BRITISH STANDARD BS 5978-1:

1989

Safety and performance

of gas-fired hot water
boilers (60 kW to 2 MW
input) —
Part 1: Specification for general
requirements

UDC 697.326 – 62:614.8

BS 5978-1:1989

Committees responsible for this

British Standard

The preparation of this British Standard was entrusted by the Gas Standards
Policy Committee (GSE/-) to Technical Committee GSE/28 upon which the
following bodies were represented:

Associated Offices Technical Committee

Boiler and Radiator Manufacturers’ Association Ltd.
British Combustion Equipment Manufacturers’ Association
British Gas plc
Chartered Institution of Building Services Engineers
Department of Energy (Energy Efficiency Office)
Department of the Environment (PSA)
Health and Safety Executive
Institution of Gas Engineers
Liquefied Petroleum Gas Industry Technical Association (UK)
Loss Prevention Council
Society of British Gas Industries

This British Standard, having

been prepared under the
direction of the Gas Standards
Policy Committee, was
published under the authority
of the Board of BSI and
comes into effect on
31 August 1989

© BSI 06-1999

First published September 1983

New edition
Amendments issued since publication

Amd. No. Date of issue Comments

The following BSI references
relate to the work on this
standard:
Committee reference GSE/28
Drafts for comment 76/75448 DC
85/75811 DC
88/70995 DC

ISBN 0 580 17517 0

 BS 5978-1:1989

Contents

Page
Committees responsible Inside front cover
Foreword ii
1 Scope 1
2 Definitions 1
3 Additional requirements for boilers 1
4 Electrical requirements 1
5 General conditions of test 1
6 Design and construction 2
7 Flue system 4
8 Flue dampers 4
9 Combustion air inlet dampers 5
10 Gas soundness of burner train 5
11 Temperature 5
12 Heat input 6
13 Combustion 6
14 Manual gas valves 7
15 Controls 7
16 Electricity supply 8
17 Manufacturer’s instructions 8
18 Identification and marking 9
19 Thermal efficiency 9
Figure 1 — Paint scratch test apparatus 11
Table 1 — Surface temperature rise 5
Table 2 — Permissible temperature rise for windings 6
Publications referred to 12

© BSI 06-1999 i
BS 5978-1:1989

Foreword

This Part of BS 5978 has been prepared under the direction of the Gas Standards
Policy Committee and it replaces BS 5978-1:1983, which is withdrawn.
This edition introduces technical changes to bring the standard up to date, by
including alterations made by Amendment No. 1 to the 1983 edition and further
technical changes to clauses 3, 6, 13 and 19. It does not reflect a full review of the
standard, which will be undertaken in due course.
Account has been taken by the committee of experience and current practice, both
national and international, in the preparation of this Part of BS 5978.
The constructional requirements for the boilers are specified in BS 779, BS 855
and BS 2790 and test methods used for the determination of boiler thermal
performance are described in DD 65-11).
BS 5978 is published in three Parts as follows:
— Part 1: Specification for general requirements;
— Part 2: Specification for additional requirements for boilers with
atmospheric burners;
— Part 3: Specification for additional requirements for boilers with forced or
induced draught burners.
A British Standard does not purport to include all the necessary provisions of a
contract. Users of British Standards are responsible for their correct application.

Compliance with a British Standard does not of itself confer immunity

from legal obligations.

Summary of pages
This document comprises a front cover, an inside front cover, pages i and ii,
pages 1 to 12, an inside back cover and a back cover.
This standard has been updated (see copyright date) and may have had
amendments incorporated. This will be indicated in the amendment table on the
inside front cover.

1) Under revision.

