EN 1804-2:2001

SLOVENSKI STANDARD
SIST EN 1804-2:2002
01-junij-2002
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Machines for underground mines - Safety requirements for hydraulic powered roof
supports - Part 2: Power set legs and rams
Maschinen für den Bergbau unter Tage - Sicherheitsanforderungen für hydraulischen
Schreitausbau - Teil 2: Stempel und Zylinder
Machines pour mines souterraines - Exigences de sécurité relatives aux soutenements
marchants applicables aux piles - Partie 2: Etançons et vérins a pose mécanisée
Ta slovenski standard je istoveten z: EN 1804-2:2001
ICS:
73.100.10 Oprema za gradnjo predorov Tunnelling and tubbing
in podzemnih železnic equipment
SIST EN 1804-2:2002 en
2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.

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EUROPEAN STANDARD
EN 1804-2
NORME EUROPÉENNE
EUROPÄISCHE NORM
October 2001
ICS 73.100.10
English version
Machines for underground mines - Safety requirements for
hydraulic powered roof supports - Part 2: Power set legs and
rams
Machines pour mines souterraines - Exigences de sécurité Maschinen für den Bergbau unter Tage -
relatives aux soutènements marchants applicables aux Sicherheitsanforderungen für hydraulischen Schreitausbau
piles - Partie 2: Etançons et vérins à pose mécanisée - Teil 2: Stempel und Zylinder
This European Standard was approved by CEN on 21 September 2001.
CEN members are bound to comply with the CEN/CENELEC Internal Regulations which stipulate the conditions for giving this European
Standard the status of a national standard without any alteration. Up-to-date lists and bibliographical references concerning such national
standards may be obtained on application to the Management Centre or to any CEN member.
This European Standard exists in three official versions (English, French, German). A version in any other language made by translation
under the responsibility of a CEN member into its own language and notified to the Management Centre has the same status as the official
versions.
CEN members are the national standards bodies of Austria, Belgium, Czech Republic, Denmark, Finland, France, Germany, Greece,
Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway, Portugal, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36  B-1050 Brussels
© 2001 CEN All rights of exploitation in any form and by any means reserved Ref. No. EN 1804-2:2001 E
worldwide for CEN national Members.

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EN 1804-2:2001 (E)
Contents
page
Foreword. 3
0 Introduction. 4
1 Scope . 4
2 Normative references . 5
3 Terms and definitions . 6
4 List of hazards . 7
5 Safety requirements . 8
6 Verification of the safety requirements. 11
7 User information . 12
Annex A (normative) Tests for verification of the safety requirements. 16
Annex B (normative) List of tests. 27
Annex ZA (informative) Relationship of this document with EC Directives . 33
Bibliography. 34
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EN 1804-2:2001 (E)
Foreword
This European Standard has been prepared by Technical Committee CEN/TC 196 "Machines for
underground mining - Safety", the secretariat of which is held by BSI.
This European Standard shall be given the status of a national standard, either by publication of an
identical text or by endorsement, at the latest by April 2002, and conflicting national standards shall be
withdrawn at the latest by April 2002.
This European Standard has been prepared under a mandate given to CEN by the European
Commission and the European Free Trade Association, and supports essential requirements of EC
Directive(s).
For relationship with EC Directive(s), see informative Annex ZA, which is an integral part of this standard.
This standard is Part 1 of a European Standard specifying the safety requirements for hydraulic powered
roof supports.
Other parts are:
Part 1: Support units and general requirements
Part 3: Hydraulic control systems
1
Part 4 ): Electro-hydraulic control systems
Annexes A and B are normative.
This standard includes a Bibliography.
According to the CEN/CENELEC Internal Regulations, the national standards organizations of the
following countries are bound to implement this European Standard: Austria, Belgium, Czech Republic,
Denmark, Finland, France, Germany, Greece, Iceland, Ireland, Italy, Luxembourg, Netherlands, Norway,
Portugal, Spain, Sweden, Switzerland and the United Kingdom.

