EN 1804-3:2006+A1:2010

2003-01.Slovenski inštitut za standardizacijo. Razmnoževanje celote ali delov tega standarda ni dovoljeno.Maschinen für den Bergbau unter Tage - Sicherheitsanforderungen an hydraulischen Schreitausbau - Teil 3: Hydraulische SteuerungenMachines pour mines souterraines - Exigences de sécurité concernant les soutènements marchants applicables aux piles - Partie 3: Systèmes de commande hydrauliquesMachines for underground mines - Safety requirements for hydraulic powered roof supports - Part 3: Hydraulic control systems73.100.10Oprema za gradnjo predorov in podzemnih železnicTunnelling and tubbing equipmentICS:Ta slovenski standard je istoveten z:EN 1804-3:2006+A1:2010SIST EN 1804-3:2006+A1:2010en,fr,de01-marec-2010SIST EN 1804-3:2006+A1:2010SLOVENSKI
STANDARD
EUROPEAN STANDARD NORME EUROPÉENNE EUROPÄISCHE NORM
EN 1804-3:2006+A1
January 2010 ICS 73.100.10 Supersedes EN 1804-3:2006English Version
Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 3: Hydraulic control systems
Machines pour mines souterraines - Exigences de sécurité concernant les soutènements marchants applicables aux piles - Partie 3: Systèmes de commande hydrauliques
Maschinen für den Bergbau unter Tage - Sicherheitsanforderungen an hydraulischen Schreitausbau - Teil 3: Hydraulische Steuerungen This European Standard was approved by CEN on 21 September 2004 and includes Amendment 1 approved by CEN on 21 December 2009.
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 CEN 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 CEN Management Centre has the same status as the official versions.
CEN members are the national standards bodies of Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre:
Avenue Marnix 17,
B-1000 Brussels © 2010 CEN All rights of exploitation in any form and by any means reserved worldwide for CEN national Members. Ref. No. EN 1804-3:2006+A1:2010: ESIST EN 1804-3:2006+A1:2010

Tests for verification of the safety requirements . 21A.1Load tests . 21A.1.1General . 21A.1.2Lifting points . 21A.1.3Testing of type A valves . 21A.1.4Testing of type B valves . 26A.1.5Testing of type C valves . 29A.1.6Testing of type D valves . 30Annex B (normative)
Deviations from EN 982:1996 . 31B.1General . 31B.25.1.7 (EN 982:1996) . 31B.35.3.4.1.3 Contamination control (EN 982:1996) . 32B.45.3.4.3.2 Failure (EN 982:1996) . 32B.55.3.6 Sequence control (EN 982:1996) . 32B.67.3.4.1 Non-electrical control mechanisms (EN 982:1996) . 32Annex ZA (informative)
!!!!Relationship between this European Standard and the Essential Requirements of EU Directive 2006/42/EC"""" . 33Bibliography . 34 SIST EN 1804-3:2006+A1:2010

According to the CEN/CENELEC Internal Regulations, the national standards organizations of the following countries are bound to implement this European Standard: Austria, Belgium, Bulgaria, Croatia, Cyprus, Czech Republic, Denmark, Estonia, Finland, France, Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Romania, Slovakia, Slovenia, Spain, Sweden, Switzerland and United Kingdom.
1 In preparation SIST EN 1804-3:2006+A1:2010

The machinery concerned and the extent to which hazards, hazardous situations and events are covered are indicated in the scope of this document.
When provisions of this type C standard are different from those which are stated in type A or B standards, the provisions of this type C standard take precedence over the provisions of the other standards for machines that have been designed and built according to the provisions of this type C standard.
The extent to which hazards are covered is indicated in the scope of this document.
While preparing this document, 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 code; b) of sound mechanical construction; c) free of defects;  components are kept in good working order;  a negotiation took place between the user and the manufacturer concerning the use of the machinery.