ii © BSI 06-1999

1 Scope
This Part of BS 5978 specifies general
requirements, including performance and safety
requirements and methods of test, for gas-fired hot
water boilers operating at internal pressures up
to 4.5 bar2) and having heat inputs from 60 kW up
to 2 MW inclusive, calculated on the gross calorific
value.
NOTE Electrical requirements are given in BS 5986.
This Part of BS 5978 applies to cast iron and steel
boilers constructed in compliance with BS 779,
BS 855 or BS 2790 as appropriate. The
requirements of this Part of BS 5978, in respect of
safety and performance, also apply to boilers
constructed of other materials and for which there
are no constructional standards.
This Part of BS 5978 applies to boilers designed for
use with open flues but does not apply to boilers
designed for use with room-sealed and balanced flue
systems.
This Part of BS 5978 also applies to boilers designed
for use on normal low-pressure district supplies
of 2nd and 3rd family gases.
NOTE The titles of the publications referred to in this Part of
BS 5978 are listed on the inside back cover.
2 Definitions
For the purposes of this Part of BS 5978 the
following definitions, together with those given in
BS 1179 and BS 1179-6, apply.
2.1
lock-out
the safety shut-down condition of a control system
such that restart cannot be accomplished without
manual reset
2.2
overheat control (limit control)
a temperature-actuated device which is preset and
sealed, and designed to protect the boiler and its
surroundings in the event of failure of the water
temperature control
2.3
safety shut-down
the action of shutting off all fuel and ignition energy
by means of a safety control such that restart cannot
be accomplished without either manual reset or an
automatic recycle
2) 1 bar = 105 N/m2 = 100 kPa.
© BSI 06-1999
BS 5978-1:1989
2.4
water temperature control
a temperature-actuated control intended to
maintain the temperature of the water within the
boiler between specified limits
NOTE This is the normal means of boiler water temperature
control and should not be confused with the overheat control
defined in 2.2.
2.5
automatic burner system
a burner system in which, when starting from the
completely shut-down condition, the start-gas flame
is established and the main gas valve(s) is/are
actuated by the control without manual
intervention
NOTE Automatic burners may have pilots which are either
interrupted or intermittent.
2.6 non-automatic burner system
a burner system which is not automatic within the
meaning of 2.5, i.e. a burner with a permanent pilot
ignited under manual supervision
3 Additional requirements for boilers
In addition to complying with this Part of BS 5978,
the boiler shall comply with either BS 5978-2 or
BS 5978-3, whichever is appropriate to the boiler
design.
4 Electrical requirements
Boilers shall comply with BS 5986.
5 General conditions of test
5.1 Test facilities. The test room shall be
adequately ventilated but free from draughts that
are likely to affect the performance of the boiler.
The air in the test room shall not contain more
than 1 000 p.p.m. of carbon dioxide or 10 p.p.m. of
carbon monoxide.
The temperature in the test room shall be
maintained at 20 ± 50 °C.
NOTE Appropriate test rigs are described in DD 65-1 and
DD 65-2.
1
BS 5978-1:1989
5.2 Preparation of boiler for testing
5.2.1 The boiler shall be set up in accordance with
the manufacturer’s instructions as relevant to the
test and with particular reference to minimum
declared clearances round the boiler. It shall then be
adjusted in accordance with the manufacturer’s
instructions, using the appropriate reference test
gas at an inlet pressure of 17.5 mbar for 2nd family
gases (NGA), with 28 mbar for butane (LPGA)
and 37 mbar for propane (LPGC) for 3rd family
gases.
5.2.2 Before any tests are made, the boiler shall be
operated for a period sufficient to dry any insulation
and remove any temporary finish that might
interfere with observations.
5.2.3 Unless the test method specifically requires
otherwise, boilers with a vertical flue outlet shall be
fitted with the minimum length of vertical
secondary flue specified by the manufacturer and
having the same nominal diameter as the flue
outlet. In the absence of a manufacturer’s
specification a 1 m length of flue shall be used for
these tests.
Boilers with a horizontal flue outlet shall be fitted in
accordance with the manufacturer’s instructions
which shall state the maximum length of horizontal
run and method of adaptation to a vertical flue.
Thereafter the vertical flue shall be fitted as above.
5.3 Test procedure. The boiler, including the
fuel-carrying parts, shall be examined for soundness
before and after completion of the tests specified in
accordance with Parts 2 and 3 of this standard as
appropriate. The test results shall be deemed
invalid unless the system is sound.
During testing the initial adjustment of the boiler
shall not be altered unless specifically required by
the test method.
Precautions shall be taken to prevent thermostats
or other variable controls from acting so as to
interfere with the fuel flow, except as necessitated
by the test.
Unless the test method specifies otherwise, tests
shall be carried out using the appropriate test gas.
For boilers using 3rd family gases, test gases LPGA
and LPGB shall be used with the boiler adjusted for
butane, and test gases LPGC and LPGE shall be
used with the boiler adjusted for propane.
NOTE 1 Tables indicating the test gases (taken from BS 4947)
to be used for each of the gas families and, where appropriate,
their conditions of application, are shown in the relevant clauses
of BS 5978-2 and BS 5978-3.
Gas test pressures shall be accurate to
within ± 0.2 mbar and controlled so that the
variation does not exceed ± 0.2 mbar.
2 © BSI 06-1999
NOTE 2 In general, except for tests involving governor
performance, the boiler governor may be put out of action and the
specified test pressure obtained by adjustment of the gas
pressure at the inlet to the boiler.
The heat input to the boiler shall be determined as
specified in BS 4947.
6 Design and construction
6.1 Design and construction
6.1.1 Boiler design. The boiler manufacturer shall
specify whether or not the boiler is designed to
operate in the condensing mode.
Where the boiler is not designed to operate in the
condensing mode, the manufacturer shall specify
the minimum return water temperature for which
the boiler is suitable.
6.1.2 Boiler construction. A cast iron or steel boiler
shall comply with BS 779, BS 855 or BS 2790 as
appropriate.
6.2 Component location. Parts that are intended
to be removable for maintenance or for cleaning
shall be readily accessible, shall be easy to assemble
correctly and impossible to assemble incorrectly
where incorrect assembly would create a hazard for
the user or result in damage to the appliance and its
controls.
The burner(s) shall be positively located and so
arranged that misalignment cannot occur.
It shall not be possible to loosen complete burner
assemblies, jets or injectors without the use of tools.
6.3 Materials in contact with gas
6.3.1 Copper tubing. Copper tubing shall not be used
where it is likely to be exposed to temperatures
above 100 °C.
6.3.2 Jointing compounds. Jointing compounds
shall comply with the relevant requirements of
BS 5292.
6.3.3 Solder. Solder having a melting point
below 450 °C after application shall not be used for
gas-carrying parts.
6.4 Insulation. Thermal or acoustic insulation
shall be non-combustible within the requirements of
BS 476-4, shall be securely located and shall be
protected against mechanical damage, condensate
and vermin.
Gas-carrying parts in contact with, or passing
through, insulating material shall be adequately
protected against possible corrosive effects of the
insulant.
6.5 Gas connections. Gas inlet connections shall
be suitable for connection to one of the following:
a) tapered thread installation pipes in accordance
with BS 21;

