Bsi bs en 01804 3 2006 + a1 2010

BRITISH STANDARD

Machines for
underground mines —
Safety requirements for
hydraulic powered roof
supports —
Part 3: Hydraulic control systems

ICS 73.100.10

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BS EN
1804-3:2006
+A1:2010


BS EN 1804-3:2006+A1:2010

National foreword
This British Standard is the UK implementation of
EN 1804-3:2006+A1:2010. It supersedes BS EN 1804-3:2006 which is
withdrawn.
The start and finish of text introduced or altered by amendment is
indicated in the text by tags. Tags indicating changes to CEN text
carry the number of the CEN amendment. For example, text altered by
CEN amendment A1 is indicated by !".
The UK participation in its preparation was entrusted to Technical
Committee MRE/1, Mining mechanical equipment and machinery.
A list of organizations represented on this committee can be obtained

on request to its secretary.
This publication does not purport to include all the necessary
provisions of a contract. Users are responsible for its correct
application.
Compliance with a British Standard cannot confer immunity
from legal obligations.

This British Standard was
published under the authority
of the Standards Policy and
Strategy Committee
on 31 May 2006

Amendments/corrigenda issued since publication
Date
30 April 2010

© BSI 2010

ISBN 978 0 580 68144 8

Comments
Implementation of CEN amendment A1:2010


EUROPEAN STANDARD

EN 1804-3:2006+A1

NORME EUROPÉENNE

EUROPÄISCHE NORM

January 2010

ICS 73.100.10

Supersedes EN 1804-3:2006

English 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: E


BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

Contents

Page

Foreword ..............................................................................................................................................................4
Introduction .........................................................................................................................................................5
1

Scope ......................................................................................................................................................6

2

Normative references ............................................................................................................................6

3

Terms and definitions ...........................................................................................................................7

4

List of hazards........................................................................................................................................8

5
5.1
5.1.1
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.1.9
5.1.10
5.1.11
5.2
5.2.1
5.2.2
5.2.3
5.2.4
5.2.5

5.2.6
5.2.7
5.2.8
5.3
5.3.1
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.3.8
5.3.9
5.3.10
5.3.11
5.4
5.4.1
5.4.2
5.4.3
5.4.4
5.4.5
5.4.6
5.5
5.6

Safety requirements ........................................................................................................................... 10
General requirements ......................................................................................................................... 10
General ................................................................................................................................................. 10
Hazard areas........................................................................................................................................ 10
Arrangement of the control devices ................................................................................................. 10

Dead man's control ............................................................................................................................. 10
Automatic hydraulic control system................................................................................................. 10
Automatic guaranteed setting control .............................................................................................. 10
Shut-off devices .................................................................................................................................. 10
Pressure indicator .............................................................................................................................. 10
Pipe and hose assemblies ................................................................................................................. 10
Hydraulic fluids ................................................................................................................................... 11
Lifting points ....................................................................................................................................... 11
Design requirements .......................................................................................................................... 12
Protection against ejected fluids ...................................................................................................... 12
Roof contact advance ........................................................................................................................ 12
Pressure limiting ................................................................................................................................. 12
Interruption of the operating pressure ............................................................................................. 12
Travel speeds ...................................................................................................................................... 12
Actuating forces.................................................................................................................................. 12
Resistance to back pressure ............................................................................................................. 12
Adjustable valves................................................................................................................................ 12
Requirements of type A valves ......................................................................................................... 12
General ................................................................................................................................................. 12
Leaktightness ...................................................................................................................................... 12
Yield pressure ..................................................................................................................................... 13
Opening pressure ............................................................................................................................... 13
Closing pressure................................................................................................................................. 13
Pressure pulses .................................................................................................................................. 13
Impact resistance................................................................................................................................ 13
Pressure flow behaviour .................................................................................................................... 13
Operating reliability ............................................................................................................................ 13
Temperature effects ........................................................................................................................... 13
Resistance to back pressure ............................................................................................................. 13
Requirements for type B and C valves ............................................................................................. 13

General ................................................................................................................................................. 13
Leaktightness ...................................................................................................................................... 13
Resistance to pressure ...................................................................................................................... 14
Switching behaviour ........................................................................................................................... 14
Operating reliability ............................................................................................................................ 14
Resistance to back pressure ............................................................................................................. 14
Requirements for type D valves ........................................................................................................ 14
Materials .............................................................................................................................................. 14

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BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

5.6.1
5.6.2
5.6.3
5.6.4

Metallic materials ................................................................................................................................. 14
Light metal ........................................................................................................................................... 14
Other materials .................................................................................................................................... 14
Seals ..................................................................................................................................................... 14

