Mayer TR 4103 Instruction Manual

Pot handling robot

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Pot handling robot TR 4103

Falsches

wwBil

Instruction manual

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.

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Page 1 Pot handling robot TR 4103 Falsches wwBil Instruction manual 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.
Page 2: Table Of Contents
1 Product description 1. Inspection prior to the initial commissioning 1. Intended Use 2. Initial start-up of the machine 2. Structure of POT HANDLING ROBOT TR 4103 3. Stopping the machine 3. Functions of the machine 4. Technical specifications 6 Operation 5.
Page 3: Product Description
Should the MAYER POT HANDLING ROBOT rows. model TR 4103 be used for anything other than its intended purpose, a safe operation of the machine b) Removing plant pots from mobile benches cannot be guaranteed.
Page 4 2. Structure Top view of POT HANDLING ROBOT TR 4103 rear left right front...
Page 5: Functions Of The Machine
The pots are transported by means of conveyor the table is rolled forwards by the table feed by a belts to the accumulator of the MAYER POT previously set path length in order to secure HANDLING ROBOT TR 4103. The accumulator...
Page 6 Pot handling robot TR 4103 Table feed Conveyor belt Accumulator Pre-accumulator Mayer pot handling robot Table...
Page 7 Pots fed from the left Table Pre-accumulator Accumulator Pot handling robot TR 4103 Pots in alternating rows Gaps between pots freely adjustable Pots in parallel rows Pots fed from the right Table Accumulator Pre-accumulator Pot handling robot TR 4103 Pots in alternating rows...
Page 8: Technical Specifications
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.
Page 9 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.
Page 10: Ec Declaration Of Conformity
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 Manufacturer: Mayer hereby declares that the machine described Type:...
Page 11: General Safety Instructions
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.
Page 12: Explanation To The Safety Signs And Symbols
 Manual with special regard to the included Under no circumstances is the machine to be instructions on health and safety. started with its safety devices removed.   Before maintenance and repair work on the The machine operator is responsible for any machine is commenced, all its drive units and third person staying in the working area.
Page 13: Basic Safety Measures
 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 4103 cannot covered completely. Nevertheless, the protective shield fitted on the sides provide extra protection against the moving pot lifting unit.
Page 14: Machine-Specific Safety Measures
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.
Page 15 Schematic representation of a pot handling robot, marking the working areas and the prohibited areas. a) Automatic table feed Prohibited area Table track Pot placing unit Table track Pot placing unit Working area Table track Pot lifting unit...
Page 16 b) Manual table feed Prohibited area Table track Pot placing unit Table track Pot placing unit Working area Working area Table track Pot lifting unit...
Page 17: Requirements Regarding The Operating Personnel
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.
Page 18  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:...
Page 19: Transportation
3 Transportation In order to prevent property damage or personal The transportation of this equipment represents injury during transportation of the machine, the the following types of hazards: following instructions must be strictly followed:  Suspended loads may be subject to falling and ...
Page 20: Installation
4 Installation 1. General information In order to protect the machine against weather conditions, it must be installed in an enclosed space. 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.
Page 21: Installation Of The Machine
2. Installation of the machine When installing the machine, please ensure that the following steps and guidelines are strictly followed: a) When transporting and moving the machine always use the fixture over the table tracks. b) Position the machine. c) Remove transport fixture. d) Arrange the machine: - aligning with the table track and - at a height appropriate for the table base.
Page 22 Electric motor Table When assembling the MAYER POT HANDLING ROBOT TR 4103 at its place of operation for the first time, the table feed must be attached to the table track of the table transport in a way that allows for the middle of...
Page 23 Arranging the bracket for light sensors 10B1 to 10B5 Table direction Start of table switch End of table switch Table full switch 10B1 10B2 10B3 Light sensor bracket Table Table track Table feed approx. 20-30 cm Table direction Switch Switch 10B4 10B5 Light sensor...
