Mayer EM 6012 User manual

I
ssue date: 01.
03
.201
4
/ V1.
3
Before the initial start-up, read and keep at the machine for future use.
Operating instructions
Soil mixer EM 6012

2
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
2.3 V-belt
3. Maintenance schedule
9 Part list
10 Circuit diagrams for electric and
pneumatic system
11 Guarantee

3
1 Product description
1. Intended use
The MAYER Soil mixer EM 6012 may be used for precise
mixing of different soils in the shortest possible time to meet
your requirements and in accordance with your experience.
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 Soil mixer EM 6012 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 Soil mixer EM 6012 takes responsibility.

4
2. Structure
Plan view of soil mixer EM 6012
back
right
left
front

5
3. Functional description
The task of the soil mixer is to mix various components into a
soil which meets the needs of the plants.
A rubber conveyor belt inside the soil hopper transports the
components towards the elevator which is swivelled backward.
The elevator chains and the rubber conveyor belt turn
continuously, thereby mixing the soil. The mixing time can be
selected as required.
After the mixing time has elapsed, the elevator swivels forward
into the unloading position. The soil is now transported out of
the soil mixer into a waiting container or the soil hopper of the
potting machine. It is also possible to select the discharging
time.
A moistening system is available as an accessory. It can be
installed in order to moisten the soil before it is discharged.
Mixing
Emptyi
ng
from the front
Emptying
from the rear

6
4. Technical data
Make:
Mayer
Machine type:
Soil mixer
Series:
6012
Leng
th, retracted / extended:
299 / 366 cm
Width:
187 cm
Height, retracted / extended:
219 / 243 cm
Weight
1380 kg
Power connection:
400V/50Hz, 5-pole
Power input:
0,7 kW
Capacity of soil hopper
:
2 m³
Workplace related emission value
:
70dB (A)
Available accessories (for an additional charge)
•watering device (with ball tap)
•watering device (with magnetic valve)
•heavy-duty execution for extreme soils with heavy-duty motor
•towing bar
•emptying control (Laser light sensor)
•emptying by means of pedal switch
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!

7
5. 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: Soil mixer
Series: 6012
Year constructed: From 2011
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 March 2014 ......................................
Dipl.-Ing. (TU)
1
Arpad G. Meszaros
Head of Development and Design
1
Graduate engineer (from a technical university)

8
2 General safety instructions
1. Due diligence of the operating company
The MAYER soil mixer EM 6012 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.

9
•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!

10
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 soil hopper.
•… it is not allowed to reach into the soil 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 soil hopper while the
machine is running.

11
4. Machine-related safety precautions
The workplaces are spread over various areas of
the soil mixer.
a) Controlling the working steps from the control
desk.
b) Filling the soil hopper with soil from the rear,
from the right-hand side or from the left-hand side.
c) Monitoring the discharging cycle
•When discharging from the front: Next to the
container being filled
•When discharging from the rear: Next to the
rear of the soil mixer
Responsibilities for the various activities must be
clearly defined and complied with.
Unclear competencies represent a safety risk.
The side walls of the soil hopper do provide a
certain degree of protection against the revolving
elevator chains.
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

12
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.

13
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.

14
2. Handling
The soil mixer is fitted with 2 pneumatic tyres on one axle on
the front and 2 feet on the soil hopper. A tow bar makes it easy
to move the machine over level ground.
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.

15
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.
The machine must be connected to a socket which has a 0.03
amp residual current operated 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.
2. Installing the machine
a)
A hard soil surface shall be provided under the machine to
prevent the wheels and feet from sinking into the soil.
b)
Make sure the individual components of the soil to be mixed
and the finished soil after mixing only need to be transported a
short distance.
Setup example:
Potting
machine
Soil mixer

16
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.

17
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.

18
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 or in the elevator.
b)
The elevator is secured by a transport fixture in order to protect
the spindle of the swivel drive against excessive loading during
transport.
It is essential that this transport fixture (strut between the
elevator and the soil hopper) is removed before the machine is
taken into operation
c)
Put main switch of the machine to OFF („Null”) position before
plug of the connection cable would be connected to the socket.
d)
The MAYER soil mixer is fitted with a phase-sequence
watchdog which ensures it always moves in the same working
direction.
If the "Control on" check lamp on the control cabinet does not
light up after the start key is pressed, this indicates that the
phase-sequence watchdog has been triggered and the polarity
of the socket must be reversed.
Check all sockets on your premises to make sure they have the
same polarity. This is a safeguard for you as well as

19
guaranteeing that the machine will move in the same working
direction no matter which of your sockets it is connected to.
IMPORTANT!
Only specialist personnel are allowed to perform work on the
electrival system.
e)
•Set the "Mixing time" dial to a short running time for the
mixing cycle.
•Turn the "Elevator" switch to "Forward 1" and the
"Discharging" switch to "Continuous".
•Set the master switch to "1 ON".
•The mixing cycle is started by pressing the "Start" key.
("Control on" comes on.)
•The machine operates for the preset mixing time.
•The elevator automatically swings forward into the
discharging position after the mixing time has elapsed.
•Interrupt the discharging cycle by setting the "Discharging"
switch to "0".
•Press the stop key.
f)
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”.

20
3. Stopping the machine
There are two ways provided to switch off the machine.
a)
In normal case by switch „Stop” mounted on the switch board.
b)
In emergency case by „Emergency Stop” switch.
Note:
See also section "6.2 – Shutting down the machine"