tripping system
Contents
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6. INSTALLATION amp SERVICE MANUAL TRIPPING SYSTEM COMPONENTS C00612 13 AIR TRIP TUBE MT 3 4 CYLINDER PARTS LIST ITEM PARTNUMBER DESCRIPTION QTY fasmo CLEMSARCYUNDER 2 asotoss 9 AIRCYLINDER s PIVOT BRACKET 5 AIR CYLINDER _ AsMMS W PPENPPLE _ 90 MALE 3 8 1 AIR COMPRESSOR _ FLOWREGULATOR o PANTEDARTRPBRACKET 1 10 etai POSARTRIPLONGWREPANTEDERAME 1 M SPRING ATTACHMENT CONDUIT CLAMP 2 12 oroo 1A 20x11AHEKHEADSCREN 4 _ 15 etm 9821D x10D x 25TKFLATWASHER 4 _ won 15 ots ____ 14 20 34 HEX HEAD CAPSCREWSS 2 _ 717 est HOOK ZING 7900838 2 18 oons ____ 14 20HEXNUTSTAINLESS 2 19 ALOCKWASHER T2 720 ozs 1A 20x34HEXHEADSCREW 2 oos IALOCKWASHER 227 22 W MWREROR 1 ASMOS STAINLESS MUFFLER W NPT 1 23 AS01050 1 8 TO 1 4 PIPE NIPPLE 25 1612037 TRIPPER CYLINDER GUIDE ____ 727 2 _ 12 9 2 _ 1780 0 RUBBER
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9. m 63 32 1 5 Ey 1 4 INSTALLATION amp SERVICE MANUAL C50300T WPS 27 MECHANICAL CORNER ITEM PARTNUMBER DESCRIPTION HARDENED AXLE FOR CORNER IDLER BRONZE CORNER BUSHING bee CORNER IDLER 38 BIDIRECTION W HOLE 4 300544 BOTTOM PLATE 2 IN CORNER Low 5 3005021 TOP PLATE 2 IN CORNER 4 3005031 CLAMP 20 CORNER2IN 2 est ____ 2 a oons ____ 14 20HEXNUTSTAINLESS w 9 01026 1 4 20 x CAP BOLT S S 10 10 spacer tan 0 0 27 osr amm METRICNUT PLATED REPLACEMENT PARTS AVAILABLE 300385A CORNER IDLER 38 BIDIRECTION WITH BRONZE BUSHINGS INSTALLED 30000SHK INNER CORNER REPLACEMENT KIT 1 HARDENED AXLE amp 2 BRONZE BUSHINGS 300007 CORNER WEATHERPROOF KIT NOTE ALWAYS BE SURE CORNER IS WELL SUPPORTED NEVER PLACE CORNER VERTICALLY IF MATERIAL IS TO PASS THROUGH IT corner 2 INSTALLATION amp SERVICE MANUAL CABLE C38201 Galvanized Cable w 1 1 4 Discs INSTALLATION INSTRUCTIONS Mount spool of cable on an axle and thread end over lower idler and out right end port of larg
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11. woys SS4 2 4 2HEXBOLT 7m CYUNDERISNPTEXMAUST _ NOT IN B O M INSTALLATION amp SERVICE MANUAL TRIPPING SYSTEM COMPONENTS C00612 7 GESTATION TRIPPING SYSTEM Q e 4 cP aus aan agde er 2 QUE l Ee 1 X 225 C 4 or 2 INSTALLATION amp SERVICE MANUAL ss TRIPPING SYSTEM TRIPPING SYSTEM COMPONENTS C00612 7 GESTATION TRIPPING SYSTEM PARTS LIST ITEM PART NUMBER DESCRIPTION 1 asomar RODCLEVIS PIN JAMNUT 772 9 _____ AIRCYLINDER2 BORE 9 STROKE asore PNOTBRACKETANDPN 1 9 erossa PANTEDARTRPBRACKET 4 710 6 20 69 POSAKTRIPLONGWREPANTEDFRAME 1 600026 SPRING ATTACHMENT CONDUIT CLAMP 2 12 bows 14 20x1U4HEXHEADSCREN a 15 oto 9321D x10D x 25TKFLATWASHER a otn 14 2HEXNUT 15 oii 38 18x34HEKHEADSCREN 2 16 omm Xr onar _____ 2 01020 O 2 ow 38LOCKWASHER 720 14 2 x34HEKHEADSCREN a oms iMLOCKWASHER 320 zz 600037 5 8 TWO PIECE SH
12. 2 78 orsa RELAY 240V 2 POLE NORMALLY OPEN 1 _ 79 oti _____ J _ ____ 3ALOCKWASHER m eon m an 12 0 24x34 ROUND HEAD CARRIAGE BOLT 2 _ 1s omma carton rs Box mora STRANRELEFCONNECTOR GRE 2 _ onz SDTCONTROLCABLEVM4 TERMNALMRBaSE _ 2 emt WINWRETE 18 SS HOSECLAMR2SHE 3UP 1 19 MASAEWASHER INSTALLATION amp SERVICE MANUAL CONTROL HOPPER AUGER C00161 FUNCTION The Control Hopper Auger Cap mounts on top of the CABLEVEY Hoppers to receive materials from alterna tive fill systems It allows hoppers to be mounted closer to the ceiling and can eliminate the need for hopper extensions in certain applications The Control Hopper Auger Cap increases waterproofing benefits 108396P C00708C INSTALLATION amp SERVICE MANUAL HOPPER AUGER CAP 26 CONTROL HOPPER AUGER C00161 ITEM PART NUMBER DESCRIPTION 108396P COVER PLATE FOR AUGER CAP 108395P 3 HOLE PLATE FOR AUGER CAP 01944 PROTECTIVE EDGE TRIM 108398P HOPPER CAP PRESSURE SWITCH 01078L EYEBOLT 1 4 x 20 3 THREAD 2 3 4 708008 GASKET SWITCH 7 708003 PADDLE PRESSURE SWITCH 1 2 CONNECTOR RACO 2711 708007 STRAP GASKET REPAIR ITEMS ONLY REPLACED BY ITEM 23 27 HOPPER AUGER CAP
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14. Id ELECTRICAL LAYOUT CO CONTROL PANELS CONVEYING 5 8 SYSTEMS lt Z lt gt 2 Lr 2 2 lt z a Un Z 01588 CONTROL PANELS CONVEY DISPENSE 01581 CONVEY DISPENSE PANEL ITEM PART NUMBER DESCRIPTION QTY 16 x 14 CARLON BOX NM1614B DIN RAIL DISPENSE CONVEY PANEL 02045A SIEMENS LOGO RELAY W O DISPLAY 13 1 2 x 15 CONVEYING DECAL AS01021K 110 VAC 3 4 WAY AIR VALVE KIT SWITCH BRACKET DISPENSE CONVEY PANEL 110 VOLT CONTACTOR az 1 2 a 4 i _ 5 _ 1 6 a 3 Le TERMINAL BLOCK END _9 19 03 13 2 EN O5 15 ELE 106 O1 TERMINAL BLOCK 01467TC TIME CLOCK 24519 FOR 01467HW 01618 RH1B UAC120V RELAY RH1B SHIB 05 BASE FOR RELAY MOMENTARY START BUTTON 2X894 SINGLE POLE 2 WAY SWITCH ON OFF GREEN PILOT LIGHT ELECTRICAL SHOCK DECAL INSTALLATION amp SERVICE MANUAL
15. SS CMS i Bb We 4 EN S A SA a P O Box 148 2397 Hwy 23 Oskaloosa lowa 52577 0148 U S A Tel 641 673 8451 Fax 641 673 7419 U S Toll Free 800 247 3344 Email info cablevey com n m t x D October 2007 Pliease visitlus atiwww cableveyag com INSTALLATION AND SERVICE MANUAL SECTION Page GENERAL INFORMATION 5 Warranty Length Capabilities and Material Recommendations V Belt Tension Cable Speed Installation Guide C50100TM 2 50 System 1 HP w METAL COVER C50100TMK 2 50 System 1 HP w METAL COVER amp LIGHT KIT C50108HWPR Power Hopper 110 w Prox Recycler C50108HWPRK Power Hopper 110 w Prox Recycler Klauber C501082HWPR Power Hopper 220 w Prox Recycler C501082HWPRK Power Hopper 220 w Prox Recycler Klauber C50120 2 Proximity Recycler Feed Sensor 110 Volt C50120 220 2 Proximity Recycler Feed Sensor 220 Volt C50120 220 CANADA 2 Proximity Recycler Feed Sensor 220 Volt INSTALLATION amp SERVICE MANUAL 2 INSTALLATION AND SERVICE MANUAL SECTION C00161 Control Hopper Auger Cap C00155 Hopper Auger Cap Assembly C50300TWPS 2 Bi Directional Mechanical Corner C38201 Galvanized Cable w 1 1 4 Discs C50605PCL Contact Clear Volumetric Drop C50606PCL Clear Volumetric Drop
16. 20 x 1 HEX HEAD BOLT USE 010285 WITH KLAUBER 28 29 30 31 INSTALLATION amp SERVICE MANUAL MOTORIZED HOPPERS W PROXIMITY S RECYCLER FEED SENSOR C50108HWPR POWER HOPPER 110 W PROX RECYCLER C50108HWPRK POWER HOPPER 110 W PROX RECYCLER KLAUBER C501082HWPR POWER HOPPER 220 W PROX RECYCLER C501082HWPRK POWER HOPPER 220 W PROX RECYCLER KLAUBER PARTS LIST CONTINUED FROM PREVIOUS PAGE C50108HW 110 VOLT W PORT ITEM PART NUMBER DESCRIPTION QTY 108011 1 40 GEARMOTOR 3M327 OR 108011B 7 6 RPM 1 15 H P GEARMOTOR B 01173 CARLON F S BOX E980C B 01174 1 BLANK COVER F S BOX E980C 3E D 107501P PAINTED 2 IN HOPPER PORT C50108HWPR 110 VOLT W PROX RECYCLER ITEM PART NUMBER DESCRIPTION oone 76RPMTVISHRGEARMOTOR 1 04732 59247 SCEPTER BOX FXCISPLASTICBOX 1 onm BLANKCOVERFS BOx E9800 108011KL IS OBSOLETE REPLACE WITH 108011B C501082HW 220 VOLT W PORT ITEM PARTNUMBER DESCRIPTION 1080HB6 220 7 6 RPM 115 220 VOLTGEARMOTOR fons CARLONFS BOX E900 0 7 B COVER FS BOX ES800 3E D roro ______ PAINTED 214 HOPPER PORT C501082HWPR 220 VOLT W PROX RECYCLER ITEM PARTNUMBER DESCRIPTION 108012B 220 VOLT GEARMOTOR F HOPPER W O RECYCLER 108011BB 220 7 6 RPM 1 15 H P 220 VOLT GEARMOTOR 01174 BLANK COVER F S BOX E980C C50120 220 2 IN PROXIMITY RECYCLER 2
