Mayer TR 4103 User manual

Falsches ww wwBil
Date of Issue: 01.02.2016 / V1.0
Read carefully before installation, commissioning and operation. For further reference
please keep this manual within easy reach of the equipment at all times.
Instruction manual
Pot handling robot TR 4103

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Table of contents
1 Product description
1. Intended Use
2. Structure of POT HANDLING ROBOT TR 4103
3. Functions of the machine
4. Technical specifications
5. EC Declaration of Conformity
2 General safety instructions
1. Operator’s duty of care
2. Explanation to the safety signs and symbols
used
3. Basic safety measures
4. Machine-specific safety measures
5. Requirements regarding the operating personnel
3 Transportation
1. Transportation
2. Storage
4 Installation
1. General information
2. Installation of the machine
3. Requirements for structural stability
4. Dismantling and disposal of the machine
5 Commissioning
1. Inspection prior to the initial commissioning
2. Initial start-up of the machine
3. Stopping the machine
6 Operation
1. Standard operating procedures
2. Shutdown procedure
3. Measures before and after a prolonged standstill
period
7 Machine malfunction
1. Malfunction procedures
2. Malfunctions, probable causes and corrective
action
8 Maintenance
1. General information
2. Maintenance schedule
9 List of spare parts
1. Mechanical spare parts
2. Electrical spare parts
10 Pneumatic and electrical diagrams
11 Warranty

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1 Product description
1. Intended use
The MAYER POT HANDLING ROBOT model
TR 4103 offers optimized solutions for various
indoor plant transport and pot handling processes.
The MAYER POT HANDLING ROBOT TR 4103
can be used for the following purposes:
a) Placing plant pots on mobile benches
The plant pots are arranged on a conveyor belt by
means of an accumulator at a preselected
distance. From there the MAYER POT HANDLING
ROBOT TR 4103 places them onto the mobile
benches standing by the conveyor system.
It can further be selected by the user whether the
pots should be placed in parallel rows or alternating
rows.
b) Removing plant pots from mobile benches
With the help of the MAYER POT HANDLING
ROBOT model TR 4103 pots can be removed from
mobile benches and placed onto a conveyor belt.
c) Spacing pots
(With at least 2 interlinked POT HANDLING
ROBOTS in operation)
The first POT HANDLING ROBOT lifts the pots
from the mobile bench and places them onto the
conveyor belt.
The second POT HANDLING ROBOT places AND
spaces the pots as described under
a) ‘Placing plant pots on mobile benches’.
d) Sorting potted plants
(With at least 3 interlinked POT HANDLING
ROBOTS in operation)
The first POT ROBOT lifts the pots from the mobile
bench and places them onto the conveyor belt.
While on the conveyor belt, the pots are sorted and
each sort is transported to a corresponding POT
HANDLING ROBOT by means of conveyor belts.
Any utilization of the machine other than the
intended uses specified in this Instruction manual is
considered improper use.
Should the MAYER POT HANDLING ROBOT
model TR 4103 be used for anything other than its
intended purpose, a safe operation of the machine
cannot be guaranteed.
In order to fulfil the requirements for proper use
and care, this instruction manual must be fully read
and all included instructions must be strictly
followed, with special regard to the ones on health
and safety. Under this term it is further required
that all inspection and maintenance duties are
carried out on a regular basis at the specified time
intervals.
All personal injury and property damage claims
arising from an improper use of the machine shall
become void. The producer excludes liability for
any such injury or damage and all responsibility
shall be borne exclusively by the user/ operator of
the MAYER POT HANDLING ROBOT TR 4103.

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2. Structure
Top view of POT HANDLING ROBOT TR 4103
rear
right
left
front

