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AS 4557-2004

[Available Superseded]

Domestic outdoor gas barbecues

Specifies the uniform minimum requirements for manufacturers, designers, regulatory authorities, testing laboratories and similar organizations for the safety, performance and use of domestic outdoor gas barbecues and solid fuel-to-gas conversion kits intended for use with natural gas, town gas, tempered liquefied petroleum gas and low pressure (2.75 kPa) liquefied petroleum gas.
Published: 04/08/2004
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Table of contents
Cited references
Content history
Table of contents
Header
About this publication
Preface
1 Scope and definitions
1.1 Scope
1.2 Definitions
2 Design and construction
2.1 General
2.1.1 Preliminary specification
2.1.2 Physical inspection
2.1.3 Certification of safety components
2.1.4 Programmable electronic systems
2.1.5 Manual shut off valves
2.1.6 Power failure
2.1.7 Sharp edges
2.1.8 Continuation of satisfactory operation
2.1.9 Compliance in alternative forms
2.1.10 Locking means for adjusting devices
2.1.11 Means for gas pressure measurement
2.1.12 Design to minimize contact with hot surfaces
2.1.13 Protection of vitreous enamel
2.1.14 LPG cylinder mounting means
2.1.14A Separation of cylinder compartments
2.1.15 Ventilation of cylinder compartment
2.1.15.1 Ventilation of cylinder compartments for cylinders exceeding 1.25 kg gas capacity
2.1.15.2 Cylinder compartments for cylinders not exceeding 1.25 kg gas capacity
2.1.15.3  Accessibility of cylinder valve
2.1.16 Means to prevent accidental closure of cover
2.1.17 Provision and location of grease receptacle
2.1.18 Design to prevent ignition of accumulated grease
2.1.19 Protection of cylinder, hose and regulator
2.1.20 Design to avoid obstruction of air inlets and outlet for products of combustion
2.1.21 Weatherproofing
2.1.22 Pan supports for side burners
2.1.23 Side burner pan support stability
2.1.24 Jointing
2.1.25 Protection of wiring and controls from weather conditions
2.1.26 Prevention of separation of barbecues from detachable trolleys
2.1.27 Side burner pan support stability
2.2 Materials and standards
2.2.1 Suitability of materials and finishes
2.2.2 Materials in contact with gas
2.2.3 ‘Text deleted’