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18. compressor must be on at least 20 amp breaker Start compressor let it build up pressure Then let pressure off until compressor starts Hook air line from panel to compressor Set regulator to 100 PSI Then you should have air to panel Check all flow regulator valves at each air cylinder Regulator closet to panel should be open less than the ones at the end of the system Flip manual open switch to open When all doors are open check for any air leaks If none are found close switch Push manual dispensing button Doors should open and close two times If some rows of doors do not open all the way adjust air regulator at air cylinder If all doors open and close this means all is ok 63 TROUBLESHOOTING INSTALLATION amp SERVICE MANUAL
19. 3 INSTALLATION amp SERVICE MANAUL INSTALLATION AND SERVICE MANUAL SECTION 01580 Dispensing Panel 1 System 01581 Convey Dispense Panel 3 Systems 01582 Convey Panel 2 Systems 01583 Convey Dispense Panel 6 Systems 01584 Convey Panel 3 4 Systems 01588 Convey Panel 5 8 Systems C00612 13 Air Trip Tube MT 3 4 Cylinder C00612 13A Air Trip Tube MT 3 4 Cylinder C00612 7 Gestation Air Tripper C00612 5 Inline Quick Exhaust TROUBLESHOOTING 58 Buttons Wearing Cablevey Feeding System Start Up Buttons Broken Cable Cablevey Feeding System Start Up For Tripping Cable Connector Breaking Cable Jerks and Pulls Extremely Hard Corners Drop Doors Sticking Open Drops Fill Baffle Bending When Adjusting Feed Clogging Due to Moisture Feed Not Moving Fast Enough Holddowns Hoppers Prox Switch Not Working System Won t Shut Off Prox Switch Trips Too Fast Recycle Switch Rusting Feed Tube Slack in Cable amp Disc System Plugs Tripping System INSTALLATION amp SERVICE MANUAL 4 HISTORY Intraco Inc was founded December 22 1971 as an import export company for agricultural equipment During the early years Intraco Inc began distributing many lines of equipment both in the U S A and many foreign markets The intense desire to satisfy the needs of the agriculture industry gave Intraco Inc a chance to improve a sector of the industry that was lacking efficiency the feeding system Intraco
20. A natural progression was the design of the 2 diameter tubular conveyor system for industrial applications Representatives of Intraco Inc have been involved with trade delegations going to underdeveloped and emerging countries coordinated by the United States Department of Commerce Intraco Inc will continue to be a leader in the industrial and agriculture markets with an aggressive approach to the manufacturing marketing and distribution of CABLEVEY along with many other products serving the entire world 5 GENERAL INFORMATION INSTALLATION amp SERVICE MANAUL WARRANTY INTRACO INC warrants its CABLEVEY Feed Conveying System components when installed within its recommended limitations to be free from defects in material and workmanship under normal use and service for which intended for a period of one year from date of purchase Any parts which are proven defective and the company s inspection and examination shall disclose to have been thus defective will be replaced or repaired free of charge f o b Oskaloosa lowa Any defective part must be returned to INTRACO prepaid for examination and inspection INTRACOS s responsibility covers cost of replacement parts only and does not include repair or replacement caused by misuse abuse or normal wear and tear No claim of any kind whether as to goods delivered or for non delivery of goods shall be greater in amount than the purchase price of the goods in respect of which such
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22. 3 Check to see if green light is on If not check switches in drive units and reset them This should give you a gree light 4 Push manual start switch All systems should come on and run 5 Check each motorized hopper to be sure it is running Each proximity switch should have a red and green light at the hopper and it should be running Green light shows you have power to prox if red light is on the hopper motor should be running If red light 1s not on prox switch is set to sensitive Take small screwdriver attached to hopper and turn set screw to the minus until red light comes on and stays on 6 After all systems are running start auger and fill hoppers After hoppers are full start with 1 system open slide gate for 20 30 seconds Close slide gate and let system run Do this with each system to clean out systems The systems should run for two hours when the manual start switch 1s pushed It does NOT hurt to run system empty 7 After systems have run open the last 6 drops each system and set for 6 165 start systems and empty old feed Then open slide gate on hopper half way Let system run like this for a few days Then open slide gate 3 4 open this should be enough feed for system DO NOT open slide gate all the way 8 Always start loading crates from auger control end INSTALLATION amp SERVICE MANUAL TROUBLESHOOTING 62 CABLEVEY FEEDING SYSTEM START UP FEEDING SYSTEM START UP FOR TRIPPING 1 2
23. INSTALLATION amp SERVICE MANUAL CONTROL HOPPER AUGER C00161 1 220V ELECTRIC CONTROL BOX HOPPER AUGER CONTROL CAP ITEM 23 QD CORD H gt AUGER CAP SWITCH LABELING CORDS BLACK 110 VOLT LINE RED 110 VOLT LINE GREEN GROUND Ox eS S ai a M ITEM PART NUMBER DESCRIPTION 1 06 RELAY 240V 2 POLE NORMALLY OPEN 2 1084048 7 120 240 VOLT 10 SECOND TIMER Lr 4 3 011132 CONNECTOR RSR 1007 E 4 01143 COPPER 14 3 SJ CORD 42 FT 5 01036 10 24 1 CARRIAGE BOLT PLATED 108407 4 x 4 x 2 JUNCTION BOX INSTALLATION amp SERVICE MANUAL C00155 E 9 ITEM PART NUMBER DESCRIPTION QTY The HOPPER AUGER CAP ASSEMBLY is used as a supple mental component with the Control Hopper Auger Cap INSTALLATION amp SERVICE MANUAL CONTROL HOPPER AUGER CAP ASSEMBLY A
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25. System Doesn t Shut Off From Excess Slack Feed Build Up Behind Tensioner UNIT RUNS JERKILY Foreign Object in Corner Obstruction in System Tubing Not Straight Circuit Too Long Misaligned Corner Feed Buildup in Drive Unit Idler Item 7 1n Wrong Bracket Item 26 Hole Top Hole for 2 System 1 1 2 Disc Middle Hole for 2 System 1 1 4 Disc Bottom Hole for 1 1 2 System 1 Disc WORN IDLERS Cable Too Short NOTE Disconnect power before Servicing Keep cover in place when unit is operating Keep hands and loose clothing away from moving parts Be sure belt guard is in place before operating unit INSTALLATION amp SERVICE MANUAL MOTORIZED HOPPERS W PROXIMITY RECYCLER FEED SENSOR C50108HWPRK POWER HOPPER 110 W PROX RECYCLER KLAUBER C501082HWPR POWER HOPPER 220 W PROX RECYCLER C501082HWPRK POWER HOPPER 220 W PROX RECYCLER KLAUBER DIRECTION OF CABLE TRAVEL FUNCTION INSTALLATION 1 Determine the direction in which the feed cable will be traveling 2 Position Motorized Hopper so the cable enters the hopper into the recycler switch and exits the hopper through the restrictor port under the motor see photo above Make sure the feed line going through the Motorized Hop per 1s level and the holddowns are on each side of the hopper The Motorized Hopper 15 a metering device and transition for product to flow from the source Auger in the the conveying system Hopper
