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education and knowledge, the attached public safety standard is made available to promote the
timely dissemination of this information in an accurate manner to the public.

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“The Right to Information, The Right to Live” “Step Out From the Old to the New”

IS 302-2-204 (1994): Safety of household and similar

electrical appliances, Part 2: Particular requirements:
Section 204 Electric water boilers [ETD 32: Electrical
Appliances]

“!ान $ एक न' भारत का +नम-ण”

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“Invent a New India Using Knowledge”

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है”
ह
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“Knowledge is such a treasure which cannot be stolen”
 IS 302-2-204 : 1994

( Reaffirmed 2004 )

SAFETY OF HOUSEHOLD AND SIMILAR

ELECTRICAL APPLIANCES
PART 2 PARTICULAR REQUIREMENTS

Section 204 Electric Water Boilers

UDC 641’542’1 - 83 : 614’825

0 BIS 1994

BUREAU OF INDIAN STANDARDS

/

Price Group 4
Electrical Appliances Sectional Committee, ETD 32

FOREWORD

This Indian Standard was adopted by the Bureau of Indian Standards, after the draft finalized by
the Electrical Appliances Sectional Committee had been approved by the Electrotechnical Division
Council.

This standard covers the general and safety requirements for Electric Water Boilers to ensure
personal safety against electric shock, effect of excessive temperature and fire, etc.

For the sake of convenience of reference the format of the standard has been followed with the
pattern followed in IS 302-I ( 1979 ) ‘Safety of household and similar electrical appliances : Part 1
General requirements (fifth revision )‘. The performance requirements and the detail list of
performance characteristics along with the methods for evaluation of these characteristics are covered
in a separate standard IS 3412 : I993 ‘Specification for electric water boilers ( second revision )‘.

This standard is to be read in conjunction with IS 302-l ( 1979 ). For the sake of convenience,
where the clause of this standard corresponds to that of IS 302-I ( 1979 ), instead of reproducing
full text of each clause of IS 302-I ( 1979 ) which are applicable ( which means that relevant
provision of the clause applies ) or not applicable and the sub-clauses or portion thereof which are
not applicable are indicated as under:

a) In case of a clause where it is applicable or not applicable, the wording used is ‘This clause
of IS 302-l ( 1979 ) is applicable/not applicable’.
b) In case of a sub-clause or part thereof ‘Not applicable’.-

Wherever a sub-clause of IS 302-I ( 1979 ) is to be replaced by a new text, it has been indicated
as under:
Replacement - Followed by the new text.

Any addition to the existing provision of sub-clause of IS 302- 1 ( 1979 ) has been indicated as
under:
Addition - Followed by the text of additional clause.

Clauses/Tables which are additional to those of IS 302-l ( 1979 ) are numbered starting from 101
and additional sub-clauses are numbered with the main clause number followed by 101, 102, 103,
etc, for example 2.101 should however any deviations exist between IS 302-l ( 1979 ) and this
standard, the provision of latter shall apply.

For the purpose of deciding whether a particular requirement of this standard is complied with, the
final value, observed or calculated, expressing the result of a test, shall be rounded off in accordance
with IS 2 : 1960 ‘Rules for rounding off numerical values ( revised )‘. The number of significant
places retained in the rounded off value should be the same as that of the specified value in this
standard.
 IS 302-2-204 : 1994