1
) in preparation
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EN 1804-2:2001 (E)
0 Introduction
This European Standard is a Type C-standard as stated in EN 1070
The extent to which hazards are covered is indicated in the scope of the standard.
While producing (or when compiling) this standard it was assumed that:
- only trained and competent persons operate the machine;
- components without specific requirements are:
a) designed in accordance with the usual engineering practice and calculation codes;
b) of sound mechanical construction;
c) free of defects.
- components are kept in good working order;
- negotiations have taken place between the user and the manufacturer of the legs and rams
(manufacturer of the roof support unit or final user in case of replacement parts) concerning the use
of the machinery.
1 Scope
This standard specifies the safety requirements for legs and rams when used as specified by the
manufacturer or his authorised representative. Examples covered by the standard include legs, support
rams and rams with their mechanical extensions, internal valves and safety devices, seals, hydraulic
connections (up to the first hose or Type B valve, see Part 3) and their lifting points but excluding
protective pipes and gaiters, external valves and hydraulic and electrohydraulic control systems.
NOTE Some components are dealt with in other parts of this standard.
This standard applies to legs, support rams and rams used at ambient temperatures from –10 °C to 60
°C.
This standard identifies and takes account of:
- Possible hazards which may be caused by the operation of legs, support rams and rams;
- Areas and operating conditions which may create such hazards;
- Hazardous situations which may cause injury or may be damaging to health.
This standard describes methods for the reduction of these hazards.
A list of hazards covered appears in clause 4.
This standard is applicable to all legs, support rams and rams placed on the market for the first time and
which are manufactured after the date on which this standard was published.
This European standard does not establish the additional requirements for:
- Specially corrosive environments;
- Hazards occurring during construction, transportation, decommissioning;
- Earthquake.
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EN 1804-2:2001 (E)
2 Normative references
This European Standard incorporates by dated or undated reference, provisions from other publications.
These normative references are cited at the appropriate places in the text, and the publications are listed
hereafter. For dated references, subsequent amendments to or revisions of any of these publications
apply to this European Standard only when incorporated in it by amendment or revision. For undated
references the latest edition of the publication referred to applies (including amendments).
EN 287-1 Approval testing of welders - Fusion welding - Part 1: Steels.
EN 288-1 Specification and approval of welding procedures for metallic materials - Part 1:
General rules for fusion welding.
EN 288-2 Specification and approval of welding procedures for metallic materials - Part 2:
Welding procedure specification for arc welding
.
EN 288-3 Specification and approval of welding procedures for metallic materials - Part 3:
Welding procedure tests for the arc welding of steels.
EN 292-2:1991 + A1:1995
Safety of machinery - Basic concepts, general principles for design - Part 2: Technical
principles and specifications.
EN 1050:1996 Safety of machinery – Principles for risk assessment.
EN 1804-1:2001 Machines for underground mines - Safety requirements for hydraulic powered roof
supports - Part 1: Support units and general requirements.
prEN 1804-3 Machines for underground mines - Safety requirements for hydraulic powered roof
supports – Part 3: Hydraulic control systems.
EN 10002-1 Metallic materials - Tensile testing - Part 1: Method of test.
EN 10045-1 Metallic materials - Charpy impact test - Part 1: Test method.
prEN 13463-1:1999Non-electrical equipment for potentially explosive atmospheres- Part 1: Basic
methodology and requirements.
ISO 7745:1989 Hydraulic fluid power - Fire-resistant (FR) fluids - Guidelines for use.
EURONORM 103:1971
Microscopic determination of the ferrite or austenitic grain size of steels.
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EN 1804-2:2001 (E)
3 Terms and definitions
For the purposes of this standard the following terms and definitions apply.