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27. 200003 CONNECTORCLAMPSLEEVE _ 2 2o81 BODY SPCONNECTOR 4 200002 CONNECTOR WASHER PLATED 1 s CONNECTORSNAPRNG 2 RAVEL key Nu LY 2 13 9 pe INSTALLATION amp SERVICE MANUAL ACCUDIAL FEED DROP 50005 CONTACT CLEAR VOLUMETRIC DROP C50606PCL CLEAR VOLUMETRIC DROP 50605 C50606PCL _ 1 2 INCHES 9 Ife INCHES CENTER UF ER ROP BJITLET 3 16 INCH Nb H HOLE PUNCHED IN mar FUNCTION simply dial in your desired feed setting for each drop in either pounds Ib or kilograms kg Markings are visible from either side of the Volumetric Drop Easy to adjust Closure Pat ented Positive Close Feed Dispenser guards against feed spills and insures accurate feedings ML 7 2 NE INSTALLATION amp SERVICE MANUAL 2 TEE 8 x 167 16001255 STAINLESS S
28. CONVEY DISPENSE 01583 CONVEY DISPENSE PANEL ITEM PARTNUMBER DESCRIPTION QTY 016208 16x 14HOFFMANFIBERGLASS BOX 1 2 064 DINRALDIPENSE CONEYPANEL 1 3 020458 SIMENSLOGORELAYWODISPLAY 1 4 1 13N 2x15CONEYNGDECAL 1 5 asmoz MOVACSAWAYARVALVEKT 6 062 SWITCH BRACKET DISPENSE CONVEY PANEL 1 7 omne ____ 7 omea 1 9 oii TERMNALBLOCK TMECLOCK2ASIBFORQMAGTHW 2 ots RHBUACIAVRELAY iz oit RHIBSHBOSBASEFORRELAY 6 01921 MOMENTARY START BUTTON 2x894 2 ow 1 SNGLEPOLEZWAYSWTCHONOFF 5 ote GRENPLOTUGHT 16 otess ELECTRICALSHOCKDECAL 1 INSTALLATION amp SERVICE MANUAL
29. GROMMET 2 0022 1 4 S S INTERNAL TOOTH WASHER 1 32 oma SS WASHERTHAXIKOA 1 s M6x12SELFTAPPNGSCREW 1 INSTALLATION amp SERVICE MANUAL TRIPPING SYSTEM COMPONENTS C00612 13A AIR TRIP TUBE MT 3 4 CYLINDER INSTALLATION amp SERVICE MANUAL TRIPPING SYSTEM COMPONENTS C00612 13A AIR TRIP TUBE MT 3 4 CYLINDER PARTS LIST ITEM PART NUMBER DESCRIPTION QTY CLEVISAIRCYLNDER 3 003 PIVOT BRACKET FOR 9 AIR CYLINDER a 4 Ass ___ 14 5 AsMOMS STAINLESS 6 asnos ____0 __ 7 SMALE 1 TAIR COMPRESSOR 1 s _ FLowREGUATOR 1 9 PANTEDARTRPBRACKET 10 AS01047 1 8 TO 1 4 PIPE NIPPLE 0202 14SS NTERNALTOOTHWASHER 1 12 ASMOMSK KIT FOR STAINLESS MUFFLER 14 NPT 18 oto 125 TKFLATWASHER 2 4 fotos T4 20x1 HEXHEADBOLT a 15 oons 14 20HEXNUTSTAMESS f 16 MALOCKWASHER 8 47 600026 SPRING ATTACHMENT CONDUIT CLAMP 1 187 414U BOLTTRIPPERCHANEL 19 PLASTICCHANNELGUDEBLOCK i 20 SUPPORT BRACKET DROP LEVELING WIRE 1 2 612057 SUPPORT CYLINDERBRACKEL TRIPPER CHANNEL 1 wons 8 4
30. Inc decided to manufacture and market its own line of feed conveying equipment with the trade name CABLEVEY The first CABLEVEY system was installed in Ontario Canada in 1974 Extensive research and marketing of the CABLEVEY feeding system began later that year involving shipments to Canada Australia and England Since that time thousands of CABLEVEY systems have been manufactured and installed 47 states and 35 foreign countries The component parts of the CABLEVEY system totaling over 470 are manufactured and fabricated by 50 suppliers located throughout the Midwest U S A Over 300 people are involved in the CABLEVEY systems fabricating and marketing chain including a manufacture assembly packing crating shipping sales service office and administrative personnel Intraco s percentage of exports to total sales has grown from 25 in 1974 to 50 at the present time Intraco Inc was presented the President s Award a certificate signed in the name of the President of the United States by the Secretary of Commerce at a special ceremony held in conjunction with a World Livestock amp Poultry Seminar in August of 1979 In 1985 Intraco applied it s knowledge obtained from agriculture conveying and began to develop products for the industrial markets 1990 was the first installation of the 4 diameter tubular conveyor now being used for a wide variety of materials and installed various applications
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32. WIRING FOR 00161 220 AUGER eh B Cy WIRING FOR C00161 220 AUGER BLACK JUMPER TO NORMALLY CLOSED AND TO TI ON TIME DELAY BLACK WIRE FROM CORD TO COMMON AND RED FROM CORD TO T2 TIME DELAY GREEN GROUNDS UNDER SCREW HOLDING SWITCH SET TIME DEALY SWITCH TO TEN SECONDS TESTING BLACK FROM AUGER CAP TO WHITE FROM 220 GRAY CORD WHITE FROM CAP TO BLACK FROM 220 GRAY CORD ALSO BLACK FROM MOTOR LABELING CORDS BLACK 110 VOLT LINE RED 110 VOLT LOAD GREEN GROUND INSTALLATION amp SERVICE MANUAL C50300T WPS 27 MECHANICAL CORNER FUNCTION The CORNERS are used to change the directions of cable travel The corners are specially designed to transfer the conveyed material from one tube to the other and reduce drag on the system This 15 accomplished by means of an idler wheel mounted on bronze bushings The idler wheel 15 formed to reduce buildup of material inside the aluminum housing by forcing it to the outside as the idler turns allowing the cable to carry it away The aluminum housing 15 structured so that it can be waterproofed and so that it will hold tubes rigidly in line with itself All corners for the 2 50 system are now weatherproofed E NO
33. be provided for materials to be tested CAPACITIES The capacity of a CABLEV EY system varies with the speed of the cable and the density of the material being transported Figures given are based on 40 pounds per cubic foot 641 kgs cu meter material and cable speed of 82 feet 25m per minute 1 1 2 38 System 1200 pounds 540kg per hour 2 50 System 2100 pounds 950kg per hour With certain materials 1 may be necessary to use a lower cable speed to reduce carryover of material past the intended drop The cable speed 15 altered by changing ratio of the belt drive on the drive unit The capacity will vary with type and moisture content of materials being trans ported CABLE SPEED MOTOR PULLEY BELT 01291C AK27 01259 41 280 2 ocak 01259 4 280 25 Ot293C AKM 01259 1280 042946 akao 01260 1 290 308 akaa 01260 41290 PROPER V BELT TENSION Push on belt between the sheaves The force required to deflect the belt 1 8 3mm should be between 4 165 1 81 kg and 8 165 3 62 kg A new belt should be tensioned to require near 8 Ibs 3 62 kg force for 1 8 deflection A 4 Ib 1 81 kg force 15 adequate for a belt that has operated over 50 hours OVERTENSIONING CAN CAUSE GEAR REDUCER BEARING DAMAGE INSTALLATION amp SERVICE MANUAL GENERAL INFORMATION 8 THE NEW CABLEVEY FEEDING AND CONVEYING SYSTEM CABLEVEY 15 a registered trademark of a feeding
