Roxell FLEX-AUGER FA 55 User manual

030-051603000031 *03000031*
Original use and assembly guide
Use and Assembly Guide
Instructions
for the user Components Installation
instructions
EN ENGLISH

FLEX-AUGER TABLE OF CONTENTS ROXELL - 031 - 0516
TABLE OF CONTENTS
TABLE OF CONTENTS
GENERAL INFORMATION
PART I : INSTRUCTIONS FOR THE USER
GENERAL SAFETY RULES I-3.......................................................
OPERATOR'S GUIDE I-4............................................................
MAINTENANCE I-5.................................................................
TROUBLE SHOOTING GUIDE I-6....................................................
WIRING DIAGRAM AUTOMATI OUTLET I-7...........................................
FLEX AUGER MIX I-81...............................................................
DECLARATION OF INCORPORATION OF PARTLY COMPLETED MACHINERY
PART II : COMPONENTS
GENERAL VIEW II-2.................................................................
COMPONENT NUMBERS II-3........................................................
GENERAL LAY-OUT CDS-SYSTEM II-4...............................................
GENERAL LAY-OUT CDS-SYSTEM : STANDARD - FA 75/90/125 II-4.....................
GENERAL LAY-OUT CDS-SYSTEM : BROILER CAGES - FA 90/125 II-5...................
COMPONENT NUMBERS II-5........................................................
SUSPENSION- AND LINE COMPONENTS II-6.........................................
POWER UNIT II-7..................................................................
CONTROL UNIT FA 55 - 03501236 II-8................................................
CONTROL UNIT W/O SAFETY SWITCH FA 55 - 03501244 II-9...........................
CONTROL UNIT FA 75 - 03103256 II-10................................................
CONTROL UNIT FA 90 F/FA75 - 03202553 II-11.........................................
CONTROL UNIT FA 90 - 03202496 II-12................................................
CONTROL UNIT II-13.................................................................
EXTENSION BOOT FA 55 - 03501350 II-14..............................................
EXTENSION BOOT FA 55 - 03501350 II-15..............................................
EXTENSION BOOT FA 75 - 03103884 II-16..............................................
EXTENSION BOOT FA 75 - 03103884 II-17..............................................
EXTENSION BOOT FA 90 - 03202652 II-18..............................................
EXTENSION BOOT FA 90 - 03202652 II-19..............................................
EXTENSION BOOT FA 125 - 03701092 II-20............................................
THUMPER ASS'Y - 03000007 II-21.....................................................
PELLET GUIDES FA 75-FA 55 - 03101425 II-21..........................................
PELLET GUIDES FA 90 - 03200854 II-21................................................
PELLET GUIDE DOUBLE - 03102910 II-21..............................................
PELLET GUIDES FA 125 - 03700564 II-21...............................................
CLOSING PLATE KIT FOR INTAKE BOOT - 13000146 II-22...............................
FEED INTAKE BOOT FA 55 - 03501335 II-22............................................
FEED INTAKE BOOT FA 75 - 03103850 II-23............................................
FEED INTAKE BOOT FA 90 - 03202629 II-24............................................
FEED INTAKE BOOT 90F/FA75 - 03202694 II-25......................................
FEED INTAKE BOOT FA 125 - 03700531 II-26...........................................
DOUBLE INTAKE BOOT FA 55 - 03501343 II-27.........................................
DOUBLE INTAKE BOOT FA 75 - 03103868 II-28.........................................
DOUBLE INTAKE BOOT FA 90 - 03202637 II-29.........................................
DOUBLE INTAKE BOOT FA 90-FA75 - 03000569 II-30....................................
DOUBLE INTAKE BOOT FA 90-FA55 - 03000593 II-31....................................
DOUBLE INTAKE BOOT FA 75-FA55 - 03000882 II-32....................................
TANDEM IN LINE FA 75 - 03103876 II-33...............................................
