Mayer TM 2018 User manual

Issue date: 01.10.2009 / V1.0
Before the initial start-up, read and keep at the machine for future use.
Operating instructions
Potting machine TM 2018

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List of Contents
1 Product description
1. Intended use
2. Structure
3. Functional description
4. Technical Data
5. EU Declaration of conformity
2 General safety instructions
1. Due diligence of the operating company
2. Explanation of the safety symbols used
3. Basic safety precautions
4. Machine-related safety precautions
5. Demands on operating personnel
3 Transport, handling and
storage of the machine
1. Transport
2. Handling
3. Storage
4 Installation
1. General notes
2. Installing the machine
3. Measures for the machine’s stability against
overturning
4. Disassembly and disposal of the machine
5 Initial start-up
1. Check prior to first start
2. Starting the machine for the first time
3. Stopping the machine
6 Operation
1. Normal operation
2. Shutting down the machine
3. Measures prior to and after a longer shutdown
7 Malfunctions
1. Behaviour in case of malfunctions
2. Possible malfunctions and trouble shooting
8 Maintenance
1. General notes
2. Inspection and preventive maintenance
2.1 Elevator chains
2.2 Rubber conveyor belt
3. Maintenance schedule
9 Part list
10 Circuit diagrams for electric and
pneumatic system
11 Guarantee

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1 Product description
1. Intended use
The MAYER TM 2018 potting machine may be used for planting
and replanting plants into round or square containers or
poly bags with a minimum of working force and of time.
Other means of use of the machine, besides the ones listed
here, are not permitted – and they are not the usage for
intended purpose.
If the MAYER TM 2018 potting machine is not used in
accordance with the regulations, the safe operation of the
machine is not guaranteed.
The usage for intended purpose involves the reading of the
operating instructions, and the compliance of the regulations,
specially safety regulations stated in it. Furthermore, every
inspection and maintenance should be performed in specified
time.
For damages that are originated from the usage for not the
intended purpose, neither the manufacturer, nor the operator of
the MAYER TM 2018 potting machine takes responsibility.

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2. Structure
Standard equipment (basic machine) Version with vibrating grid (optional)
Soil chute for 1 workplace Soil chute for 2 workplaces
Different pot sizes can be filled

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3. Functional description
The empty containers are put onto the pot supports by one
person (in case of version with optional vibrator they are put
onto the grid).
Plates are fixed on endless chains located in elevator housing
which take the soil from the soil hopper. When the plates reach
the upper turning point the soil falls into container being there
by means of the soil chute.
A controlled conveyor belt is installed into the soil hopper which
forwards the soil always towards the elevator.
One or several person(s) standing in front of the machine may
plant plants into the containers. Plant holding trays may be
located beside the machine.
The filled containers are manually taken away from the machine
and new empty containers are manually put onto the pot
supports.
Warning!
Special care shall be taken on section 2 „General safety
instructions”.

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4. Technical data
Make:
Mayer
Machine type:
Potting machine
Series:
2018
Length / width / height:
300 x 130 x 200 cm
Weight:
480 kg
Working height:
approx. 85 cm
Current consumption
:
16 A
Control voltage:
24 V DC
Po
wer connection:
400V/50Hz, 5-pole
Power input:
3,2 kW
Pot size:
containers 25 l and larger
Capacity of soil hopper:
1,5 m³
2,5/3,5/4 m³ on request
Production speed:
depending on container size
Workplace related emission value:
73dB (A)

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Available accessories (for an additional charge)
•Soil hopper extension 2,5 m³
•Soil hopper extension 3,5 m³
•Soil hopper extension 4 m³
•Heavy duty wheels in connection with soil hopper extension
•Conveyor belts
•Roller conveyors and roller curves
•Towing bar
•Stainless steel elevator shovels
•Stainless steel chains
•Special tyres (used for cars)
•Vibrating unit
Important note!
When placing repeat orders for accessories and spare parts,
make sure to have information about the machine type and
number at your hand!

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3. EU declaration of conformity
According to Appendix IIA of the EU Machinery Directive (2006/42/EC)
The manufacturer:
Mayer GmbH &
Co. KG
Maschinenbau u. Verwaltung
Poststrasse 30
89522 Heidenheim | Germany
hereby attests that the machine described in
the following:
Make:
Mayer
Model: Potting machine
Series: 2018
Year constructed: From 2008
fulfils the safety and health requirements of the
following EU Machinery Directive:
2006/42/EC
Harmonised standards applied:
Part 1 EN ISO 12100-1
Part 2 EN ISO 12100-2
EN ISO 13857
ISO 13854
EN ISO 13849-1
EN ISO 14121
ISO 14119
ISO 13850
IEC 60204-1
Safety of machinery, basic terminology, general guiding
principles for organisation
Part 1: Basic terminology, methodology
Part 2: Guiding technical principles and specifications
Safety distances to keep the upper limbs from reaching
danger points
Safety of machines, minimum distances to avoid any
crushing of body parts
Safety-related parts of control systems
Part 1: General principles for design
Principles for risk assessment
Interlocking devices associated with guards
EMERGENCY SHUT-OFF systems
Electrical equipping of industrial machines
Part 1: General requirements
Any design alterations that effect the technical specifications given in the Operating Instructions or
the intended use, i.e. change the machine substantially, will invalidate this EU Declaration of
Conformity.
Heidenheim, 01 October 2009 ......................................
Dipl.-Ing. (TU)
1
Arpad G. Meszaros
Head of Development and Design
1
Graduate engineer (from a technical university)