34. cable with cable cutters 1 16 in 1 5mm off the center of the large slot toward the disc in the gauge If the cable 15 cut directly at the center of the large slot cable wires may extend beyond the cable sleeve end causing interference 6 Slide washer onto cable cable cut in step 5 with beveled edge toward end of cable Thread sleeve on cable until flush Slide washer to end of sleeve and insert set screws Care must be taken to avoid cross threading Do not com pltely tighten set screws yet CONTINUED ON FOLLOWING PAGE INSTALLATION amp SERVICE MANUAL 38209 T Fit two ends of connector together and insert snap ring into groove of body Rotate the snap ring in the groove to be certain that it is seated NOTE Snap ring must be inserted with sharp edge out Round Side Down 8 Place connected cable in gauge under slight tension with connector center slot If it goes into place easily connector spacing is correct and the set screws can now be tightened If connector is not centered on the slot loosen the four set screws and move the connector Now tighten the set screws to 50 60 inch 165 of torque which is a 15 Ib pull on the end of the 4 in Long AI len Key 01104L NOTE Do not reuse set screws after they have been tightened Used set screws will not sufficiently clamp to the cable C38209 Cable Connector ITEM PART NUMBER DESCRIPTION QTY 1 ote 14 280xS82SOCKETSETSCREN 10 2
35. damages are claimed and failure to give notice of claim within 30 days from date of delivery or the date fixed for delivery as the case may be shall constitute a waiver by Buyer of all claims in respect of such goods The remedy hereby provided shall be the exclusive and sole reedy of the Buyer and any right of the Buyer to consequential and incidental damages is excluded INTRACO INC will use all reasonable means to deliver the property sold hereunder within the terms and the time specified but will not be liable for any loss damage detention or delay caused by accident strike walkout fire explosion theft lightning windstorm earthquake flood riot civil commotion malicious mischief act of God or any other cause beyond its reasonable control whether or not the same is herein specified and in any event INTRACO INC SHALL NOT BE LIABLE FOR ANY CONSEQUENTIAL OR INDIRECT DAMAGE ARISING FROM ANY DELAY This guarantee is made expressly in place of all other guarantees or warranties expressed or implied with respect to quality merchantability of fitness for a particular purpose INSTALLATION amp SERVICE MANUAL GENERAL INFORMATION 6 LENGTH CAPABILITIES AND MATERIAL RECOMMENDATIONS Maximum recommendations vary with the configuration of the system cable speed and the material being transported As noted below the numbers of corners influences the maximum recommended length of the system In most cases the lower the bulk
36. hardware etc in the system Is there excessive feed buildup through small drive unit Clean out the feed buildup Is there open tube to closed tube with no holddowns at tube connector Install open tube with holddowns every 4 feet in place of closed tube Make sure there are holddowns in the system at drive unit hopper and corner connections V Are the tubes in and out of the hopper straight Realign the tubes in out of the hopper Are there rough edges on tubing File off burrs INSTALLATION amp SERVICE MANUAL TROUBLESHOOTING 58 Cable connector Did the cable connector break or pull apart If the set screws are not set deep enough breaking into the cable they will pull apart Do not reuse the set screws snap rings or sleeves when putting on a new connector New set screws with a deeper hex and a longer allen wrench are now available Tighten the set screw as deeply as you can 50 60 Ib torque inch using the longer allen wrench 15 the cable connector body touching either side of the drive sprocket teeth The connector body should be centered between the drive sprocket teeth when passing around the drive sprocket V Are cable connectors placed too close together in the system Cable connectors should be at least 2 feet apart V Was the cable connector gauge used when connectors were installed Always use the gauge to put connector together If itever breaks you must change out sleeve snap ring and set screws New
37. improved set screws with a deeper hex and longer allen wrenches are now available Is there too much drag strain on the system See System Plugs sections for possible causes of drag strain Are there more corners in the system than the maximum recommendations Too many corners will cause excessive pull on the system See Maximum Length Recommendations on Page 4 Is the system longer than the maximum recommendations Systems which are longer than the maximum recommended length create excessive pull on the system See Maximum Length Recommendations on Page 4 What type of feed are they feeding Pellets put too much of a strain on a 1 gt system Consider switching to a 2 system Cable jerks and Is the corner idler wheel turning Check for foreign object in idler wheel and proper pulls extremely hard direction of rotation of idler wheel Remove object Place idler in correctly Replace idler wheel with corner slide 2 system only if feed continues to plug in idler Are there rough edges on tubing File off burrs Is tubing seated properly in the corners Loosen corner clamp and reseat reasons given for System Plugs can cause the cable to jerk and pull hard See System Plugs section Corners Which corner idler bushing is most likely to wear out first The corner just before the drive unit The heaviest loaded corner is the one that the cable passes through just before entering the drive Th
38. the drive unit frame Snap into place insert two 10 x 3 8 sheet metal screws into belt guard through drive unit frame INSTALLATION amp SERVICE MANUAL GENERAL INFORMATION 10 g h i Electrical Connection Have qualified electrician wire power supply to drive safety switch and motor Check direction of motor sprocket must turn counterclockwise Attach Cover Slip cover into place behind spring covers Provide good secure support for unit either suspended from ceiling or place on floor or drive unit stand Proximity Recycler Feed Sensor Never install on return side of drive unit Installation of Hopper a Determine the direction in which the feed cable will be traveling b Position hopper so the cable enters the hopper into the recycler unit and exits the hopper through the restrictor port under the motor Make sure the feed line going through hopper 15 level and the holddowns are on each side of the hopper The slide gate under the hopper must be opened to let feed flow Open slowly until feed tube is 2 3 to 3 4 full d VERY IMPORTANT The ports and the trough bottom MUST line up evenly so they will not cause the cable to catch or slip Run feed in the CABLEVEY system Watch feed level in the tube and the rotor on the hopper When the tube come back at 2 3 to 3 4 the recycler switch should shut the hopper off Install Cable a Block Idler Wheel on tension take up assembly in Large Drive Unit forward