b) flanged pipes and fittings in accordance with
BS 4504-1 and BS 4504-2 or BS 10.
6.6 Unions and flanges. Unions in fuel lines shall
be of the cone or spherical-seated type. Flange joints
shall include a gasket or “O” ring seal resistant to
the action of components of the gas and suitable for
the temperature to which it is likely to be exposed.
6.7 Injectors and jets. Injector and jet orifice areas
shall be non-adjustable.
6.8 Bolts and screws. Drillings for bolts and
screws shall not connect with fuel or water-carrying
parts.
The use of self-tapping screws is not recommended
but where they are used to secure components
which are moved during servicing, they shall be
fitted with spring steel fasteners.
6.9 Viewing ports. Adequate means such as
viewing ports shall be provided to allow observation
of pilot, if any, and burner flames.
6.10 Servicing. The boiler shall be fitted with
access doors or removable panels to facilitate
servicing, e.g. of heat exchange surfaces. Means
shall be provided to permit ready removal of the
burner assembly for servicing, if necessary.
6.11 Facility for remote control. The
manufacturer shall provide information to enable
the boiler to be controlled remotely, e.g. by means of
thermostat(s) and a time control.
6.12 Circulating pumps. Where a circulating
pump forms an integral part of the boiler and is
rated up to 2 kW, it shall comply with BS 1394-1
and BS 1394-2 as appropriate. In addition the
following requirements apply.
a) All information markings on the pump shall be
visible without extensive dismantling of the
pump being necessary.
b) The pump shall be orientated within the limits
specified by the pump manufacturer.
c) Any emergency freeing device shall be readily
accessible.
d) There shall be union or flange connections on
either side of the pump to facilitate maintenance
or exchange and adequate means for locating any
union washers.
e) A stop valve shall be fitted on each side of the
pump for complete isolation purposes.
© BSI 06-1999
BS 5978-1:1989
6.13 Materials, fittings and finishes
6.13.1 General. Materials, fittings and finishes, the
failure of which might affect the safe operation of
the boiler, shall comply with the requirements of the
relevant British Standards and shall be appropriate
to the conditions arising in the part of the boiler in
which they are used. The boiler and its associated
parts shall be free from swarf, grit or other foreign
matter.
6.13.2 Galvanized parts. Galvanized parts shall
comply with BS 729, BS 1706, BS 2989, or BS 4921
as appropriate.
6.13.3 Painted and plastics coated parts. Painted or
plastics coated surfaces shall comply with the
following requirements.
a) Resistance to heating. There shall be no
significant change of colour on any part of the
boiler and the finish shall not become tacky or
show other signs of deterioration at the end of the
operation referred to in 5.2.2. This requirement
shall not apply to parts that come into direct
contact with the flame.
b) Resistance to abrasion. Surfaces subject to
abrasion, e.g. the outer casing(s), shall be tested
for resistance to scratching as described in the
method below. The hardness shall be such that
the protective film is not penetrated. The scratch
shall not have a width greater than 1 mm at any
point along its length.
Method. Apply the apparatus (see Figure 1) to
the surface under test and move the ball, after
loading with a force of 10 N, at 30 mm/s
to 40 mm/s relative to the surface. If the
indicator lamp lights, the surface shall be
deemed to have been penetrated.
A metallic paint applied directly to the surface
will show a light without penetration and, in this
case, the paint surface should be visually
examined for penetration. Clean the ball after
each test and inspect it frequently to verify that
it remains a 1 mm sphere.
6.13.4 Plated parts. Electroplated metal parts shall
have a standard of adhesion and resistance to
corrosion equivalent to the requirements of BS 1224
for service condition number 2.
6.13.5 Other finishes. Where finishes other than
those referred to above are employed and where an
appropriate British Standard exists, the finish shall
satisfy its requirements.
6.13.6 Plastics parts. Where any plastics component
is in contact with combustion gases, the failure by
overheating of such components shall cause lockout.
Alternatively, the boiler shall incorporate a device
specifically intended to prevent overheating of the
plastics material.
3
BS 5978-1:1989