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3. Functions of the Machine
a) Placing of pots
The pots are transported by means of conveyor
belts to the accumulator of the MAYER POT
HANDLING ROBOT TR 4103. The accumulator
arranges the pots at a preselected distance from
one another, which facilitates an easy and smooth
lifting of the pots.
Once the number of plant pots within the
accumulator reaches the required and pre-set level,
the locking cylinder stops the feeding process. The
pots transported towards the accumulator during
the pot placing process are collected in the pre-
accumulator.
The count switch on the accumulator actuates the
placing process. The lifting unit controlled via two
cylinders swivels in. During the pot placing
operation the pot-filled lifting fork is held in a
horizontal position by means of a chain between
the cylinders and the pot lifting unit.
When the cylinders are retracted, an electric motor
is started. With the help of a chain on the left and
right hand side this motor enables the fork with the
pots to move over the table positioned via electrical
table feed. Once the fork is over the table, the pots
will be placed on it and released, and the pot lifting
unit swivels out.
Now the arm moves back into its starting position
over the conveyor belt and waits until the
accumulator is filled with pots again.
While the arm is swivelling back and inwards again,
the table is rolled forwards by the table feed by a
previously set path length in order to secure
enough space for the next row of pots to be placed
on the table.
Once the accumulator is filled with pots, the placing
process starts again.
b) Lifting of pots
For the lifting of plant pots from the mobile benches
no accumulator is required.
The pot lifting fork must be equipped with at least
one switch.
Once the mobile bench has taken up its position
after the start, the fork swivels over the bench. The
lifting unit swivels in and the table feed starts to
move the pots towards the fork. The table feed
keeps running until a switch on the fork is activated.
The pot lifting unit then slightly lifts the pots from
the table, following which the table feed rolls the
table back by a previously set path length so that
plants eventually grown into each other can be
disentangled.
Once the process is ended and a light sensor
signals that the conveyor belt is clear, the fork with
the pots moves over the unmoving conveyor belt
and places the pots on it.
The pot lifting unit then swivels back and the
conveyor belt starts to move.

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Table
Accumulator
Pre-accumulator
Pot handling robot
TR 4103
Conveyor belt
Table feed
Mayer
pot handling robot

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Pots fed from the left
Pots fed from the right
Table
Table
Accumulator
Accumulator
Pre-accumulator
Pre-accumulator
Pot handling robot
TR 4103
Pot handling robot
TR 4103
Pots in alternating rows
Pots in alternating rows
Gaps between pots freely
adjustable
Gaps between pots freely
adjustable
Pots in parallel rows
Pots in parallel rows

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4. Technical specifications
Manufacturer:
Mayer
Type of machine:
Pot handling robot
Model no.:
TR 4103
Length:
2740 mm (incl. table drive)
Width:
700 mm (excl. table drive)
Height:
2050 mm (minimum ceiling height =
2500 mm)
Weight:
370 kg (incl. control cabinet)
Current consumption:
10 A
Voltage:
400V/50Hz, 5-phase
Compressed air supply:
max. 9 bar / min. 5 bar
dry, filtered compressed air
Air consumption:
ca. 80 l/min. per pot handling robot at 7 bar
Pot sizes:
diameters of 8 to 14 cm
(depending on pot type and manufacturer)
Alternation:
max. 140 mm
Fork width:
when working with alternation max. 1600 mm
when working without alternation max. 1740 mm
Table width (inner) with alternation:
max. 1640 mm + alternation
Table width (inner) without alternation:
max. 1780 mm
Additional parts:
Forks and accumulators to be selected according
to pot size and gap between pots
Hourly output rate:
see output chart
Workplace-related emission value:
70dB (A)
Output chart
The output rates of MAYER POT HANDLING ROBOT TR 4103 are influenced by the diameter of
the applied pots as well as the table width.
The output rates presented in the following chart are based on theoretical calculations.
Pot diameter
(mm)
Output/
hour
Output per
8 hours
Output/day
at 80% cap. util.
80
6,000
48,000
38,400
90
6,000
48,000
38,400
100
5,000
40,000
32,000
120
4,000
36,000
28,800
140
3,000
24,000
19,200
160
2,000
16,000
12,800

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Optional extras (available for extra charge)
Pot forks
Pot accumulator
Blow-off unit for cleaning the conveyor belt
Table drive with query
Attention!
When ordering spare parts and optional extras, kindly
remember to state the type and model number of your
machine.

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5. EC Declaration of Conformity
in accordance with Annex II A of the EC Machinery Directive (2006/42/EG)
The manufacturer: Mayer Ipari es Kereskedelmi BT.
Kossuth ut. 106
9341 Kisfalug | Hungary
hereby declares that the machine described
hereinafter:
Manufacturer: Mayer
Type: Pot handling robot
Year of construction: from 2015 onwards
fully meets the health and safety regulations
specified in the following EC Machinery
Directive(s):
2006/42/EG
Applicable harmonized standards:
EN ISO 12100:2011
EN ISO 13857
ISO 13854
EN ISO 13849-1
EN ISO 14121
ISO 14119
ISO 13850
IEC 60204-1
EN 349:1993+A1:2008
EN 953:1997+A1:2009
EN ISO 4254-1:2010
Safety of machinery, basic terminology, general guiding
principles for organization
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 pl.:”C”
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 (category „0” STO (Safe
torque off).)
Safety of machinery - Minimum gaps to avoid crushing of
parts of the human body
Safety of machinery Guards General requirements for
the design and construction of fixed and movable guards
Agricultural machinery –Safety - Part 1: General
requirements
Commissioning of the machine is prohibited until it is proved that that the whole of the mobile bench
configuration is in line with the regulations of all relevant harmonized EC directives and guidelines.
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 machine and will,
therefore, render this EC Declaration of Conformity void.
Kisfalud, 01.02.2016 ......................................
Arpad G. Meszaros (MSc)
Head of Development and Construction