TANDEM IN LINE FA 90 - 03202645 II-34...............................................
TANDEM IN LINE FA125 - 03700580 II-35...............................................
RETURN TANDEM FA 75 - 03102969 II-36..............................................
RETURN TANDEM FA 90 - 03202009 II-37..............................................
RETURN BOX FOR CDS MODEL FA 75 - 03102977 II-38.................................

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RETURN BOX FOR CDS FA 90 - 03202025 II-39.........................................
RETURN TANDEM BOOT FA 125 - 03700572 II-40......................................
THUMPER FOR RETURN TANDEM - 03102951 II-41.....................................
PELLET GUIDES TANDEM RETURN - 03202470 II-41....................................
THUMPER ASSEMBLY FA 125- 03700556 II-41..........................................
UPPER BOOT 15_PE - BLACK 03000577 II-42..........................................
QUADRUPLE BOOT - 03102845 II-42..................................................
COVER ASS'Y FOR UPPER BOOT - 03001195 II-42.....................................
TRANSFER PLATE ASS'Y - PE - BLACK - 03000585 II-42.................................
OUTLET DROP ASS'Y W/SHUT-OFF MODEL 55 II-43....................................
OUTLET DROP ASS'Y W/SHUT-OFF MODEL 75 II-43....................................
OUTLET DROP ASS'Y W/SHUT-OFF MODEL 90 II-43....................................
OUTLET DROP ASS'Y W/SHUT-OFF MODEL 125 II-44...................................
TELESCOPICAL DROP TUBE - 03100435 II-44..........................................
EXCENTRIC DROP ASS'Y - MODUL. CONTROL UNIT. - 04905402 II-45....................
EXTENSION MODULAR CONTROL UNIT - 04904249 FA 90 II-46..........................
CLOSING PLATE KIT FOR MODULAR CONTROL UNIT - 04904280 FA 90 II-46.............
EXTENSION MODULAR CONTROL UNIT Ø125 - 04909238 II-47..........................
CLOSING PLATE KIT FOR MODULAR CONTROL UNIT 125 - 04909600 II-47...............
EXTENSION FOR INTAKE BOOT II-48.................................................
CONNECTION KIT FOR MODULAR CONTROL UNIT FA55 - 04904736 II-48................
CONNECTION KIT FOR MODULAR CONTROL UNIT FA 90- 04904751 II-49................
CONNECTION KIT FOR MODULAR CONTROL UNIT FA 125- 04904759 II-50...............
SENSOR HOLDER + CONN. KIT - 03103074 II-51.......................................
SENSORS II-51......................................................................
HOPPER LEVEL SWITCH - 03100864 II-52..............................................
LEVEL SWITCH FOR TUBE - 03000551 II-52............................................
DROP TUBE LEVEL SWITCH W/DELAY - 03100872 II-53.................................
DROP TUBE LEVEL SWITCH - 03101102 II-53..........................................
SAFETY SWITCH - 13000757 II-53.....................................................
DROP TUBE LEVEL SWITCH W/DELAY II-53...........................................
DROP TUBE LEVEL SWITCH II-53.....................................................
SAFETY SWITCH II-53................................................................
MOTOR STARTER II-54..............................................................
AUTOMATIC OUTLET - Ø 56-24VDC(I) - 04906954 II-55..................................
AUTOMATIC OUTLET - Ø75 - 24VDC(I) - 04906962 II-56.................................
AUTOMATIC OUTLET - Ø89 - 24VDC(I) - 04906913 II-57.................................
AUTOMATIC OUTLET - Ø 125-24VDC(I) - 04909364 II-58.................................
GENERAL VIEW FLEX-AUGER MIX II-59...............................................
COMPONENT NUMBERS II-59........................................................
FLEX-AUGER MIX - 03000536 II-60....................................................
POWER UNIT II-61..................................................................
CONTROL UNIT FLEX AUGER 125 MIX - 03001211 II-62.................................