39. 20 VOLT NEN 011732 59247SCEPTERBOXFSCISPLASTICBOX NOTE The slide gate under the hopper must be opened to let feed flow Open slowly until feed tube 15 2 3 to 3 4 full VERY IMPORTANT The ports and the trough bottom MUST line up evenly so they will not cause the cable to catch or slip CAUTION Never operate system with space between discs more than 2 3 to 3 4 full 21 MOTORIZED HOPPER INSTALLATION amp SERVICE MANUAL 2 PROXIMITY RECYCLER FEED SENSOR C50120 110 VOLT 50120 220 220 VOLT 50120 220 CANADA 220 VOLT LOOKING AT MOTORIZED HOPPER LOOKING AT DRIVE UNIT INSTALLATION amp SERVICE MANUAL 2 PROXIMITY RECYCLER FEED SENSOR C50120 110 VOLT 50120 220 220 VOLT 50120 220 CANADA 220 VOLT To adjust sensitivity on switch use a precision screwdriver to turn screw between the and slightly to the right of left INSTALLATION amp SERVICE MANUAL 2 PROXIMITY RECYCLER FEED SENSOR C50120 110 VOLT 50120 220 220 VOLT 50120 220 CANADA 220 VOLT PARTS ASSEMBLY PARTS LIST ITEM PART NUMBER DESCRIPTION 1 50204 OPEN TUBE CONNECTOR 6 IN 2 01647 7 FLATPACK PROX SENSOR 20 250VAC N C 3 12000 J 2 O D x 1 3 4 1 0 x 18 POLYCARB TUBE 4 50203 CLOSED TUBE CONNECTOR 5 twswP PAINTED 21N HOPPER P
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41. AFT COLLAR TRIPPER CYLINDER 1 om0 MESHSLEEVE SC oss se 1D x11780 RUBBER GROMMET 2 SS WASHERTMAxixDA gt C osa e x12 SELF TAPPINGSCREW S Asow s CYUNDERTANPTEXHAUST _ NOT IN B O M INSTALLATION amp SERVICE MANUAL TRIPPING SYSTEM COMPONENTS C00612 5 INLINE QUICK EXHAUST NOTE WHEN CUSTOMER ORDERS C00612 5 THEY WILL RECEIVE NEW PART AS SHOWN AT BOTTOM OF PAGE OLD C00612 5 ITEM PART NUMBER DESCRIPTION 1 5010415 STAINLESS MUFFLER 1 4 NPT 2 AS01038 QUICK EXHAUST VALVE s ommwo won _____ 1 SELF TAPPING SCREW 1 75 _ DIAPHRAM AND RING 1 REPLACEMENT KIT NEW 00612 5 ITEM PART NUMBER DESCRIPTION QTY 1 AS01070 QUICK EXHAUST VALVE 1 2 AS01040 1 4 IN AIR HOSE GIN _ INSTALLATION amp SERVICE MANUAL Troubleshooting Problem QuestionstoAsk Solution Buttons wearing Buttons Broken uw Button wear patterns give clues about system problems Oval shaped buttons The cable is sliding over the feed and the buttons are pushing up against the inside of the closed tube Install open tube with holddowns every 4 feet in place of the closed tube Two V notches The cable is being pushed up against the inside of the open tube Add holdd
42. EGLEVELERSCREN 6 BEARNGSMALL SPECIAL NOTE ADJUST CABLE TENSION After cable has been installed turn the drive unit by hand with the V belt observing the disc leaving the tube just before it enters the sprocket The disc should be approximately 1 16 off the tube bottom If it contacts the tube bottom it can snap off the end of the tube causing wear and excessive drag If it too high feed can accumulate on the tube bottom If adjustment 15 required slightly loosen the bolts holding the mount bracket Item 23 to the frame adjust as necessary and retighten INSTALLATION amp SERVICE MANUAL DRIVE UNIT TROUBLE SHOOTING UNIT WILL NOT START Check Electrical Supply pi Reset Drive Unit Roller Switch Item 57 Check Control Switch Check Motor Reset Check Door Switch UNIT TRIES TO START BUT CAN T System Overloaded and Tension Incorrect 6 Motor Defective Gear Reducer Defective Item 16 Reset Drive Unit Roller Switch Item 57 MOTOR RUNS SPROCKET DOES NOT TURN Check Belt Check Shear Pin Item 43 Sprocket Loose Item 10 Gear Reducer Defective Item 16 UNIT SHUTS OFF 7 System Overfull Cable Tension Incorrect Foreign Object in Hopper Foreign Object in Corner Foreign Object in Drop Opening Cable Broken Control Device Malfunction CABLE COMES OFF SPROCKET Check Cable Connector Positioning Sprocket Worn Flip Sprocket Over or Replace Item 10 Broken Buttons
43. ORT omn BLANK COVER FS BOX E9800 otis _____ 8 RELAY 120v 1 POLE NORMALLYOPEN 79 14 20x1HEXHEADBOLT a _ oti T4LOCKWASHER m otn E 7 1024 3 4 ROUND HEAD CARRIAGE BOLT 2 Cas omma CARLONFS BOx WO7sE 74 STRAIN RELIEF CONNECTOR 2 5 ona ______ ___________ fonon nwmmE 7717 omo SS HOSECLAMR2SiE SUP E omo 18 onm TERMNALMRBSF 2 INSTALLATION amp SERVICE MANUAL 2 PROXIMITY RECYCLER FEED SENSOR C50120 110 VOLT 50120 220 220 VOLT 50120 220 CANADA 220 VOLT PARTS ASSEMBLY iD PARTS LIST ITEM PART NUMBER DESCRIPTION 1 1850204 OPEN TUBE CONNECTOR 6 IN 2 01647 FLATPACK PROX SENSOR 20 250VAC N C 3 12000 ___ 2 0 13 4 1 0 x 18 POLYCARB TUBE 4 50203 CLOSED TUBE CONNECTOR 5 107501P PAINTED 2 IN HOPPER PORT e BLANK COVERS 1
44. STALLATION 1 With cable meshed in sprocket after removing slack mark discs to be replaced by connector Remove Remove the left the right side disc side disc NOTE NINE INCHES BETWEEN THE IDLER SHUT OFF FRAME AND LEFT END OF DRIVE UNIT FRAME STEP 5 2 Remove cable from sprocket Hold disc to be removed with vise grips and cut with hacksaw Cut cable do not cut cable Turn cable over and make another cut 180 degrees from last cut Pull disc halves from cable 2 Place cable coming from right side of sprocket with disc removed in cable connector gauge Be sure now on gauge 15 pointing in same direction as cable travel arrow on drive unit Cut cable with cable cutters 1 16 in 1 5 mm off the center of the large slot toward the disc in the gauge If the cable is cut directly at the center of the large slot cable wires may extend beyond the cable sleeve end causing interference 4 Slide BODY of connector over end of cable cable cut in step 3 Thread SLEEVE onto cable turn counterclockwise until end of cable 1s flush with end of SLEEVE Slide BODY to outer end of SLEEVE and insert two SET SCREWS Care must be taken to avoid cross threading Do not completely tighten set screws yet 5 Place cable coming from the left side of the sprocket with disc removed in cable connector gauge with empty spot over center slot in gauge Again be ure arrow on gauge 15 pointing same direction as cable travel arrow on the drive unit Cut
45. TEEL ITEM PARTNUMBER DESCRIPTION NOT IN B O M 2 60201 2 SLIDE CLOSURE 1 TO 6 LB VOL DROP WHEN 8 602017S DOOR IS ORDERED AS A 3 6020122 CLOSER ROD 1 TO 6 LB VOL DROP 14 REPAIR PART 4 602013 _____ SLIDE STRIP 1 6 LB VOL DROP 1 18 amp 19 TO ATTACH DROP TO AUGER PMOTROD 10618 1 eoms 18NYLONINSERT 1 78 LONG WIRE DOOR WITH PIVOTHOLES 1 o 090 S16 IBNYLONGINSERTJAMNUT 710 1 2 HEX HEAD SHEET METAL SCREW TYB 2 oros S16 18 HEX NUT YELLOW CHROME FINISH 1 242 02465 SS 10 24x 58 HEXWASHER HD SCREW 2 3 105008 ______ _____________ 1 71 roxa nwa screw Piao z 745 ons RUBBER O RING BRAKE SLEEVE 1 716 coso To 7 47 02486 HEX HEAD SHEET METAL SCI SEALWASHER 1 748 RUBBER WASHER 062x 120x 2510 1 19 021485 _____ SS 6 HEX WASHER SHT METAL SCREW 1 NN INSTALLATION amp SERVICE MANAUL Control Panel Instructions da wry A NE Y Dp 5 MONY E 350 2 MANUAL START SWITCH iM 6 MANUAL STOP SWITCH SWITCH 3 o 1 b 7 4 DRIVE UNIT SAFETY E 4 ee ee 1 Clock for Con
