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Mayer PT 5000 Operating Instructions Manual

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Buffer belt PT 5000
Operating instructions
Release date: 24/03/2023 / V1.0
Read before initial start-up and keep by the machine for future use

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Summary of Contents for Mayer PT 5000

  • Page 1 Buffer belt PT 5000 Operating instructions Release date: 24/03/2023 / V1.0 Read before initial start-up and keep by the machine for future use...

  • Page 2: Table Of Contents

    Table of contents 1 Product description 5 Initial start-up 1. Intended use 1. Checks before initial start-up 2. Structure 2 Starting the machine for the first time 3. Functional description using the touchscreen 4. Technical specifications 3. Stopping the machine 5.

  • Page 3: Product Description

    The machine is not intended for purposes other than those listed here - this is considered improper use! If the MAYER PT 5000 buffer belt is not used according to these specifications, safe operation of the machine cannot be guaranteed.

  • Page 4: Structure

    2. Structure Push-over unit Buffer belt Colleting belt Pre-collection belt Drive shaft and motor...

  • Page 5: Functional Description

    3. Functional description When working with the Mayer buffer belt, pots or trays are fed via a conveyor belt to a pre-collection belt. The pots or trays are collected on the push-over belt and pushed over the push-over unit onto a wide buffer belt.
  • Page 6 Accessories that can be supplied (at additional cost)  Pneumatic device for diagonal bracing  Start-up aids for fork lift  Custom-manufactured push-over templates  Different collection belt lengths – and widths Important! When ordering accessories and spare parts, always give the machine type and number!

  • Page 7: Ec Declaration Of Conformity

    5. EC declaration of conformity pursuant to appendix II A of the EC Machinery Directive (2006/42/EC) The manufacturer: Mayer GmbH & Co. KG Maschinenbau u. Verwaltung Poststr. 30 89522 Heidenheim / Germany Manufacturer: Mayer hereby declares that the machine described...
  • Page 8 EN 1005-5:2007 Safety of machinery - Human physical performance - Part 5: Risk assessment for repetitive handling at high frequency Structural changes which can have an impact on the technical specifications quoted in the operating instructions and intended use, and which hence significantly modify the machine, shall invalidate this declaration of EC conformity! Heidenheim, 01/02/2024 ........

  • Page 9: General Safety Instructions

    2 General safety instructions 1. Due diligence of the operating company The MAYER Buffer belt PT 5000 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.

  • Page 10: Explanation Of The Safety Symbols Used

      Before beginning with any work on the machine, The machine may not be started if any safety secure its drives and accessory parts against devices are removed. being switched on unintentionally.  In the working area the operator is responsible ...

  • Page 11: Basic Safety Measures

    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 measures Basically, it is important to ensure that:  Tight-fitting clothing is worn at all workstations.

  • Page 12: Machine-Related Safety Measures

    4. Machine-related safety measures The workstations are distributed around the different Tripping hazards caused by cables which are areas of the buffer belt. connected to the power supply systems must be avoided. The responsibilities for the different activities on the All supply lines to the machine must be protected machine must be clearly defined and adhered to.

  • Page 13: Demands On Operating Personnel

    5. Demands on operating personnel The machine may only be operated by personnel experienced individual. It should be confirmed in who have been trained for such, shown what is writing that the training has been successfully involved and are authorised to do so. These completed.

  • Page 14: Transport

    3 Transport To prevent damage to the machine as well as When transporting the machine, the following injuries while transporting the machine, it is special dangers must be expected: absolutely necessary to comply with the following points:  Suspended loads can drop, which would be a lethal danger –...

  • Page 15: Handling

    2. Handling After being set down, the machine is pushed with a crane lorry/forklift to the planned production location. This is ensured thanks to rollers on the feet. If the machine must be transported over an inclined surface, it must be ensured that: ·...

  • Page 16: Installation

    4 Installation 1. General notes To protect the machine against weather caused damages it is suggested to use and store it inside. Electrical connection: 400V/50Hz. Connection is permitted only to socket-outlets which are protected by an AC/DC sensitive RCCB (residual-current circuit- breaker).

  • Page 17: Setting Up The Machine

    2. Setting up the machine The subsurface for the machine should be level and solid, so that the machine feet cannot sink into it. To relieve the load on the wheels, support the machine together with the feet (with a forklift truck), then remove the transport wheels 3.

  • Page 18: Initial Start-Up

    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.

  • Page 19: Starting The Machine For The First Time

    2. Starting the machine for the first time  Set the main switch to the ‘Zero’ position  Plug in the cable Check the input voltage  Set the main switch to ON (by turning it)  In the Service area, control the individual parts of the system “Manually”. ...

  • Page 20: Stopping The Machine

    3. Stopping the machine  Stop the machine using the Stop button  Only stop the machine using the Emergency Stop switch in an emergency.  Reach into the collision protection light barrier (will continue to run after exiting the light barrier) ...