This device shall cause the boiler to go to lockout
before the plastics material reaches a temperature
likely to cause its degradation. The design of the
device shall be such that, after it has operated, the
attention of a service engineer or other competent
person is required before the boiler can be put back
into service.
NOTE The use of a tool to gain access to the device is deemed to
satisfy this requirement.
6.14 Formation and disposal of condensate
6.14.1 Condensing boilers. Boilers that are specified
by the manufacturer to be designed to operate in the
condensing mode shall be provided with means for
the collection and disposal of condensate.
NOTE Surfaces in contact with condensate, apart from purpose
designed sumps, siphons and water traps, should be so designed
as to avoid the retention of condensate.
The condensate discharge system incorporated in
the boiler shall comply with the following
requirements.
a) It shall be so designed that it cannot transmit
combustion products to the room where the boiler
is installed, or permit the ingress of air.
b) It shall be capable of being cleaned.
c) It shall be designed so as to inhibit blockage.
d) The size of the discharge pipe shall be
appropriate to the boiler rating but shall have a
minimum internal diameter of 15 mm.
With the incorporated condensate discharge system
blocked at its outlet and with the boiler operating at
its maximum heat input on the appropriate
reference test gas, and with a nominal return water
temperature of 40 °C, the ratio of carbon monoxide
to carbon dioxide in the products of combustion shall
not exceed 0.02.
This requirement shall be deemed to be complied
with if the boiler proceeds to safety shut-down
before the CO/CO2 ratio reaches 0.02.
During this test there shall be no spillage of
condensate from the appliance and condensate shall
only come into contact with parts of the boiler that
are protected against corrosion.
6.14.2 Non-condensing boilers. Boilers that are
specified by the manufacturer to be designed to
operate in the non-condensing mode, and which are
suitable for use with return water temperatures
below 50 °C, shall not give rise to condensation in
the combustion chamber and associated flueways
when operated at thermal equilibrium at the lowest
return water temperature specified in the
manufacturer’s instructions.
Where a boiler incorporates a condensate discharge
system, e.g. to dispose of condensate arising at
start-up, 6.14.1 shall be complied with.
4 © BSI 06-1999
6.15 Electric motors. Motors shall comply with
BS 5000-11 or BS 5000-99 as appropriate.
6.16 Flexible pipes. Flexible pipes shall be metal
armoured and have screwed or flanged connections.
They shall withstand at least three times the
working pressure with a minimum of 3.5 bar at both
maximum and minimum service temperatures.
There shall be electrical continuity across flexible
pipes. A manual isolating valve shall be placed in a
readily accessible position upstream of the inlet of
any section of flexible pipe.
7 Flue system
7.1 The boiler shall be designed so as to prevent the
escape of combustion products other than to the
flue.
7.2 Where the flue outlet of the boiler is circular in
cross section it shall be suitable for connection to
flue pipes complying with BS 715 or BS 835 as
appropriate.
8 Flue dampers
8.1 General. Where a flue damper is fitted, it shall
be of the automatic type and shall comply with 8.2
and 8.3.
Where such an automatic flue damper is fitted on a
boiler equipped with a permanent pilot the damper
blade shall have a purpose designed opening
equivalent to at least 5 % of the cross-sectional area
of the flue.
8.2 Damper blades and spindles. The damper
blade shall not be able to move relative to its
spindle.
8.3 Provision of interlocks
8.3.1 Where a flue damper is fitted it shall comply
with 8.3.2 and 8.3.3 or 8.3.4 as appropriate.
8.3.2 Any flue damper shall be provided with an
interlock to prove that the damper has reached the
fully open position before the boiler ignition
sequence is initiated.
Failure of the interlock to prove that the damper is
in the correct position prior to start-up shall prevent
start-up.
8.3.3 Any non-modulating flue damper shall be
provided with an interlock, which may be the same
as that specified in 8.3.2, to prove that the damper
is fully open throughout the burner operating
period.
Failure of the interlock to prove that the damper is
fully open during burner operation shall cause
safety shut-down.