6
6.1
6.2

Verification of the safety requirements ............................................................................................. 15

Type testing ......................................................................................................................................... 15
Additional tests .................................................................................................................................... 15

7
7.1
7.2
7.2.1
7.2.2
7.2.3
7.2.4
7.2.5
7.3
7.3.1
7.3.2
7.3.3
7.4
7.4.1
7.4.2
7.5
7.6
7.6.1
7.6.2
7.6.3
7.6.4
7.6.5
7.7
7.8
7.9

User Information .................................................................................................................................. 17

General requirements ......................................................................................................................... 17
Technical and application data .......................................................................................................... 17
Introduction .......................................................................................................................................... 17
General description ............................................................................................................................. 17
Performance data ................................................................................................................................ 17
Hydraulic data ...................................................................................................................................... 17
List of additional drawings and documents ..................................................................................... 17
Handling, transport and storage ........................................................................................................ 18
Introduction .......................................................................................................................................... 18
Handling and transport ....................................................................................................................... 18
Storage ................................................................................................................................................. 18
Installation and commissioning ......................................................................................................... 18
Installation ............................................................................................................................................ 18
Commissioning .................................................................................................................................... 18
Operation .............................................................................................................................................. 18
Maintenance ......................................................................................................................................... 19
Introduction .......................................................................................................................................... 19
Technical description.......................................................................................................................... 19
Maintenance instructions ................................................................................................................... 19
Fault diagnosis and correction .......................................................................................................... 19
Preventative maintenance schedules ............................................................................................... 19
Parts identification lists ...................................................................................................................... 19
Marking ................................................................................................................................................. 19
Residual risks ...................................................................................................................................... 20

Annex A (normative) Tests for verification of the safety requirements ...................................................... 21
A.1
Load tests ............................................................................................................................................. 21
A.1.1 General ................................................................................................................................................. 21
A.1.2 Lifting points ........................................................................................................................................ 21

A.1.3 Testing of type A valves ..................................................................................................................... 21
A.1.4 Testing of type B valves ..................................................................................................................... 26
A.1.5 Testing of type C valves ..................................................................................................................... 29
A.1.6 Testing of type D valves ..................................................................................................................... 30
Annex B (normative) Deviations from EN 982:1996 ...................................................................................... 31
B.1
General ................................................................................................................................................. 31
B.2
5.1.7 (EN 982:1996) .............................................................................................................................. 31
B.3
5.3.4.1.3 Contamination control (EN 982:1996) ................................................................................ 32
B.4
5.3.4.3.2 Failure (EN 982:1996) ........................................................................................................... 32
B.5
5.3.6 Sequence control (EN 982:1996) ............................................................................................... 32
B.6
7.3.4.1 Non-electrical control mechanisms (EN 982:1996) .............................................................. 32
Annex ZA (informative) !Relationship between this European Standard and the Essential
Requirements of EU Directive 2006/42/EC"
" .................................................................................. 33
Bibliography ...................................................................................................................................................... 34

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BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

Foreword
This document (EN 1804-3:2006+A1:2010) has been prepared by Technical Committee CEN/TC 196

“Machines for underground mines - Safety”, the secretariat of which is held by DIN.
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 July 2010, and conflicting national standards shall be withdrawn at the
latest by July 2010.
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent
rights. CEN [and/or CENELEC] shall not be held responsible for identifying any or all such patent rights.
This document includes Amendment 1, approved by CEN on 2009-12-21.
This document supersedes EN 1804-3:2006.
The start and finish of text introduced or altered by amendment is indicated in the text by tags ! ".
This document has been prepared under a mandate given to CEN by the European Commission and the
European Free Trade Association, and supports essential requirements of EU Directive(s).
For relationship with EU Directive(s), see informative Annex ZA, which is an integral part of this document.
This document is Part 3 of a European Standard specifying the safety requirements for hydraulic control
systems.
The other parts are:
Part 1: Support units and general requirements
Part 2: Power set legs and rams
Part 41: Electro-hydraulic control systems
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

4


BS EN 1804-3:2006+A1:2010

EN 1804-3:2006+A1:2010 (E)

Introduction
This document is a type C standard as stated in EN ISO 12100-1.
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.

