prEN 1804-4

Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 4: Electro-hydraulic control

This standard specifies the safety requirements for the electro-hydraulic control systems of hydraulic powered roof supports and their emergency stop, pre-start-warning, monitoring and control devices when used as specified by the manufacturer or his authorised representative.

Maschinen für den Bergbau unter Tage - Sicherheitsanforderungen an hydraulischen Schreitausbau - Teil 4: Elektrohydraulische Steuerungen

Diese Norm legt die Sicherheitsanforderungen für die vom Hersteller oder seinem bevollmächtigten Vertreter vorgesehene bestimmungsgemäße Verwendung von elektrohydraulischen Steuerungen für Schreitausbau und ihrer Not-Aus-, Anlaufwarn-, Sperr- und Überwachungs-Einrichtungen fest.
Für die hydraulischen Komponenten der elektrohydraulischen Steuereinrichtungen gelten zusätzlich die Anforderungen nach EN 1804 Teil 3.
Diese Norm gilt für elektrohydraulische Steuerungen, die bei Umgebungstemperaturen zwischen -10°C bis 40°C und Betriebstemperaturen zwischen -10°C und 60°C eingesetzt werden.
Diese Norm identifiziert und berücksichtigt
-   die Gefährdungen, die durch hydraulische Steuerungen hervorgerufen werden können;
-   die Gefahrenbereiche und die Betriebsbedingungen, die irgendeine Gefährdung verursachen können;
-   die Situationen, die zu Gefährdungen führen können, die eine Verletzung oder Gesundheitsschädigung verursachen und
-   Gefahren, die durch Grubengas und/oder brennbare Stäube verursacht werden können.
Diese Norm beschreibt Methoden zur Reduzierung dieser Gefährdungen.
Abschnitt 4 enthält eine Liste der behandelten Gefährdungen.
Diese Norm gilt für alle elektrohydraulischen Steuerungen, die nach dem Ausgabedatum dieser Norm erstmalig in Verkehr gebracht werden.
Diese Europäische Norm spezifiziert keine zusätzlichen Anforderungen für:
-   Kabellose Fernsteuerungen
-   besonders korrosive Umgebung;
-   Risiken bei Herstellung, Transport und Außerbetriebnahme;
-   Erdbeben

Machines pour l'exploitation de mines souterraines - Exigences de sécurité relatives aux soutènements marchants applicables aux piles - Partie 4 : Commande électro-hydraulique

Stroji za podzemno pridobivanje - Varnostne zahteve za hidravlično nosilno podporje - 4. del: Elektrohidravlični krmilni sistemi

General Information

• Status: Not Published
• Technical Committee: CEN/TC 196 - Machines for undergroung mines - Safety
• Drafting Committee: CEN/TC 196/WG 3 - Hydraulic driven supports
• Current Stage: 3098 - Decision to reject - Consensus building
• Start Date: 10-Oct-2008
• Completion Date: 10-Oct-2008
• Directive: 2004/108/EC - Directive 2004/108/EC of the European Parliament and of the Council of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC
• Directive: 2004/108/EU - DIRECTIVE 2004/108/EC OF THE EUROPEAN PARLIAMENT AND OF THE COUNCIL of 15 December 2004 on the approximation of the laws of the Member States relating to electromagnetic compatibility and repealing Directive 89/336/EEC
• Directive: 2006/42/EC - Directive 2006/42/EC of the European Parliament and of the Council of 17 May 2006 on machinery, and amending Directive 95/16/EC (recast)
• Directive: 89/336/EEC - Electromagnetic compatibility (EMC)
• Directive: 94/9/EC - Directive 94/9/EC of the European Parliament and the Council of 23 March 1994 on the approximation of the laws of the Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres
• Directive: 98/37/EC - Machinery
• Mandate: M/BC/CEN/91/1 - Standardization request to CEN/CENELEC concerning machines presenting hazards due to mobility or load lifting
• Ref Project: oSIST prEN 1804-4:2005 - Machines for underground mines - Safety requirements for hydraulic powered roof supports - Part 4: Electro-hydraulic control systems

Standards Content (Sample)