3.1
support unit
type of hydraulic powered roof support e.g. frame support, chock support, shield support, consisting of
support components and support accessories [EN 1804-1:2001]
3.2
support components
all components which lie within the flow of the support bearing force
3.2.1
actuator
any type of hydraulic linear reciprocating device referred to in this standard
3.2.2
legs and support rams
hydraulic actuators for producing the support bearing force of the support unit
3.2.3
single telescopic legs and support rams
hydraulic legs and support rams with one extension stage
3.2.4
multi telescopic legs and support rams
hydraulic legs and support rams with several extension stages
3.3 rams
all actuators which do not lie within the flow of the support bearing force but which are necessary for the
functioning of the powered roof support
3.4
valve
device for controlling the hydraulic functions
3.5
pressures
3.5.1
setting pressure
hydraulic pressure in the legs and support rams on completion of the setting procedure. This pressure is
supplied by the hydraulic system
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EN 1804-2:2001 (E)
3.5.2
yield pressure of an actuator
hydraulic pressure in an actuator when the relevant pressure limiting valve is opened. This pressure in
the actuator is induced by external forces (yield forces; see 3.5.2 of EN 1804-1:2001)
3.5.3
maximum permissible working pressure of an actuator
maximum hydraulic pressure at which a hydraulic component is intended be operated and/or yielded
3.6
rated actuator force
maximum force to which an actuator is designed. It is a calculated value which is determined from the
actuator geometry and the maximum permissible working pressure, neglecting friction
3.7
functions
3.7.1
extension
pushing out of the actuator operating piston by means of hydraulic pressure
3.7.2
retraction
drawing in of the actuator operating piston by means of hydraulic pressure
3.7.3
setting
extending of the support unit between the roof and the floor by pressuring the legs and support rams
3.7.4
yielding
alteration in length of an actuator which occurs when external forces cause the yield pressure to be
exceeded
4 List of hazards
All the items in the following list of hazards refer to continuous operation and to installation and
maintenance.
This list contains the hazards and hazardous situations, as far as they are dealt with in this European
Standard, identified by risk assessment as being significant for this type of machinery and which require
action to eliminate or reduce risk.
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EN 1804-2:2001 (E)
Table 1 - List of hazards with cross references to safety requirements
No. EN 1050:1996 Safety requirements (clause) Hazards
1 1.1; 1.2; 1.3 5.8 Crushing, shearing and cutting
2 1.9 5.2; 5.4 High pressure fluid jets
3 17 5.2; 5.6; 5.7; 5.8 Ejected parts
4 1e; 1.8 5.2; 5.5; 5.6; 5.7; 5.8; 5.10 to 5.13 Fatigue, overload; friction or wear
5 2.4 5.12.3 Electrical energy resulting from
electrostatic phenomena
6 7.1 5.9 Inhalation of harmful fluids, mists and
fumes
7 7.2 5.3; 5.12.2 Fire or explosion
8 17 5.4 to 5.14 Unexpected ejection of machine parts
or fluids
9 5.15 Errors of fitting
10 27.8 5.1; 5.15 Absence or incorrect installation of
devices and accessories for assembly
and maintenance
11 10.6 5.1; 5.15 operating error
12 1.C 5.1; 5.15. Potential energy of actuators parts
which may move under the effect of
gravity
5 Safety requirements
5.1 Lifting points
Where lifting points are fitted to actuators they shall be suitable for their intended purpose. They shall be
designed to have a calculated minimum factor of safety of 4 on ultimate breaking load in relation to their
intended load carrying capacity. They shall be clearly and permanently marked with their load carrying
capacity e.g. by welding.
5.2 Internal valves and safety devices
Actuators, that can be externally overloaded, shall be protected against excessive pressure.
This can be by means of
internal valves
external valves (see prEN 1804-3)
safety devices such as bursting blanks.
The pressure in the piston compartment of hydraulic legs shall be capable of being monitored so that
leakages are recognised in good time and hazards from inadequate strata control as a result of a
pressure drop in the legs are avoided.
As a result of the type of fluid used and the small number of pressure cycles per day, actuators of
hydraulic powered roof supports need neither to be self-bleeding nor shall they have external air bleeds.
In addition, internal valves, excluding constant yield valves, are covered by prEN 1804-3 of the standard.