5


BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

1

Scope

This document specifies the safety requirements for hydraulic control devices, including hydraulic valves and
their control elements, valve combinations, control systems, pipes and hose assemblies, fittings, shut-off
devices, measuring devices, filters, built-in pressure limiting and check valves in legs and rams and water
spraying and dust suppression valves when used as specified by the manufacturer or his authorized
representative. Excluded are electronic control devices, pressure generators, and internal valves of legs and
rams (e.g. constant yield valves, see EN1804-2).
Some components are dealt with in other parts of this standard.
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

6


BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

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
EN 1804-2:2001, Machines for underground mines — Safety requirements for hydraulic powered roof
supports — Part 2: Power set legs and rams
prEN 1804-4:2004,
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

3

Hydraulic fluid power — Fire-resistant (FR) fluids — Guidelines for use

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)

7


BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

3.2.5
closing pressure
pressure at which the valve is closed and the flow of hydraulic fluid is shut off (see Figure A.2 and 5.3.5)
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.

8


BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

This list contains the hazards and hazardous situations, as far as they are dealt with in this document,
identified by risk assessment significant for this type of machinery and which require action to eliminate or
reduce risk.
Table 1 — List of significant hazards with cross-references to corresponding requirements
No.
acc. to
EN
1050:1996
1

Hazards

Essential
requirements
of Directive
98/37/EC
Annex 1

Relevant clause/subclause of
this document

1.3

5.1.2, 5.2.5, 5.4, 5.5

Mechanical hazards due to:
- machine parts or work pieces, e.g.
- accumulation of energy inside the machinery, e.g.:

1.1

Crushing hazard

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
2
2.4
7

7.1
7.2
8

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

1.5.2

5.6

1.1.3, 1.5.13,
1.6.5

5.2.2

1.5.6, 1.5.7

5.1.10, 5.6

1.1.2d, 1.1.5,
1.6.2, 1.6.4

5.1.3, 5.2.6

Electrical hazards due to:
Electrostatic phenomena
Hazards generated by materials and substances
(and their constituent elements) processed or used by
the machinery
Hazards from contact with or inhalation of harmful
fluids, gases, mists, fumes, and dusts
Fire or explosion hazard
Hazards generated by neglecting ergonomic
principles in machinery design, e.g. hazards from:

8.1

Unhealthy postures or excessive effort

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:

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

27.8

From abnormal conditions of
assembly/testing/use/maintenance

34

Mechanical hazards and hazardous events due to:

34.1

Inadequate mechanical strength – inadequate working

coefficients
Absence or incorrect installation of starting and
stopping devices
Absence or incorrect installation of power supply shutoff devices

5.1.4, 5.1.6, 5.2.7, 5.2.8, 5.3, 5.4,
5.5, 5.6

4.1.2.3

5.2.3, 5.3, 5.4, 5.5, 5.6

4.4.1, 4.4.2d

5.1.11

6.1.2

5.2.3, 5.3, 5.4, 5.5, 5.6
5.1.4, 5.1.5
5.1.7

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BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

5

Safety requirements

5.1
5.1.1

General requirements
General

Hydraulic control systems of hydraulic roof supports shall comply with the safety requirements of
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:

10


BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

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
Pressure at which all
Maximum
Pressure for
a
working
additional 5 000 hoses are tested
cycle test
pressure
MPa (bars)
MPa (bars)
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

a)

Preferably, the requirements of option a) above should be met.

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).

11

BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

5.2
5.2.1

Design requirements
Protection against ejected fluids

Hydraulic control systems shall be designed, located or guarded to minimize the risk from ejection of fluid.
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
5.3.1

Requirements of type A valves
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.

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BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

5.3.3

Yield pressure

The measured yield pressure of type A valves can differ by a maximum of ± 5 % from the specified yield
pressure. This requirement applies to ambient and fluid temperatures of 20 °C to 40 °C.
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

5.4.1

Requirements for type B and C valves
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.

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BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

Type C valves shall be leaktight in all switching positions 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
5.6.1

Materials
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.

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BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

6

Verification of the safety requirements

6.1

Type testing

One specimen of the hydraulic control devices 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 for the type
test:
 user information;


manufacturing drawings;



drawings of welded parts;



data relating to the material characteristics;



specification of the seals used;



hydraulic circuit diagrams.

NOTE

6.2

The specimen which has been tested according to Annex A should not be placed on the market.

Additional tests

If no provision has been made in Annex A for verification of the requirements in clause 5 of this standard by
specified tests, they shall be verified by means of inspection, function tests or reference to documentation or
standards. Verification of the safety requirements is shown in Table 3.

