HYDRAULICALLY REGULATED DOOR CLOSER

Transcription

1 DRAFT PRODUCT CERTIFICATION MANUAL FOR COMMENTS Our Ref.CRO 22 / MDD-1 13 Dec 2013 Please find enclosed the following draft certification manual : HYDRAULICALLY REGULATED DOOR CLOSER Kindly examine the draft product certification manual and forward your comments on the draft manuals. Last date for comments: 30 Dec Comments, if any, may please be made in the format as given below and mailed to DLBO (MCM) at the following id: mdd1.bis 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 incase comments are lengthy and cannot be incorporated in the

2 DRAFT PRODUCT MANUAL ON HYDRAULICALLY REGULATED DOOR CLOSER IS 3564 : P age ISSUE NO 1

3 BUREAU OF INDIAN STANDARDS MARKS DEPARTMENT DELHI I 0.0 AMENDMENT SHEET S NO AMENDMENT NO DATE PAGE NO CLAUSE NO 3 P age ISSUE NO 1

4 0.1 FOREWORD Automatic door closers are being increasingly used at present in buildings. They are particularly needed in air-conditioned buildings, restaurants, hospitals and other public buildings where doors are frequently used and keeping them in closed position after usage is considered essential to reduce outside noise, to maintain inside temperature condition and privacy. Door closers are made in several designs and types; some are made to be fixed in concealed positions while others are made to function in exposed positions; some work only on spring action while others require hydraulic check to arrest motion/speed in closing the door and to avert banging. This manual covers the hydraulic door closers of exposed type which are being widely used in the country and lays down the requirements for their manufacture and performance. 4 P age ISSUE NO 1

5 0.2 TABLE OF CONTENTS SECTION CONTENT DETAIL PAGE NO. I PRODUCT DESCRIPTION 5 8 II RAW MATERIALS/COMPONENTS 9 10 III MANUFACTURING PROCESS & IN PROCESS QUALITY CONTROLS IV CERTIFICATION CRITERIA V INSPECTION AND TESTING P age ISSUE NO 1

6 PRODUCT DESCRIPTION SECTION 1.1 DESCRIPTION OF PRODUCT This standard covers the requirements for exposed type hydraulically regulated door closers for vertical hinge type doors opening to one side only and not weighing more than 80 kg. This standard does not cover the requirements for concealed type hydraulic door closers and also the pneumatic or mechanical type of door closers. Designation of Door Closers is as given in Table 1 below. SI No. (1) Designation of Closer (2) Table 1 Designation of Door Closers (Clause 6) Mass of the Door Width of the Door (3) (4) Remarks (5) i) 1 Up to 35 Up to 700 For light doors, such as double leaved and toilet doors ii) 2 36 to to 850 Interior doors, such as of bedrooms, kitchen and store iii) 3 61 to to 1000 Main doors in a building, such as entrance doors SECTION 1.2 LATEST INDIAN STANDARDS WITH PRODUCT TITLE AND NUMBER OF AMENDMENTS 6 P age ISSUE NO 1

7 IS 3564 : 1995 AMENDMENTS: NIL SECTION 1.3 LIST OF REFERRED INDIAN STANDARDS FOR RAW MATERIALS/COMPONENTS AND TEST METHODS IS NO. 28 : 1985 Phosphor bronze ingots, and castings (fourth revision) (Reaffirmed 1991) 110 : 1983 Ready mixed paint, brushing, grey filler, for enamels for use over primers (first revision) (Reaffirmed 1991) 210 : 1978 Grey iron castings (third revision) (Amendments 2 (Reaffirmed 1991) 292 : 1983 Leaded brass ingots and castings (second revision) (Amendment 1) (Reaffirmed 1988) 513 : 1994 Cold rolled low carbon steel sheets and strips (fourth revision) (Reaffirmed 1992) 617 : 1975 Aluminium and aluminium alloy ingots and casting for general engineering purposes (Second revision) (Amendments 3) (Reaffirmed 1991) 737 : 1986 Wrought aluminium and aluminium alloy sheet and strip for general engineering purposes (third revision) (Reaffirmed 1991) 742 : 1981 Zinc base alloy die castings (second revision) (Reaffirmed 1993) 1868 : 1982 Anodic coatings on aluminium and its alloys (second revision) (Reaffirmed 1991) 1875 : 1992 Carbon steel billets, blooms, slabs and bars for forgoing (fifth revision) (Amendment 1) 2062 : 1992 Steel for general structural purposes (fourth revision) (Supersedes IS 226 : 1975) 2507 : 1975 Cold rolled steel strips for springs (first revision) (Amendments 2) (Reaffirmed 1992) 3098 : 1983 Specification for oil, hydraulic, mineral oil type (second revision) (Reaffirmed 1988) 3618 : 1966 Phosphate treatment of iron and steel for protection against corrosion (Reaffirmed 1991) 4253 (Part 1) : 1980 Cork composition sheets : Part 1 Plain cork (Amendments 2) (reaffirmed 1989) Title 7 P age ISSUE NO 1