NOTE prEN1804-4 also applies to electro-hydraulic control devices. Part 4 also contains requirements for electrical control elements of valves. This document applies to hydraulic control devices at ambient temperatures from –10 °C to 60 °C. This document identifies and takes into account:
 possible hazards which may be caused by the operation of hydraulic control devices;  areas and operating conditions which may create such hazards;  hazardous situations which may cause injury or may be damaging to health;  hazards which may be caused by firedamp and/or combustible dusts. This document describes methods for the reduction of these hazards. A list of significant hazards covered appears in clause 4. This document is applicable to all hydraulic control devices placed on the market for the first time after the date of issue of this standard. This document does not specify any additional requirements for:
 use in particularly corrosive environments;  hazards occurring during construction, transportation, decommissioning;  earthquakes. 2 Normative references The following referenced documents are indispensable for the application of this document.
For dated references, only the edition cited applies.
For undated references, the latest edition of the referenced document (including any amendments) applies. EN 853, Rubber hoses and hose assemblies — Wire braid reinforced hydraulic type — Specification EN 854, Rubber hoses and hose assemblies — Textile reinforced hydraulic type — Specification EN 855, Plastic hoses and hose assemblies — Thermoplastics textile reinforced hydraulic type — Specification EN 856, Rubber hoses and hose assemblies — Rubber-covered spiral wire reinforced hydraulic type — Specification EN 857, Rubber hoses and hose assemblies — Wire braid reinforced compact type for hydraulic applications — Specification EN 982:1996, Safety of machinery — Safety requirements for fluid power systems and their components —Hydraulics SIST EN 1804-3:2006+A1:2010

Machines for underground mines — Safety requirements for hydraulic powered roof supports — Part 4: Electro-hydraulic control systems EN 13463-1:2001, Non-electrical equipment for potentially explosive atmospheres — Part 1: Basic method and requirements EN ISO 12100-1:2003, Safety of machinery — Basic concepts, general principles for design — Part 1: Basic terminology, methodology (ISO 12100-1:2003) EN ISO 12100-2:2003, Safety of machinery — Basic concepts, general principles for design — Part 2: Technical principles (ISO 12100-2:2003) EN ISO 6743-4:2001, Lubricants, industrial oils and related products (class L) — Classification — Part 4: Family H (Hydraulic systems) (ISO 6743-4:1999). ISO 1219-1 Fluid power systems and components — Graphic symbols and circuit diagrams — Part 1: Graphic symbols ISO 6805:1994, Rubber hoses and hose assemblies for underground mining — Wire-reinforced hydraulic types for coal mining — Specification ISO 7745:1989 Hydraulic fluid power — Fire-resistant (FR) fluids — Guidelines for use
3 Terms and definitions For the purposes of this document, the terms and definitions given in EN 1804-1:2001, EN 1804-2:2001,
prEN 1804-4:2004 and the following apply: 3.1 hydraulic control devices system required to control all the functions of the hydraulic powered roof supports 3.2 pressures
3.2.1 maximum permissible working pressure maximum hydraulic pressure at which a hydraulic component may be operated (see EN 1804-2:2001)
3.2.2 setting pressure hydraulic pressure in the legs and support rams on completion of the setting procedure. This pressure is supplied by the hydraulic system (see EN 1804-2:2001)
3.2.3 yield pressure of a pressure limiting valve nominal hydraulic pressure to which a pressure limiting valve is adjusted and at which it should operate (see Figure A.2 and 5.3.3)
3.2.4
opening pressure of a pressure limiting valve hydraulic pressure at which a valve begins to open and hydraulic fluid is passing through it (see Figure A.2 and 5.3.4)
3.3
valves devices for controlling the hydraulic functions (see EN 1804-2:2001)
3.3.1
type A valves (pressure limiting valves) limit the internal hydraulic pressure of actuators