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BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

Table 3 — Test for verification of the safety requirements

Safety requirements
5.1.2
5.1.3
5.1.4
5.1.5
5.1.6
5.1.7
5.1.8
5.1.9

5.1.10
5.1.11
5.2.2
5.2.3
5.2.4
5.2.5
5.2.6
5.2.7
5.2.8
5.3.2
5.3.3
5.3.4
5.3.5
5.3.6
5.3.7
5.3.8
5.3.9
5.3.11
5.4.2
5.4.3
5.4.4
5.4.5
5.4.6
5.5
5.6.1
5.6.2
5.6.3
5.6.4
*Type test

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Verification
*Inspection/comparison with manufacturer's drawings
*see A.6 EN 1804-1:2001
*Inspection/comparison with manufacturer's drawings
*Inspection/comparison with manufacturer's drawings
*see A.1.6
*Inspection/comparison with manufacturer's drawings
*Inspection/comparison with manufacturer's drawings
*Inspection/comparison with manufacturer's drawings and documentation
*Inspection of manufacturer’s test documentation
*see A.1.3.3
*Inspection/comparison with manufacturer's drawings
*Inspection/comparison with manufacturer's drawings
*Inspection/comparison with manufacturer's drawings
*Inspection together with support unit/comparison with manufacturer’s
drawings
* Force measuring using a recording device
*Measurements/comparison with manufacturer’s drawings t
*Inspection/comparison with manufacturer's drawings
*see A.1.3.2
*see A.1.3.3 and A.1.3.4
*see A.1.3.3 and A.1.3.4
*see A.1.3.3 and A.1.3.4
*see A.1.3.5
*see A.1.3.6
*see A.1.3.7
*see A.1.3.8
*see A.1.3.9

*see A.1.4.2 and A.1.5.2
*see A.1.4.3 and A.1.5.3
*see A.1.4.5 and A.1.5.6
*see A.1.4.6 and A.1.5.4
*see A.1.4.4 and A.1.5.5
*see A.1.6
*Inspection/comparison with manufacturer’s material specification
*Inspection/comparison with manufacturer’s material specification
*Inspection/comparison with manufacturer’s material specification
*Comparison with manufacturer’s documentation


BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

7

User Information

7.1

General requirements

The hydraulic control system manufacturer shall provide user information meeting the requirements of clause
6 of EN ISO 12100-2:2003 and clause 7.
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.

The user information in clause 7 of EN 1804-1:2001 also applies to EN 1804-2 and prEN 1804-42 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 hydraulic
control system.

7.2
7.2.1

Technical and application data
Introduction

The user information shall describe the intended use of the hydraulic control system under normal conditions
and for operations as described by the manufacturer.
The operating instructions 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.
7.2.2

General description

This description shall explain in clear, easily understandable language and in logical sequence, the overall
function of the hydraulic control system with all special features, markings and characteristics. General
arrangement drawings and function block diagrams shall be provided as appropriate.
7.2.3

Performance data

The principal dimensions, weights and performance data of the hydraulic control system shall be given.
7.2.4

Hydraulic data

The data necessary to define the hydraulic supply system shall be given. In addition, it shall include a list of
the hydraulic fluids specified by the manufacturer of the hydraulic control system (see 5.1.10).
7.2.5 List of additional drawings and documents
A complete list of all drawings, illustrations and other documents which are provided separately from the user
information, but which form part of the information required by this document shall be provided, with
appropriate cross-references to the text of the user information.

2 In preparation

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BS EN 1804-3:2006+A1:2010
EN 1804-3:2006+A1:2010 (E)

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 hydraulic control system or its components.
7.3.2

Handling and transport

The details shall include:
a)

mass and outline dimensions of all the supplied hydraulic control system;

b)

precautions to be taken during handling and transportation. In addition, indications of possible damage to
the hydraulic control system 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 hydraulic control system.

7.3.3

Storage

The following information shall be given for the storage of the hydraulic control system on the surface and
underground:
a)

methods of preservation and

b)

instructions for preparing the hydraulic control system for use after storage.

7.4

Installation and commissioning

7.4.1

Installation

The installation of the hydraulic control system shall be described together with details of any special tools
which may be required.
Reference shall be made to the user information supplied for the support unit.
7.4.2

Commissioning

Details shall include:
a)

checking correct installation prior to connection to the pressure supply and information on the necessary
cleaning and flushing procedures;

b)

connection of the hydraulic pressure supply;

c)

commissioning the hydraulic control system and testing individual functions.

7.5

Operation

This section of the user information shall include the information and instructions necessary for the safe
operation of the hydraulic control system.
The instructions on correct use shall include details on the scope of use and the prevention of impermissible
applications.

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