46. a few inches with a short piece of open tube b Feed cable under Idler Wheel and push around system with 01602HW cable pushing tool Stay near the front end of cable while pushing DO NOT force or kink cable Prestretch cable using 01604HW cable lock tool d Connect cable using C38208 cable connector kit 01275 cable cutters and instructions on Page 33 35 of Installation and Service Manual Adjust Cable Tension After cable has been installed turn the drive unit by hand with the belt observing the disc leaving the tube just before it enters the sprocket This disc should be approximately 1 16 off the tube bottom If it contacts the tube bottom it can snap off end of the tube causing wear and excessive drag If it 1s too high feed can accumulate on the tue bottom If adjustment 15 required slightly loosen the bolts holding the mount bracket to the frame adjust as necessary and retighten Install Drops a Mount the drops in proper position over holes GENERAL INFORMATION INSTALLATION amp SERVICE MANAUL 10 11 12 13 14 INSTALLATION amp SERVICE MANUAL Positive Close Installantion a b Attach all drop door wires to the channel If holes do not line up with wires on doors move forward toward tripper to next closest hole Attach flared end of channel to narrow end of next piece of channel If attachment comes up on wire for door shorten the narrow
47. and conveying system produced and mar keted by INTRACO INC of Oskaloosa Iowa U S A The NEW CABLEVEY system use a simple principle Material is moved through a tube with an air craft cable that has plastic discs molded to the cable at regular intervals The cable moves at high speed in a continuous circuit carrying the material with it at the same speed this reduces the grinding action and seperation The flexibility of the cable enables it to be installed almost any configuration with the use of corner assemblies having an idler to reduce friction wear and pull requirements The material 1s introduced into the system by means of a hopper which helps keep the material flowing The cable is pulled through the circuit by a drive unit having an automatic cable tensioning device The material can be discharged from the circuit at any desired location by placing a hole the bottom of the tube Any of a variety of styles of drops can be installed on the tube under the hole the style used will depend on the fuction to be performed The drop styles and functions are described later in this manual NOTE electrical connections are to be made by a qualified electrician in compliance with all local state and national codes DESIGNING and INSTALLING OF A CABLEVEY SYSTEM INSTALLATION AND PREPLANNING A well designed and properly installed system will help insure quality and long life of the CABLEV EY feeding system 1 Confer
48. density of the material the farther it can be moved Figures are given based on 40 pounds per cubic foot 641 kgs cu meter material and cable speed of 82 feet 25m per minute No circuit should exceed maximum lengths as show below All lengths are based on total circuit lengths We recommend that all applications excluding poultry should use the 2 50 System All inclines and declines in heights should be 45 or less 1 1 2 38 System rated at 20 pounds per minute at 40 pounds per cubic foot 2 50 System rated at 35 pounds per minute at 40 pounds cubic foot Air Trippers can open maximum 200 Drops Hand Trippers can open maximum 100 Drops SYSTEM GROUND MASH MAXIMUM PELLETS MAXIMUM 1472 0 System Up to 900 275m up to 900 75m toto sn Usern uestem Urns sn Beane evra semen veteran semen 7 GENERAL INFORMATION INSTALLATION amp SERVICE MANAUL LENGTH CAPABILITIES AND MATERIAL RECOMMENDATIONS MATERIAL RECOMMENDATIONS The CABLEVEY system will handle a variety of materials Limitations of the system in trans porting materials depend upon many factors such as moisture content friction qualities and size Examples of these are cohesive materials such as molasses large particles such as sow cubes or high friction materials such as sand Any material about which there 15 a question should be sent to us in an adequate amount for testing MSDS sheets must
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50. e drive unit See Photo A Push cable from one corner to the next through tube As soon as the cable has passed a corner fasten the cover in place When both ends of cable are drive unit hook 3 or 4 discs of one end in sprocket and pull slack from system by hand pulling the opposite end Place discs in sprocket to hold cable in this position Cut cable using 01275 Cable Cutter and attach con nector according to cable connector installation instructions Photo A FUNCTION The CABLE is the heart of the CABLEVEY systems As the cable is pulled through the circuit it carries conveyed material with it The cable is an aircraft quality steel cable with specially designed plastic discs spaced at regular intervals The discs are sized to transfer the highest quantity of material with the least amount of friction 38208 Cable Connector Kit ITEM PART NUMBER DESCRIPTION SNAP RING PLIERS 0022 SOCKETSETScREWS 12 ____ s 34 QTY C38219 CABLE CONNECTOR TEMPLATE EN s ______ RING CONNECTOR 01275 Cable Cutter INSTALLATION amp SERVICE MANUAL CABLE CONNECTOR C38209 FUNCTION The CABLE CONNECTOR attaches the two ends of the cable together to complete the loop The two piece metal connector is joined together with an internal snap ring which allows any rotational twist the cable to be self correcting IN
51. e lightest loaded corner is the one just after the drive unit Which corner idlers are most likely to plug with feed The lightest loaded corners corners just after the drive unit at the top of inclines Usually the second corner after the hopper at the top of an incline will plug before any other corner This corner idler is lightly loaded and feed naturally falls back into the idler Drop doors V Are drop doors sticking open and causing feed spills Pull the trip handle more than sticking open once 2 or 3 times or change over to the new positive close system 59 TROUBLESHOOTING INSTALLATION amp SERVICE MANUAL Feed not moving fast enough Holddowns Hoppers Prox Switch not working system won t shut off Prox Switch trips too fast Recycle Switch Rusting Feed tube Slack in cable amp disc INSTALLATION amp SERVICE MANUAL What size system is installed 172 or 2 17 system convert to 2 system Refer to Maximum Length Recommendations on page 4 What size motor pulley and belt are being used Check alternative sizes and cable speeds on Maximum Length Recommendations on page 4 V Are holddowns placed properly throughout the system Holddowns should be installed every 4 feet level every 2 feet incline and before and after corners hoppers recyclers and N a Are hoppers leaking Are they hooked up to the double boot extension If so replace it with the new 17 Double Boot E