Page 24: Requirements For Structural Stability
3. Requirements for structural stability Note: In order to safeguard the structural stability of the MAYER POT HANDLING ROBOT TR 4103, it is essential that the legs of the machine are dowelled on a concrete foundation with the following dimensions: Length: min.
Page 25: Commissioning
5 Commissioning While commissioning the machine, the following safety instructions must be observed in order to eliminate the risk of personal injuries, property damage and damages to the machine.  Commissioning of the machine is to be performed by qualified personnel only, under the strictest observance of the relevant regulations on health and safety.
Page 26: Initial Start-Up Of The Machine
2. Initial start-up of the machine Control panel Omron NQ5 TQ010-B – display and keyboard In order to test run the machine after installation please go through the following procedure: For a smooth operation of the machine it is essential that the operating pressure be set properly.
Page 27 For test-running the machine please complete the following procedure (test-running of the machine only to be performed in manual mode): After switching on the machine the starting screen will be displayed on the control panel for 6 seconds.
Page 28 Error messages, here you can read messages indicating machine error (e.g.: low pressure) Settings: Service technicians of the company Mayer can set machine functions through this option. The machine can be operated as a single machine or interlinked in a configuration with various different functions.
Page 29 Through this option the required parameters can be set for the different programmes. Programme selection: You can select the required programme from 25 options. Machine function: If the machine is operated as part of a configuration, the machine functions can be selected through this option. Error message: Messages of machine malfunction will be displayed here.
Page 30 Now you can select the type of function you wish to perform with the help of the machine. For this simply press the relevant field and wait for the title of the selected function to appear in the top line of the display. If you are using the robot as a single machine, there will be only two options to choose from: Single machine...
Page 31 Here you can key in the number of the required programme and confirm your choice by pressing the ENT button. After entering the programme number, the field selection must be pressed in order to activate the selected programme. By the pressing of key F1 you can return to the starting screen. If there is no programme saved under programme selection, please press the option parameter entry on the starting screen.
Page 32 By activating key F4, you can move on to the next entry field. Gap between rows: Distance between the pot rows on the table Should the length of the table track be set here, 1 must be entered for the number of rows. Number of rows: Here you can enter the number of pot rows to be placed on the table depending on the table length.
Page 33 Alternating rows: Through this option you can select the way how the pots should be placed on the table: in parallel rows or in alternating rows. For a schematic representation please refer to page 7. Should you opt for the placement of pots in alternating rows, please remember that the distance for the cylinder must be set mechanically.
Page 34 Parameter entry field 4 will only appear on the display if the required password has been entered under the settings. Language: Here you can select and change the language. Conveyor belt off: Here you can set the time at which, with the pot barrier closed, the conveyor belt and the pot handling robot will be stopped.
Page 35 Disentangling (backwards): In this function the table rolls backwards up to a predetermined distance once the pots are lifted and in the fork and the lifting time has run up. This allows for the pot rows to be disentangled. Lifting: This refers to the time interval during which the arm moves back to the conveyor belt (pots are lifted from the table) before the table rolls back.
Page 36 Parameter entry field 3 will only appear on the display if the required password has been entered under the settings. Language: Here you can select and change the language. Conveyor belt clear: Through this option you can set a safety time interval that runs out when light sensor 12B5 cannot detect any more pots on the conveyor belt.
Page 37 Selection Through this function you can select the type of operation you wish the machine to perform. IN/forwards OUT/backwards By activating these keys the selected function will be completed. Operations that involve a cylinder need only to be tipped. Operations that require motoric control will only be active as long as the relevant field is being pressed.