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EN 1804-2:2001 (E)
5.3 Hydraulic fluids
Actuators shall be designed such that they may be used with:
a) fire-resistant fluids category HFA (ISO 7745:1989) specified by the support unit manufacturer in
according to 6.2.1 of ISO 7745:1989
or
b) water without additives.
NOTE Hydraulic systems of roof supports, designed for coal mines and other mines with potentially explosive
th
atmospheres, should be designed for use with non-toxic and fire-resistant fluids in accordance with SHCMOEI 7
Report (see Bibliography).
5.4 Protection against ejecting fluids
Actuators that intentionally eject fluid in to the atmosphere shall be designed to prevent any hazard due to
the releasing fluid (e.g. by means of a guard)
5.5 Yield capability
Legs and support rams shall be designed such that at yield pressure they are capable of supporting the
forces and the movements of attached components, see annex A (see 5.3.1 of EN 1804-1:2001).
5.6 Behaviour under axial overload
Legs and support rams, including their mechanical extensions, shall be designed so that their function is
not affected it they are subjected statically to 1,5 times the rated compressive or tensile force and
dynamically to a mechanical impact load resulting in 1,5 times the maximum permissible working
pressure. (See annex A)
Where dynamic load testing is not practicable legs and support rams shall be subjected statically to 2
times the rated compressive or tensile force.
Rams, including their mechanical extension pieces, shall be designed so that their function is not affected
it subjected statically to 1,5 times the rated compressive or tensile force. (See annex A)
In the fully retracted condition legs and support rams shall be capable of withstanding 2 times the rated
compressive force.
5.7 Eccentric loading
Legs and support rams including their extension pieces shall be capable of withstanding eccentric and/or
lateral forces without their function being impaired. (See annex A)
5.8 Functional reliability
The functional reliability of legs and supporting rams including their extension pieces shall not be impaired
after 21000 load cycles. (See annex A)
5.9 Leak tightness
Pressure compartments of actuators shall be leak tight when isolated. (See annex A)
5.10 Extension limit
Extension limits of legs and support rams shall withstand a pressure of at least 80 % of the maximum
permissible working pressure without damage when the fully extended piston is loaded 100 times with
this pressure. If the design of the hydraulic circuitry of the support unit is such that it is possible
operationally to generate pressures higher than 80 % of the maximum permissible working pressure, legs
and support rams shall remain undamaged at these higher pressures and under the above mentioned
conditions.
Rams shall withstand 1,5 times the maximum permissible working pressure when the piston is in fully
extended in contact with the internal stop.
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EN 1804-2:2001 (E)
Support rams that are subjected to tensile load in operation shall not be damaged when they are fully
extended in contact with the internal stop and loaded with 1,5 times the rated tensile force.
5.11 Force introduction points of actuators
The force introduction points of actuators and their extension pieces shall be capable of withstanding 1,5
times the rated actuator force without their function being affected.
5.12 Materials
5.12.1Steel
5.12.1.1 General
The tensile strength of the steel grades used shall be at least 1,08 times the determined yield point or 0,2
% proof stress if the calculated stresses are more than 90 % of the permissible stresses (see 5.13.1).
The elongation at fracture (A) of the steel grades used shall be not less than 10 %.
5.12.1.2 Steel for welded actuator components
The steel shall be of fine grain, (ferrite grain size 6 or finer as described in EURONORM 103: 1971) and
shall have an impact value of at least 27 J at a temperature of -20 °C.
5.12.1.3 Steel for non-welded actuator components
The steel used for the non-welded tubes of actuators shall have properties as described in 5.12.1.1 and
5.12.1.2.
The steel used for the other components shall have an impact value of at least 25 J at a temperature of
20 °C.
5.12.2 Light metal
Surfaces of actuators consisting of light metal or light metal alloys (including paints and coatings
containing light metal) intended by the manufacturer to be used in potentially gaseous mines shall meet
the requirements of clause 8 of prEN 13463-1:1999.
5.12.3 Other materials
For materials that are used for the manufacturer of actuator components, equivalent ductility
characteristics to those specified for steel in 5.12.1 shall be proven. Non-metallic materials shall meet the
requirements of clause 7 of prEN 13463-1:1999.