TUBE ANCHOR WELDMENT - 13701412 II-63..........................................
CONTROL PANEL FOR FLEX-AUGER MIX II-63.........................................
GENERAL LAY-OUT OVERHEAD SYSTEM II-64.........................................
MOTOR COVER MOUNTING KIT Ø90 - 03000900 II-65...................................
MOTOR COVER MOUNTING KIT Ø125 - 03001219 II-65..................................
COVER - FLEX-AUGER FILL SYSTEM 182X182MM - 15902513 II-66.......................
MOTOR COVER - TOP PLATE Ø90 - 03000902 II-66.....................................
MOTOR COVER - SIDE PLATE - 03000904 II-66.........................................
CONNECTION CONTROL UNIT-BIN - SUSPENDED - 03000874 II-66......................
EXTENSION BOOT COVER MOUNTING KIT - Ø90 II-67..................................
EXTENSION BOOT COVER MOUNTING KIT Ø125 - 03001227 II-67.......................
MOTOR COVER - F. PLATE L - 03000894 II-68..........................................
MOTOR COVER - F. PLATE R - 03000896 II-68..........................................
MOTOR COVER - F. PLATE L - 03701204 II-68..........................................
MOTOR COVER - F. PLATE R - 03701220 II-68..........................................
CONNECTION CONTROL UNIT-BIN - FIXED- 03000866 II-69.............................

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EXTENSION BOOT FOR OVERHEAD FA90 - 03202678 II-70..............................
EXTENSION BOOT FOR OVERHEAD FA90- 03202678 II-71..............................
EXTENSION BOOT FOR OVERHEAD FA90- 03202678 II-71..............................
EXTENSION BOOT FOR OVERHEAD FA125- 03701228 II-72.............................
SPARES SET BEAR.CAP HOLD II-73..................................................
PART III : INSTALLATION INSTRUCTIONS
GENERAL VIEW III-2.................................................................
COMPONENT NUMBERS III-3........................................................
GENERAL LAY-OUT CDS-SYSTEM III-4...............................................
GENERAL LAY-OUT CDS-SYSTEM : STANDARD III-4...................................
GENERAL LAY-OUT CDS-SYSTEM : BROILER CAGES III-5.............................
COMPONENT NUMBERS III-5........................................................
TOOLS III-6.........................................................................
GENERAL TECHNICAL INFORMATION III-7............................................
GUIDELINES FOR DESIGNING THE FLEX AUGERIII-9................................
FLEX AUGERFROM HOPPER TO HOUSE III-10.......................................
RETURN FLEX AUGERTO HOPPER - CDS III-11......................................
POSITION OF THE CONTROL UNIT DROP TUBE III-11...................................
LOCATION OF THE OUTLETS - CDS - STANDARD III-12.................................
LOCATION OF THE OUTLETS - CDS - BROILER CAGE III-13.............................
BIN LOCATION III-14..................................................................
ELBOW DIAGRAMS III-14.............................................................
ELBOW DIAGRAM FLEX-AUGER MODEL 55-75-90 III-15.................................
ELBOW DIAGRAM FLEX-AUGER MODEL 125 - R = 1700 III-16............................
ELBOW DIAGRAM FLEX-AUGER MODEL 125 - R = 2200 III-17............................
GRAPH WITH MAXIMUM LENGTHS - MODEL 55 III-18...................................
GRAPH WITH MAXIMUM LENGTHS - MODEL 75 III-19...................................
GRAPH WITH MAXIMUM LENGTHS - MODEL 90 III-20...................................
GRAPH WITH MAXIMUM LENGTHS - MODEL 125 - 33M III-21.............................
GRAPH WITH MAXIMUM LENGTHS - MODEL 90/125 - CDS BROILER CAGE III-22..........
GRAPH WITH MAXIMUM LENGTHS - MOD. 90 - HEAVY DUTY AUGER (HD) III-22..........