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2 General safety instructions
1. Due diligence of the operating company
The MAYER TM 2018 potting machine was designed
and built taking a danger analysis into consideration
and after careful selection of the harmonised
standards to be complied with as well as other
specifications. It therefore meets the state of the art
and guarantees a maximum degree of safety.
However, only if all the measures required for such
are taken can this safety be achieved in actual
operational practice. Planning these measures and
checking their implementation is subject to the
operating organisation's duty to take due care.
The operating organisation must in particular
guarantee that:
•… the machine is only used in accordance
with its intended use (cf. the Product
description section).
•… the machine is only operated when in
flawless working order and, especially,
that the working order of the safety
equipment is regularly checked.
•… the Operating Instructions are always
available in legible condition and complete
at the location where the machine is used.
•… only sufficiently qualified and authorised
personnel operate, service and repair the
machine.
•… these personnel are regularly instructed
about all relevant matters concerning
industrial safety and environmental
protection and that they know the
Operating Instructions and especially the
safety instructions they contain.
•… none of the safety and warning signs
attached to the machine are removed and
that all remain legible.
•Users must obligate themselves only to
ever operate the machine when it is
flawless condition.
•No unauthorised conversions or
alterations are allowed that influence the
machine's safety.
•Only when it has stopped, must any work
ever be carried out on the machine.

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•Before beginning with any work on the machine,
secure its drives and accessory parts against
being switched on unintentionally.
•The protective devices may only be removed
when the machine has been stopped.
•Local safety and accident-prevention
regulations always apply to any operation of the
machine.
•The machine may not be started if any safety
devices are removed.
•In the working area the operator is responsible
for other people.
•In case of non-compliance with any one of
the points cited above, the manufacturer
shall be released from all liability.
1. Explanation of the safety symbols used
The safety symbols along with the text of the safety instructions
are meant to point out unavoidable residual dangers that exist
when dealing with this machine. These residual hazards relate
to:
•People
•The machine
•Other things and objects
•The environment
The following safety symbols are used in these Operating
Instructions:
This symbol indicates that there are dangers to the machine,
things and the environment, but that no dangers to people are
to be expected.
If these instructions are not followed, it might result in
malfunctions and damage to the machine. Property damage
and environmental damage might also come about
This symbol identifies instructions contributing to better
understanding of the machine information that helps you to use
the machine in optimum fashion. This symbol does not identify
safety instructions.
This symbol warns against the danger of electric shock.
Be sure to also note that a safety symbol can never replace the
text of safety instructions—the text of safety instructions must
therefore always be read completely!

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3. Basic safety precautions
Always be sure that:
•… tight-fitting working clothes are worn at all the
workplaces.
•… it is not allowed to wear chains, rings, bracelets or
wristbands.
•… for operationally relevant reasons, it is not possible to
completely cover the compost hopper.
•… it is not allowed to reach into the compost hopper (to
push in more soil, for example), because when doing so
there would be a danger of getting caught by the scraping
chain.
•… it is not allowed to get into the compost hopper while the
machine is running.

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4. Machine-related safety precautions
The workplaces are spread over various areas of
the potting machine.
a) Filling the soil hopper with substrate from the
rear or from the right or left side.
b) Putting containers onto the pot supports, filling
containers with soil and potting plants on the front
side of the machine.
Responsibilities for the various activities must be
clearly defined and complied with.
Unclear competencies represent a safety risk.
In case of malfunctions during the work flow it is
forbidden to touch the running machine in order to
resolve the malfunction.
It must always be possible to access the
emergency cut-off switch.
The emergency cut-off switch should always be
located on the relevant workplace (during normal
operation preferably on the panel, next to the right
of the worker).
It is forbidden to climb onto the running machine.
The machine must be set up on even and solid
surface so that it stands securely in place.
There is danger of life in case of a machine falling
over.
The floor (workplaces at the machine and traffic
routes) must be regularly cleaned from dirt and
water in order to avoid danger of slipping.
Stumbling blocks in the form of cables connected to
the energy supply systems must be avoided
All feed lines to the machine must be protected
against damage.
Only a skilled electrician is allowed to carry out
works on the electrical equipment.
Protection devices
•are fitted for the safety of operating personnel
•must in no case be changed, removed or
evaded by modifications to the machine.
Frequency converters can cause fault currents that
are not detected by means of a standard earth
leakage circuit breaker. So the machine may be

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5. Demands on operating personnel
The machine may only be operated by personnel
who have been trained for such, shown what is
involved and are authorised to do so. These
individuals have to know and act in accordance with
the Operating Instructions. The respective
authorisations for the operation personnel must be
clearly prescribed.
In addition to this, special qualifications are required
for the following activities:
Operation personnel being trained may at first only
work with the machine under the supervision of an
experienced individual. It should be confirmed in
writing that the training has been successfully
completed.
Only trained personnel may ever operate any of the
control and safety equipment.
All individuals that carry out any activities with the
machine have to read the Operating Instructions
and confirm by their signature that they have
understood the Operating Instructions.