8.3.4 Any modulating flue damper shall be provided
with an interlock, additional to that specified
in 8.3.2, to prove that the damper is in at least the
minimum open position consistent with the normal
operation of the burner at its lowest rated heat
input.
Failure of the interlock to prove that the damper is
in at least its minimum open position during normal
operation of the boiler at its lowest rated heat input
shall cause safety shut-down.
8.4 Safe-start check facility. The interlocks
required by 8.3.2, 8.3.3 and 8.3.4 shall, in addition,
be provided with a safe-start check facility to prove
that the interlocks are each in their correct position
prior to the damper being opened. The safe-start
check facility shall prevent opening of the damper if
the interlocks are in an incorrect position.
9 Combustion air inlet dampers
Where a combustion air inlet damper is fitted it
shall be of the automatic type.
10 Gas soundness of burner train
10.1 General. All gas-carrying parts of the burner
train shall be sound, and when connected shall form
a complete assembly which is sound. The basic test,
as specified in 10.2, shall be carried out on the
complete assembly.
10.2 Complete assembly from gas inlet to
injector. That part of the system between the inlet
and last shut-off valve(s) shall be sound when tested
to 1.5 times the manufacturer’s stated maximum
inlet pressure, or 50 mbar for 2nd family gases,
or 150 mbar for 3rd family gases, whichever is the
greater.
Gas-carrying parts downstream of the last shut-off
valve(s) shall be tested at the above-mentioned
pressures and shall be sound.
These requirements shall be deemed to be satisfied
if the leakage rate over a period of 1 min does not
exceed 85 cm3/h.
10.3 Method. Connect to the appliance inlet an air
supply maintained constant at the appropriate
pressure and embodying a suitable meter for
measuring air flow. Subject all gas-carrying parts of
the appliance to this pressure under the following
conditions:
a) with all gas valves in the CLOSED position;
b) with all gas valves in the OPEN position.
The flame supervision device shall be maintained,
by suitable means, in the open position and all
igniters, pilots and injectors capped off.
© BSI 06-1999
BS 5978-1:1989
NOTE Care has to be taken to ensure that any means
(e.g. thermal or mechanical) used to maintain the flame
supervision device in the open position is compatible with the
normal operation of the device.
11 Temperature
11.1 Requirements for surface temperatures.
When the boiler is operated according to the method
given in 11.2 the temperature rise of the parts listed
in Table 1 shall not exceed the values specified.
11.2 Method. Measure the temperatures of
accessible surfaces by means of a surface pyrometer
(see BS 1041).
Connect the boiler to an appropriate test rig as
described in DD 65-1 or DD 65-2 and operate at the
maximum rated heat input.
Adjust the test rig to give the manufacturer’s
recommended maximum water flow
temperature ± 2 °C when the appliance is operated
at the maximum rated heat input. The flow/return
temperature difference shall be that specified by the
manufacturer or, in the absence of a manufacturer’s
specification, 15 ± 2 K.
Take the temperature measurements when the
boiler has reached thermal equilibrium.
Table 1 — Surface temperature rise
Parts of the appliance Temperature
rise
K
Handles, knobs, grips and the like
that, in normal use, are held for short
periods only:
of metal 35
of porcelain or vitreous material 45
of plastics, rubber or wood 60
Parts that are likely to be touched
accidentally during normal
operation:
of metal 80
of vitreous enamelled steel and 95
similar surfaces
of plastics, rubber or wood 100
11.3 Requirements for component
temperatures. When the boiler is operated as
described in 11.2 the temperature of any component
shall not exceed the maximum allowable
temperature stated by the manufacturer of the
component. The temperature of any component
incorporating a leather diaphragm shall not
exceed 60 °C.
5
BS 5978-1:1989
11.4 Motor temperatures
11.4.1 Motor bearings
11.4.1.1 Requirement. The maximum temperature
of motor bearings shall not exceed the maximum
stated by the motor manufacturer when measured
in accordance with 11.4.1.2.
11.4.1.2 Method. Operate the boiler at its maximum
rated heat input with the electricity supply at the
most unfavourable voltage between 85 % of the
minimum and 110 % of the maximum stated
operating voltage. Take temperature measurements
when the boiler has reached an equilibrium
condition and after the boiler has been switched off.
11.4.2 Motor windings. The maximum temperature
rise of the motor windings shall not exceed that
given in Table 2, in accordance with BS 3456-101,
and according to the class of insulation when the
appliance is operated at its maximum rated heat
input with the electricity supply at the most
unfavourable voltage between 85 % of the minimum
and 110 % of the maximum stated operating
voltage, and when the appliance is shut-down.
At the beginning of the test the windings are at
room temperature. It is recommended that the
resistance of the windings at the end of the test be
determined by taking resistance measurements as
soon as possible after switching off, and then at
short intervals so that a curve of resistance against
time can be plotted for ascertaining the resistance at
the instant of switching off.
12 Heat input
12.1 Measurement. The heat input is that which
would be obtained with a reference gas having a
Wobbe number, under standard conditions of
temperature, pressure and humidity, as specified
for the appropriate gas family as classified in
BS 4947.
The heat input shall be measured with the
appliance at thermal equilibrium in its normal
operating condition.
12.2 Tolerance. Burners operating individually or
in combination shall have a heat input within ± 5 %
of that stated by the manufacturer when operated at
the manufacturer’s stated setting pressure.
6 © BSI 06-1999
Table 2 — Permissible temperature rise for
windings
Windings (see note 1) and core Temperature
laminations in contact therewith, if the rise
winding insulation is:
K
of class A material (see notes 2 75
and 3)
of class E material (see notes 2 90
and 3)
of class B material (see notes 2 95
and 3)
of class F material (see note 2) 115
of class H material (see note 2) 140
NOTE 1 The value of the temperature rise of a copper winding
is calculated from the formula:
R2 – R1
%t = ---------------------- (234.5 + t 1 ) – ( t 2 – t 1 )
R
1
where
%t is the temperature rise (K);
R1 is the resistance at the beginning of the test (7);
R2 is the resistance at the end of the test (7);
t1 is the room temperature at the beginning of the
test (° C);
t2 is the room temperature at the end of the test (° C).
NOTE 2 The classification is in accordance with BS 2757.
NOTE 3 For totally enclosed motors, the permissible
temperature rise for class A, class B and class E materials may
be increased by 5 K. A totally enclosed motor is one so
constructed that circulation of air between the inside and the
outside of the case is prevented, but not necessarily sufficiently
enclosed to be termed airtight.
13 Combustion
13.1 Requirements. When tested under the
conditions described in clause 5 of BS 5978-2:1989
or in clause 5 of BS 5978-3:1989, the ratio of carbon
monoxide to carbon dioxide in the products of
combustion shall not exceed 0.02 in the following
circumstances:
a) when the boiler is supplied with the reference
gas of the appropriate family under the still air
and adverse flue conditions described in 5.1
and 5.2 of BS 5978-2:1989 or in 5.1 of
BS 5978-3:1989;
b) when the boiler is supplied with the incomplete
combustion test gas NGB, except for boilers
designed to burn 3rd family gases.
NOTE 1 Because the Wobbe numbers of LPGB and LPGE are
lower than those of LPGA and LPGC respectively, tests with the
reference gases according to a) represent the most stringent case
for boilers designed for 3rd family gases.
For boilers intended to operate in the high/low or
modulating mode, the requirements of this
subclause shall apply only in respect of the
maximum heat input declared by the manufacturer.

