Mayer TM 2400DR User manual

Issue date: 01.08.2020 / V1.7
Before the initial start-up, read and keep at the machine for future use.
Operating instructions
Potting machine TM 2400DR

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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 Guarantee

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1 Product description
1. Intended use
The MAYER TM 2400DR potting machine may be used for
planting and replanting plants 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 2400DR 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 2400DR potting machine takes responsibility.

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2. Structure
Plan view of potting machine 2400DR
back
right
left
front

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3. Functional description
a) Working without automatic pot dispenser
When there is no pot dispenser installed then empty pots are
loaded by one person on the turntable located on the right side
of the machine when it is viewed from front side.
The turntable is driven by a worm drive mechanism and is
moved intermittently in counter clockwise.
The pots are forwarded under the elevator.
Plates are fixed on endless chains located in the elevator
housing which take the soil from the hopper. When the plates
reach the upper turning point the soil falls into pot being there.
A controlled conveyor belt is installed into the soil hopper which
forwards the soil always towards the elevator.
The turntable is inched and a drilling motor being synchronous
with the inching mechanism drills a hole into the soil that’s
inside the pot by means of a replaceable drill.
One or several person(s) standing around the machine may
plant plants into the pots. Plant holding trays may be located
either beside the machine or in a separate storing place or on
top of the turntable.
A pot take-off is installed to remove the planted pots from the
turntable and to push them on a conveyor belt connected to the
machine.
Warning!
When there is no automatic pot dispenser installed, special
care shall be taken on section 2 „General safety
instructions”.

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b) Working with automatic pot dispenser
When there is an automatic pot dispenser installed then feeding
by hand is not necessary and one person may be saved.
Further instructions are detailed in Operation instructions of pot
dispenser.
4. Technical data
Make:
Mayer
Machine type:
Potting machine
Series:
2400DR
Length / width / height:
410 / 190 / 195 cm
Weight:
1,500 kg
Working height:
approx. 92 cm
Power connection:
400V/50Hz, 5-pole
Power input:
3 kW
Pot size:
8 –13 cm diameter
(for round and square pots)
Capacity of soil hopper:
1,500 litres
2,200/3,000/4,500 litres on request
Production speed:
Up to 7,000 pots/hour (with double pot
holder)
Usable drill sizes:
2 -13 cm
larger drill diameter on request
Workplace related emission value:
73dB (A)

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Available accessories (for an additional charge)
•Drill sleeve 100 mm
•Standard drills from 3.5 –13 cm
•Special drills from 3.5 –16 cm
•Container drill from 11 –16 cm
•Plate from 4.0 –14 cm
•Plates for tree nurseries from 12 –18 cm
•Closed pressure plate
•Special pressure plate
•Chrysanthemum plate
•Plates for pouring edge
•Roller conveyor and roller curves
•Counting device
•Various belt storage dispensers
•Automatic pot transport in combination with conveyor belts
•Broadening devices and attachments for soil hoppers
•Trailer coupling
•Stainless steel elevator buckets
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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5. EU declaration of conformity
According to Appendix IIA of the EU Machinery Directive (2006/42/EC)
The manufacturer:
Mayer Ipari és Kereskedelmi BT.
Georg Mayer út 1. 9341 Kisfalud / Magyarország
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: 2400DR
Year constructed: From 2020
fulfils the safety and health requirements of the
following EU Machinery Directive:
2006/42/EC
Harmonised standards applied:
EN ISO 12100:2011
Safety of machinery. General principles for design. Risk
assessment and risk reduction (ISO 12100:2010)
EN 60204-1:2010
Safety of machinery. Electrical equipment of machines. Part 1:
General requirements (IEC 60204-1:2005, modified)
EN ISO 13849-1:2016
Safety of machinery. Safety-related parts of control systems.
Part 1: General principles for design (ISO 13849-1:2015)
EN ISO 13850:2008
Safety of machinery. Emergency stop. Principles for design
(ISO 13850:2006)
EN ISO 13857:2008
Safety of machinery. Safety distances to prevent hazard zones
being reached by upper and lower limbs (ISO 13857:2008)
EN ISO 14119:2014
Safety of machinery. Interlocking devices associated with
guards. Principles for design and selection (ISO 14119:2013)
EN 349:1993+A1:2008
Safety of machinery. Minimum gaps to avoid crushing of parts
of human body.
EN ISO 14120:2016
Safety of machinery. Guards. General requirements for the
design and construction of fixed and movable guards. (ISO
14120:2015)
EN 1037:1995+A1:2008
Safety of machinery. Prevention of unexpected start-up
EN ISO 14738:2009
Safety of machinery. Anthropometric requirements for the
design of workstations at machinery.
(ISO 14738:2002, + Cor 1:2003 + Cor 2:2005)
EN 1005-2:2003+A1:2009
Safety of machinery. Human physical performance. Part 2:
Manual handling of machinery and component parts of
machinery
EN 1005-5:2007
Safety of machinery. Human physical performance. Part 5: Risk
assessment for repetitive handling at high frequency.