Indian Standard
SAFETY OF HOUSEHOLD AND SIMILAR
L ELECTRICAL APPLIANCES

PART 2 PARTICULAR REQUIREMENTS

Section 204 Electric Water Boilers

1 SCOPE 2.103 Immersion Heating Element - A totally

enclosed heating element the heating portion of which
1.1 Replacement is immersed in water.
This standard covers the general and safety 2.184 Rated Water Capacity -The quantity of water
requirements for electric water boilers of rated loading which the water boiler is designed to hold and which
not exceeding 5.0 kW and connection to supplies of is marked on the rating plate.
voltages not exceeding 250 V ac single phase 50 Hz
or dc. 2.105 Fixed Water Boiler - It denotes an appliance
for permanent connection to the water supply mains,
1.2 Replacement which if filled through a valve in the inlet pipe and
This standard does not apply to : is open to the atmosphere, so that under no conditions
of use can the pressure at the surface of the water be
a) Appliances intended to be used in locations other than atmospheric.
where special conditions pervail, such as the
presence of a corrosive or explosive atmosphere 3 GENERAL REQUIREMENTS
(dust, vapour or gas);
This clause of IS 302-l(1979) is applicable except as
b) Appliances for high-frequency heating; follows :
4 Appliances of the electrode type;
3.1 Para 3 Replacement
4 Storage water heaters, which are covered by
a separate standard; In general, compliance is checked by carrying out the
relevant tests specified.
e>Instantaneous water heaters, which are covered
by separate standard; 4 GENERAL NOTES ON TESTS
f) With rated capacity not exceeding 10 1 are
covered under a separate Indian Standard. This clause of IS 302-l(1979) is applicable except as
follows :
2 TERMINOLOGY 4.2 Note 3 and Note 4 not applicable.

This clause of IS 302-l(1979) is applicable except as Addition

follows :
For water boilers intended to be immersed in water
2.9, 2.11, 2.25 and 2.28 not applicable. for cleaning, two additional samples are required for
tests of sub-clause 15.101.
2.29 Replacement
4.8, 4.10 and 4.13 Not applicable.
Conditions of Adequate Heat Discharge - Water
boilers are operated filled with a quantity of initially Additional Sub-clause
cold water equal to its rated capacity and with the lid,
where provided, closed. 4.101 The appliances are tested as portable
appliances, unless it is clear from their design and the
2.38, 2.31, 2.33, 2.34 and 2.46 not applicable. manufacturer’s instructions that they are intended to
be fixed to a supporting surface.
Additional Sub-clauses
5 RATING
2.101 Electric Water Boiler-An electrically heated
vessel with free outlet for the steam, intended for This clause of IS 302-l(1979) is applicable except as
boiling water for bathing, washing fabrics, preparing follows.
beverages, etc.
5.1 Replacement
2.102 Clamp-on Heating Element-A heating element
clamped or similarly attached to the outer surface of The rated voltage shall not exceed 250 V. The preferred
rated voltage is 240 V.
the water container.
1
IS 302-2-204 : 1994
5.2 Rated Input This appliance must only be used with the appropriate
connector.
The rated input of water boilers shall not exceed
5.0 kW. 7.3, 7.4 and 7.8 Not applicable.

5.2.1 Recommended input for various capacities of 7.12 Addition

water boilers ( see 5.161 ) are as follows :
The instruction sheet should state that the appliance
should be cleaned by pouring water in the imter
Rated Capacity Recommended Input
container.
litres kilowatt
Additional Sub-clause
15 1.5
20 7.101 The water boilers may also be marked with
25 ;:: the Standard Mark.
30 2.5
35 3.0 8 PROTECTION AGAINST ELECTRIC SHOCK
40 3.0
50 3.0 This clause of IS 302-l(1979) is applicable except as
follows :
5.2.2 and 5.2.3 not applicable
8.2, 8.3 and 8.8 not applicable.
Additional Sub-clause
9 STARTING OF MOTOR-OPERATED
APPLIANCE
5.101 Rated Capacity
The rated capacity for water boilers shall be one of This clause of IS 302-l(1979) is not applicable.
the following :
10 INPUT AND CURRENT
15, 20, 25, 30, 35, 40 and 50 litres.
This clause of IS 302-l(1979) is applicable except as
follows :
6 CLASSIFICATION
10.2 Not applicable.
This clause of IS 302-l(1979) is applicable except as
follows : 11 TEMPERATURE RISE
6.1 (a) (2) and (3), and 6.1 (b) (4) Not applicable. This clause of 1$302-l(1979) is applicable except as
follows :
Addition
11.2 Para 3 (a) Replacement
NOTE - This standard recognises appliances which are
intended IO be cleaned by pouring water in the inner container Water boilers provided with a temperature limiter and
but it does not recognize water tight appliances.
normally used on a floor or a table are placed on the
floor of the test corner at a distance of about 15 cm
7 MARKING
from the walls of the test corner.
This clause of IS 302-l(1979) is applicable except as NOTE - This distance includes the natural projection such as
follows. hooks, bolts, appliance inlets, etc, of the appliances.

