Gas Interchangeability Testing Report
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Gas Interchangeability Testing Report Report Prepared for: Air Conditioning, Heating and Refrigeration Institute (AHRI) American Gas Association (A.G.A.) Association of Home Appliance Manufactures (AHAM) November 12, 2009 Date of Testing: February 2008 to April 2009 Program Objective The objective of this program was to investigate the operation of current designs of gas appliances when tested on four (4) different test gases representing possible gas mixtures that may be utilized in the United States in coming years. An advisory committee assembled by GAMA/AHRI and funded through various industry groups did the selection of gas composition. The four tests gases are presented as variations of their Wobbe Index (See the Appendix for a definition of Wobbe Index and its significance to appliance safety). The test program detailed in this report used 78 new (from stock), current production products and technologies. The program did not review products that are no longer produced, often referred to as legacy products, but rather focused on products currently in production and available to the consumer. A list of products by sample number only (manufacturers’ names omitted) is contained in the tables at the end of this report. Since the manufacturers supplied the samples without cost to the program, it is believed that anonymity of the test results is appropriate. The testing was conducted in a manner that represents what would be required for that product to meet the national safety and performance tests that are outlined in the various ANSI standards that govern the design, testing and production of those products. The appliance industry has 80+ years of evaluating products per the protocols outlined in these standards and believes that compliance with these test procedures insures the upmost safety to the consumer over the life of the product when installed, maintained and serviced per the manufacturer’s instructions. 2 Test Results Contained at the end of this report is a section labeled “Tables” and those tables contain the consolidated results in a condensed format along with a list of products submitted (by sample number only – manufacturers’ names withheld). The actual data for each sample tested has been provided to the sponsors and is not included herein due to its voluminous nature (approx. 430 pages) When reviewing the individual data sheets, please be advised that any value of CO (carbon monoxide) recorded as “1050” ppm means that the upper CO range of the instrument has been exceeded. It was not determined how far above 1050 ppm the actual value was, but the 1050 value was used for computational purposes in determining the minimum Air Free CO value that the results could have been, hence there are times where the CO values may be recorded (air free) on the data sheets as 1200, 2000, or more ppm. This is just the result of the mathematics of using 1050 ppm (maximum range of instrument) inserted into the air free calculation. Hence, the value is at least the number shown and may be much higher. Most likely any recorded CO air free value over 1100 ppm in the tables (attached) were generated because the measured CO was above 1050 ppm1. Some comments are in order when reviewing the consolidated data sheets (Tables). The individual sample data is presented with the lowest Wobbe Index gas (E) shown on the top row of data and the highest Wobbe Index gas (D) is shown as the fifth row of data, with test gas A in the middle or 3d row. The column labeled “Measured Input” is the measured input after any orifice or pressure change adjustments were made to bring the appliance within specifications as explained below. The column labeled “% of Data Plate Input” is the “Measured Input” column divided by the Data Plate Input. It is the data in the third row for gas “A” that should be within the specifications of tolerance detailed in the appropriate standard and as explained below in the test procedure write up. The column labeled “% of Test Gas A Input” reflects the change in input that occurred as the various Wobbe Index gas are used. By definition Test Gas “A” will always be 100.0%. In some cases the values do not follow the expected increase in input. This may have been human error in recording the results. But some of the reason may be that with some appliance designs, on a “hotter” gas such as gas D, there may have been conditions in which the actual heat on the manifold pipe or orifice increased to a point where the gas within the appliance 1 To make that determination: Multiply the stated value in the table by 12.2% and then divide the resultant value by the recorded CO2. This will give the reader the base CO value used for the calculation. 3 piping system became “hot”. Such a condition causes a density change in the gas before it travels through the flow control orifices, with the result that the measured gas input is reduced. It is expected that there will always be some density change of the gas in the appliance plumbing as the unit runs longer, and for this reason the appliance standards detail when the input rate is to be recorded. Ranges, water heaters and some boilers are very prone to rate reduction issues over elapsed time from a cold start. It was also noted that gas pressure regulator settings were changing by just changing the gas selection. This may be due to changes in mass flow through the regulators on products that are near the limit capacity of the regulator design. The word “Fail” is utilized in the test data as a way of stating the unit is not in compliance with the test criteria. This only means that the unit has exceeded the permissible values for some test parameter (CO, NOx, temperature, time for ignition, etc.) as detailed in the appropriate ANSI Z21 standard for that product type. It should not be taken in a negative context but only in the sense that most gas appliance testing has to meet a pass/fail criteria and this test program is utilizing these criteria to assist in the decision process. Of the 79 products tested that worked satisfactorily on Test Gas “A”, 40 units encountered some form of non-compliance on the remaining 4 test gases (B, C, D, & E). Or stated another way, within the scope of this limited testing, 39 units successfully met the established pass/fail criteria on all gas mixtures. Yet, even within those 39 units that were under the established CO generation limits, many exhibited increased CO generation as the Wobbe Index increased. 4 Test Protocols – General The following is to assist the reader in understanding some of the tests that were performed on the various test appliances and what some of the notes and comments in the presented data may be referring to. The discussions in this section are more generic in nature and specific deviations (by product type) from this general discussion can be found in each section detailing specific appliances. The actual tests procedures for conducting the tests noted below are found in the appropriate ANSI standard. For instance, gas furnaces are tested to ANSI Z21.47, boilers are tested per ANSI Z21.13, domestic water heaters to Z21.10.1, etc. See the Appendix for a complete list of the appropriate standards and their full titles. The normal test sequence for gas appliances as tested under this program was: 1. Rate the product to match the data plate input (Btu/Hr) in accordance with the procedures outlined in the appropriate ANSI standard for that appliance type using test gas A. In all cases that input had to be within either ±2% or ±5% depending upon product type. 2. Run ignition evaluation under a series of different adverse conditions to prove the reliability of safe ignition of the gas over the expected life of the product 3. Run Burner Operating Characteristics (B.O.C.) to prove the continued safe and satisfactory operation of the burners under a series of adverse conditions that proves the reliability of the product for the consumer 4. Evaluation of Carbon Monoxide (CO) emissions from the appliance under a series of conditions that proves the safety of the product under conditions of variability that are historically considered to provide safe operation of gas appliance over the life of the product. 5. Conduct NOx 2 emission testing for products subject to state or regional NOx regulations (furnaces, boilers, water heaters) or where specified, by the ANSI standard such as for vent free heaters. 6. On some furnaces, additional data was accumulated concerning metal heat exchanger temperatures, but the test procedure utilized does not represent the full, and very in depth, manner of looking at possible heat exchanger fatigue as detailed in the ANSI Z21.47 standard. The goal of this program was to look at trends rather than absolute values. A more in depth discussion of the appropriate test procedure is found in discussions below. Procedures for Placing the Appliance “On Rate” The appliance rate (input) was measured upon receipt of the appliance to verify that it was within the specifications detailed in the appropriate ANSI standard. As an example, 2 NOx=Nitrousoxide+Nitrogendioxide or NOx=NO+NO2 5 a furnace must be within ± 2% of the input as stated on the data plate as measured 15 minutes after starting the appliance from a cold start (room temperature). To achieve those tolerances a slight variance of the manifold pressure is permitted (± 0.3” w.c.) from the nominal manifold pressure that is also stated on the data plate.