Page 38 If the option alternating rows has been selected, every second row will automatically be placed in alternation in manual mode as well. The conveyor belt is started automatically in manual mode as well, after the arm with the swivelled out gripper has moved back.
Page 39 Screen for the lifting unit: Programme data The parameters of the selected programme can be read from this screen. With this setting the parameters cannot be changed. The programme data can only be modified through the starting screen option parameter settings.
Page 40 Start Through this option you can start the automatic operation mode. At the same time all start buttons on the machine remain active. All operations of the machine will be performed automatically according to the parameters pre-set for the required programme. Stop Through this option the automatic mode can be stopped.
Page 41 Placing unit: Lifting unit: After pressing the option selection, the control image ARM will appear. The arm can be navigated with the help of the buttons IN/FORWARDS and OUT/BACKWARDS. With the gripper swivelled out the arm can always be moved. With the placing unit: - Arm forwards can be used in all cases.
Page 42 After pressing the option selection, the control image FEED will appear. Table feed can be controlled by means of the buttons IN/FORWARDS and OUT/BACKWARDS. After pressing the option selection, the control image FORK will appear on the screen for the lifting unit. The fork can be navigated with the help of the buttons IN/FORWARDS and OUT/BACKWARDS.
Page 43: Stopping The Machine
3. Stopping the machine This machine can be stopped in the following two ways: In an ordinary case the machine will be stopped by activating the STOP button on the control panel or by activating the flexible START / STOP switch. In the event of emergency, the machine can be stopped by activating the “Emergency OFF”...
Page 44: Operation
6 Operation Drawing of the electrical operational procedure Table START-STOP- 3 8S4 / 8S7 Barrier Conveyor Drive 3M1 Pre-Accumulator Accumulator Pot Counter 12S2 Flexible START-STOP Brake 4Y1 8S2 / 8S5 Drive 4M1 LT10B2 Table-End Stop LT 10B5 Table-Pos. START-STOP-2 8S3 / 8S6 Emergency OFF 2 7S2 LT 10B3 Table full...
Page 45: Standard Operating Procedures
Changing the forks and accumulators The MAYER POT HANDLING ROBOT will be installed at your facility by our own technicians. While assembling the machine, the mounting of the accumulator will be fixed in its initial position.
Page 46 The electric plug of the switch control must then be connected to the network again (only on the lifting unit). c) Basic settings of the MAYER POT HANDLING ROBOT TR 4103 Automatic and manual operation mode In order to secure a smooth operation of the machine, you must make sure that the operational pressure is set properly.
Page 47 d) Table-feed The tables are rolled by means of two friction wheels on two electric drives. When the gripper has swivelled out and the arm is moving towards the conveyor belt, the table feed is started. e) Table-change Should the table end switch (10B2) be passed during the table feeding process, the table will be rolled back while the gripper swivels out.
Page 48 The work operation can then be repeated. After the MAYER POT HANDLING ROBOT has placed the last two pot rows on the table, the gripper will not swivel out at its usual speed, it will slow down. At the same time the table feed...
Page 49 Once the gripper is swivelled out to its end position, the arm moves back into its initial position. In the case of MAYER POT HANDLING ROBOT with an additional fork swivel (available on demand) the gripper speed will not be reduced.
Page 50 The work operation can be started again. After the MAYER POT HANDLING ROBOT has taken the first three rows of pots off the table, the fork will stop swivelling and the gripper moves in directly.
Page 51 NOTE: Should the handled tables be provided with a rim that is not low enough, the POT HANDLING ROBOT functioning as lifting unit must be equipped with an additional fork pivoting. If, in order to avoid further expenses, the additional fork pivoting shall not be invested in, the first three pot rows must be lifted manually from all tables whose rim proves too high.
Page 52: Shutdown Procedure
2. Shutdown Procedure This machine can be stopped in the following two ways: In an ordinary case the machine will be stopped by pressing the STOP button on the control panel. Upon pressing the STOP button, the machine completes the movement it has started.
Page 53: Measures Before And After A Prolonged Standstill Period
3. Measures before and after a prolonged standstill period a) Before a prolonged standstill period  The machine must be cleaned thoroughly.  All machine parts must be greased and lubricated according to maintenance schedule.  The machine must be protected (covered) against eventual contamination and moisture.
Page 54: Machine Malfunction