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2 General safety instructions
1. Operator’s duty of care
The design and construction of the MAYER POT
HANDLING ROBOT model TR 4103 was based on
careful risk assessment and performed in line with
the relevant prevailing harmonized standards and
other technical specifications. As a result, this state-
of-the-art equipment guarantees the highest level of
safety.
In practice, however, maximum safety can only be
achieved if all relevant requirements are fully met.
The careful planning and consequent enforcement of
measures safeguarding the fulfilment of these
requirements fall within the liability of the operator
(Operator’s duty of care).
The operator is, therefore, solely liable to
ensure that
the machine is only used for its Intended
Purpose (fur further details please refer to
chapter 1 on product description)
the machine is only operated in an unimpaired
and fully functional condition, with special
regard to the protective guards and safety
devices, which must be checked on a regular
basis and kept in a fully functional condition at
all times
the instruction manual is kept in a full and
readable condition and within easy reach of the
machine at its place of operation
the equipment is used, serviced and repaired by
fully qualified and authorized operating
personnel only
all signs, symbols and warnings on the
equipment related to health and safety are kept
unimpaired and in a readable condition at all
times.
All users of the machine are liable to ensure that
they do not attempt to operate the machine
unless it is in an unimpaired condition.
Arbitrary modifications on the machine or any
changes that affect its safe operation are not
permitted.
All maintenance and repair work on the machine
must be conducted with the machine turned off.
This operating personnel is trained and regularly
updated on all relevant matters of health, safety
and environmental protection, and that they are
fully aware of the contents of this Instruction

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Manual with special regard to the included
instructions on health and safety.
Before maintenance and repair work on the
machine is commenced, all its drive units and
additional equipment must be secured against
being inadvertently turned on.
Protective guards and safety devices are only to
be removed if the machine is fully and safely
turned off.
The operating of this machine is subject to
prevailing local and regional laws and
regulations on health and safety.
Under no circumstances is the machine to be
started with its safety devices removed.
The machine operator is responsible for any
third person staying in the working area.
Should any of the instructions set forth
above not be observed, the manufacturer
will automatically be released from all his
liabilities.
2. Explanation to the safety signs and symbols ssed
The safety signs and symbols, together with the related warning
texts, are meant to call attention to the unavoidable residual
risks associated with the use of the machine. These residual
risks may affect
people
the machine
other objects and properties
the environment.
In this instruction manual the following safety symbols are used:
This symbol suggests that the related hazards primarily
endanger the machine, objects and the environment. However,
this sign does not refer to any danger to people.
Not following these instructions can cause machine malfunction
or damage to the machine and other properties, and the
environment might be harmfully affected as well.
This symbol calls attention to information that contributes to a
better understanding of the machine. This information helps you
optimize the use of the equipment. This symbol, however, does
not refer to any health and safety instructions.
This symbol warns of electric shock hazards.

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Please note that on no account is a safety sign or symbol meant
to replace the actual text of a safety instruction. The relevant
safety instructions are, therefore, always to be read fully and
thoroughly.
3. Basic safety measures
Please make sure that the following safety measures are
strictly followed at all times:
The personnel is to wear tight fitting work clothes at all
workstations.
Wearing rings, chains or bracelets is strictly prohibited.
For technological reasons, the MAYER POT HANDLING
ROBOT TR 4103 cannot be covered completely.
Nevertheless, the protective shield fitted on the sides
provide extra protection against the moving pot lifting unit.
It is strictly prohibited to reach behind the protective shields
in order to eliminate eventual disturbances while the
machine is in operation.