TRANSPORT LINE LOCATION III-23....................................................
DISTANCE BETWEEN SUSPENSION POINTS III-23......................................
TO INSTALL THE SUSPENSION POINTS III-24..........................................
SUSPENSION COMPONENTS III-24....................................................
SUSPENSION IN A HOUSE WITH SEPARATED PENS III-25..............................
CONTROL UNIT ASSEMBLY AND INSTALLATION III-26..................................
TO INSTALL THE MULTIPLE CONTROL UNIT III-27......................................
EXTENSION BOOT ASSEMBLY AND INSTALLATION III-28...............................
TO MAKE THE DROP HOLES IN THE TUBES III-29......................................
TO INSTALL THE TUBES III-30.........................................................
TO INSTALL THE OUTLETS III-33......................................................
TO INSTALL THE AUTOMATIC OUTLET III-35...........................................
TO REMOVE THE DROP III-35.........................................................
POSITION OF THE DROP TUBES III-37.................................................
POSITION OF THE CONTROL UNIT DROP TUBE III-37...................................
TO INSTALL THE THUMPER - MODEL 55 / 75 / 90 III-38..................................
TO INSTALL THE BOOT ASSEMBLY III-38..............................................
TO INSTALL THE BOOT ASSEMBLY III-39..............................................
QUADRUPLE BOOT ASSEMBLY III-40..................................................
TO CONNECT THE TRANSPORT SYSTEM TO THE BIN III-41.............................
TO INSTALL THE AUGER III-44........................................................
TO CONNECT THE AUGER III-45......................................................
BEARING CAP HOLDER III-46.........................................................
FLOW REGULATION MODEL 75 & 90 III-46.............................................
TO INSTALL THE THUMPER - FLOW REGULATION - MODEL 125 III-47....................
TO INSTALL THE DROP TUBES III-48..................................................
TO ADJUST THE TELESCOPICAL TUBE III-49...........................................

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TO INSTALL THE RETURN TANDEM SYSTEM (MODEL 75 & 90) III-50.....................
TO INSTALL THE TANDEM IN LINE (MODEL 75/90) III-51.................................
TO INSTALL THE TANDEM IN LINE (MODEL 125) III-52..................................
REDUCING THE CAPACITY III-52......................................................
TO INSTALL THE TUBE III-53..........................................................
AUGER STRETCHING (STRAIGHT THROUGH TANDEM) III-54............................
TO INSTALL THE HOPPER LEVEL SWITCH III-55........................................
TO INSTALL THE DROP TUBE LEVEL SWITCH III-55....................................
TO INSTALL THE SENSOR ON A FLAT SURFACE III-56..................................
TO INSTALL THE SENSOR ON A DROP TUBE III-56.....................................
TO INSTALL THE DROP TUBE LEVEL SWITCH IN A LINE WITH EXTENSION BOOT III-57...
TIME DELAY III-58....................................................................
ELECTRICITY .... WATCH OUT ! III-58..................................................
ELECTRICAL SYMBOLS III-59.........................................................
WIRING DIAGRAM FOR 1X230V III-60..................................................
WIRING DIAGRAM FOR 3X230V III-61..................................................
WIRING DIAGRAM FOR 3X400V III-62..................................................
WIRING DIAGRAM CDS FEED SUPPLY SYSTEM III-63...................................
WIRING DIAGRAM AUTOMATIC OUTLET III-64..........................................
FLEX-AUGER FEED MIX III-65.........................................................
GENERAL LAY-OUT OVERHEAD SYSTEM III-69.........................................
FLEX-AUGER OVERHEAD III-70.......................................................
ASSEMBLY III-71/73.....................................................................
ASSEMBLY III-74/75.....................................................................
MOTOR PROTECTION III-76...........................................................
MAXIMUM CABLE LENGTHS TO THE MOTORS III-77....................................