7 Machine malfunction In order to eliminate the risk of property damage and personal injuries in the event of machine malfunction and during corrective action, the following regulations must be strictly followed:  Please do not attempt correcting a malfunction unless you are fully qualified to undertake the required action.
Page 55: Malfunctions, Probable Causes And Corrective Action
2. Malfunctions, probable causes and corrective action a) Mechanical malfunction Failure / Malfunction Cause Corrective action An Arm has some play on the The feather keys are worn or Replace worn parts drive shaft damaged. The two arms are not moving The chains situated on the right - Tighten chains parallel to each other...
Page 56 The pots are not transported into Distance between the two Adjust accumulator settings the accumulator accumulator angles too narrow The pots are transported into the The levers in the accumulator are Clean accumulator accumulator in an irregular stuck (e.g. due to substrate manner between lever and track) b) Error messages on the control panel...
Page 57: Maintenance
 All intervention affecting the control software of the machine must exclusively be performed by MAYER GmbH & Co. KG.  All fuels, lubricants and auxiliary materials that are not re-used must be disposed off in line with the relevant environmental safety regulations.
Page 58: General Information
Through the use of original MAYER components this requirement is automatically fulfilled. 2. Maintenance schedule The maintenance demand of the machine has been reduced to a minimum through the application of maintenance-free machine elements.
Page 59 Grease nipples on the arm every quarter of a year Grease chain in the arm on the left (cover to be twice a year opened) Tighten chain as required Grease guides every week The oil filling in the drives of the conveyor belt, the placing unit and the table feed shall be exchanged after ca.
Page 60: List Of Spare Parts
9 List of spare parts...
Page 61: Mechanical Spare Parts
1. Mechanical spare parts Hauptantrieb oben Main drive above Stück Pos. Benennung Artikelnummer Description Part number Amount Kupplung 111137 Coupling Flanschlager 111126 Flange bearing Kettenantrieb rechts (Motorseite) Chain drive to the right (on the motor side) Stück Pos. Benennung Artikelnummer Description Part number Amount...
Page 62 Rollenkette 111282 Chain belt Verschlussglied 111143 Chain lock Flanschlager 4100-02-02-04-00 Flange bearing Aufnahme Verband: Recording joint: Stück Pos. Benennung Artikelnummer Description Part number Amount Flanschlager 4100-04-01-02-00 Flange bearing Laufschiene 4100-04-01-04-00 Rail Führungsrolle 4100-04-01-05-03 Guide roller Buchse 4100-04-01-05-04 Bush Exzenterbuchse 4100-04-01-05-05 Eccentric bush Schrägkugellager 111320...
Page 63 Pneumatisch Pneumatics Aufnahme Verband: Taking-off staggered order: Stück Pos. Benennung Artikelnummer Description Part number Amount Druckluftzylinder 111204 Compressed-air cylinder Drosselrückschlagventil 111205 Throttle check valve Flexo-Kupplung 111207 Flexo-coupling Schwenkantrieb: Swivel drive: Stück Pos. Benennung Artikelnummer Description Part number Amount Druckluftzylinder 111208 Compressed-air cylinder Drosselrückschlagventil 111212...
Page 64: Electrical Spare Parts
Pneumatik allgemein: Pneumatics – general: Stück Pos. Benennung Artikelnummer Description Part number Amount Wartungseinheit 111181 Maintenance unit 5/2 Wegeventil 111182 Valve 5/2 3/2 Wegeventil 111183 Valve 3/2 Druckwächter 111184 Pressure checker Druckregler 111185 Pressure controller Manometer 111186 Manometer Drosselrückschlagventil 111193 Throttle check valve 2.
Page 65 Sammler: Collector: Stück Pos. Benennung Artikelnummer Description Part number Amount Mikroschalter 109963 Microswitch Schutzhaube 102085 Protecting cover Tüllengehäuse 102115 Cable clip box Steckereinsatz 102111 Connecting part Aufnehmgabel: Pick-up fork: Stück Pos. Benennung Artikelnummer Description Part number Amount Mikroschalter 109963 Snap switch Schutzhaube 102085 Protecting cap...
Page 66: Pneumatic And Electrical Diagrams
10 Pneumatic and electrical diagrams...
Page 69: Warranty
10 Warranty Horticultural equipment machines special purposes We undertake warranty against defective delivery as well as on the quality and performance of the product as set forth above. With the exclusion of all other warranty claims and rights, our company warrants that any part or parts of the machine that show evidence of material, manufacturing or constructional defects and/or are thus rendered unusable or impaired in their serviceability will be repaired or replaced as elected by our...
Page 70 Thank you for your decision to purchase this state-of-the- art product. We wish your company every success in the future. If our products and services have been to your satisfaction, please recommend us to others. Yours truly, Your MAYER TEAM...