  • Page 21: Operation

    6 Operation 1. Normal operation  Turn on the main switch  Check the preset programme and if necessary, select a new programme based on the pot size  Check the collector setting (cylinder) and adjust, if necessary, so that the pots are positioned upright (pot to pot) ...

  • Page 22: Shutting Down The Machine

    2. Shutting down the machine There are two ways provided to switch off the machine. In normal case by pressing switch „Stop” mounted on the swinging cable. In this case the machine may be restarted by pressing switch „Start”. In emergency case by „Emergency Stop” switch. When push button „Emergency Stop”...

  • Page 23: Faults

    b) After a long shutdown  Grease and oil certain parts of the machine according to maintenance plan.  Visually check the machine.  Connect the machine to required energy sources.  Start the machine as it is described in section „Initial start-up”. Further setting and operation options Settings ...
  • Page 24  Status display for individual queries Push-over unit Main menu Push-over unit end switch, front Stations Push-over unit end switch, rear Settings Collection belt full Programmes Pot count Package at end of belt Functions Fork lift at side of belt Service Counter Date/Time...
  • Page 25 Stations  Optical status display for queries Push-over unit Main menu Stations Settings Programmes Functions Service Counter Date/Time Faults...
  • Page 26 Functions  The machine must be reset after any programme setting or change, same as after any manual intervention in the machine process  Activating the “Run” function switches off the push-over process. The collection belt and push- over belt operate continuously. ...
  • Page 27 Service  Service settings are password-protected (4321) Push-over unit Main m Stations Settings Password Progra Functio Service Counter Date/Ti Faults  The individual drives and functions can be switched on and off using the buttons. Please note that if anything is turned on in the Service area, it must be turned off again before starting normal operations.
  • Page 28  Display of the travel routes for the individual drives Logout Push-over unit Push-over mechanism Main menu Stations FORWARDS BACKWARDS Basic setting Buffer belt Settings Maintenance setting Push-over belt incremental encoder Programmes Bracing Functions Buffer belt forward Service Buffer belt reverse Counter Buffer belt incremental encoder Date/Time...
  • Page 29 Counter  Displays push-over strokes  Pot counter  Operating hours counter (periods after starting the machine. Push-over unit Main menu Total counter Strokes Push-over device Stations Settings Total counter - Pots Pots Programmes Operating hours counter Functions Service Counter Date/Time PROGRAMME COUNTER Faults...
  • Page 30 Date time  For documenting fault messages Push-over unit Main menu Stations Date/Time Settings Date Programmes Time Functions MODIFY Service Counter Date/Time Faults Faults  Displays malfunctions and fault messages  Reset after a fault occurs. Push-over unit Main menu Time Description State...
  • Page 31 5. Programmes a) Programme per pot size  A new programme must be entered for each pot size  A new programme must be entered for identical pot sizes with different row or pot spacings. Push-over unit Main menu Programme data Stations Programme number SAVE...
  • Page 32 b) Programme settings  Programme name: A programme name must be entered for each programme  Maintenance setting - Push-over unit: Value at which the push-over unit waits for the next pushover process (pot diameter + safety)  Number of pots: Number of pots to be pushed over. ...
  • Page 33  Pot release time delay: Start delay for pots from the collection belt to the push-over belt following the push-over process.  Package 1: Number of rows to be included in a package Distance between packages Number of identical packages to be pushed over ...

  • Page 34: Behaviour In Case Of Malfunctions

    7 Malfunctions To prevent damage to the machine as well as injuries while remedying malfunctions at the machine, it is absolutely necessary to comply with the following points:  Only eliminate a malfunction if you have the qualification specified to do so. ...

  • Page 35: Possible Malfunctions And Trouble Shooting

    2. Possible malfunctions and trouble shooting a) Mechanical malfunctions Fault / malfunction Cause Measure Pot jam on collection belt Pots not clean when fed in Eliminate the fault and reset Substrate residue on the collection unit b) Electrical malfunctions Fault / malfunction Cause Measure Emergency Stop pressed...

  • Page 36: Maintenance

     Release pressure of every unit that is under pressure.  Only Mayer GmbH & Co. KG may ever manipulate the machine's control programme.  un-recycled operational materials, lubricants and supplies must be disposed of in an environmentally friendly manner.

  • Page 37: Maintenance Plan

    1. Maintenance plan Description Time Lubrication of linear guides after 80 operating hours Visual inspection for damage or leaks on the drive motor Weekly...

  • Page 38: Part List

    9 Part list...

  • Page 39: Pneumatics And Electrical Circuit Diagrams

    10 Pneumatics and electrical circuit diagrams...

  • Page 40: Guarantee

    11 Guarantee Horticultural machinery and special machinery We will accept liability for faults in the supplied goods and for any failure to provide features for the existence of which an express assurance had been given. In such a case we undertake – to the exclusion of all further claims –...
  • Page 41 You have chosen to purchase a product of true quality. We wish you every success with your product. We would be most grateful if you would recommend our products to others. Thank you Your MAYER-TEAM...

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