52. ence with customer before installation Visually inspect the CABLEVEY installa tion site gathering the following information a Identify and obstructions b _ Check for hanger supports advise 1f necessary to recess ceilings Determine height at which tubing will be installed d Location of bulk bin and or feed container source or fill auger system 9 GENERAL INFORMATION INSTALLATION amp SERVICE MANAUL Determine direction of feed flow f Select Drive Unit location Preferably install on return line after last drop and allow for ad equate support of the Drive Unit 2 Sketch proposed system Several rough sketches will help establish best system layout If not using fill auger set the builk tank at different locations and rotate the hopper 90 degrees at each of these loca tions Keep the incoming feed line angle as gradual as possible maximum 45 degrees The number of corners should be kept to a minimum to increase the cable life Consider weather protection serviceability electrical hookup and recycling of feed in locating the Drive Unit Place Drive Unit directly after the last drop if possible INSTALLATION OF THE SYSTEM l Lay out open tubing end to end in aisles or over pens Locate and punch at desired locations Note location of holes for AccuDial drops are different than for volumetric drops Support tube on both ends to prevent burred and jagged edges surrounding the hole from catching cable File al
53. end of channel enough to get the attachment before the wire on the door Continue to attach wires from drop doors until line 15 complete to the end of the row Spring at end of channel should not have tension on it until drop doors begin to open After the spring is attached cut channel at proper length and attach If drops are more than 4 apart install channel support J Brackets Tripping System Installation a b Mount Air Trip Cylinder in proper location on the open tube Cylinder must pull on the channel to open drop doors Tube Mount Tripper will bolt directly to open tube over tube cover Support frame with S hooks amp chains Bolt rod to channel with cylinder rod extended Hand Trip Handle to be mounted to the wall and cabled to the channel through pulleys Connect Power Control Panels are available for most applications Wiring diagrams are available for systems not using control panels Have qualified electrician connect power in compliance with all Local State and National Codes New CABLEVEY Conveying Panel and Dispensing Panel Observe System in Operation a b c Operate system to check performance Introduce feed into system and adjust feed flow to proper level by viewing feed flow through Inspection Section set Recycle Unit Cleanup Installation crew 15 to leave installation site free of all boxes packing materials etc brough by the installer Review CABLEV EY Feeding System operating pr
54. ether when installed or they will work their way together while running and cause slack in the cable due to decreased length of the total circuit TROUBLESHOOTING 60 System Plugs Is too much feed flowing from the hopper Reduce the flow level The proper level is 2 3 to 3 4 full tubes for most feeds 1 2 full for high moisture materials How steep is the incline of incoming feed tube If the incline is too steep this will cause system plugs Reduce tube angle and or add holddowns to open tube to give even flow Is tube cover properly installed Check all tube cover inside and outside to be sure it is securely attached to the tube Is water getting into the system at hopper tube connectors or corners Keep doors on hoppers Be sure slide gate is not partially inserted Tape ends of tube connectors Seal corners with weatherproofing kits Is there a foreign object in the system Example rodents and hardware They usually wedged in the corner remove Bunching of feed Feed roll by in tube causes bunching of feed Replace closed tube with open tube and holddowns or add holddowns to existing open tube every 4 feet 15 moisture freezing in tubing in extremely cold climates In humid buildings in extremely cold climates moisture may freeze in return tubes out of the building Attach heat tape and insulation around tube Do tube and or corners sag This allows feed to roll by thus causing bunching of feed Add su
55. features include slide gate a paddle rotor and an observation window Run feed in the CABLEVEY system Watch feel level in the tube and the rotor on the Motorized Hop per When the tube comes back at 2 3 to 3 4 full the recycler switch should shut the hopper rotor off If it does not shut off or if it shuts off too soon the sensitivity of the Proximity Recycler may need to be adjusted see Proximity Recycler for these instructions INSTALLATION amp SERVICE MANUAL MOTORIZED HOPPER 18 ww MOTORIZED HOPPERS W PROXIMITY RECYCLER FEED SENSOR 50108 POWER HOPPER W PROX RECYCLER _ 50108 POWER HOPPER 110 W PROX RECYCLER KLAUBER 501082 POWER HOPPER 220 W PROX RECYCLER 501082 POWER HOPPER 220 W PROX RECYCLER KLAUBER PARTS ASSEMBLY INSTALLATION amp SERVICE MANUAL MOTORIZED HOPPERS W PROXIMITY RECYCLER FEED SENSOR C50108HWPR POWER HOPPER 110 W PROX RECYCLER _ C50108HWPRK POWER HOPPER 110 W PROX RECYCLER KLAUBER C501082HWPR POWER HOPPER 220 W PROX RECYCLER C501082HWPRK POWER HOPPER 220 W PROX RECYCLER KLAUBER PARTS LIST ITEM PART NUMBER DESCRIPTION GASKET 1 16 046 076 40 DURO CONNECT FEMALE 4731 AVAILABLE SEPERATELY 7 E 7 2 21 22 23 24 25 01024 1 4 20 WING NUT YELLOW CHROME 26 010285 1 4 20 x 3 4 HEX CAP BOLT 5 5 27 01041 1 4
56. l tubes make sure there are no burrs or rough edges 2 Hang tubing a Locate the cup hooks for attaching the tube hangers every 8 for all systems b Support tubing close to either side of the tube joint and each corner to keep lines leve Level tubing d Open tube feed lines from hopper into building 3 Install 90 Degree Corners and Connect System Place supports close to either side of Corner so Corner does not sag 4 Large Drive Unit Installation Instructions a Determine Location This Drive Unit can be located almost anywhere in the circuit butif pos sible it should be located inside the building on the return line of the system Consider ease of service when locating it remembering that the cable travels from left to right and the sprocket turns counterclockwise b Install Port Mount port to outlet on right end of drive frame Install breather in Gear Reducer by replacing top plug Mount Drive Unit Unit can be suspended from chains by using eyebolts attached to mounting angle d Install Motor Attach motor to motor base and secure pulley to motor shaft Thread adjusting bolt through motor base and into nut Attach this assembly to Drive Unit with pivot rod and cotter pins Install Belt Align belt by moving motor pulley Check pulleys make sure they are tight Adjust belt tension by moving the adjusting bolt f Install Belt Guard Position belt guard in place between the guard clip and
57. ocedure with the customer of his representative a b c d e f How to connect the cable Cable Connector s position on sprocket Review maintenance schedule Adjusting recycle switch Scan the Installation amp Service Manual identifying sections relevant to customer s CABLEVEY system Help the customer complete his CABLEVEY information card to be mailed to the factory GENERAL INFORMATION 12 50100 C50100TMK 2 50 SYSTEM 1 HP W METAL COVER LIGHT KIT INSTALLATION 1 DETERMINE LOCATION This Drive Unit can be located al most anywhere in the circuit but if possible it should be located inside the building on the return line of the system Consider ease of service when locating it remembering that the cable travels from left to right and the sprocket turns counterclockwise 2 INSTALL PORT Mount port Item 28 to outlet on right end of the drive frame Install breather in Gear Reducer by replacing top plug 3 MOUNT DRIVE UNIT Unit can be suspended from chains by using eyebolts attached to mounting angle Item 22 4 INSTALL MOTOR Attach motor to motor base Item 19 and se cure pulley to motor shaft Thread adjusting bolt Item 49 through motor base and into nut Item 39 Attach this assembly to Drive Unit with pivot rod Item 20 and cotter pins included in bag kit See figure 5 INSTALL BELT Align belt by moving motor pulley Check pul leys make sure they are tight Adjust bel