8 4454 (Part 2) : 1975 Steel wires for could formed springs: Part 2 oil hardened and tempered springs steel wire and value spring wire unalloyed (first revision). (Amendment 1) (Reaffirmed 1992) 4905 : 1968 Method for random sampling. (Amendment 1) ( Reaffirmed 1991) 7283 :1992 Hot rolled bars foe production of bright bars and machined parts for engineering applications (first revision) SECTION 1.4 A CHECK LIST FOR SUBMISSION OF AN APPLICATION FOR GRANT OF LICENCE 8 P age ISSUE NO 1

9 9 P age ISSUE NO 1

10 SECTION 1.4 B 10 P age ISSUE NO 1

11 RAW MATERIALS/ COMPONENTS SECTION 2.1 LIST OF IMPORTATNT RAW MATERIALS/COMPONENTS INCLUDING THOSE WHICH ARE REQUIRED TO CONFORM TO RELEVANT INDIAN STANDARDS The materials used for the manufacture of different component parts shall conform to the requirements given in Table 2 below. Table 2 Materials for Component Parts of Hydraulically Regulated Door Closer (Clause 7) SI No. Component Part Suitable Material Ref to IS No. (1) (2) (3) (4) i) Non porous body and back Cast iron/aluminium 210 : 1978/617 : 1975/742 plate alloy/zinc alloy : 1981 ii) Torsion spring helical spring Steel 4454 (part 2) : 1975/ 2507 : 1975 iii) Nuts Cast iron/steel/brass 210 : 1978/7283 : 1992/292 : 1983 iv) Piston or Rack piston/pinion Cast iron/ Steel/Aluminium 210 : 1978/7283 : 1992/ alloy/zinc alloy 617 : 1975/742 : 1981 v) Packing/washers Cork 4253 (Part 1) : 1980 sheet/nylon/neoprene rubber vi) Control valve screw Brass/Bronze/Aluminium 292 : 1983/28 : 1985/ alloy/steel/zinc alloy 617 : 1975/ Grade A of 2062 : 1992/742 : 1981 vii) All weather resistant Hydraulic oil 3098 : 1983 homogenous high viscosity hydraulic fluid viii) Adjusting arm Aluminium alloy/steel/zinc 617 : 1975/7283 : 1992/ alloy/forged steel 742: 1981/1875 : 1992 ix) Main arm Aluminium alloy/steel/zinc 617 : 1975/7283 : 1992/ alloy/forged steel 742: 1981/1875 : 1992 x) Clamp Cast iron/steel/forged 210 : 1978/7283 : 1992/ steel 1875 : 1992 xi) Concentric ratchet (For bottle Steel/Aluminium alloy/zinc 7283 : 1992/617 : type) alloy 1975/742 : 1981 xii) Eccentric shaft Steel 7283 : 1992 xiii) Internal bearing and gland Cast iron/brass/steel/with 210 : 1978/292 : 1983/ 11 Page ISSUE NO 1

12 washer made out of 7283 : 1992 mineral oil resistant material xiv) Main arm bolt Steel 7283 : 1992 xv) Top nut Steel 7283 : 1992 xvi) Pawl Steel/Brass 7283 : 1992/292 : 1983 xvii) Top lid Steel sheet/aluminium alloy sheet/cast iron/zinc alloy/aluminium alloy 513 : 1994/737 : : 1978/742 : 1981/ 617 : P age ISSUE NO 1

13 MANUFACTURING PROCESS AND IN PROCESS QUALITY CONTROLS SECTION 3.1 DESCRIPTION OF MANUFACTURING PROCESS(ES) (TYPICAL) MANUFACTURING FLOW CHART FOR Hydraulically Regulated Door Closer RAW MATERIAL (ALUMINIUM/CAST IRON SECTION) CUTTING MILLING LATHE PROCESSING BROACH WORK DRILLING WASHING FITTING 13 P age ISSUE NO 1