3.3.2 type B valves (e.g. check valves) shut off the hydraulic fluid directly from the actuators
3.3.3 type C valves (e.g. directional control valves) in their neutral position, block off the supply pressure to the actuators . When these valves are operated, the hydraulic fluid is switched to the actuators or is used to control other valves
3.3.4 type D valves all those valves that cannot be classified specifically in one of the types A to C. These may be special types of valves or integrated types (e.g. valve combinations and control systems)
3.4 types of control systems
3.4.1 adjacent control system type of control system in which the individual functions of
one support unit are manually operated from an adjacent support unit
3.4.2 unit sequence control system control system in which a functional sequence, (e.g. lowering - advancing - setting) operates in one single support unit
3.4.3 automatic guaranteed setting control type of control system where the setting function of legs and/or support rams is operated automatically, at least until the rated value of the setting pressure of legs and/or support rams in the support unit has been attained
3.5 pushbutton override control (dead man's control)
function that remains active for as long a pushbutton is pressed
3.6 intended roof support yield parameters parameter of the valves that is maintained at the intended yield of the hydraulic roof support
4 List of hazards The following list of hazards relates in all points to continuous operation and to installation and maintenance. SIST EN 1804-3:2006+A1:2010

Table 1 — List of significant hazards with cross-references to corresponding requirements No. acc. to EN 1050:1996 Hazards Essential requirements of Directive 98/37/EC Annex 1 Relevant clause/subclause of this document 1 Mechanical hazards due to:
- machine parts or work pieces, e.g. - accumulation of energy inside the machinery, e.g.:
1.1 Crushing hazard 1.3 5.1.2, 5.2.5, 5.4, 5.5 1.2 Shearing hazard
5.1.2, 5.2.5, 5.4, 5.5 1.3 Cutting or severing hazard
5.1.2, 5.2.5, 5.4, 5.5 1.9 High pressure fluid injection or ejection hazard 1.3.2 5.1.3, 5.1.9, 5.2.1, 5.3, 5.4, 5.5 2 Electrical hazards due to:
2.4 Electrostatic phenomena 1.5.2 5.6 7 Hazards generated by materials and substances (and their constituent elements) processed or used by the machinery
7.1 Hazards from contact with or inhalation of harmful fluids, gases, mists, fumes, and dusts 1.1.3, 1.5.13, 1.6.5 5.2.2 7.2 Fire or explosion hazard 1.5.6, 1.5.7 5.1.10, 5.6 8 Hazards generated by neglecting ergonomic principles in machinery design, e.g. hazards from:
8.1 Unhealthy postures or excessive effort 1.1.2d, 1.1.5, 1.6.2, 1.6.4 5.1.3, 5.2.6 8.2 Inadequate consideration of hand-arm or foot-leg anatomy 1.1.2d, 2.2 5.1.3, 5.2.6 8.3 Neglected use of personal protection equipment 1.1.2e 5.2.1, 5.2.8, 5.3, 5.4, 5.5 10 Unexpected start-up, unexpected overrun/overspeed (or any similar malfunction) from:
5.1.4, 5.1.6, 5.2.7, 5.2.8, 5.3, 5.4, 5.5, 5.6 13 Failure of the power supply 1.2.6 5.2.4 17 Falling or ejected objects or fluids 1.3.3 5.1.9, 5.2.3, 5.3, 5.4, 5.5, 5.6 26 Insufficient instructions for the driver/operator 3.6 5.1.3, 5.1.6, 5.1.8, 5.2.5 27 Mechanical hazards and hazardous events
27.4 From insufficient mechanical strength of parts 4.1.2.3 5.2.3, 5.3, 5.4, 5.5, 5.6 27.8 From abnormal conditions of assembly/testing/use/maintenance 4.4.1, 4.4.2d 5.1.11 34 Mechanical hazards and hazardous events due to:
34.1 Inadequate mechanical strength – inadequate working coefficients 6.1.2 5.2.3, 5.3, 5.4, 5.5, 5.6
Absence or incorrect installation of starting and stopping devices
5.1.4, 5.1.5
Absence or incorrect installation of power supply shut-off devices
5.1.7
EN 982 except for the deviations listed in normative Annex B. Hydraulic control systems of hydraulic powered roof supports which are designed according to this part of EN 1804 shall also meet the requirements of the other parts of EN 1804, if relevant. Hydraulic control systems of hydraulic powered roof supports should comply as appropriate with
EN ISO 12100-1:2003 and EN ISO 12100-2:2003 for hazards which are not covered in this document.