SLOVENSKI oSIST prEN 1804-4:2005

PREDSTANDARD
januar 2005
Stroji za podzemno pridobivanje – Varnostne zahteve za hidravlično nosilno
podporje – 4. del: Elektrohidravlični krmilni sistemi
(istoveten prEN 1804-4:2004)
Machines for underground mines - Safety requirements for hydraulic powered roof
supports - Part 4: Electro-hydraulic control systems
ICS 73.100.10 Referenčna številka
oSIST prEN 1804-4:2005(en)
©  Standard je založil in izdal Slovenski inštitut za standardizacijo. Razmnoževanje ali kopiranje celote ali delov tega dokumenta ni dovoljeno

---------------------- Page: 1 ----------------------
EUROPEAN STANDARD
DRAFT
prEN 1804-4
NORME EUROPÉENNE
EUROPÄISCHE NORM
November 2004
ICS
English version
Machines for underground mines - Safety requirements for
hydraulic powered roof supports - Part 4: Electro-hydraulic
control systems
Machines pour mines soterraines - Exigences de sécurité Maschinen für den Bergbau unter Tage -
relatives aux soutènements marchants applicables aux Sicherheitsanforderungen an hydraulischen Schreitausbau
piles - Partie 4 : Systèmes de commande électro- - Teil 4: Elektrohydraulische Steuerungen
hydrauliques
This draft European Standard is submitted to CEN members for enquiry. It has been drawn up by the Technical Committee CEN/TC 196.
If this draft becomes a European Standard, 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.
This draft European Standard was established by CEN 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, Cyprus, Czech Republic, Denmark, Estonia, Finland, France,
Germany, Greece, Hungary, Iceland, Ireland, Italy, Latvia, Lithuania, Luxembourg, Malta, Netherlands, Norway, Poland, Portugal, Slovakia,
Slovenia, Spain, Sweden, Switzerland and United Kingdom.
Warning : This document is not a European Standard. It is distributed for review and comments. It is subject to change without notice and
shall not be referred to as a European Standard.
EUROPEAN COMMITTEE FOR STANDARDIZATION
COMITÉ EUROPÉEN DE NORMALISATION
EUROPÄISCHES KOMITEE FÜR NORMUNG
Management Centre: rue de Stassart, 36  B-1050 Brussels
© 2004 CEN All rights of exploitation in any form and by any means reserved Ref. No. prEN 1804-4:2004: E
worldwide for CEN national Members.

---------------------- Page: 2 ----------------------
prEN 1804-4:2004 (E)
Contents Page
Foreword .4
Introduction.5
1 Scope.5
2 Normative references.6
3 Terms and definitions .8
4 List of hazards.12
5 Safety requirements.17
5.1 General requirements.17
5.1.1 General.17
5.1.2 Hazardous areas.17
5.1.3 Arrangement of the control devices.17
5.1.4 Push button override control (dead man's control).17
5.1.5 Location of components and routing of cables.17
5.2 Hardware.17
5.2.1 General requirements.17
5.2.2 Electro-hydraulic valves.18
5.2.3 Transducers.18
5.2.4 Connecting cables.19
5.2.5 Emergency stop switch.19
5.2.6 Face safety valve (dump valve).19
5.2.7 Test devices.19
5.2.8 Installation control unit.19
5.3 Software.20
5.3.1 General.20
5.3.2 Requirements .20
5.4 Emergency stop system and local lock-out device .21
5.4.1 Emergency stop device.21
5.4.2 Local lockout.22
5.4.3 Normal stopping device.23
5.5 Operational requirements .23
5.5.1 Types of control .23
6 Verification of the safety requirements .27
6.1 General.27
6.2 Type test .27
6.3 Other tests.27
7 User information.29
7.1 General requirements.29
7.2 Technical and application data.29
7.2.1 Introduction .29
7.2.2 General description.29
7.2.3 Electrical specification.30
7.2.4 Equipment description (system components).30
7.2.5 System layout.30
7.2.6 Drawings and documentation.30
7.3 Handling, transport and storage.30
7.3.1 Introduction .30
7.3.2 Handling and transport .30
7.3.3 Storage.30
2

