hydraulically regulated door closerbureau of indian standards product manual on hydraulically...

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 2013. Comments, if any, may please be made in the format as given below and mailed to DLBO (MCM) at the following email 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

BUREAU OF INDIAN STANDARDS

PRODUCT MANUAL ON HYDRAULICALLY REGULATED DOOR CLOSER as per IS 3564 : 1995

PREPARED BY‐ A.K.POPLI, Sc. C, MDD‐I APPROVED BY

2 | P a g e I S S U E N O 1

DRAFT

PRODUCT MANUAL ON

HYDRAULICALLY REGULATED DOOR CLOSER

IS 3564 : 1995






MARKS DEPARTMENT DELHI‐I

0.0AMENDMENT SHEET

S NO AMENDMENT NO DATE PAGE NO CLAUSE NO





0.1FOREWORD

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.





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 11 – 13

IV CERTIFICATION CRITERIA 14 ‐ 19 V INSPECTION AND TESTING 20 – 23





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.

Table 1 Designation of Door Closers (Clause 6)

SI No. (1)

Designation of Closer (2)

Mass of the Door (3)

Width of the Door(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 60 701 to 850 Interior doors, such as of bedrooms, kitchen and store

iii) 3 61 to 80 851 to 1000 Main doors in a building, such as entrance doors

SECTION 1.2LATEST INDIAN STANDARDS WITH PRODUCT TITLE AND NUMBER OF AMENDMENTS





IS 3564 : 1995

AMENDMENTS: NIL

SECTION 1.3 LIST OF REFERRED INDIAN STANDARDS FOR RAW MATERIALS/COMPONENTS AND TEST METHODS

IS NO. Title

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)





SECTION 1.4 A‐ CHECK LIST FOR SUBMISSION OF AN APPLICATION FOR GRANT OF LICENCE

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)




10 | P a g e I S S U E N O 1

SECTION 1.4 B




11 | P a g e I S S U E N O 1

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. (1)

Component Part (2)

Suitable Material (3)

Ref to IS No. (4)

i) Non‐porous body and back plate

Cast iron/Aluminium alloy/Zinc alloy

210 : 1978/617 : 1975/742 : 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 alloy/Zinc alloy

210 : 1978/7283 : 1992/ 617 : 1975/742 : 1981

v) Packing/washers Cork sheet/Nylon/Neoprene rubber

4253 (Part 1) : 1980

vi) Control valve screw Brass/Bronze/Aluminium alloy/Steel/Zinc alloy

292 : 1983/28 : 1985/ 617 : 1975/ Grade A of 2062 : 1992/742 : 1981

vii) All weather resistant homogenous high viscosity hydraulic fluid

Hydraulic oil 3098 : 1983

viii) Adjusting arm Aluminium alloy/Steel/Zinc alloy/Forged steel

617 : 1975/7283 : 1992/ 742: 1981/1875 : 1992

ix) Main arm Aluminium alloy/Steel/Zinc alloy/Forged steel

617 : 1975/7283 : 1992/ 742: 1981/1875 : 1992

x) Clamp Cast iron/Steel/Forged steel

210 : 1978/7283 : 1992/ 1875 : 1992

xi) Concentric ratchet (For bottle type)

Steel/Aluminium alloy/Zinc alloy

7283 : 1992/617 : 1975/742 : 1981

xii) Eccentric shaft Steel 7283 : 1992

xiii) Internal bearing and gland Cast iron/Brass/Steel/with 210 : 1978/292 : 1983/




12 | P a g e I S S U E N O 1

washer made out of mineral oil resistant material

7283 : 1992

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 : 1986 210 : 1978/742 : 1981/ 617 : 1975




13 | P a g e I S S U E N O 1

MANUFACTURING PROCESS AND INPROCESS QUALITY CONTROLS

SECTION 3.1DESCRIPTION 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




14 | P a g e I S S U E N O 1

BURRING

PAINTING

PACKING

TESTING

DESPATCH




15 | P a g e I S S U E N O 1

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 per IS 3564 : 1995

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




16 | P a g e I S S U E N O 1

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.




17 | P a g e I S S U E N O 1

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 : 7.1.1 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 9.2.1 & 9.2.2. 8.0 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.