NOTE 2 Requirements to cover the combustion performance of
high/low and modulating boilers at heat inputs other than the
declared maximum are under consideration.
13.2 Method. Set up the boiler to the requirements
given in clause 5 and connect to an appropriate test
rig. (Appropriate test rigs are described in DD 65-1
and DD 65-2.)
Adjust the test rig to give the manufacturer’s
recommended minimum water flow
temperature ± 2 °C when the appliance is operated
at the manufacturer’s maximum rated heat input.
The flow/return temperature difference shall be
that specified by the manufacturer or, in the
absence of a manufacturer’s specification, 15 ± 2 K
for boilers designed to operate at temperatures up
to 100 °C.
For boilers designed to operate at temperatures
above 100 °C the manufacturer shall specify the
flow/return temperature difference to be used.
Collect the products of combustion in such a manner
as to ensure a representative sample and determine
the carbon monoxide and carbon dioxide contents.
NOTE The carbon dioxide and carbon monoxide contents of the
products of combustion should be determined with respective
accuracies of 0.05 % and 0.001 % of the volume of the sample.
The concentrations of the two gases can be determined
conveniently with adequate accuracy by a variety of methods
(see BS 1756-1 to BS 1756-5).
14 Manual gas valves
14.1 Manual valves shall be of the 90° turn type.
14.2 Manual valves shall be so designed or
positioned as to prevent inadvertent operation but
shall be easy to operate when required. They shall
be so designed that, in operation, the “OPEN” and
“CLOSED” positions are readily distinguishable.
14.3 A manual valve used solely for OPEN/CLOSED
operation shall be provided with positive stops at
the “OPEN” and “CLOSED” positions.
15 Controls
15.1 General. Electrically operated controls shall
comply with BS 800 so as to avoid radio and
television interference.
Operation of push-buttons, switches etc., incorrectly
or out of sequence shall not adversely affect the
safety of the system.
No single component failure shall lead to the main
gas safety shut-off system, or any part thereof, being
permanently energized, nor shall it result in the
occurrence of a hazardous condition.
© BSI 06-1999
BS 5978-1:1989
For the purposes of checking compliance with this
requirement, a component that fails but
nevertheless allows the burner to continue to cycle
safely and where the fault does not manifest itself to
the user, shall not be regarded as having failed and
shall be left in this condition during checking of all
other components. Any mode of failure that does not
meet the above criteria shall be considered as a
component failure.
15.2 Governors. Governors shall comply with
BS 3554-1 or BS 3554-2, or BS 3016, as appropriate.
The main gas and, except as specified in BS 5978-2,
the start gas or pilot supplies shall each be under
the control of a constant pressure governor
upstream of at least one safety shut-off valve.
15.3 Safety shut-off valves. Safety shut-off valves
shall comply with BS 5963 which describes three
classes of valve.
Requirements for the application of safety shut-off
valves are given in BS 5978-2 and BS 5978-3.
15.4 Thermally sensitive flame supervision
devices. Thermally sensitive flame supervision
devices shall comply with BS 6047-1.
15.5 Multi-functional controls. Multi-functional
controls shall comply with BS 6067.
15.6 Thermostats and control of water
temperature
15.6.1 General. Thermostats shall comply with
BS 3955 and BS 4201.
15.6.2 Control of water temperature
15.6.2.1 Normal operating conditions. Means shall
be provided on the boiler for controlling the water
temperature during normal running conditions.
When operating with this control device at its
maximum setting, the boiler water temperature
shall never rise so high as to cause the overheat
control device (see 15.6.2.2) to operate.
15.6.2.2 Overheat control device. An overheat
control device shall be provided, in addition to the
normal water temperature control device
(see 15.6.2.1), to cause lock-out in the event of an
overheat condition occurring as a result of:
a) failure of the normal means of water
temperature control (see 15.6.2.1);
or
b) cessation of water circulation in the boiler.
7
BS 5978-1:1989
16 Electricity supply
16.1 The burner and its associated equipment shall
function normally when the electricity supply
voltage is a) reduced to 85 % of the minimum stated
operating voltage and b) increased to 110 % of the
maximum stated operating voltage and shall either
remain safe outside these limits or proceed to safety
shut-down.
16.2 Interruption of the electricity supply at any
time during the starting up or operation of the boiler
shall result in shut-down in the case of
non-automatic burners and in safety shut-down in
the case of automatic burners.
16.3 Interruption and subsequent restoration of the
electricity supply shall not override any lock-out
condition.
16.4 Where three-phase supplies are used for some
of the power requirements of the appliance and one
phase is used to provide the remaining power
requirements of the appliance, this phase shall be
clearly and unambiguously identified.
17 Manufacturer’s instructions
17.1 General. Installation, commissioning,
servicing and user’s instructions shall be provided
with the boiler by the manufacturer.
The meaning of names ascribed to parts referred to
in the manufacturer’s instructions shall agree,
where applicable, with the meanings given in
BS 1179-6.
17.2 Installation instructions
17.2.1 General. The installation instructions shall
make reference to BS 6644 and shall include
information regarding the following items:
a) the method of assembly;
b) the siting of the boiler;
c) flueing;
d) the combustion and ventilation air
requirements;
e) the fuel, water and electrical supply
connections;
f) water treatment requirements (if any);
g) condensate disposal (where necessary);
h) burner supply pressure, injector sizes and
number of injectors;
i) the procedure to be followed for commissioning
the boiler;
j) the use of flue materials where necessary
(see 6.14), which are resistant to the corrosive
effects of condensate;
k) the minimum clearances around the boiler
necessary for servicing and cleaning.
8 © BSI 06-1999
The installation instructions shall also include:
1) a wiring diagram showing the connections
between all the controls and the external
connections;
2) a technical data table which shall give the
rated heat input(s), heat output(s), rating of
permanent pilot (where fitted), flue size, physical
dimensions, weight, electric motor details and
such other technical data as may be necessary.
The installation instructions shall recommend:
i) the fitting of a fuel isolation valve, or valves,
immediately adjacent to the boiler, which, when
closed, allows the burner and control assemblies
to be disconnected for maintenance or repair;
ii) the provision of facilities for electrical
isolation.
The installation instructions shall state that any
electrical work carried out during installation of the
appliance shall be in accordance with the IEE
Regulations.
Any electrical work required during assembly of the
appliance shall be so described as to enable
compliance with BS 5986.
17.2.2 Water circulation. The manufacturer shall
state in the installation instructions the pressure
drop across the boiler over the recommended range
of flow rates.
Where a pump is integral with the boiler, the
available pump head at these flow rates shall be
stated. The manufacturer shall also give details of
any essential design features of the boiler water
circulation system.
17.3 Servicing instructions. The servicing
instructions shall indicate the frequency of servicing
and the scope of the service programme
recommended by the manufacturer.
The servicing instructions shall include a line or
block diagram showing the arrangement of the gas
controls.
The procedure for removing or gaining access to
parts or components to be serviced, together with
the recommended service work and the associated
procedures, shall be clearly defined.
The servicing instructions shall include an electrical
wiring diagram and a short list of parts and part
numbers of those items which the manufacturer
considers may be required for replacement purposes
during the life of the boiler.
The servicing instructions shall include a fault
finding chart as an aid to servicing. If special tools
or equipment are required for any servicing
procedure, details of these shall be included in the
servicing instructions.

