Mayer 1417 User manual

Issued: 20th February 2020
Please read these instructions before taking the conveyor into operation and
keep them for future use at the conveyor
Operation instructions
Conveyor
with cardan shaft
1417,1421,1425,1430

2
Contents
1 Technical data
1 Intended use
2 Structure
3 Functional description
4 Technical data
5 EC Declaration of conformity
2 General safety instructions
1 Due diligence of the operating company
2 Explanation of safety symbols used
3 Basic safety precautions
4 Machine-related safety precautions
5 Demands on operating personnel
3 Transport, handling and
storage of the conveyor
1 Transport
2 Handling
3 Storage
4 Installation
1 General notes
2 Installing the conveyor
3 Measures for the conveyor ‘s stability against
overturning
4 Disassembly and disposal of the conveyor
5 Initial start-up
1 Check prior to first start
2 Starting the conveyor for the first time
3 Stopping the conveyor
6 Operating instructions
1 Settings
2 Normal operation
3 Shutting down the conveyor
4 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
3 Maintenance schedule
4 MAYER –Service stations
9 Part list
10 Circuit diagrams
11 Guarantee

3
1 Product description
1 Intended use
The MAYER conveyor may be used for transporting pots filled
with soil from the last workstation of the potting machine.
Other means of use of the conveyor, besides the ones listed here,
are not permitted –and they are not the usage for intended
purpose.
If the MAYER conveyor is not used in accordance with the
regulations, safe operation of the conveyor is not guaranteed.
The usage for intended purpose involves reading of operating
instructions, and compliance with the regulations, especially
safety regulations stated in them. Furthermore, every inspection
and maintenance should be performed in specified time.
The manufacturer accepts no liability for damages resulting from
improper use. The operator of the MAYER Conveyor is solely
responsible for personal injuries or property damages.

4
2 Structure
Structure of the conveyor:
Drive belt (type G)
Clutch belt (type J)
motor with
gearbox
profile
clamping unit
electrics
cardan shaft
profile
clamping unit
cardan shaft

5
3 Functional description
The conveyor is powered by an adjustable gear motor
(type G).
The motor drives the cardan shaft with a chain underneath
the conveyor.
This cardan shaft drives the drive rollers of the belt with an
angle gear and gear wheels. The clutch belt (type J) does
not have a motor, it needs to be clutched on Type G, it is
driven by that.
The clamping unit enables precise setting of belt tension
and belt running.
Special coupling devices at each end of the conveyor belt
allow several conveyor belts to be assembled into long
lines.
The cardan shaft has gear wheels at each end, with the
help of which the drive belt can drive the clutch belt.

6
4 Technical data
Manufacturer
Mayer
Type of machine
Conveyor
Standard length
1 m –2 m –3 m –4 m –5 m –6 m
Special length
…… m
Width of belt
Type 1417: 170 mm
Type 1421: 210 mm
Type 1425: 250 mm
Type 1430: 300 mm
Weight (with drive)
25 cm wide, 6 m long „G”= 82 kg
25 cm wide, 6 m long „J”= 49 kg
Weight of drive
18 kg
Drive
adjustable geared motor
Conveying speed
adjustable: 2,5 –13 m/min
Electrical power connection (type G)
400V/50Hz, 5 pole
Energy consumption
0,55 kW
Pot size
pot diameter between 5 - 32 cm
Noise level
70 dB (A)

7
5EC –Declaration of Conformity
In accordance with Annex II / A of the EC Machinery Directive (2006/42/EC)
The manufacturer: Mayer Ipari és Kereskedelmi BT.
Kossuth str. 106. 9341 Kisfalud / Hungary
Mayer GmbH & Co. KG
Maschinenbau und Verwaltung
Poststr. 30 89522 Heidenheim / Germany
hereby attests that the machine described in
the following:
Manufacturer: Mayer
Type: Conveyor
Series: 1417,1421,1425,1430,1435
Year of construction: since 2019
fully meets the health and safety regulations
specified in the following EC Machinery
Directives:
Applicable harmonized standards:
2006/42/EK
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 13855:2010
Safety of machinery. Positioning of safeguards with
respect to the approach speeds of parts of the human
body (ISO 13855:2010)
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 618:2002+A1:2011
Continuous handling equipment and systems. Safety
and EMC requirements for equipment for mechanical
handling of bulk materials except fixed belt conveyors