7.1 Replacement Para 4 Not applicable.

The water boilers shall be marked with the following 11.3 Para 6 Not applicable.
information: 11.5 and 11.6 Not applicable.
a) Rated voltage in volts,
11.7 Replacement
b) Rated input in watts or kilowatts,
c) Rated capacity, Water boiler shall be tested for 15 minutes after the
water in the container has attained a temperature of
d) Name of the manufacturer or his trade-mark, 95°C or if this temperature cannot be attained, after
e) Maker’s model or type reference, and water has attained its maximum temperature.
f) Country of origin. 11.9 and 11.10 Not applicable.

Addition 12 OPERATION UNDER OVERLOAD

CONDITIONS OF APPLIANCES WITH
Appliances intended to be used with a connector HEATING ELEMENT
incorporating a thermostat shall be marked with the
substance of the following warning, unless this warning This clause of IS 302-l(1979) is applicable except as
is given in the instruction sheet. follows :

2
 IS 302-2-204 : 1994
12.2 Para 1 Not applicable. 18, ENDURANCE (Under consideration).
12.3 Not applic.able. 19 ABNORMAL OPERATION
13 ELECTRICAL INSULATION AND LEAKAGE This clause of IS 302-l(1979) is applicable except as
CURRENT AT OPERATING TEMPERATURE follows.

This clause of IS 302-l(1979) is applicable except as 19.1 Replacement

follows.
Appliances shall be so designed that the risk of fire
mechanical damage impairing safety or the protection
13.1 Replacement
against electric shock as a result of abnormal or careless
Compliance is checked by the tests of 13.2 and 13.3, operation is obviated as far as is practicable.
the water boiler being operated under the conditions
Compliance is checked by the tests of 19.2 and, if
specified in 11.
necessary, by the test of 19.3.
14 RADIO AND TELEVISION INTERFERENCE If, in any of the test, a non self resetting thermal
SUPPRESSION cutout operates, an ejector type device operates, a
heating element ruptures or if the current is otherwise
14.1 This clause of IS 302-l(1979) is applicable. interrupted before steady conditions are established,
the heating period is consider- to be ended, but if
15 MOISTURE RESISTANCE the interruption is due to the’rupture of a heating
element or of an intentionally weak part, the relevant
This clause of IS 302-l(1979) is applicable except as test is repeated on a second sample which shall then
follows. also comply with the conditions specified in 19.11.

15.2.2 Not applicable Rupture of a heating element or of an intentionally

weak part in the second sample will not in itself entail
15.2.3 Replacement a rejection.
An intentionally weak part designed to fail under
Test for Splashing conditions of abnormal operation so as to prevent the
The water boiler shall be allowed to stand on a level occurrence of a condition which is unsafe within the
surface and a volume of water equal to 95 percent meaning of this standard. Such as a resistor capacitor,
of the rated capacity is poured in. No overflow of thermal fuse or part of a component to be replaced,
water shall take place. such as an inaccessible and non-resettable thermal
cut-out incorporated in a motor.
The water boiler shall then be filled to 85 percent of
the rated capacity, and with the lid on, if any, it is Fuses, thermal cutouts, ejector type devices, overcurrent
allowed to stand on a sheet of blotting paper of suitable releases or the like, incorporated into the appliance,
dimensions and coqnected to a supply voltage adjusted may be used to provide the necessary protection.
to given rated input. The water boiler shall be If more than one of the tests are applicable for the
maintained on circuit for a period of two minutes after same appliance, these tests are made consecutively.
boiling has commenced. There shall be no signs of
moisture on the blotting paper after further period of Provisions of 19.11 apply to all appliances.
20 minutes.
19.2 The water boilers are tested empty under
16 INSULATION RESISTANCE AND conditions specified in 11. The supply voltage is such
ELECTRIC STRENGTH that the input is 0.85 times the rated input if any, are
in the open or closed position whichever imposes
This clause of IS 302-l(1979) is applicable except as more severe conditions. The thermostat is short-circuited
follows. during the test.