5.12.4 Seals
Actuator seals shall full fill the test requirements given in annex A.
5.13 Calculated permissible stresses
5.13.1 Permissible stresses under axial central rated force conditions
The axial stresses in the individual parts of the actuators shall not exceed 70 % of the guaranteed yield
point, 0,2 % proof stress or compressive limit of the materials (also valid for annular stresses as a result
of fluid pressure).
The axial stresses in the bases of actuators shall not exceed 80 % of the guaranteed yield point, 0,2 %
proof stress or compressive limit of the materials.
The shear stresses shall not exceed 65 % of the guaranteed yield point, 0,2 % proof stress or
compressive limit of the materials.
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EN 1804-2:2001 (E)
5.13.2 Permissible stresses under double axial central rated force conditions
In the case of twice the central rated force in the fully retracted state of legs and support rams, the
stresses shall not exceed the guaranteed yield point or 0,2 % proof stress of the materials.
NOTE This requirement only involves mechanical loading. There are no hydraulic pressures.
5.13.3 Permissible stresses under eccentric rated force conditions
In the case of the eccentric rated force as described in A.1.3.1 the axial stresses of the leg and support
ram components involved in bending shall not exceed the guaranteed yield point or 0,2 % proof stress or
compressive limit of the materials. The deflections determined by means of a test as specified in A.1.3.2
shall be used as a basis for calculating the stresses.
In the case of an eccentric rated force and simultaneous lateral loading (e.g. to stabilize the support unit),
the axial stresses of the leg and support ram components involved in bending shall not exceed the
guaranteed yield point or 0,2 % proof stress or compressive limit of the materials.
5.13.4 Permissible weld stresses
The weld stresses shall not exceed the permissible stresses of the adjacent materials given in Table 2, if
the welds are not subjected to any non-destructive testing.
Table 2 - Permissible weld stresses (5.13.1 to 5.13.3)
Weld types Axial stresses Shear stresses Combined stresses
Fillet welds 65 % 65 % 100 %
Butt welds 80 % 80 % 100 %
Where these stresses are exceeded due to result of non-destructive testing the manufacturer shall
document them specially.
5.14 Welding
All welding shall be carried out in accordance with EN 288-1, EN 288-2 and EN 288-3. The manufacturer
shall make use of competent welding shops and welders. This can be reached by either:
a) operating a certified quality system according to EN ISO 9001; or
b) a certificate issued by an accredited body confirming compliance with the quality requirements of
EN 729-3.
The welding shall be done by welders qualified in accordance with EN 287-1.
5.15 Correct assembly and installation
It shall be possible to assemble and install the actuator correctly in accordance with the assembly
instructions or other documents provided by the manufacturer.
6 Verification of the safety requirements
6.1 Type testing
One specimen of the actuator shall be type tested in accordance with annex A. The test requirements
given in annex A shall be met. The following documents shall be made available to the laboratory running
the type test:
- User information;
- Results of a static calculation in accordance with A.2;
- Manufacturing drawings;
- Drawing of welded parts;
- Evidence of the competence of the welding workshop;
- Data relating to the material characteristics;
- Data relating to the seals used.
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EN 1804-2:2001 (E)
NOTE The specimen which has been tested according to Annex A should not be placed on the market.
If no provision has been made in annex A for verification of the requirements in clause 5 by specified
tests, they shall be verified by means of visual inspection, function test or reference to documents.
Verification of the safety requirements is shown in Table 3.
Table 3 - Tests for verification of the safety requirements
Safety requirements Verification
5.1 *see A.1.5
5.2 *visual Inspection/comparison with manufacturer's drawings
5.3 *Inspection of the oil-manufacturer's test documentation
5.4 *visual Inspection/ comparison with manufacturer's drawings
5.5 *see A.1.2.2
5.6 *see A.1.2.3
5.7 *see A.1.3
5.8 *see A.1.4
5.9 *see A.1.2.4
5.10 *see A.1.2.1 and A.1.4.3
5.11 *see A.1.2.3.1
5.12 **see A.3
5.13 *see A.2
5.14 **see A.3.2
5.15 *Inspection of manufacturer's test documentation
*type test; **series test
6.2 Series verification
See Table 3; Verification with **
7 User information
7.1 General requirements
The actuator manufacturer shall provide user information meeting the requirements of clause 5 of
EN 292-2:1991 + A1:1995 and clause 7.