5.1.2 Hazard areas Hydraulic control devices shall be designed and positioned so that it is not necessary for personnel to be located in the area of the operated support units. (e.g. by operating with adjacent control system according to 3.3.1)
5.1.3 Arrangement of the control devices Hydraulic control devices shall be designed and located so that they cannot be operated unintentionally from the travel way. They shall not restrict the travel way (see 5.1.1 of EN 1804-1:2001). Information and warning devices (e.g. symbols, pressure indicators) shall be arranged so that they are clearly visible from the travel way.
5.1.4 Dead man's control The controls for operating the individual functions to move the hydraulic powered support (lowering, advancing, setting) shall interrupt the movement when the control is released. This also applies to other individual functions which may lead to the narrowing of the travel way and/or the alignment functions.
5.1.5 Automatic hydraulic control system The automatic hydraulic control system shall control the movement of the hydraulic powered supports (lowering, advancing and setting) only if they are fitted with pre-start warning and emergency stop devices. This also applies to other automatically hydraulic controlled functions which may lead to the narrowing of the travel way. Excluded from this requirement is the automatic guaranteed setting control.
5.1.6 Automatic guaranteed setting control The automatic guaranteed setting control shall not come into operation until a minimum pressure of 80 MPa (bar) is reached in the leg. The automatic guaranteed setting control shall be capable of being switched off.
5.1.7 Shut-off devices It shall be possible to isolate each support unit from the hydraulic pressure supply. 5.1.8 Pressure indicator Hydraulic circuits of each leg of the support unit shall be fitted with a device indicating the pressure in the leg.
5.1.9 Pipe and hose assemblies Pipe and hose assemblies for hydraulic control systems of hydraulic roof supports shall be designed to withstand the maximum permissible working pressure in that system. Hose assemblies shall meet either conditions a) or b) as follows: SIST EN 1804-3:2006+A1:2010

a) Hose assemblies shall comply with the requirements of ISO 6805:1994. Additionally, type 4 hoses shall be extended to sizes DN 6 and DN 10 which will comply with the requirements listed in the Table 2. Table 2 — Maximum working pressure
Maximum working pressure MPa (bars) Pressure for additional
5 000a cycle test MPa (bars) Pressure at which all hoses are tested
MPa (bars) DN 6 450 760 860 DN 10 380 655 800 a The test requirements shown above are additional to those test requirements for Type 4 hoses in ISO 6805:1994. Type 6 hose assemblies shall be pressure impulse tested either:
 in accordance with the requirements of ISO 6805:1994 or;
 with 400 000 cycles at 1,33 times of the maximum working pressure at 100 °C. b) hose assemblies shall meet the mechanical requirements of EN 853, EN 854, EN 855, EN 856 and
EN 857. With type 2 ST (EN 853) and 4 SP (EN 856) hose assemblies which are subjected mainly to static loading, the maximum permissible working pressure may be increased to 1,4 times the nominal pressure given in EN 853 and EN 856. NOTE 1
Special requirements for underground hose assemblies with respect to their fire and electrical resistance properties, currently being developed by CEN/TC 305, should be taken into account. NOTE 2 Preferably, the requirements of option a) above should be met. a) pipes and hose assemblies shall be arranged, assembled and, if necessary, also fixed and protected so that external damage is minimized and ejecting fluids are deflected. 5.1.10 Hydraulic fluids Hydraulic control systems on roof supports for coal mines and other mines with potentially explosive atmospheres shall be designed for use with non-toxic and fire-resistant fluids in accordance with the SHCMOEI 7th report (see Bibliography). Hydraulic control systems shall be designed so that they may be used with: a) fire-resistant fluids of category HFA specified by the roof support manufacturer in accordance with 6.2.1 of ISO 7745:1989 in conjunction with ISO 6743-4:2001; or b) water without additives (temperatures from + 5 °C to + 60 °C).
