers, the control and safety related requirements, the design requirement, the technical heating requirements (taking into account the environmental requirements) and testing, as well as the marking requirements.

2 Normative references

The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.

CEN/TS 14778-1, Solid biofuels — Sampling — Part 1: Methods for sampling

EN 287-1, Qualification test of welders — Fusion welding — Part 1: Steels

EN 303-1:1999, Heating boilers — Part 1: Heating boilers with forced draught burners — Terminology, general requirements, testing and marking

EN 304:1992+A1:1998+A2:2003, Heating boilers — Test code for heating boilers for atomizing oil burners

EN 1551, Safety of industrial trucks — Self propelled trucks over 10 000 kg capacity

EN 1561, Founding — Grey cast irons

EN 1563, Founding — Spheroidal graphite cast irons

EN 10025-1, Hot rolled products of structural steels — Part 1: General technical delivery conditions

EN 10027-2, Designation systems for steels — Part 2: Numerical system

EN 10028-2, Flat products made of steels for pressure purposes — Part 2: Non-alloy and alloy steels with specified elevated temperature properties

EN 10029, Hot rolled steel plates 3 mm thick or above — Tolerances on dimensions, shape and mass

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EN 10088-2, Stainless steels — Part 2: Technical delivery conditions for sheet/plate and strip of corrosion resisting steels for general purposes

EN 10120, Steel sheet and strip for welded gas cylinders

EN 10204, Metallic products — Types of inspection documents

EN 10222-2, Steel forgings for pressure purposes — Part 2: Ferritic and martensitic steels with specified elevated temperature properties

EN 12619, Stationary source emissions — Determination of the mass concentration of total gaseous organic carbon at low concentrations in flue gases — Continuous flame ionisation detector method

EN 13284-1, Stationary source emissions — Determination of low range mass concentration of dust — Part 1: Manual gravimetric method

EN 13384-1:2002+A2:2008, Chimneys — Thermal and fluid dynamic calculation methods — Part 1: Chimneys serving one appliance

EN 13501-2, Fire classification of construction products and building elements — Part 2: Classification using data from fire resistance tests, excluding ventilation services

EN 13526, Stationary source emissions — Determination of the mass concentration of total gaseous organic carbon in flue gases from solvent using processes — Continuous flame ionisation detector method

EN 14597, Temperature control devices and temperature limiters for heat generating systems

EN 14789, Stationary source emissions — Determination of volume concentration of oxygen (O2) — Reference method — Paramagnetism

EN 14792, Stationary source emissions — Determination of mass concentration of nitrogen oxides (NOx) — Reference method: Chemiluminescence

EN 14961-2, Solid biofuels — Fuel specifications and classes — Part 2: Non industrial wood pellets (under development)

EN 14961-3, Solid biofuels — Fuel specifications and classes — Part 3: Non industrial wood briquettes (under development)

EN 15058, Stationary source emissions — Determination of the mass concentration of carbon monoxide (CO) — Reference method: Non-dispersive infrared spectrometry

EN 15270, Pellet burners for small heating boilers — Definitions, requirements, testing, marking

EN 22553, Welded, brazed and soldered joints — Symbolic representation on drawings (ISO 2553:1992)

EN 60335-2-102:2006, Household and similar electrical appliances — Safety — Part 2-102: Particular requirements for gas, oil and solid-fuel burning appliances having electrical connections (IEC 61/3444/CDV) (Amendment)

EN 60730-1, Automatic electrical controls for household and similar use — Part 1: General requirements

EN 60730-2-5, Automatic electrical controls for household and similar use — Part 2-5: Particular requirements for automatic electrical burner control systems

EN 61000-6-2, Electromagnetic compatibility (EMC) — Part 6-2: Generic standards — Immunity for industrial environments (IEC 61000-6-2:2005)

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