The user information shall be the primary source of information on a complete actuator and shall contain
all the information relating to its safe application and this shall be produced as an instruction handbook as
specified in 5.5 of EN 292-2:1991 + A1:1995.
1)
Clause 7 User information of EN 1804-1:2001 also applies to prEN 1804-3 and prEN 1804-4 and is
complemented, as appropriate, by corresponding clauses in those parts.
Care shall be taken to ensure that the user information is available to the user on receipt of the actuator.
7.2 Technical and application data
7.2.1 Introduction
The user information shall describe the intended use of the actuator.

1)
in preparation
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EN 1804-2:2001 (E)
The operating instruction shall include all design and performance data necessary, either for the user or
for the manufacturer of the hydraulic powered roof support, to make an assessment of suitability for use
in particular applications and environments, and for the identification of any energy supply requirements
and other ancillary facilities that may be needed. The information provided shall comply with 7.2.2 to
7.2.5.
7.2.2 General description
This description shall explain in clear, easily understandable language of the user and in logical sequence
the overall function of the actuator with all special features and characteristics. General arrangement
drawings shall be provided as appropriate.
7.2.3 Performance data
The principal dimensions, weights, and performance data of the complete actuator shall be given.
7.2.4 Hydraulic data
The data necessary to design the hydraulic system including yield and setting characteristics shall be
given. In addition, it shall include a list of the hydraulic fluids specified by the manufacturer of the actuator
(see 5.3).
7.2.5 List of additional drawings and documents
A complete list of all drawings, illustrations and other documents including e.g. information about welding
qualification, which are part of the information for use but provided separately from the user information,
but which form part of the information required by this standard shall be provided. The list shall include,
appropriate cross-reference to the text, of the user information.
7.3 Handling, transport and storage
7.3.1 Introduction
This section of the user information shall include information and instructions for the safe handling,
transport and storage of the actuator.
7.3.2 Handling and transport
The details shall include:
a) Weights and outline dimensions of all the supplied actuators.
b) Precautions to be taken during handling and transportation. In addition, indications of possible
damage to the actuators during handling and transport.
c) Information on the number and rated load of any ancillary lifting equipment (e.g. shackles, eye bolts)
not supplied but necessary in order to enable safe lifting/installation of the actuators.
7.3.3 Storage
The following information shall be given for the storage of the actuator on the surface and underground:
a) methods of preservation; and
b) instructions for preparing the actuator for use after storage.
7.4 Installation, commissioning and operation
7.4.1 Installation
The installation of the actuator into the support unit shall be described together with details of any special
tools that may be required.
Reference shall be made to the user information supplied for the support unit (e.g. compatibility).
7.4.2 Commissioning
Details shall include:
a) checking the correct installation prior to connection to the pressure supply and information on the
necessary cleaning and flushing procedures;
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EN 1804-2:2001 (E)
b) connection of hydraulic pressure supply;
c) commissioning the actuator and testing individual functions.
7.4.3 Operation
This section of the user information shall include the information and instructions necessary for the safe
operation of the actuators.
Details shall be given for the correct use, with information on the operating range and prohibited
applications.
7.5 Maintenance
7.5.1 Introduction
This section of the user information shall contain the necessary information and instructions to enable the
actuator to be maintained in, or restored to, safe working order. The information provided shall be
according to 7.5.2 to 7.5.5.
7.5.2 Maintenance instructions
Instructions shall be provided, with illustrations where necessary, detailing the methods and procedures
for preventative and corrective maintenance. The instructions shall include reference to the following:
a) dismantling and re-assembly;
b) replacement and adjustment;
c) a parts identification list;
d) special tools and additiona
...