16.1 Para 2 Replacement If an ejector type device operates, or if the current

is otherwise interrupted before steady conditions are
Compliance is checked by the tests of 16.2 and 16.4 established and is allowed to cool down to approximately
which are made on the cold water boiler not connected room temperature, the appliance is then subjected to
to the supply, after the test given in 15.4 in the the test of 19.3, 19.4 to 19.10 not applicable.
humidity cabinet or in the room in which the sample
was brought to the prescribed temperature, after 20 STABILITY AND MECHANICAL HAZARDS
reassembly of those parts which may have been
removed. This clause of IS 302-l(1979) is applicable except as
follows.
16.3 Not applicable.
20.1 Para 5 Replacement
17 OVERLOAD PROTECTION
The water boiler shall be filled with the maximum
This clause of IS 302-l(1979) is applicable. amount of water it will hold in the tilted position. If

3
IS 302-2-204 : 1994
castors or rollers are fitted they are rendered inoperative 22.103 The lagging material, when provided, shall
during the test. be packed and supported in a manner which precludes
the possibility of large air pockets developing within
20.2 Not applicable. it.
21 MECHANICAL STRENGTH 22.104 All surfaces in contact with water shall be
protected, if necessary, ac that resistance to corrosion
This clause of IS 302-l(1979) is applicable except as is not inferior to that of copper coated with a layer
follows : of 0.025 mm thickness of tin of 99.i.5 percent purity
( see IS 26 : 1979 ).
21.1 Addition
22.105 For fixed water boilers having provision for
The water boiler while standing on its feet or plinth
discharging steam or overflowing water, the discharge
without water, is dragged 10 times over a concrete
orifice shall be at the base of the appliance and shall
floor backwards and forward for a distance of 1.5
discharge vertically downwards.
metres, at a rate of approximately 15 metres per
minute. After this test there shall be no damage to 22.106 Fixed water boilers shall allow connection to
the water boiler nor loosening of the legs, castor or the water supply mains in a reliable mamter. In addition,
plinth fixings. they shall have reliable provisions for fixing them to
NOTE - The water boiler is dragged hy the handle, rim or a supporting surface.
other suitable projection and not by the flexible cord.
Compliance with the requirements of 22.105 and 22.106
Breakage of glass parts is neglected, provided that is checked by inspection.
live parts do not become exposed so as to impair
22.107 The water boiler shall be provided with a
compliance with 8.1, l5.1, 15.2 and 15.101.
draw-off tap made of metal. The knob or handle of
the tap shall be of heat insulating material. The tap
22 CONSTRUCTION
shall be so located and designed that it shall lead the
This clause of IS 302-l(1979) is applicable except as water clear off from the electrical components, wiring
follows. and fittings, and from the body of the container.

22.9 Addition 22.108 Facility of Maintenance - Similar parts of

water boilers of the same make, model and size shall
Insulated fixed water boiler shall be so designed that be readily interchangeable. The parts which may
condensed water can flow out, if otherwise there require maintenance or replacement shall, as far as
would be a possibility of such water affecting the practicable, be so located as to ensure easy access.
electrical insulation. If a drain hole is provided for
this purpose, it shall be at least 5 mm in diameter, 22.109 Imrer containers shall be made of copper
or 20 sq mm in area with a width of at least 3 mm (conforming to IS 1550 : 1967) or non-magnetic stainless
and so arranged that water can drain off without steel of Grade 04 Cr 18 Ni 11 or 07 Cr 18 N 19
impairing the electrical insulation. conforming to IS 1570 (Part 5) : 1985.
The outer casing of the water boiler shall be made
Replacement of corrosion resisting material or shall be adequa.tely
Compliance is checked by inspection and, if necessary, protected from corrosion on all surfaces. The lid shall
by measurement. be made of corrosion resisting material.