18 | P a g e I S S U E N O 1

9.0 MATERIALS – Materials to be used for main component parts of door closers are given in Table 2 of IS 3564 : 1995. 10.0 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. 11.0 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. 12.0 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. 13.0 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. 14.0 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 31st 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




19 | P a g e I S S U E N O 1

SECTION 4.3 MARKING FEE RATES

closing time 9.1 Thickness of

anodize coating (if applicable)

IS 1868:1982

One One batch/lot of bodies anodized at the same time.

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.

10 Visual Inspection B-1.2 IS

3564:1995

Each door closer

Surface B-1.3 -do- -do-

10 Performance test 8.3.1 -do- -do-

B-1.4 -do- -do-

10 Endurance test 14.3.2

B-1.5

-do- -do- Every six months

In case of failure the marking shall be stopped. Matter should then be investigated and improvements be made. From the improved lot, two more samples shall be tested and subjected to endurance test. If both samples pass, marking any be resumed.

14.3.1 Construction, finish dimensions, inter

14.3.1 -do- Each door closer




20 | P a g e I S S U E N O 1

Description Value

L S Marking Fee 34000

S S Marking Fee 29000

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 : 1995.

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)




21 | P a g e I S S U E N O 1

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/NONRETURNABLE, 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.




22 | P a g e I S S U E N O 1

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)




23 | P a g e I S S U E N O 1

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 www.bis.org.in

or click the following link http://www.bis.org.in/lab/osl_query.asp?form_is=3564 &Submit=Run+Query

List of BIS Laboratories

Lab Quantity Lab Type Testing Facility Remarks

1 Endurance Testing Door 15‐20 Sec/ operation

1

2 Oven L.C‐0. 10 C Range‐0‐3000 C

1

3 Deep Freezer L.C‐ 0.10 C Range‐ ‐10‐00 C

1

4 External Micrometer L.C‐0.01mm Range‐0‐25mm

1

5 External Micrometer L.C‐0.01mm Range‐25‐50mm

1

6 Digital Stop Watch L.C‐0.01Sec. Range‐0‐30Min.

1

7 Spring Balance L.C‐500g Range‐0‐50kg

1

8 Vernier Caliper L.C‐0.02 mm Range‐0‐200mm

1

9 Dry Wet Thermometer L.C‐ 10 C Range‐10‐500 C

1




24 | P a g e I S S U E N O 1

IS Number :- IS 3564 - 0 : 1986 NROL Mech C IS Number :- IS 3564 - 0 : 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

IS Number :- IS 3564 - DOOR CLOSURES (HYDRAULICALLY REGULATED) Sl

No. Name of the Recognized Laboratory Lab Code Testing Charges Remarks

1 Bharat Test House 454/2, 1st Floor, Timber Market, Azadpur Delhi-110033 Delhi Contact : Mr. Rajiv Gupta, CEO Tel : 011-27672629 Fax : 011-27681204

8118506 BIS TESTING CHARGES [10% discount to BIS]

2 Gujarat Test House Plot No.292, Road No.4, GIDC Kathwada Ahmedabad-382430 Gujarat Contact : Shri A.N. Barua, CEO Tel : 09825063601 Fax : 079-22168817

7109836 BIS testing charges Included w.e.f.07-Feb-2013

3 Hindustaan Test House 80-HSIIDC, 2nd Floor, Industrial Area, Ambala Cantt-133001 Haryana Contact : Ms. Rachna Nayyar, CEO Tel : 09355002828 Fax : 0171-2698089

9122136 Rs.26,000/- (20% discount for BIS on the given charges)(Except Material test ) Included w.e.f. 01-Oct-2012




25 | P a g e I S S U E N O 1

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 ‐100 C Performance test at +500 C Finish

SURVEILLANCE SAMPLES

Closing time Closing angle Performance test at ‐100 C Performance test at +500 C Finish




26 | P a g e I S S U E N O 1

RAW MATERIAL SAMPLES TO BE GOT TESTED AS PER RELEVANT ISS GIVEN IN TABLE 2 (Clause 7)

hydraulically regulated door closerbureau of indian standards product manual on hydraulically...

Documents