---------------------- Page: 3 ----------------------
prEN 1804-4:2004 (E)
7.4 Installation and commissioning. 31
7.4.1 Installation . 31
7.4.2 Commissioning. 31
7.5 Operation . 31
7.5.1 General. 31
7.5.2 Operator safety Instructions . 31
7.5.3 Modes of control. 31
7.5.4 Monitoring facilities. 31
7.6 Maintenance. 32
7.6.1 Introduction . 32
7.6.2 Technical description. 32
7.6.3 Maintenance instructions. 32
7.6.4 Fault diagnosis and correction . 32
7.6.5 Preventative maintenance schedules. 32
7.7 Parts identification list . 32
7.8 Marking . 33
7.9 Residual hazard . 33
Annex A (normative) Tests for verification of the safety requirements. 34
A.1 Tests. 34
A.1.1 Type test . 34
A.1.2 Vibration test. 35
A.1.3 Shock test . 35
A.1.4 Drop test . 35
A.1.5 Climate test. 36
A.1.6 Water tightness. 37
A.1.7 Pressure safety test. 37
A.1.8 Impulse test . 37
A.1.9 Explosion prevention and protection reference to ATEX/prEN 1710 . 37
A.1.10 EMC tests. 37
Annex B (normative) Manufacturer's EMC documentation. 38
B.1 Manufacturer's documentation . 38
B.2 Interference emission limits. 39
B.3 Immunity . 39
B.3.1 Performance assessment criteria. 39
B.3.2 Test conditions. 40
B.3.3 Immunity limits . 41
Annex C (informative) Checklist for testing. 45
C.1 Support units. 45
C.2 Control system . 45
Annex ZA (informative) Relationship between this European Standard and the Essential

Requirements of EU Directives. 48
Bibliography. 49

3

---------------------- Page: 4 ----------------------
prEN 1804-4:2004 (E)
Foreword
This document (prEN 1804-4:2004) has been prepared by Technical Committee CEN/TC 196 “Machines for
underground mines - Safety”, the secretariat of which is held by DIN.

This document is currently submitted to the CEN Enquiry.
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 4 of a European Standard specifying the safety requirements for hydraulic powered roof
supports.
The other parts are:
Part 1: Support units and general requirements
Part 2: Power set legs and rams
Part 3: Hydraulic control systems
Annexes A and B are normative. Annexes C and ZA are informative.
4

---------------------- Page: 5 ----------------------
prEN 1804-4:2004 (E)
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 this standard.
While preparing 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 methods;
b) of sound mechanical and electrical construction;
c) free from defects;
 components are kept in good working order;
 a consultation took place between the manufacturer of the electro-hydraulic control systems and the user
(manufacturer of the support unit or user in the case of replacement parts) concerning the conditions of
use of the machinery.
1 Scope
This standard specifies the safety requirements for electro-hydraulic control devices for support units,
including their emergency stop, pre-start warning, monitoring and control devices, when used as specified by
the manufacturer or his authorized representative.
The requirements of EN 1804 Part 3 also apply to the hydraulic components of the electro-hydraulic control
systems
This standard applies to electro-hydraulic control systems used at ambient temperatures from –10 °C to
40 °C and operating temperatures from –10 °C to 60 °C.
This standard identifies and takes into account:

 possible hazards which can be caused by the operation of hydraulic control devices;
 areas and operating conditions which can create such hazards;
 hazardous situations which can cause injury or may be damaging to health;
 hazards which can be caused by firedamp and/or flammable dust.
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 electro-hydraulic control devices placed on the market for the first time
which are manufactured after the date on which this standard was issued.
5

---------------------- Page: 6 ----------------------
prEN 1804-4:2004 (E)
This European Standard does not specify any additional requirements for:

 cable less remote control systems;
 specially 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 457:1992, Safety of machinery — Auditory danger signals — General requirements, design and testing
(ISO 7731:1986, modified).

EN 954-1:1996, Safety of machinery — Safety-related parts of control systems — Part 1: General principles
for design.

EN 981:1996, Safety of machinery — System of auditory and visual danger and information signals.

EN 1050, Safety of machinery — Principles for risk assessment.

EN 1070, Safety of machinery — Terminology.

EN 1127-2:2002, Explosive atmospheres — Explosion prevention and protection — Part 2: Basic concepts
and methodology for mining.
prEN 1710, Equipment and components intended for use in potentially explosive atmospheres in mines.
EN 1804-1, Machines for underground mines — Safety requirements for hydraulic powered roof supports —
Part 1: Support units and general requirements.