17.4 User’s instructions. The user’s instructions
shall contain information on the care and operation
of the boiler including the lighting procedure.
The user’s instructions shall include notes on the
procedure to be followed for shutting the boiler down
for short periods, e.g. weekends, and for long
periods, e.g. during the summer.
Where thermo-electric flame safeguards are fitted
the user shall be advised not to use the boiler
isolation valve in any case other than long-term
shutdowns, emergencies, or during servicing.
18 Identification and marking
18.1 Boiler data plate. A plate, or plates, shall be
securely fitted to the boiler in a readily accessible
position.
The plate(s) shall take account of the identification
and marking requirements of BS 779, BS 855 or
BS 2790 as appropriate.
The minimum lettering size shall correspond to
Helvetica Medium 10 point (2.5 mm) or any other
comparable type face.
The plate(s) shall have a matt surface and the
contrast between lettering and background shall be
as great as possible.
The plate(s) shall include, with indelible marking,
the following information:
a) the name and address of the manufacturer and
his agent, if the manufacturer is not based in the
United Kingdom;
b) the country of origin, if other than the United
Kingdom;
c) the boiler type, name and/or serial number,
with identification of more detailed variations or
modifications, e.g. by suffix or prefix, by serial
number, batch number, date of manufacture, etc.;
d) the gas family for which the boiler is suitable
(the category system of identification shall be
used, e.g. category IN as in BS 4947);
e) the stated range of heat input and heat output
in kilowatts;
f) the heat input of any continuous pilot in
kilowatts;
g) the maximum permissible water-side working
pressure in bars;
h) the maximum permissible flow temperature.
18.2 Marking of electrical items
18.2.1 A wiring diagram showing appropriate
internal and external connections shall be marked
on or fixed to the boiler in an easily visible position.
Wire coding shall be such that it is easily
identifiable with the wiring diagram.
© BSI 06-1999
BS 5978-1:1989
18.2.2 Every fuse or circuit breaker shall have on its
case or cover, or in an adjacent position, indelible
indication of its rated current appropriate to the
circuit(s) it protects.
18.2.3 All electrical components likely to be
exchanged during maintenance or servicing shall be
marked with their electrical characteristics.
Such electrical components when supplied for
service replacement shall be marked with their
electrical characteristics.
18.2.4 The electrical supply requirements,
e.g. voltage, frequency, starting and running
current, switch ratings and voltage of any external
controls shall be clearly marked on the boiler.
18.3 Warning notices. Permanent warning notices
shall be provided in a readily visible position on the
boiler stating that the boiler is to be electrically
isolated and the fuel turned off before carrying out
any service operations.
The warning notice shall be of red lettering on a
white background. The minimum lettering size
shall correspond to Helvetica
Medium 12 point (3.0 mm) or any other comparable
type face.
The notices shall also draw attention to the need to
replace any protective covers that give direct access
to live components before the electrical supply is
restored.
18.4 Start-up and shut-down instructions.
Start-up and shut-down instructions shall be
permanently fixed to the boiler in an accessible and
readily visible position. The minimum lettering size
shall correspond to Helvetica
Medium 10 point (2.5 mm) or any other comparable
type face.
19 Thermal efficiency
19.1 Efficiency requirement
19.1.1 The manufacturer’s claimed efficiency, based
on operation at the following return water
temperatures:
a) all boilers: 65 °C;
b) condensing boilers: 40 °C.
and expressed on the gross calorific value basis,
shall be not less than 73 % for boilers with heat
inputs of 60 kW up to and including 1.3 MW and not
less than 75 % for boilers with heat inputs
above 1.3 MW up to and including 2 MW.
NOTE In certain circumstances it may be desirable to quote the
efficiencies on the net calorific value basis. The gross and net
efficiencies are related as follows:
i) for NGA, net value = 1.100 × gross value;
ii) for LPGA, net value = 1.080 × gross value;
iii) for LPGC, net value = 1.085 × gross value.
9
BS 5978-1:1989
19.1.2 The efficiency determined during type testing
by the method given in DD 65-1 or DD 65-2, and
under the test conditions specified in 19.3, shall be
not less than that claimed by the manufacturer
minus two percentage points.
19.1.3 The efficiency determined during any
surveillance or check testing of production samples
shall be not less than that claimed by the
manufacturer minus five percentage points.
19.2 Heat input for efficiency determination.
The efficiency shall be determined at the
manufacturer’s maximum heat input for a fixed
rating boiler and at the maximum and minimum
rated heat input for a range rated boiler.
For a boiler designed to operate on a modulating or
high/low basis the efficiency shall be determined at
the maximum rated heat input and at the minimum
heat input specified by the manufacturer.
10
19.3 Test conditions
19.3.1 Return water temperature. The test rig shall
be adjusted to give a return water temperature as
follows when the boiler is operated at the maximum
rated heat input specified by the boiler
manufacturer:
a) all boilers: 65 ± 0.5 °C;
b) condensing boilers: 40 ± 0.5 °C.
NOTE Additional efficiency determinations at other return
water temperatures may be carried out at the discretion of the
test authority and by agreement with the boiler manufacturer.
19.3.2 Flow return temperature difference. The
temperature difference between the flow and return
water shall be that specified by the manufacturer, or
in the absence of a manufacturer’s
specification, 15 ± 2 K for boilers designed to
operate at temperatures up to 100 °C.
For boilers designed to operate at temperatures
above 100 °C the manufacturer shall specify the
flow return temperature difference to be used,
provided that the specified difference is not greater
than 20 K.
© BSI 06-1999
 BS 5978-1:1989