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DISCLAIMER :The original, authoritativeversion ofthis manualis theEnglish versionproducedby
ROXELLbvba.Subsequentchangestoanymanualmadebyanythirdpartyhavenotbeenreviewednorauthenticatedby
Roxell. Such changes may include, but are not limited to, translation into languages other than English, and additions to or
deletionsfromtheoriginalcontent.Roxelldisclaimsresponsibilityforanyandalldamages,injuries,warrantyclaimsand/or
anyotherclaimsassociatedwithsuchchanges,inasmuchassuchchangesresultincontentthatisdifferentfromtheauthoritat-
iveRoxell--publishedEnglishversionofthemanual. For current productinstallationandoperationinformation, pleasecon-
tactthecustomerserviceand/ortechnicalservicedepartmentsofRoxell.Shouldyouobserveanyquestionablecontentinany
manual, please notify Roxell immediately in writing to: ROXELL bvba -- Industrielaan 13, 9990 Maldegem -- Belgium.

ROXELL - 0516
GENERAL INFORMATION
THESE INSTRUCTIONS MUST BE READ, UNDERSTOOD AND ALL POINTS OBSERVED BY THE
USER, THE RESPONSIBLE AND OPERATING PERSONNEL.
1. OBEY THE LEGAL REGULATIONS AND THE APPLICABLE RULES!
This concerns, among other things, the European directives transposed into national legislation and/or the laws,
safety and accident prevention regulations that apply in the user's country.
During assembly, operation and maintenance of the installation the legal regulations concerned and the applicable
technical rules must be obeyed.
2. INTENDED USE
The installation has been designed solely for intensive livestock use and has been developed according to the ap-
plicable rules of good workmanship. Extra loading of the product istherefore prohibited. Any other use is considered
to be improper use. The manufacturer is not responsible for damage resulting there from. The user bears sole re-
sponsibility.
3. NOT-INTENDED USE
All use different than described in point 2” intended use” is at the responsibility of the end user.
4. LIABILITY
The (Extended) Warranty will not apply if any of the following has occurred: failure to conduct incoming goods
inspection with regards to the Products, improper handling, transportation, modification or repair; accident, abuse
or improper use; improper assembly, installation, connection or maintenance (having regard to Roxell’s most
current assembly, installation, connection and maintenance manuals); force majeure; negligence, lack of
supervision or of maintenance on the part of customer; normal wear and tear; use of cleansing agents and
disinfectants that are excluded in Roxell’s most current use and maintenance manuals; use of cleansing agents and
disinfectants in violation with the instructions received from the suppliers; or use of the Products in an ATEX-
surrounding.
The (Extended) Warranty shall not apply in the event of a defectcaused either bymaterials or accessories supplied
by or services rendered by Customer; or by an intervention by a person or entity which is not authorised or qualified
for carrying out such intervention. Furthermore, the (Extended) Warranty will only apply if the Products are used in
livestock houses and if all parts or components of the Products are supplied by Roxell.
Roxell will not be liable for any damages caused due to improper use, assembly, installation, connection or
maintenance of the Products. In this respect, the Customer expressly acknowledges that (i) all use, assembly,
installation, connection or maintenance must be donein accordance with Roxell’s most current assembly,
installation, connection and maintenance manuals and (ii) the electrical installation on which the Products must be
connected must be done in accordance with applicable local legislation on electrical installations. Furthermore, the
Products must be tested both mechanically and electrically in accordance with state of the art techniques and
applicable local legislation.
5. PERSONNEL QUALIFICATIONS
USER:
The person who uses a function or operation of a product for their work or who works on the product. The user must
be able to read the instructions for use and fully understand them. The user has knowledge of the functioning and
construction of the installation.
TECHNICALLY TRAINED PERSON:
An expert who can assemble and maintain the installation (mechanically/electrically), and resolve malfunctions.
Onthe basis of his/hertechnicaltrainingandexperience,he/shehas sufficient knowledge to be ableto assess activ-
ities, recognise possible dangers and rectify dangerous situations.