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

prEN 1804-3, Machines for underground mines — Safety requirements for hydraulic powered roof supports —
Part 3: Hydraulic control systems.

EN ISO 12100-2:2003 Safety of machinery — Basic concepts, general principles for design — Part 2:
Technical principles (ISO 12100-2:2003).

EN 13463-1:2001, Non-electrical equipment for potentially explosive atmospheres — Part 1: Basic method
and requirements.

EN 50014:1997+A1+A2, Electrical apparatus for potentially explosive atmospheres — General requirements.

EN 50015:1998, Electrical apparatus for potentially explosive atmospheres — Oil immersion "o".

EN 50017:1998, Electrical apparatus for potentially explosive atmospheres — Powder filling "q".

EN 50018:2000+A1:2002, Electrical apparatus for potentially explosive atmospheres — Flameproof
enclosure "d".

6

---------------------- Page: 7 ----------------------
prEN 1804-4:2004 (E)
EN 50020:2002, Electrical apparatus for potentially explosive atmospheres — Intrinsic safety "i".

EN 50028:1987, Electrical apparatus for potentially explosive atmospheres — Encapsulation "m".

EN 50281-1-1:1998, Electrical apparatus for use in the presence of combustible dust — Part 1-1: Electrical
apparatus protected by enclosures — Construction and testing.
EN 55011, Industrial, scientific and medical (ISM) radio-frequency equipment — Radio disturbance
characteristics — Limits and methods of measurement (CISPR 11:1997, modified).
EN 55014-1, Electromagnetic compatibility — Requirements for household appliances, electric tools and
similar apparatus — Part 1: Emission (CISPR 14-1:2000).
EN 55014-2, Electromagnetic compatibility — Requirements for household appliances, electric tools and
similar apparatus — Part 2: Immunity product family standard (CISPR 14-2:1997).
EN 55022, Information technology equipment — Radio disturbance characteristics — Limits and methods of
measurement (CISPR 22:1997, modified).
EN 60079-7:2003, Electrical apparatus for explosive gas atmospheres — Part 7: Increased safety "e"
(IEC 60079-7:2001).
EN 60079-25:2004, Electrical apparatus for explosive gas atmospheres — Part 25: Intrinsically safe systems
(IEC 60079-25:2003).
EN 60204-1:1997, Safety of machinery — Electrical equipment of machines — Part 1: General requirements.
EN 60529:1991+A1:2000, Degrees of protection provided by enclosures (IP code) (IEC 60529:1989).
EN 61000-4-2, Electromagnetic compatibility (EMC) — Part 4: Testing and measurement techniques —
Section 2: Electrostatic discharge immunity test — Basic EMC publication (IEC 61000-4-2:1995).
EN 61000-4-3, Electromagnetic compatibility (EMC) — Part 4-3: Testing and measurement techniques —
Radiated, radio-frequency, electromagnetic field immunity test (IEC 61000-4-3:2002).
EN 61000-4-4, Electromagnetic compatibility (EMC) — Part 4: Testing and measurement techniques —
Section 4: Electrical fast transient/burst immunity test — Basic EMV publication (IEC 61000-4-4:1995).
EN 61000-4-5, Electromagnetic compatibility (EMC) — Part 4: Testing and measurement techniques —
Section 5: Surge immunity test (IEC 61000-4-5:1995).
EN 61000-4-6, Electromagnetic compatibility (EMC) — Part 4: Testing and measurement techniques —
Section 6: Immunity to conducted disturbances, induced by radio-frequency fields (IEC 61000-4-6:1996).
EN 61000-4-8, Electromagnetic compatibility (EMC) — Part 4: Testing and measurement techniques —
Section 8: Power frequency magnetic field immunity test — Basic EMC publication (IEC 61000-4-8:1993).
EN 61000-4-11, Electromagnetic compatibility (EMC) — Part 4: Testing and measurement techniques —
Section 11: Voltage dips, short interruptions and voltage variations immunity tests (IEC 61000-4-11:1994).
ISO 6805, Rubber hoses and hose assemblies for underground mining — Wire-reinforced hydraulic types for
coal mining — Specification.
IEC 60038-2-6, Environmental testing — Part 2: Tests — Test Fc: Vibration (sinusoidal).
IEC 60038-2-27, Environmental testing — Part 2: Tests — Test Ea and guidance: Shock.
IEC 60038-2-32, Basic environmental testing procedures — Part 2: Tests — Test Ed: Free fall.
7