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4. Machine-specific safety measures
Responsibilities related to the individual operations performed
with the machine must be clearly specified and strictly
observed.
Unclear or undefined competences represent a safety hazard.
The Emergency-OFF button must always be freely and easily
accessible.
The machine must be installed stably on a firm and level surface.
If falling over, the machine can cause death.
In order to eliminate the danger of slipping, the floor (at the
workstations around the machinery, in passageways and
transport routes) must be kept clean and dry at all times.
Tripping hazards represented by connected power cables must
be eliminated.
All supply lines connected to the machine must be unimpaired.
Maintenance and repair work on the electrical equipment must
be conducted by qualified and authorized electricians only.
Protective guards and safety devices
are installed to protect the health and safety of the operating
personnel, and
are under no circumstances to be changed, removed or
bypassed through altering the machine.
Residual currents that cannot be detected by means of an
ordinary residual current circuit breaker can arise in frequency
converters. The machine can, therefore, only be operated if it is
equipped with an all-current sensitive FI circuit breaker.
Frequency converters are fitted with capacitors that discharge
after the machine has been switched off. The machine can,
therefore, only be unplugged from the socket 1 to 2 minutes
after the main switch has been turned off.

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Schematic representation of a pot handling robot, marking the working areas and the
prohibited areas.
a) Automatic table feed
Working area
Prohibited area
Table track
Working area
Working area
Table track
Table track
Pot placing unit
Pot placing unit
Pot lifting unit

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b) Manual table feed
Working area
Prohibited area
Table track
Working area
Working area
Table track
Table track
Pot placing unit
Pot placing unit
Pot lifting unit
Working area

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5. Requirements regarding the operating personnel
The machine is to be operated by properly trained, qualified and
authorised personnel only. This operating personnel must be
aware of the contents of this manual and strictly follow the
instructions and regulations set forth in it. The individual
responsibilities and liabilities of operating staff members must
be clearly specified.
In addition to the above, the following duties require special
qualifications and authorization:
Operating personnel still in training is only allowed to operate
the machine under the strictest supervision of an authorized
person with sufficient experience. The successful completion of
an initiation training must be certified in a written format.
Control units are only to be operated by personnel properly and
specifically trained for this purpose.
All employees conducting work on and around the machine
must carefully read this instruction manual and sign a
declaration stating that they have fully understood the
instructions and provisions set forth in it.
Further requirements:
While the machine is running it is strictly prohibited to
reach into the work space of the machine! At the
guards the following warning decals are attached:
While the machine is running it is strictly prohibited to
approach the movable arm! At the guards the following
warning decals are attached:

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While the machine is running it is strictly prohibited to
loose screws of the safety guards and to remove the
guards! The guards may only be removed when
servicing the machine! At the guards the following
warning decals are attached:

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3 Transportation
In order to prevent property damage or personal
injury during transportation of the machine, the
following instructions must be strictly followed:
Transport-related activities can only be
conducted by qualified personnel, under the
strictest observance of all relevant safety
regulations and instructions.
The equipment is only to be lifted at the
designated lifting points.
For the transportation of this machine no other
than the hereinafter listed lifting tools,
equipment and slings must be used.
Please consult the chapter on general safety
instructions as well.
The transportation of this equipment represents
the following types of hazards:
Suspended loads may be subject to falling and
thus represent a death hazard. Standing
underneath such loads must be avoided at all
times.
Should other than the hereinafter listed lifting
tools and equipment be applied, this can cause
severe damage to the machine.
1. Transportation
While transporting the machine, all due care must be paid to avoid
it being damaged through any external force or due to careless
loading and/or unloading.
The consignment must be firmly fixed and secured during
transportation as appropriate based on the method of transport and
the length of the transport route.
During transportation condensation due to considerable changes in
temperature or transport-related impact must be prevented.
The equipment must be handled with due care at all times.
2. Storage
Should the machine or its structural components not be installed
directly after their arrival at the place of operation, they will require
careful storing in a protected place. During storage the machine
and its structural components must be covered properly to prevent
dust and moisture from gaining access to them.
For instructions on machine standstill please refer to chapter 6.3.

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4 Installation
1. General information
a)
In order to protect the machine against weather conditions, it
must be installed in an enclosed space.
b)
Voltage: 400 V / 50 Hz, 5-phase, 10 A
Compressed air supply: coupling SV-1087/KY6451 Hoerbiger
The pot handling robot shall be installed and connected to the
available supply systems by personnel authorized by our
company.
The machine can only be connected to sockets that are
secured by means of an all-current sensitive FI circuit breaker.
c)
Enough space must be secured for the assembly and
installation work to be performed on the machine. This
requirement should be taken into account when arranging
upstream and downstream machines.
d)
In order to make optimum use of the available machine
capacity, a continuous flow of pots and plants on the conveyor
belts must be ensured. Maximum operational efficiency is
further secured by a smooth and well-organized moving and
handling of the mobile benches.
e)
The machine must be installed and commissioned by our
technicians, who are also to test-run the machine during the
initial commissioning.