Figure 1 — Paint scratch test apparatus

© BSI 06-1999 11
BS 5978-1:1989

Publications referred to

BS 10, Specification for flanges and bolting for pipes, valves and fittings3).
BS 21, Specification for pipe threads for tubes and fittings where pressure-tight joints are made on the
threads (metric dimensions).
BS 476, Fire tests on building materials and structures.
BS 476-4, Non-combustibility test for materials.
BS 715, Specification for metal flue pipes, fittings, terminals and accessories for gas-fired appliances with
a rated input not exceeding 60 kW.
BS 729, Specification for hot dip galvanized coatings on iron and steel articles.
BS 779, Specification for cast iron boilers for central heating and indirect hot water supply (44 kW rating
and above).
BS 800, Specification for radio interference limits and measurements for household appliances, portable
tools and other electrical equipment causing similar types of interference.
BS 835, Specification for asbestos-cement flue pipes and fittings, heavy quality.
BS 855, Specification for welded steel boilers for central heating and indirect hot water supply (rated
output 44 kW to 3 MW).
BS 1041, Code for temperature measurement.
BS 1179:1967, Glossary of terms used in the gas industry.
BS 1179, Glossary of terms used in the gas industry.
BS 1179-6, Combustion and utilization including installation at consumers’ premises.
BS 1224, Specification for electroplated coatings of nickel and chromium.
BS 1394, Stationary circulation pumps for heating and hot water service systems.
BS 1394-1, Specification for safety requirements.
BS 1394-2, Specification for physical and performance requirements.
BS 1706, Specification for electroplated coatings of cadmium and zinc on iron and steel.
BS 1756, Methods for sampling and analysis of flue gases.
BS 1756-1, Methods of sampling.
BS 1756-2, Analysis by the Orsat apparatus.
BS 1756-3, Analysis by the Haldane apparatus.
BS 1756-4, Miscellaneous analyses.
BS 1756-5, Semi-routine analyses.
BS 2757, Method for determining the thermal classification of electrical insulation.
BS 2790, Specification for design and manufacture of shell boilers of welded construction.
BS 2989, Specification for continuously hot-dip zinc coated and iron-zinc alloy coated steel: wide strip,
sheet/plate and slit wide strip.
BS 3016, Specification for pressure regulators and automatic changeover devices for liquefied petroleum
gases.
BS 3456, Specification for safety of household and similar electrical appliances.
BS 3456-101, General requirements.
BS 3554, Specification for gas governors.
BS 3554-1, Independent governors for inlet pressures up to 25 mbar.
BS 3554-2, Independent governors for inlet pressures up to 350 mbar.
BS 3955, Specification for electrical controls for household and similar general purposes.
BS 4201, Specification for thermostats for gas-burning appliances.
BS 4504, Specification for flanges and bolting for pipes, valves and fittings. Metric series.
BS 4504-1, Ferrous.
BS 4504-2, Copper alloy and composite flanges.

3)
Obsolescent.

12 © BSI 06-1999
 BS 5978-1:1989

BS 4921, Specification for sherardized coatings on iron or steel.

BS 4947, Specification for test gases for gas appliances.
BS 5000, Specification for rotating electrical machines of particular types or for particular applications.
BS 5000-11, Small-power electric motors and generators.
BS 5000-99, Machines for miscellaneous applications.
BS 5292, Specification for jointing materials and compounds for installations using water, low-pressure
steam or 1st, 2nd and 3rd family gases.
BS 5963, Specification for electrically operated automatic gas shut-off valves.
BS 5978, Safety and performance of gas-fired hot water boilers (60 kW to 2 MW input).
BS 5978-2, Specification for additional requirements for boilers with atmospheric burners.
BS 5978-3, Specification for additional requirements for boilers with forced or induced draught burners.
BS 5986, Specification for electrical safety and performance of gas fired space heating appliances with
inputs 60 kW to 2 MW.
BS 6047, Flame supervision devices for domestic, commercial and catering gas appliances.
BS 6047-1, Specification for heat sensitive types.
BS 6067, Specification for multifunctional gas controls for domestic, commercial and catering appliances.
BS 6644, Specification for installation of gas-fired hot water boilers of rated inputs between 60 kW
and 2 MW (2nd and 3rd family gases).
DD 65, Methods of type testing of heating boilers for thermal performance.
DD 65-1, Direct method4).
DD 65-2, Indirect method.

4)
Under revision.

© BSI 06-1999
BS 5978-1:
1989
BSI — British Standards Institution
BSI is the independent national body responsible for preparing
British Standards. It presents the UK view on standards in Europe and at the
international level. It is incorporated by Royal Charter.

Revisions

British Standards are updated by amendment or revision. Users of

British Standards should make sure that they possess the latest amendments or
editions.

It is the constant aim of BSI to improve the quality of our products and services.
We would be grateful if anyone finding an inaccuracy or ambiguity while using
this British Standard would inform the Secretary of the technical committee
responsible, the identity of which can be found on the inside front cover.
Tel: 020 8996 9000. Fax: 020 8996 7400.

BSI offers members an individual updating service called PLUS which ensures
that subscribers automatically receive the latest editions of standards.

Buying standards

Orders for all BSI, international and foreign standards publications should be
addressed to Customer Services. Tel: 020 8996 9001. Fax: 020 8996 7001.

In response to orders for international standards, it is BSI policy to supply the

BSI implementation of those that have been published as British Standards,
unless otherwise requested.

Information on standards

BSI provides a wide range of information on national, European and

international standards through its Library and its Technical Help to Exporters
Service. Various BSI electronic information services are also available which give
details on all its products and services. Contact the Information Centre.
Tel: 020 8996 7111. Fax: 020 8996 7048.

Subscribing members of BSI are kept up to date with standards developments

and receive substantial discounts on the purchase price of standards. For details
of these and other benefits contact Membership Administration.
Tel: 020 8996 7002. Fax: 020 8996 7001.

Copyright

Copyright subsists in all BSI publications. BSI also holds the copyright, in the
UK, of the publications of the international standardization bodies. Except as
permitted under the Copyright, Designs and Patents Act 1988 no extract may be
reproduced, stored in a retrieval system or transmitted in any form or by any
means – electronic, photocopying, recording or otherwise – without prior written
permission from BSI.

This does not preclude the free use, in the course of implementing the standard,
of necessary details such as symbols, and size, type or grade designations. If these
details are to be used for any other purpose than implementation then the prior
written permission of BSI must be obtained.

If permission is granted, the terms may include royalty payments or a licensing

agreement. Details and advice can be obtained from the Copyright Manager.
BSI Tel: 020 8996 7070.
389 Chiswick High Road
London
W4 4AL