---------------------- Page: 8 ----------------------
prEN 1804-4:2004 (E)
IEC 60038-2-38, Environmental testing — Part 2: Tests — Test Z/AD: Composite temperature/humidity cyclic
test.
IEC 60870-5-1, Telecontrol equipment and systems — Part 5: Transmission protocols — Section 1:
Transmission frame formats.
3 Terms and definitions
For the purposes of this European Standard, the definitions given in EN 1070 apply as far as relevant for this
standard and those of the EN 1804 series of standards and the following apply
3.1
types of control systems

3.1.1
unit control system
control system in which individual functions of a support unit are operated from within that support unit
3.1.2
adjacent control system
type of control system in which the individual functions of one support unit are manually operated from an
adjacent support unit (see EN 1804-3:2004)
3.1.3
sequence control system
control system in which a functional sequence, (e. g. lowering - advancing - setting) operates in one single
support unit (see EN 1804-3:2004)
3.1.4
batch sequence control system
control system in which a series of sequence controls are carried out consecutively in a specified number of
support units
3.1.5
positive setting control system
control system where the setting function of legs and/or support rams and any front cantilever is operated
automatically at least until the rated value of the setting pressure to the legs and/or support rams in the
support unit has been attained or a timing system operates
3.1.6
automatic synchronized fore pole control system
control system where the fore pole is operated as a function of the stroke of the advancing ram
3.1.7
automatic water spray control

3.1.7.1
automatic canopy water spray control system
control system where the canopy water spray system is operated as a function of the time/date and/or position
of the mineral production machine and/or the internal condition of the working face or the shield
3.1.7.2
automatic water curtain control system
control system where the water spraying system for the mineral production machine track is operated as a
function of the mineral production machine position, direction and speed of travel, and direction of ventilation
8

---------------------- Page: 9 ----------------------
prEN 1804-4:2004 (E)
3.1.8
automatic control system for conveyor push
control system which pushes the conveyor automatically by initiated different criteria
3.1.9
automatic conveyor horizon control system
control system where the transverse inclination of the conveyor above the steering ram is controlled as a
function of the position and direction of travel of the mineral production machine, the rate of advance and the
inclination of the conveyor from set points
3.1.10
automatic base lift control system
control system where the base lift ram(s) are operated as a function of the movement of the support unit
3.1.11
automatic conveyor creep control system
control system where the anchor rams can be control by a number of functions including the movement of the
support unit, the position and direction of travel of the mineral production machine
3.1.12
automatic face sprag control system
control system where the face sprags are operated as a function of the position and direction of travel of the
mineral production machine and the movement of the support unit
3.1.13
automatic control system for the stabilizing ram
control system where the stabilizing ram(s) are operated as a function of the movement of the support unit
and of the pressure in the legs
3.1.14
automatic control system for support steering
control system where the steering rams of the advancing support and of the adjacent support units are
operated in order to steer the advancing support unit
3.1.15
automatic control system for conveyor pullback
control system where the conveyor is pulled back a specified amount
3.1.16
limited remote
control system where support units beyond the adjacent unit (e. g. next but one) are operated as in the normal
adjacent control mode (visible range)
3.1.17
remote control
control system where support units are controlled by a means other than adjacent control
3.1.18
cable less control unit
control system where data and control commands are transmitted by a means other than galvanic or fibre-
optic connections
3.1.19
minimum setting pressure for pushing the conveyor
minimum pressure in at least one of the legs of the support unit to allow automatic pushing of the conveyor
3.1.20
minimum setting pressure for pulling back the conveyor
minimum pressure in at least one leg of the support unit to allow automatic pulling back of the conveyor
9

---------------------- Page: 10 ----------------------
prEN 1804-4:2004 (E)
3.1.21
transfer pressure
minimum pressure in at least one leg of a support unit to allow an auto sequence in the adjacent support
unit(s)
3.1.22
residual leg pressure
maximum pressure in at least one leg of the support unit to allow that support unit to be advanced
3.1.23
control device
device by which control comma
...