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6. INFORMATION ABOUT THE RESIDUAL RISKS - USED SAFETY SIGNS
There are three levels of danger, which you can recognize from the signal word
* DANGER
* WARNING
* CAUTION
The nature and source of the imminent danger and possible consequences of not obeying warnings is stated here!
DANGER
DANGER indicates a direct imminent dange
r
that can result in a serious or even
fatal accident if the safety measures are not respected.
WARNING
WARNING indicates a possible imminent danger that can result in a serious acci-
dent or damage to the product if the safety measures are not respected.
CAUTION
CAUTIONindicates possible, dangerous situations that can result in minor physical
injury or material damage if the safety measures are not respected.
This symbol refers to supporting information.
not allowed
allowed
7. STORAGE
Put all parts to be assembled in a room or at a location where the not yet assembled components are protected
against weather influences.
8. TRANSPORT
Depending on the size of the parts and according to local circumstances and local legislation, the parts of the ma-
chine have to be transported with a forklift.
The forklift must be operated by a qualified person and in accordance with the rules of good workmanship.
When lifting the load, always check if the center of gravity of the load is stable.

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9. DISMANTLING
Dismantle the installation and its components in accordance with the environmental legislation of the country or the
local authorities applicable at that time. All functioning products and exchange parts must be stored and disposedof
in accordance with the applicable environmental regulations.
Environmental information for customers in the European Union
European directive 2002/96/EC amended by the Directive 2008/34/EC requires that equipment that
bears this symbol on the product or packaging must not be disposed of with unsorted household
waste. This symbol indicates that the product must be disposed of separately. Your are yourself re-
sponsible for the destruction of this and other electrical and electronic equipment via the disposal
channels designated for that purpose by the national or local government. The correct destruction
and recycling of this equipment prevents anynegative consequences for the environment and health.
For more information about destroying your old equipment, contact your local authorities or waste
disposal service.
Information about waste disposal - electrical/electronic material for companies
1. In the European Union
If you have used the product for commercial purposesand you want to dispose of it,contact Roxell who will give you
information about the return of the product. It is possible that you willhave to pay a disposal charge for the return and
recycling. Small products (and small quantities) can be processed by the local collection agencies.
2. In other countries outside the European Union
If you want to dispose of this product, contact the local authorities for information concerning the correct disposal
procedure.
10. THE LEVEL OF NOISE EMISSION
The noise level of the installation in operation does not exceed 70dB(A).
11. LOCK OUT TAG OUT – LOCK METHOD GENERAL
- Everyone needs his own lock and tag (label), which can’t be removed by other persons.
- Inform all persons who are influenced by the procedure.
- Localize all sources of energy (electric, hydraulic, pneumatic).
- Switch off.
- Lock out and tag out.
- Check if the source of energy is switched off.
- Remove any remaining energy.
12. USE PERSONAL PROTECTIVE EQUIPMENT.
Ensure you wear personal protective equipment (gloves, dust masks...).
13. SUFFICIENT LIGHTING - ILLUMINANCE
-A minimum illuminance of 200 lux is necessary during usage, maintenance and installation.
- Provide at the installation (portable) emergency lighting in case of power failure.
14. ELECTRICAL EQUIPMENT, CONTROL PANELS, COMPONENTS AND DRIVE
UNITS
- To operate control panels, there must be atleast70cmoffreespace.
- Control panels must always remain closed. The key of the control panel must be in possession of an au-
thorized person.
- The necessary measures must be taken by the user to keep out rats, mice and other vermin from the
control panels
- If electrical equipment, control panels, components and drive units are damaged, the system must be
stopped IMMEDIATELY!
- Electrical equipment, control panels, components and drive units should NEVER be sprayed with water or
other liquid!
- Electrical equipment, control panels, components and drive units should NEVER be covered with any ma-
terial.