8
EN 619:2002+A1:2011
Continuous handling equipment and systems. Safety
and EMC requirements for equipment for mechanical
handling of unit loads.
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.
Any constructional changes that affect the technical parameters and intended purpose set forth in
this Instruction Manual are bound to result in considerable changes in the conveyor and will,
therefore, render this EC Declaration of Conformity void.
Heidenheim, 20th February 2020
......................................
Geschäftsführer | Managing Director
Ügyvezető igazgató

9
2 General safety instructions
1 Due diligence of the operating company
Mayer conveyor belts –1417,1421,1425,1430,1435 –
are 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 of technics and guarantees a maximum degree
of safety.
However, this safety can only be achieved in actual
operational practice only if all necessary measures
are taken. Planning these measures and checking
their implementation is subject to the operating
organisation's duty to take due care.
The operation organisation must guarantee in
particular that
•The conveyor is only used in accordance with its
intended use (cf. the Product description section).
•The conveyor 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 conveyor is used.
•Only sufficiently qualified and authorised
personnel operate, service and repair the
conveyor.
•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 conveyor are removed and that all remain
legible.
•None of the safety and warning signs attached to
the conveyor are removed and that all remain
legible.
•Users must obligate themselves only to operate
the conveyor when it is in flawless condition. No
unauthorised conversions or alterations are
allowed that influence the conveyor 's safety.
•Users must obligate themselves only to operate
the conveyor when it is in flawless condition. No
unauthorised conversions or alterations are
allowed that influence the conveyor 's safety.
•Protective devices may only be removed when
the conveyor has been stopped.

10
•The conveyor may not be started if any safety
devices have been removed.
•Local safety and accident-prevention
regulations always apply to any operation of the
conveyor.
•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 safety symbols
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
conveyor. These residual hazards relate to:
•People
•The conveyor
•Other things and objects
•The environment
The following safety symbols are used in these Operating
Instructions:
This symbol indicates there are dangers to the
conveyor, 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 conveyor. Property
damage and environmental damage might also
come about.
This symbol identifies instructions contributing to
better understanding of the conveyor information
that helps you to achieve optimum performance.
This symbol does not identify safety instructions.
This symbol warns about danger of electric shock.
Please note, that a safety symbol can never replace
the text of safety instructions —the text of safety
instructions must therefore always be read
completely.

11
3 Basic safety precautions
Always be sure that:
•The conveyor belt may only be used when it is
plugged into the jack of the potting machine.
•It is not allowed to reach into rotating or running
components. It is only allowed to take pots
down.
•The conveyor must be fixed with supporting feet
to avoid tilting or tumbling.
•The maximum load of the conveyor is 90 kg.
•Cables must be placed without causing barriers.
•Screws must be tightened properly.
•Always make sure that personnel at all
workplaces wear close-fitting working clothes.
•Wearing chains, rings or bracelets during work
is forbidden.

12
4 Machine-related safety precautions
Responsibilities for the various activities must be
clearly defined and complied with.
Unclear competencies represent a safety risk.
Persons who are engaged in operating the conveyor
must have been given special training, during which
it was pointed out to them that there is a potential
danger of being drawn into the conveyor if they got
stuck at the conveyor belt.
For procedural reasons it is not possible for the
conveyor to be covered.
In case of malfunctions during the work flow it is
forbidden to touch the runningbelt in order to resolve
the malfunction.
Access to the emergency cut-off switch must always
be guaranteed.
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 sit on or to transport persons on the
conveyor!
The conveyor must be set up on even and solid
surface so that it stands securely in place.
The floor (workplaces at the conveyor 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 conveyor 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 and must in no case be
changed, removed or evaded by modifications to the
conveyor.

13
Frequency converters can cause fault currents that are not
detected by means of a standard soil leakage circuit breaker.
Therefore, the conveyor 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 conveyor. The conveyor’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 conveyor may only be operated by personnel
who have been trained for such, shown what is
involved and are authorised to do so. These
individuals must know and act in accordance with the
Operating Instructions. The respective
authorisations for the operation personnel must be
clearly prescribed.
In addition, special qualifications are required for the
following activities:
Operation personnel being trained may at first only
work with the conveyor under the supervision of an
experienced person. 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 on the
conveyor must read the Operating Instructions and
confirm by their signature that they have understood
the Operating Instructions.

14
3 Transport, handling, storage
To prevent damage to the conveyor as well as
injuries while transporting the conveyor, it is
essential to comply with the following points:
•Transport work may only be carried out by
individuals qualified to do so, complying with the
safety instructions.
•The conveyor may only be lifted by the
supporting points provided for such (see section
3.2 Handling).
•Only the load-lifting devices and tackle specified
here may be used to transport the conveyor.
•Be sure to also read the "General Safety
Instructions" section.
When transporting the conveyor, 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 conveyor may result.
•Before transporting electrical cables must be
rolled up in order to avoid the risk of tripping over.
1 Transport
When the conveyor is transported, special care shall be taken to
avoid damage of the conveyor during loading or unloading.
During transport fixings according to type and duration of
transport shall be implemented.
Shocks during transport shall be avoided.
The conveyor shall be operated with usual care.