14 BURRING PAINTING PACKING TESTING DESPATCH 14 P age ISSUE NO 1

15 DESCRIPTION OF MANUFACTURING PROCESSES & QUALITY CONTROL The raw material (Aluminium/Cast Iron section) is cut as per requirement and then milling is done. After milling material is processed on lathe as per drawing. Then broach work is done. After broaching drilling of holes is done. Then material is washed and fitted. Next burring is done followed by painting. The final product is packed and tested as per STI before despatch. SECTION 3.2 INFRASTRUCTURE FOR PRODUCTION Following infrastructure is generally required for production of HYDRAULICALLY REGULATED DOOR CLOSER as List Of Machinery SI. No. Machinery Make Capacity Number Remarks 1 Lathe Machine KALSI 4.5 Feet 4 2 Broach machine SATKAR 9 Feet 1 3 Broach Machine SATKAR 4.5 Feet 1 4 Cutting machine JASWANT 1 Feet 1 5 Milling Machine KALSI 2.5 Feet 1 6 Lathe Machine MATCHLESS 4 Feet 1 7 Drill Machine MATCHLESS 2 Feet 1 8 Lathe Machine MATCHLESS 2.5 Feet 1 9 Painting Spray M/C LOCAL 1 10 Buffing M/C LOCAL 2 Note: Adequate Electric Power and Water supply is required 15 P age ISSUE NO 1

16 CERTIFICATION CRITERIA SECTION 4.1 CRITICAL REQUIREMENTS OF THE INDIAN STANDARD To be provided by CMD SECTION 4.2 SCHEME OF TESTING AND INSPECTION DOC : STI/3564/6 Oct : 1997 SCHEME OF TESTING AND INSEPCTION FOR CERTIFICATION OF HYDRAULICALLY REGULATED DOOR CLOSERS ACCORDING TO IS 3564 : 1995 (Fourth Revision) 1.0 LABORATRY A laboratory shall be maintained which shall be suitably equipped and staffed, where different tests given in the specification shall be carried out in accordance with the methods given in the specification. 1.1 All testing apparatus shall be periodically checked and calibrated and records of such checks/calibration shall be maintained. 2.0 TEST RECORDS All records of tests and inspection shall be kept in suitable form approved by the Bureau. 2.1 Copied of any records and other connected papers that may be required by the Bureau shall be made available at any time on request. 16 P age ISSUE NO 1

17 3.0 QUALITY CONTROL It is recommended that, as far as possible, Satisfaction Quality Control (SQC) methods may be used for controlling the quality of the product during production as envisaged in this Scheme [See IS 397 (Part I) : 1972, IS 397 (Part 2) : 1985 and IS 397 (part 3 ) : 1980]. 3.1 In addition, effort should be made to gradually introduce a Quality Management System in accordance with the Quality System Modules as per IS/ISO 9001 or IS/ISO 9002 or IS/ISO 9003 as appropriate to the activities of the organization. 4.0 STANDARD MARK The door closer shall carry the Standard Mark as Given in Column (1) of the First Schedule of the licence, in the form of paper labels or transfix labels or the Standard door closer to which the Mark is thus applied conforms to every requirement of the specification. 5.0 MARKING In addition each door closer shall be marked with following information : a) Manufacturer s name or trade mark : b) Brand name, if any : c) Right closer, left closer or universal closer or R L or U respectively, whichever is applicable; d) Size / designation of the door closer : e) Type of the closer, f) Serial number : g) Made in India, if required and h) Licence No. (CM/L No..) 6.0 PACKING The door closer shall be packed in individual cardboard/wooden boxes, with reinforcing board or straw to prevent damage to painting, Packing shall be of such type and quality that it prevents ingress of the moisture during storage. It shall be ensured that every door closer is accompanied with (a) one fitting key or a suitable spanner for adjusting the spring valve and regulating screw (b) leaflet furnishing instruction for adjustment of regulating screw as per Note below Clause 8.3 of Specification. 7.0 LEVELS OF CONTROL The tests and inspection as indicated in Table 1 attached and the levels of control specified therein, covered by this scheme and appropriate records & charts production which conforms to the Indian Standard and covered by this licence shall be marked with BIS Certification Mark. 7.1 On the basis of test results, the decision regarding conformity or otherwise of door closer to the requirements shall be made as follows : Every door closer shall be examined for construction, finish, dimensions, interchangeability of parts and tested for performance. Those found defective shall be suitably rectified, shall again be tested for all the above tests. 7.2 The door closer shall meet the requirements of clause 8 of the specification and tested to check any sign of leakage, closing time / performance at the specified temperatures. 7.3 Mild steel parts shall be given the treatment as given in clause & In respect of all other clauses of the specification and at all stages of manufacture, the factory shall maintain appropriate controls and checks to ensure that their product conforms to the requirements of these clauses. 17 P age ISSUE NO 1