22.12, 22.15, 22.20, 22.24 and 22.25 Not applicable. 23 INTERNAL WIRING
22.25 Replacement This clause of IS 302-l(1979) is applicable except as
follows.
Insulated or uninsulated fixed water boilers shall be
so constructed that the container is always open to 23.4 Not applicable.
the atmosphere through an aperture at least 5 mm in
diameter or 20 sq mm in area with a width of at least 24 COMPONENTS
3 mm. The aperture shall be so located that it is
unlikely to be obstructed in normal use. This clause of IS 302-l(1979) is applicable except as
follows :
Compliance is checked by inspection and by
measurement. 24.6, 24.9 and 24.10 Not applicable.
22.29, 22.31 and 22.32 Not applicable.
24.101 Heating Units
22.101 The water boiler shall be of double-walled The heating units shall be of immersion element type.
construction and provided with a lid. The lid shall It shall be so fixed as to be easily removable and
have a knob or handle of heat insulating material. replaceable.
22.102 The design of the water boiler shall be such
25 SUPPLY CONNECTION AND EXTERNAL
that when the lid, if placed in the intended position,
FLEXIBLE CABLES AND CORDS
emission of steam from the vents shall be directed
away from the knob or handle provided on the lid. This clause of IS 302-l(1979) is applicable.

4
 IS 302-2-204 : 1994
25.6 Addition Table 101 Schedule of Type Test

The supply cord external to the appliances (entry ( Clnuse 101.1 )

point into the appliance and the plug including any
SI No. Clause
cord guard) shall be not less than 2.05 m in case the
Reference
appliance is not provided ‘with plug. In case the
appliance is provided with a plug the length and the 9 Protection against electric shock
supply cord shall be not less than 2.0 m. ii) Input 10
iii) Temperature rise 11
26 TERMINALS FOR EXTERNAL iv) Operation under overload conditions 12
CONDUCTORS v) Electrical insulation and leakage current at 13
operating temperature
This clause of IS 302-l(1979) is applicable. vi) Radio and television interference suppression 14
vii) Moisture resistance 15
27 PROVISION FOR EARTHING viii) Insulation resistance and electric strength 16
(after humidity treatment)
This clause of IS 302-l(1979) is applicable. ix) Overload protection 17
x) Endurance (under consideration) 18
28 SCREWS AND CONNECTIONS xi) Abnormal operation 19
This clause of IS 302-l(1979) is applicable. xii) Stability and mechanical hazards 20
xiii) Mechanical strength 21
xiv) Construction 22
29 CREEPAGE DISTANCES AND
CLEARANCES xv) Internal wiring 23
xvi) Components 24
This clause of IS 302-l(1979) is applicable except as xvii) Supply connection and external flexible cables 26
follows : and cords
xviii) Terminals for external conductors 26
29.1 Paras 2 and 3 Not applicable. xix) Provision for earthing 27
xx) Screws and connections 28
30 RESISTANCE OF HEAT, FIRE AND xxi) Creepage distances and clearances 29
TRACKING xxii) Resistance to heat, fire and tracking 30
This clause of IS 302-l(1979) is applicable. xxiii) Resistance to rusting 31
xxiv) Radiation hazards 32
31 RESISTANCE TO RUSTING
This clause of IS 302-l(1979) is applicable. 101.2 Acceptance Tests