2.2.4 Zinc based alloys
2.2.5 Thermal insulation
2.2.6 Compression fittings
2.2.7 Components required to be placed in a flame
2.2.8 Protection of aluminium tubing
2.2.9 Use of soft solder
2.2.10 Resistance to corrosion
2.2.11 Spark electrodes
2.3 Electrical requirements
2.3.1 Requirements for electrical components and their installation
2.3.2 Accessibility to electrical components
2.3.3 Connection of electrical components
2.3.4 Plug and socket connections
2.3.5 Protection against accidental contact
2.3.6 Protection of low voltage electrical components and wiring
2.3.7 Protection of light globes
2.4 Appliance gas piping connection requirements
2.4.1 Appliances for connection to cylinders
2.4.1.1 Assembly of gas handling components
2.4.2 Appliances for connection to the consumer piping using a quick connect device
2.4.3 Appliances intended to be permanently connected to consumer piping
2.4.4 Disconnection of appliances from fixed installation
2.4.5 Thread connections
2.4.6 Restraining tether for appliances with hoses, for connection to fixed gas supply
2.4.7 Quick connect devices
2.4.8 Gas hose assemblies and limited flexibility connectors
2.5 Maintenance requirements
2.5.1 Accessibility for adjustment
2.5.2 Accessibility for replacement
2.5.3 Screwed connections
2.5.4 Inaccessible nuts or bolts
2.5.5 Insertion and removal of gas injectors
2.5.6 Dismantling, replacement and reassembly by the user
2.6 Pressure regulators
2.6.1 Provision of pressure regulators
2.6.2 Provision of hose assembly
2.6.3 Positioning of regulators
2.7 Gas controls
2.7.1 Accessibility by the user
2.7.2 Design of valve handles, movable dials and pointers
2.7.3 Indication of function
2.7.4 Burner controls
2.7.5 Self-latching gas valves
2.7.6 Safety devices and interlocks
2.8 Ignition, pilots and main burners
2.8.1 Burner supports
2.8.2 Gas manifolds
2.8.3 Proving ignition
2.8.4 Location of burner mixing tubes
2.8.5 Protection of ports and injectors
2.8.6 Side burner support shelf
2.8.7 Removable burner caps
2.8.8 Holes for screws, pins, etc.
2.9 Markings
2.9.1 Gas type indication
2.9.2 Packaging
2.9.3 Gas type
2.9.4 Identification of injectors
2.9.5 Permanent markings on appliances
2.9.6 Marking of flash lighting tubes
2.10 Instructions
2.10.1 Instructions to be supplied with all appliances
2.10.2 Additional instructions to be supplied with appliances designed for fixed installation
2.10.3 Operating
2.10.3.1 Operating instructions supplied with appliance
2.10.3.2 Abnormal operation, maintenance schedule, service and replacement parts
2.10.3.3 Hazardous condition resulting from incorrect lighting and shutdown procedures
3 Preliminary tests for line gases
3.1 General requirements
3.1.1 Nominal gas consumption
3.1.2 Test gases
3.1.3 Side burners and other accessory burners
3.2 Preparation for testing
3.2.1 Electrical safety requirements
3.2.2 Setting up appliance for testing
3.2.3 Appliance regulator not to be removed during testing
3.2.4 Protection from accidental draughts
3.2.5 Gas pressure and gas volume test equipment
3.3 Gas leakage
3.3.1 Gas tightness
3.3.2 Gas tightness after testing
3.4 Gas consumption
3.4.1 Tolerance on determined gas consumption
3.4.2 Tolerance on determined gas consumption of multiple burners
3.5 Gas pressure regulators
3.5.1 Pressure regulator performance
3.6 Ignition and safety shut off systems
3.6.1 Requirements applicable to all ignition and flame safeguard systems
3.6.1.1 Aerated pilots
3.6.1.2 Ignition at reduced pilot rate
3.6.1.3 Multi-port pilots
3.6.1.4 Holding time for thermoelectric flame safeguard
3.6.1.5 Flame travel at ignition
3.6.1.6 Flame failure shut off time
3.6.1.7 Manual ignition by match
3.6.1.8 Cross-ignition
3.6.1.9 Commencement of ignition after purge period
3.6.1.10 Proving of start flame
3.6.1.11 Flame establishment period–intermittent pilot