18 9.0 MATERIALS Materials to be used for main component parts of door closers are given in Table 2 of IS 3564 : REJECTIONS A separate record shall be maintained given information relating to the rejection of the production not conforming to the requirements of the specification and the method of its disposal. Such material shall in no case be stored together with that conforming to the specification SAMPLES The licensee shall supply, free of charge, the samples required in accordance with the Bureau of Indian Standards (Certification) Regulations, 1988, as subsequently amended, from the factory or godowns. The Bureau shall pay for the samples taken by it from the open market REPLACEMENT Whenever a complaint is received soon after the goods with Standard Marks have been purchased and used, and if there is adequate evidence that the goods have not been misused, defective goods or their components are replaced or repaired three of cost by the licensee in case the complaint is repaired free of cost by the licensee in case the complaint is proved to be genuine and the warranty to judge the conformity of the product to the Indian standard shall be with the Bureau STOP MARKING The marking of the product shall be stopped under intimation to the Bureau if, at any time, there is some difficulty in maintaining the conformity of their product to the specification, or the testing equipment goes out of order. The markings may be resumed as soon as the defects are removed under intimation to Bureau. The marking of the product shall be stopped immediately if directed to do so by Bureau for any reason. The marking may then be resumed only after permission by the Bureau. The information regarding resumption of marking shall also be sent to the Bureau PRODUCTION DATA The licensee shall maintain production data as per enclosed Performa 1, which may be authenticated by a Chartered Accountant or by the licensee by giving affidavit (which may be required along with renewal application). The licensee shall sent to the Bureau as per the enclosed, Performa 2 and Performa 3 a statement of quantity produced, marked and exported by him and the trade value thereof during the half year ending 3 0 June and 31 December. This statement is required to be forwarded to the Bureau on or before 31 st day of July and January for the preceding half year IS 3564: 1995 HYDRAULICALLY REGULATED DOOR CLOSERS TABLE 1 LEVELS OF CONTROL (Para 7 of the Scheme of Testing and Inspection) TEST DETAILS LEVELS OF CONTROL Test Method No. of Samples Frequency Remarks Clause Requirements Clause Reference 8.2 Device for adjusting the speed and 8.2 IS 3564:1995 Each door closer 18 P age ISSUE NO 1

19 closing time 9.1 Thickness of anodize coating (if applicable) IS 1868: Visual Inspection B-1.2 IS 3564:1995 One Surface B-1.3 -do- -do- 10 Performance test do- -do- 10 Endurance test B-1.5 B-1.4 -do- -do- Each door closer One batch/lot of bodies anodized at the same time. -do- -do- Every six months In case the sample fails, two more samples shall be tested and if both pass, the lot say be considered as conforming to specification : other wise, it shall be rejected. In case of failure the marking shall be stopped. Matter should then be investigated and improvements be made Construction, finish dimensions, inter do- Each door closer From the improved lot, two more samples shall be tested and subjected to endurance test. If both samples pass, marking any be resumed. SECTION 4.3 MARKING FEE RATES 19 P age ISSUE NO 1

20 Description Value L S Marking Fee S S Marking Fee Unit 1 Piece Rate of one unit Rs. 2.6 SECTION 4.4 GROUPING GUIDELINES: NIL. SECTION 4.5 GUIDELINES FOR WRITING SCOPE OF LICENCE The scope of licence shall include Name of the product; Type as per clause 4; Material as per clause 7 and Designation as per Table 1 of IS 3564 : SECTION 4.6 GUIDELINES FOR INCLUSION OF NEW VARIETIES NIL. SECTION 4.7 SAMPLE SIZE Product One sample comprising of one number of HYDRAULICALLY REGULATED DOOR CLOSER SECTION 4.8 MANNER OF SEALING OF SAMPLE(S) 20 P age ISSUE NO 1