32 RADIATION HA7ARDS The following shall constitute the acceptance

tests :
This clause of IS 302-l(1979) is applicable.
Tests Clause
101 TESTS Reference
101.0 Categories of Tests Protection against electric shock 8
b) Input 10
Tests are classified as type, acceptance and routine
Temperature rise 11
tests.
101.1 Type Tests
dc; Electrical insulation and leakage
current at operating temperature
13
.
The tests specified in Table 101 shall constitute the e) Moisture resistance 15
type tests and shall be carried out on two samples of 9 Insulation resistance and electric 16
the same type and rating selected preferably at random strength (after humidity treatment)
from a regular production lot. Before commencement g) Provision for earthing 27
of the tests, the samples shall be visually examined NOTE - For the purpose of acceptance tests, the humidity
and inspected for obvious visual defects in respect of treatment shall be done for 24 hours while conducting the test
for moisture resistance (15).
components, parts and their assembly, construction,
mechanical hazards, markings, provision, of suitable 101.2.1 A recommended sampling procedure for
terminals for supply connections, earthing and the acceptance tests is given in Appendix B of IS 302-
effectiveness of screws and comiections. The external 1 (1979).
surface finish shall be even and free from finishing
defects. 101.3 Routine Tests
101.1.1 Criterin of Acceptnnce
The following shall constitule the routine tests :
Both samples shall successfully pass all the type tests
for proving conformity with the requirements of the Tests Clause Reference
standard. If any of the samples fails in any of the type a) Protection against electric 8
tests, the testing authority, at its discretion, may call
shock
for fresh samples not exceeding twice the original
number and subject them again to all tests or to the b) High voltage 13.3.2 of
test(s) in which failure(s) had occurred. No failure IS 302-l(1979)
shall be permitted in the repeat test(s). c) Provision for earthing 27
IS 302-2-204: 1994

ANNEX A
TABLES OF TYPE TEST

This Annex of IS 302-l(1979) is not applicable.

ANNEX B
SAMPLING PROCEDURE FOR ACCEPTANCE TESTS

This Annex of IS 302-l(1979) is applicable.

ANNEX C
ELECTRONIC CIRCUITS

This Annex of IS 302-l(1979) is applicable if electronic circuits are used.

ANNEX D
MEASUREMENT OF TEMPERATURE WITH THERMOMETER

This Annex of IS 302-l(1979) is applicable.

ANNEX E
ALTERNATIVE TESTS FOR PROTECTED MOTOR UNITS

This Annex of IS 302-l(1979) is not applicable.

ANNEX F
IMPACT TEST APPARATUS

This Annex of IS 302-l(1979) is applicable.

ANNEX G
THERMAL CONTROLS AND OVERLOAD RELEASES

This Annex of IS 302-l(1979) is applicable if thermal controls and overload releases are used.

6
 IS 302-2-204:1994

ANNEX H
MEASUREMENT OF CREEPAGE DISTANCES AND CLEARANCES

This Annex of IS 302-l(l979) is applicable.

ANNEX J
TEST FOR FIRE RESISTING PROPERTIES

This Annex of IS 302-l(1979) is applicable.

ANNEX K
BNF JET TEST FOR DETERMINATION OF THICKNESS OF
COPPER AND NICKEL PLATING

This Annex of IS 302-l(1979) is not applicable.

ANNEX L
APPROXIMATE MEASUREMENT OF THICKNESS OF CHROMIUM ON
NICKEL, STEEL AND COPPER

This Annex of IS 302-l(1979) is not applicable.

ANNEX AA
LIST OF REFERRED INDIAN STANDARDS

IS No. Title IS No. Title

302-l (1979) Safety of household and similar and for general purposes ( first
: Part 1 revision )
General requirements ( fifth
revision ) 1570 (Part 5) : Schedules for wrought steels :
1985 Part 5 Stainless and heat resisting
1550 : 1967 Copper sheet and strip for utensils steels ( second revision )
Bureau of Indian Standards

BIS is a statutory institution established under the Bureau of lndiun Standards Acr, 1986 to promote
harmonious development of the activities of standardization, marking and quality certification of goods
and attending to connected matters in the country.

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BIS has the copyright of all its publications. No part of these publications may be reproduced in
any form without the prior permission in writing of BIS. This does not preclude the free use, in the
course of implementing the standard, of necessary details, such as symbols and sizes, type or grade
designations. Enquiries relating to copyright be addressed to the Director ( Publications ), BIS.

Revision of Indian Standards

Indian Standards are reviewed periodically and revised, when necessary and amendments, if any, are
issued from time to time. Users of Indian Standards should ascertain that they are in possession of
the latest amendments or edition.

This Indian Standard has been developed from Dot : No. ETD 32 ( 3710 1

Amendments Issued Since Publication

Amend No. Date of Issue Text Affected

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