3.6.2 Additional requirements for automatic burner ignition systems
3.6.2.1 Atmospheric burners
3.6.2.2 Start flame establishment period
3.6.2.3 Gas flow rate at ignition
4 Tests using limit conditions
4.1 General
4.2 CO/CO2 ratio limits of any burner—Overload
4.3 Ignition at maximum and minimum limiting conditions
4.4 Flame stability when changing setting
4.5 CO/CO2 ratio limits of any independent surface combustion burner - underload
4.6 CO/CO2 ratio limits for permanent pilots - overload
4.7 Flame characteristics maximum and minimum limiting conditions
4.8 Delayed ignition at maximum and minimum limiting conditions
4.9 Noise of extinction
4.10 Unburnt gas release from burner system
4.11 Burner interference at ignition or during combustion
4.12 Ignition at turndown gas consumption
5 Performance tests
5.1 Temperature hazards
5.1.1 Test conditions
5.1.2 Surrounding surfaces—Temperature limits
5.1.2.1 Floor, wall, overhead and bench surfaces, trolleys and surrounds
5.1.3 Personal safety—Temperature limits
5.1.3.1 Surfaces intended to be handled
5.1.3.2 Temperatures of surfaces likely to be accidentally touched
5.1.4 Appliance safety — Temperature limits
5.1.4.1 Bodies of gas valves
5.1.4.2 Components containing non-metallic diaphragms
5.1.4.3 Main gas and pilot lines susceptible to sulphide attack
5.1.4.4 Electric motor windings
5.1.4.5 Flexible hoses
5.1.4.6 Joints sealed with jointing materials
5.1.4.7 Electrical wiring
5.1.4.8 Grease collection tray or container
5.1.4.9 LPG Cylinders
5.1.4.10 Glass components
5.2 Heat resistance
5.2.1 Heat resistance—Nominal input
5.2.1.1 Test conditions
5.2.1.2 Observations
5.2.2 Heat resistance—Lit back condition
5.3 Strength and stability
5.3.1 Body loading
5.3.2 Resistance to tipping over
5.3.3 Adequacy of means of support
5.3.4 Resistance to load—Side burners
5.4 Flame stability to draught
5.4.1 Burner operation—Turndown gas consumption
5.4.2 Pilot burner operation — Wind conditions
5.5 Resistance to door operation
5.5.1 Door operation—Turndown setting
5.6 Cooking performance
5.6.1 Cooking performance to manufacturer’s instructions
Appendix A
Appendix B
B1 ‘Void’
B2 M.O.T. 2.1.23 – 2001 Pan stability test
B2.1 Scope
B2.2 Method
B2.3 Apparatus
B2.4 Procedure
B2.5 Result
B3 M.O.T. 2.2.4 – 98 Zinc alloy test
B3.1 Scope
B3.2 Method
B3.3 Apparatus
B3.4 Procedure
B3.5 Result
B4 M.O.T. 2.4.1.2 – 2003 Device to shut off or reduce gas flow—Operation test – Part 1
B4.1 Scope
B4.2 Method
B4.3 Apparatus
B4.4 Materials
B4.5 Preparation of apparatus
B4.6 Procedure
B4.7 Result
B5 M.O.T. 2.4.1.2 – 2003 Device to shut off or reduce gas flow—Operation test – Part 2
B5.1 Scope
B5.2 Method
B5.3 Apparatus
B5.4 Materials
B5.5 Preparation of apparatus
B5.6 Procedure
B5.7 Result
B6 M.O.T. 2.4.1.2 – 2003 Device to shut off or reduce gas flow—Operation test – Part 3
B6.1 Scope
B6.2 Method
B6.3 Apparatus
B6.4 Materials
B6.5 Preparation of apparatus
B6.6 Procedure
B6.7 Result
B7 M.O.T. 2.9 – 93 Markings and labels
B7.1 Scope
B7.2 Method
B7.3 Apparatus
B7.4 Materials
B7.5 Procedure
B7.6 Result
B8 M.O.T. 3.3.1 – 2002 Gas leakage
B8.1 Scope
B8.2 Method
B8.3 Apparatus
B8.4 Materials
B8.5 Preparation of apparatus
B8.6 Procedure
B8.7 Result
B9  M.O.T. 3.4.1/2 – 2008 Gas consumption
B9.1 Scope
B9.2 Method
B9.3 Apparatus
B9.4 Materials
B9.5 Preparation of apparatus
B9.6 Procedure
B9.7 Result
B10 M.O.T. 3.5.1 – 2001 Gas pressure regulator performance
B10.1 Scope
B10.2 Method
B10.3 Apparatus
B10.4 Materials
B10.5 Preparation of apparatus
B10.6 Procedure
B10.7 Result
B11 M.O.T. 3.6.1.1/3.6.1.3 – 93 Ignition - Aerated pilots
B11.1 Scope
B11.2 Method
B11.3 Apparatus
B11.4 Materials
B11.5 Preparation of apparatus
B11.6 Procedure
B11.7 Result
B12 M.O.T. 3.6.1.2/3.6.1.3 – 93 Ignition of a burner protected by a flame safeguard system