5.1.11 Lifting points Where lifting points are fitted to hydraulic control systems, they shall be suitable for their intended purpose. They shall be designed to have a calculated minimum factor of safety of 4 for the mean tensile strain in relation to their intended load carrying capacity. They shall be clearly and permanently marked with their load carrying capacity (e.g. by welding).
5.2.2 Roof contact advance Hydraulic control systems shall be designed so that the facility to advance the support unit in contact with the roof may be incorporated.
5.2.3 Pressure limiting Circuits of hydraulic control systems that are intended to be loaded by convergence or by horizontal shear of the strata shall be capable of being protected against excessive pressures. Pressurized compartments which can be isolated shall be protected by pressure limiting valves.
5.2.4 Interruption of the operating pressure
Any interruption or restoration of the operating pressure shall not lead to unintentional movements of the support unit.
5.2.5 Travel speeds Hydraulic control systems shall be designed so that the speed of movement of individual parts of the support unit cannot exceed 30 cm/s. For canopies and anti-spalling devices, this value applies to the extremities of the components. This requirement does not apply for operating areas of the support where the presence of people is excluded.
5.2.6 Actuating forces The actuating forces for the hand-operated hydraulic control systems shall not be less than 10 N nor exceed 160 N.
5.2.7 Resistance to back pressure Hydraulic control systems shall be capable of operating safely up to the maximum permissible back pressure in the return system. 5.2.8 Adjustable valves Adjustment of valves shall only be possible by tools, as specified by the manufacturer.
5.3 Requirements of type A valves 5.3.1 General Type A valves shall meet the test requirements as defined in Annex A.
5.3.2 Leaktightness Type A valves shall be leaktight up to 94,5 % of the yield pressure.
5.3.4 Opening pressure The opening pressure at a flow rate of 0,04 l/min can exceed the specified yield pressure by a maximum of 5 %.
5.3.5 Closing pressure The closing pressure can fall below the specified yield pressure by a maximum of 10 %.
5.3.6 Pressure pulses Type A valves shall not fail when pressure pulses occur.
5.3.7 Impact resistance The function of type A valves shall not be impaired by mechanical impacts.
5.3.8 Pressure flow behaviour The volume flow of type A valves shall be as defined in Table A.1 and shall meet the intended roof support yield parameters. At a volume flow of > 0,04 l/min up to ≤ 60l/min, the opening pressure shall not exceed the yield pressure by more than 20 % nor fall below the yield pressure by more than 10 %. If volume flows
> 60 l/min are intended, this requirement shall apply. Generally, one valve is used. Where an arrangement of valves is used, at least one valve shall satisfy this requirement. 5.3.9 Operating reliability Type A valves shall continue to meet the requirements of 5.3.2 to 5.3.5 after 10 500 opening and closing cycles.
5.3.10 Temperature effects The influence of the temperature on the function of gas-charged type A valves shall be specified by the manufacturer.
5.3.11 Resistance to back pressure The yield pressure of type A valves supporting the roof shall not be affected by back pressure. The yield pressure of other type A valves shall not be increased by back pressure in the return circuit.
5.4 Requirements for type B and C valves 5.4.1 General Type B and C valves shall meet the test requirements given in Annex A.
5.4.2 Leaktightness Type B valves shall be leaktight in the closed position up to 1,5 times their maximum permissible working pressure.
5.4.3 Resistance to pressure Type B valves shall be capable of being loaded in the closed position up to 2 times the maximum permissible working pressures without bursting. Type C valves shall be capable of being loaded in all switching positions up to 2 times the maximum permissible working pressure without bursting.