15
2 Handling
The conveyor may only be moved when it is switched off and
without load. Moving the conveyor may be done by hands easily.
Three people are required for handling to avoid accidents.
Ideal lifting points are at the ends of the belt.
The drive belt (type G) must be lifted by at least three people, the
clutch belt (type J) must be lifted by two people.
If the conveyor is to be moved over an inclined plane, it is
necessary:
•To make sufficient safety-related precautions in order to
prevent the conveyor from falling.
Such precautions may include:
•Enough personnel
3 Storage
When the conveyor is not reassembled right after transport, then
it shall be carefully stored in a protected area. It shall properly be
covered and protected against dust and moisture.
Tasks for putting it out of operation are detailed in section 6.3.
Important!
Lack of ideal lifting points or fixation may cause injuries or
property damage.

16
4Installation
1 General notes
a)
To protect the conveyor against damages caused by weather 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 the conveyor. Same
care shall be taken in case of conveyors connected in front of or
behind it.

17
2 Installing the conveyor
The conveyor (type G, J) with cardan shaft can be operated in
the following way:
•The tensioning end of the conveyor belt is hooked into the
pivot bearing of the potting machine, the other end is fixed by
a supporting leg.
•Generally, several conveyors are used asa conveyor system:
after setting up the first belt, the tensioning station of the
additional conveyor belt is hooked into the drive station of the
existing belt from above. In the meantime, the gear wheel at
the end of the drive axle must be clutched with the gear
sleeve at the end of the drive axle of the next conveyor.
•The assembly must always be done by two people, one of
them clutches the upper parts together, the other one
connects the gear wheel and the gear sleeve.
In case of conveyors with a width of 21 cm, one unit of type G
can drive 5 units of type J.
In case of conveyors with a width of 25 cm or 30 cm, one unit of
type G can drive max. 4 units of type J.
It is recommended to set up the drive unit (type G) in the middle,
so that (almost) the same number of units J can be driven
(symmetrical assembly).

18
Attention! If a longer assembly line is needed, two drive units
(type G) can be set up in the line, but in this case the drive axle
between the drive units must not be connected mechanically.
In this case, the sleeve with the gear coupling must be
dismantled.
For that one piece of screw M 6X25 and one self-locking nut M6
must be removed and the end of the axle can be pulled off.
3 Measures for the conveyor’s stability
against shifting
To avoid shifting –in case the stands can be screwed –every
stand must be fixed with two dowels to the floor.
4 Disassembly and disposal of the conveyor
After completion of its full time of operation, the conveyor must
be duly disconnected from the power supply and disposed of in
a manner according to valid legal regulations.
Dismantle!

19
5 Initial start-up
It is essential to comply with the following safety
instructions for the initial start-up of the conveyor.
This will prevent injuries to individuals, damages to
machinery and other property damages.
•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 to it have been
removed from the conveyor.
•Before the first start-up, check the electrical
connections.
•Be sure that the cover of the roller, chains and
axle is placed correctly.
1 Check prior to first start
Prior to starting up the conveyor, the following must
be checked:
•If all safety devices are available.
•If the conveyor was damaged during transport.
•All visible screws must be checked for tight seat.
•Prior to putting the conveyor into operation, the
conveyor’s connecting cable and the cable of the
emergency cut-off switch must be checked.

20
2 Starting the conveyor for the first time
After reassembly the conveyor shall be checked as
per the following:
a)
Be sure no foreign materials, or tools are left on the
belt.
b)
Put main switch of the conveyor to OFF („Zero”)
position before the plug of the connection cable
would be connected to the socket.
c)
When the conveyor is connected, put the switch (1)
to „ON” position.
d)
After starting a potting machine, the rotation direction
switch (2) must be rotated in a direction that the
conveyor belt must move from the potting machine
towards the roller of the conveyor.
e)
In case there were no problems found or any
unusual noises heard during test operation, the
conveyor may be put into operation asit is described
in section „Operating instructions”.
f)
On conveyors with an adjustable geared motor there
is a wheel (3). The speed of the belt can be adjusted
with this wheel.
Adjust the speed of the conveyor only if the
conveyor belt is running.
g)
Should the belt start to move to the side or mistrack,
adjust it according to section 8.2.
11
1 2
3