B12.1 Scope
B12.2 Method
B12.3 Apparatus
B12.4 Materials
B12.5 Preparation of apparatus
B12.6 Procedure
B12.7 Result
B13 M.O.T. 3.6.1.4 – 93 Ignition - Opening of flame safeguard system
B13.1 Scope
B13.2 Method
B13.3 Apparatus
B13.4 Materials
B13.5 Preparation of apparatus
B13.6 Procedure
B13.7 Result
B14 M.O.T. 3.6.1.6 – 93 Operation of safety shut off system
B14.1 Scope
B14.2 Method
B14.3 Materials
B14.4 Apparatus
B14.5 Preparation of apparatus
B14.6 Procedure
B14.7 Result
B15 M.O.T. 3.6.1.8 – 2001 Cross-ignition of appliances
B15.1 Scope
B15.2 Method
B15.3 Apparatus
B15.4 Materials
B15.5 Preparation of apparatus
B15.6 Procedure
B15.7 Result
B16 M.O.T. 3.6.2.2(c) – 94 Start flame establishment period - Delayed ignition tests
B16.1 Scope
B16.2 Method
B16.3 Apparatus
B16.4 Materials
B16.5 Preparation of apparatus
B16.6 Procedure
B16.7 Result
B17 M.O.T. 4.2 – 95 Determination of CO/CO2 ratio of combustion products
B17.1 Scope
B17.2 Method
B17.3 Apparatus
B17.4 Materials
B17.5 Preparation of apparatus
B17.6 Procedure
B17.7 Result
B18 M.O.T. 4.3 – 93 Ignition tests
B18.1 Scope
B18.2 Method
B18.3 Apparatus
B18.4 Materials
B18.5 Preparation of apparatus
B18.6 Procedure
B18.7 Result
B19 M.O.T. 4.5 – 2001 Determination of CO/CO2 ratio of combustion products - Surface combustion burners
B19.1 Scope
B19.2 Method
B19.3 Apparatus
B19.4 Materials
B19.5 Preparation of apparatus
B19.6 Procedure
B19.7 Result
B20 M.O.T. 4.6 – 93 Determination of CO/CO2 ratio of combustion products - Permanent pilots
B20.1 Scope
B20.2 Method
B20.3 Apparatus
B20.4 Materials
B20.5 Preparation of apparatus
B20.6 Procedure
B20.7 Result
B21 M.O.T. 4.7 – 2001 Flame abnormality
B21.1 Scope
B21.2 Method
B21.3 Apparatus
B21.4 Materials
B21.5 Preparation of apparatus
B21.6 Procedure
B21.7 Result
B22 M.O.T. 4.8 – 2001 Delayed ignition tests
B22.1 Scope
B22.2 Method
B22.3 Apparatus
B22.4 Materials
B22.5 Preparation of apparatus
B22.6 Procedure
B22.7 Result
B23 M.O.T. 4.10 – 93 Burner operation—Unburnt gas spillage from burner system
B23.1 Scope
B23.2 Method
B23.3 Apparatus
B23.4 Materials
B23.5 Preparation of apparatus
B23.6 Procedure
B23.7 Result
B24  M.O.T. 5.1 – 2008 Temperature hazards
B24.1 Scope
B24.2 Method
B24.3 Apparatus
B24.4 Materials
B24.5 Preparation of apparatus
B24.6 Procedure
B24.7 Result
B25 M.O.T. 5.1.4.4 – 93 Temperature hazards - Electric motors
B25.1 Scope
B25.2 Method
B25.3 Apparatus
B25.4 Materials
B25.5 Preparation of apparatus
B25.6 Procedure
B25.7 Calculations
B25.8 Result
B26 M.O.T. 5.2 – 95 Heat resistance
B26.1 Scope
B26.2 Method
B26.3 Apparatus
B26.4 Materials
B26.5 Preparation of apparatus
B26.6 Procedure
B26.7 Result
B27 M.O.T. 5.2.2 – 93 Heat resistance - Lit back condition
B27.1 Scope
B27.2 Method
B27.3 Apparatus
B27.4 Materials
B27.5 Preparation of apparatus
B27.6 Result
B28 M.O.T. 5.3.1 – 93 Strength of appliances
B28.1 Scope
B28.2 Method
B28.3 Apparatus
B28.4 Preparation of apparatus
B28.5 Procedure
B28.6 Result
B29 M.O.T. 5.3.2 – 94 Appliance stability
B29.1 Scope
B29.2 Method
B29.3 Apparatus
B29.4 Procedure
B29.5 Result
B30 M.O.T. 5.4.1 – 95 Flame stability to draught
B30.1 Scope
B30.2 Method
B30.3 Apparatus
B30.4 Materials
B30.5 Preparation of apparatus
B30.6 Procedure
B30.7 Result
B31 M.O.T. 5.4.2 – 2001 Pilot flames - Stability
B31.1 Scope
B31.2 Method
B31.3 Apparatus
B31.4 Materials
B31.5 Preparation of apparatus
B31.6 Procedure
B31.7 Result
B32 M.O.T. 5.5 – 93 Effect of appliance door operation on burner stability
B32.1 Scope
B32.2 Method
B32.3 Apparatus
B32.4 Materials
B32.5 Preparation of apparatus
B32.6 Procedure
B32.7 Result
Appendix C
Appendix D
Appendix E
Appendix F
Amendment control sheet
Cited references in this standard
Content history
[Available Superseded]
[Available Superseded]
[Available Superseded]
DR 03538