21 Samples may be wrapped with suitable packing material, labeled and wax sealed or as an alternate code no and signatures of IO may be marked with a permanent marker pen on the product. SECTION 4.9 REMNANTS ARE RETURNABLE/NON RETURNABLE, TO BE SCRAPPED/USED OR TO BE DESHAPED BEFORE DISPOSAL IN CASE OFSAFETY ITEMS Sample is normally consumed in testing and Remnants are not returnable and may be suitably disposed off by the laboratory. SECTION 4.10 PROCEDURE TO BE FOLLOWED FOR DESTROYING/DESHAPING/RECYCLING THE PRODUCT THAT DOES NOT MEET THE QUALITY PARAMETERS DURING REGULAR PRODUCTION BIS Standard Mark to be marked only after ascertaining the quality of the material after testing as per Indian standard and STI. 21 P age ISSUE NO 1

22 INSPECTION AND TESTING SECTION 5.1 PACKING MATERIAL REQUIRED FOR PACKING/DISPATCH OF SAMPLES Any suitable material may be used for wrapping the sample to avoid any damage during transit. SECTION 5.2 LIST OF REQUIRED TEST EQUIPMENT/FACILITIES WITH REQUIREMENT & FREQUENCY OF CALIBRATION To be provided by CL. However, tentative list is given below. SI. No. Test Equipment/Chemicals And Identification Number (Where Applicable) Least Count & Range (Where applicable) Valid Calibration (Where required) Yes/No Test Used In with Clause Reference Remarks (Indicate Number Of Equipment) 22 P age ISSUE NO 1

23 1 Endurance Testing Door Sec/ operation 2 Oven L.C C Range C 3 Deep Freezer L.C C Range C 4 External Micrometer L.C 0.01mm Range 0 25mm 5 External Micrometer L.C 0.01mm Range 25 50mm 6 Digital Stop Watch L.C 0.01Sec. Range 0 30Min. 7 Spring Balance L.C 500g Range 0 50kg 8 Vernier Caliper L.C 0.02 mm Range 0 200mm 9 Dry Wet Thermometer L.C 1 0 C Range C SECTION 5.3 STATUS OF TEST FACILITIES IN BIS LAB AND OSLs WITH TESTING CHARGES AND APPROXIMATE TIME REQUIRED FOR TESTING BY BIS LABs/OSLs For latest information, please check the BIS web site or click the following link &Submit=Run+Query List of BIS Laboratories Lab Quantity Lab Type Testing Facility Remarks 23 P age ISSUE NO 1

24 IS Number :- IS : 1986 NROL Mech C IS Number :- IS : 1995 CL Mech C IS No. Testing Charges Remarks IS 3564 : 1995 Rs 2900/- Testing Facility:: C=Complete Test facility / P=Partial Test Facility/ N=No Test Facility List of Outside Recognized Laboratories Sl No. 1 Bharat Test House 454/2, 1st Floor, Timber Market, Azadpur Delhi Delhi Contact : Mr. Rajiv Gupta, CEO Tel : Fax : IS Number :- IS DOOR CLOSURES (HYDRAULICALLY REGULATED) Name of the Recognized Laboratory Lab Code Testing Charges Remarks 2 Gujarat Test House Plot No.292, Road No.4, GIDC Kathwada Ahmedabad Gujarat Contact : Shri A.N. Barua, CEO Tel : Fax : Hindustaan Test House 80-HSIIDC, 2nd Floor, Industrial Area, Ambala Cantt Haryana Contact : Ms. Rachna Nayyar, CEO Tel : Fax : BIS TESTING CHARGES [10% discount to BIS] BIS testing charges Included w.e.f.07-feb Rs.26,000/- (20% discount for BIS on the given charges)(except Material test ) Included w.e.f. 01-Oct P age ISSUE NO 1

25 SECTION 5.4 WHETHER GRANT OF LICENCE WILL BE BASED ON: FACTORY TESTING BASIS No INDEPENDENT TESTING BASIS Yes MIXED(FACTORY TESTING BASIS PLUS INDEPENDENT TESTING OF SOME RAW MATERIALS) No SECTION 5.5 DETAILS OF TESTS TO BE CARRIED OUT IN FACTORY IN CASE OF: APPLICANT SAMPLES/VERIFICATION SAMPLES Closing time Closing angle Performance test at 10 0 C Performance test at C Finish SURVEILLANCE SAMPLES Closing time Closing angle Performance test at 10 0 C Performance test at C Finish 25 P age ISSUE NO 1

26 RAW MATERIAL SAMPLES TO BE GOT TESTED AS PER RELEVANT ISS GIVEN IN TABLE 2 (Clause 7) 26 P age ISSUE NO 1