5.4.4 Switching behaviour Type B and C valves, when switching, shall not produce pressure peaks greater than 1,5 times the permissible working pressure.
5.4.5 Operating reliability Type B and C valves shall continue to meet the requirements of 5.4.2 to 5.4.4 after 30 000 switching cycles.
5.4.6 Resistance to back pressure Type B and C valves shall not undergo any switching up to the maximum permissible back pressure in the return system circuit.
5.5 Requirements for type D valves Where type D valves contain elements or assemblies found in type A, B or C valves, then the corresponding requirements of 5.3 and/or 5.4 shall be met.
5.6 Materials 5.6.1 Metallic materials Only metals that meet the material characteristics specified by the manufacturer shall be used as the material for hydraulic control devices.
5.6.2 Light metal Surfaces consisting of light metal or light metal alloys (including paints and coatings containing light metal) of actuators intended by the manufacturer to be used in potentially gaseous mines shall meet the requirements of clause 8 of EN 13463-1:2001.
5.6.3 Other materials Other materials shall conform to the material specifications laid down by the manufacturer of the hydraulic control devices. Non-metallic materials shall meet the requirements of clause 7 of EN 13463-1:2001.
5.6.4 Seals Seals of hydraulic control devices shall be suitable for their particular application, particularly with regard to dimensions, pressure range, compatibility with the fluid and temperature. Hydraulic control system seals shall meet the test requirements given in Annex A.
Safety requirements Verification 5.1.2 *Inspection/comparison with manufacturer's drawings 5.1.3 *see A.6 EN 1804-1:2001 5.1.4 *Inspection/comparison with manufacturer's drawings 5.1.5 *Inspection/comparison with manufacturer's drawings
5.1.6 *see A.1.6 5.1.7 *Inspection/comparison with manufacturer's drawings
5.1.8 *Inspection/comparison with manufacturer's drawings 5.1.9 *Inspection/comparison with manufacturer's drawings and documentation 5.1.10 *Inspection of manufacturer’s test documentation 5.1.11 *see A.1.3.3 5.2.2 *Inspection/comparison with manufacturer's drawings 5.2.3 *Inspection/comparison with manufacturer's drawings 5.2.4 *Inspection/comparison with manufacturer's drawings 5.2.5 *Inspection together with support unit/comparison with manufacturer’s drawings 5.2.6 * Force measuring using a recording device 5.2.7 *Measurements/comparison with manufacturer’s drawings t 5.2.8 *Inspection/comparison with manufacturer's drawings 5.3.2 *see A.1.3.2 5.3.3 *see A.1.3.3 and A.1.3.4 5.3.4 *see A.1.3.3 and A.1.3.4 5.3.5 *see A.1.3.3 and A.1.3.4 5.3.6 *see A.1.3.5 5.3.7 *see A.1.3.6 5.3.8 *see A.1.3.7 5.3.9 *see A.1.3.8 5.3.11 *see A.1.3.9 5.4.2 *see A.1.4.2 and A.1.5.2 5.4.3 *see A.1.4.3 and A.1.5.3 5.4.4 *see A.1.4.5 and A.1.5.6 5.4.5 *see A.1.4.6 and A.1.5.4 5.4.6 *see A.1.4.4 and A.1.5.5 5.5 *see A.1.6 5.6.1 *Inspection/comparison with manufacturer’s material specification 5.6.2 *Inspection/comparison with manufacturer’s material specification 5.6.3 *Inspection/comparison with manufacturer’s material specification 5.6.4 *Comparison with manufacturer’s documentation *Type test
The user information shall be provided in one of the official languages of the country (limited to EU and EFTA) in which the hydraulic control system is to be used.
The user information shall be the primary source of information on a complete hydraulic control system and shall contain all the information relating to its safe application and this shall be produced as an instruction handbook as specified in 6.5 of EN ISO 12100-2:2003.
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