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3 Transport
To prevent damage to the machine as well as
injuries while transporting the machine, it is
absolutely necessary to comply with the
following points:
•The transport work may only be carried out by
individuals qualified to do so, complying with
the safety instructions.
•The machine may only be lifted by the
supporting points provided for such.
•Only the load-lifting devices and tackle
specified here may be used to transport the
machine.
•Be sure to also read the "General Safety
Instructions" section.
When transporting the machine, the following
special dangers must be expected:
•Suspended loads can drop, which would be a
lethal danger – never go under suspended
loads!
•If load-lifting equipment other than that specified
here, severe damage to the machine may
result.
1. Transport
When the machine is transported special care shall be taken to
avoid damage of the machine during loading or unloading.
During transport fixings according to type of transport shall be
implemented.
Moisture condensation caused by temperature difference during
transport as well as shocks during transport shall be avoided.
The machine shall be operated with usual care.
It is recommended to use a relevant attachment when loading
or unloading the machine by means of a forklift

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2. Handling
The potting machine is fitted with 2 pneumatic tyres on one axle
on the front and 2 castors on the soil hopper. The weight of the
empty machine is balanced on the axle. The machine can be
pushed and pulled. On request, a trailer coupling can also be
attached for an extra charge.
If the machine is to be moved over an inclined plane, it is
necessary:
•to completely empty the soil hopper,
•to make sufficient safety precautions in order to prevent the
machine from accidentally rolling away.
Such precautions may include:
•enough personnel
•to secure the wheels using a wedge
•and so on
3. Storage
When the machine or its parts are not reassembled right after
transport, then they shall be carefully stored on a protected
area. It shall regularly be covered and protected against dust
and moisture.
Tasks for putting out of operation are detailed in section 6.3.

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4 Installation
1. General notes
a)
To protect the machine against weather caused damages it is
suggested to use and store it inside.
b)
Electrical connection: 400V/50Hz.
Connection is permitted only to socket-outlets which are
protected by an AC/DC sensitive RCCB (residual-current circuit-
breaker) 0,03A.
c)
Be sure that enough space is assured for feeding and filling
pots. Same care shall be taken in case of machines connected
in front of or behind it.
d)
In order to capacity of the machine to be used efficiently it is
suggested the soil mixture, seedling, plants and pots to be
prepared on the best place and in sufficient quantity.

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2. Installing the machine
a)
A hard soil surface shall be provided under the machine to
prevent the wheels and castors from sinking into the soil.
b)
The castors are equipped with a handbrake.
3. Measures for the machine’s stability against overturning
There is no need to carry out other activity for erecting the
machine than it is described in section 4.2.
4. Disassembly and disposal of the machine
After completion of its full time of operation, the machine must
be duly separated from energy supply systems and disposed of
according to valid legal regulations.

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5 Initial start-up
It is absolutely necessary to comply with the
following safety instructions for the initial start-up of
the machine. This will prevent injury to individuals,
damage to machinery and other property damage.
•The initial start-up may only be carried out by
qualified individuals, complying with the safety
instructions.
•Before the first start-up, check whether all the
tools and parts not belonging in it have been
removed from the machine.
•Before the first start-up, check the electrical
connections.
•Activate all the safety equipment and
EMERGENCY SHUT-OFF switches before the
initial start-up.
•Also read the section "General Safety
Instructions".
1. Check prior to first start
Prior to starting up the machine, the following must
be checked:
•are all safety devices available?
•was the machine damaged during transport?
•all visible bolted joints must be checked for tight
seat.
•Prior to putting the machine into operation, the
machine’s connecting cable and the cable of
the emergency cut-off switch must be checked
for damages.

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1. Starting the machine for the first time
After reassembly the machine shall be checked as per the following:
a)
Be sure not foreign materials, such as tools or similar, are left in the
soil hopper, in the elevator or under the pot supports.
b)
Put main switch of the machine to OFF („Null”) position before plug of
the connection cable would be connected to the socket.
c)
When the machine is connected, push the button “Start”.
d)
Care shall be taken on the following:
With the switch, “Soil” means:
•Position “1”:
> smaller amount of soil and less speed
•Position “2”:
> larger amount of soil and more speed
Warning!
•Switch position to right: elevator and conveyor belt are moved in
normal operational direction.
•Switch position to left: conveyor belt is moved in normal operational
direction while elevator is moved in opposite direction.
e)
In case of there were no problems found or unusual noises heard
during test operation, the machine may be put into operation as it is
described in section „Operation”.

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Emergency
stop
Switch vibrator
(optional)
Switch
soil
Emergency stop
Controller vibrator
(optional)
Button
START
Button
STOP