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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, 01.08.2020. .....................................
Geschäftsführer | Managing Director

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2 General safety instructions
1. Due diligence of the operating company
The MAYER TM 2400DR 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.
2. 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.

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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.
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.
•… it is not allowed to reach into the turntable or pot
dispenser while the machine is running.
•… it is not allowed to reach into the drilling stand while the
machine is running.
•… it is not allowed to reach into the pot transfer 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) Feeding pots into the rotating assembly (for a
machine without pot dispenser) or feeding pots into
the pot dispenser (for machines with pot dispenser)
on the right side of the panel.
b) Filling the soil hopper with substrate from the
rear or from the right or left side.
c) Potting plants on the front left of the panel,
between drilling stand and pot transfer.
Alternatively, they can also be potted on the
conveyor belts.
Responsibilities for the various activities must be
clearly defined and complied with.
Unclear competencies represent a safety risk.
Persons who are engaged in putting single pots into
the rotating assembly must have been given
separate training, during which it was pointed out to
them that there is a potential danger of being drawn
into the machine if they got stuck at the rotating
assembly.
For procedural reasons it is not possible for the
rotating assembly to be covered.
When potting at the rotating assembly, there is a
potential hazard of getting stuck in there due to
carelessness or wearing further additional clothing
or jewellery.
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.

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Frequency converters can cause fault currents that are not
detected by means of a standard soil leakage circuit breaker.
So the machine may be operated with an AC/DC sensitive
RCCB (residual-current circuit-breaker) only.
Frequency converters have built-in capacitors that discharge
after switching off the machine. The machine’s connecting plug
may be pulled out of the outlet not before approx. 1 to 2
minutes after switching off the main circuit breaker.
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 with handbrake 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).
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, pots, trays to be
prepared on the best place and in sufficient quantity.
It is not suggested to under-estimate job to remove and
transport the filled pots, since an insufficient solution may
considerably decrease efficiency of the machine.

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2. Installing the machine
a)
A hard soil surface shall be provided under the machine to
prevent the wheels and lags from sinking into the soil.
b)
In order to ease the pneumatic tyres, prop up the machine
using the pedestals.
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.
•Transport securing, please remove before
installation

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2. 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
on the turntable.
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, put the switch to
„1 ON” position.
d)
Put switch of turntable to „1 ON” position, while
switch of elevator and conveyor belt to right to
position „1”, as well as switch of drill to position „2”.
Press pushbutton „Start” on „Start-Stop” switch of
swinging cable and the turntable starts to rotate
counter clockwise.
If it would rotate clockwise then call for an
electrician to change phases at the connecting
cable.
Plates of the elevator shall be forwarded from
bottom towards top seeing from side of soil hopper.
Care shall be taken on the following:
With the potentiometer, “Soil” means:
•turn to the right
> larger amount of soil and more speed
•turn to the left
> smaller amount of soil and less 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.
Changeover switch „Drill” ("Bohrer"):
•switch position „2”: drill is rotated clockwise
> it excavates the soil.
•switch position „1”: drill is rotated counter-
clockwise > it compacts the soil.
(only possible with standard drill)
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”.