58. owns every 4 feet A wide V notch Idlers are seized Check corner idlers for rotation Clean out foreign material and grease spindle If idler plugs with feed consistently replace idler with corner slide 2 system only narrow V notch or several narrow V notches Corners and tubes are sagging causing cable to ride up or down in the corner Support corners and tubes Cuts into buttons Old style hopper C00107 cams worn away completely and metal cutting into buttons Install new cams The drop has slipped on the tube letting the metal closer inside of the cleanout slot v Buttons tapered after cable connector This wear occurs each pass over a corner idler wheel if The cable connector spacing is incorrect Check spacing with gauge System pulls hard with old style corner idlers Replace idlers with new beveled timed notched idlers V Sudden reduction in button size for no apparent reason Generally starts with a broken button Feed rolls past the broken button and bunches especially at inclines thus pushing the cable against the top of the tube Also the cable is forced to ride up inside the corners which wears on the corner covers and edges of the idler wheels y Are the buttons in the hopper and is it a new installation The motor is wired backwards V Are the corners sagging Support corners and tube they must be level Are there foreign objects in the system Check for foreign objects rodents
59. power to the Control Panel Ath If there is power to the Control Panel you will need to check the Manual Stop Switch Item 3 If this 15 on a qualified electrician will need to open the panel box and place a jumper wire from 4 to 5 on the terminal block at the bottom of the Control Panel see Wiring Diagram included If the green light does not come on there is no power to the Control Panel and you must contact a qualified electrician to restore power to the panel If the green light comes on then it is one of the Drive Unit Safety Switches Roller Switches The jumper wire must be removed before running the system The Safety Switch should look like Photo 3 If you can reset the Safety Switch and the system stops again and it is the same Drive Unit this indicates the cable needs to be shortened If the Safety Switch looks like Photo 4 it means that the cable needs to be shortened the system 15 plugged To shorten the cable you will need to remove 3 buttons See instructions for shortening cable on Page 19 of Installation and Service Manual 2 Clock for Dispensing Item 5 A Ifthe Clock for Dispensing Item 5 will not dispense feed but the Manual Switch Item 6 will then the Clock Part No 01467TC will need to be replaced B Ifthe Manual Switch Item 6 and the Clock Item 5 will not open the doors on the drops you will need to press the small red button on the Air Valve Photo 5 This should open all the door
60. pports to corners and tubes Is the control drop working properly If the control drop malfunctions and feed cycles through the system tubes will overload Fix or replace the control drop Is there a buildup of fines in the closed tube return feed lines High moisture feeds and molasses feeds can close return tubes so that only the cable buttons can squeeze through the causing excessive pull Replace the closed tube with open tube and holddown ripping System f Doors will not open Goto Dispensing and use the Manual Open switch to open all doors lf some doors open and some do not leave the switch and check the line for air leaks If none of the doors open push the red button on the air valve on the bottom of the dispensing panel The air valve on the air cylinders control air flow to open doors The more air allowed into the line the faster the door will open Turn the value to adjust the air flow If Doors do not close The doors close with the release of air through the mufflers and the inline exhaust A Check the springs on the tripping channel to be sure they are attached B Check the mufflers on the air cylinders to be sure they are not plugged C Check the Inline Exhaust to see if it is plugged 61 TROUBLESHOOTING INSTALLATION amp SERVICE MANUAL CABLEVEY FEEDING SYSTEM START UP FEEDING SYSTEM START UP 1 sure all drops on all systems closed 2 Turn manual stop switch to on
61. s They should stay open as long as the button is depressed and should close when the button 15 released If this happens the air valve is plugged or bad and will need to be cleaned or replaced as necessary Part No AS01021K C Check the Air Compressor and be sure the water 15 drained out of it 3 Manual Bypass Switches A The switches located inside the control box to be used ONLY if the controller in the panel is not functioning These manual switches must be turned on and off manually You MUST turn the switch off if it is ever switched to on DISPENSING PANEL 40 INSTALLATION amp SERVICE MANUAL CONTROL PANELS DISPENSING 01580 DISPENSING PANEL ITEM PARTNUMBER DESCRIPTION QTY 1 165 AZ IN AZINBOXNMAZ12B ___ 1 2 1636 7 CLEAR COVER 12 x 12 NC1212L 1 3 _ 01632 ______ DISPENSING CONTROL PANEL FACE 1 2 111 2 11 1 2 DISPENSING DECAL 1 _5_ BACKPLATEJPI222 14023SECINTERVALSWITCHBI 1 TERMNALBLOCKEND 1 NN PTERMINALBLOCK 5 TME CLOCK 2A519 __ 0 MOMENTARY START BUTTON 2X894 1 SINGLE POLE 2WAYSWTICHON OFF 1 EM L1 EN 2 NUN 2 15 L3 18 E 19 RHIB SHIB 05 BASEFORRELAY 1 INSTALLATION amp SERVICE MANUAL
62. t tension see page 4 for proper tension by moving the adjusting bolt Item 49 6 INSTALL BELT GUARD Position belt guard Item 12 in place between the guard clip Item 13 and the drive unit frame Snap into place insert two 10 x 3 8 sheet metal screws provided in bag kit into belt guard through drive unit frame 7 ELECTRICAL CONNECTION Have qualified electrician wire power supply to Drive Unit Safety Switch Roller Item 57 and motor Check direction of motor sprocket must turn counterclockwise 8 ATTACH COVER Slip cover Item 9 into place behind spring covers Item 21 2 50 SYSTEM 1 HP W METAL COVER amp HONS FUNCTION The Drive Unit is the mechanism which pulls the cable through the system The cable is pulled through the Drive Unit by a sprocket driven by a 1 HP electric power motor and Gear Reducer The cable enters the left end of the Drive Unit travels around the sprocket and 15 picked up by two Idler Wheels which guide it to the outlet on the right end of the Drive Unit The outgo ing cable travels under 1 coming cable allowing material brought into the Drive Unit to drop onto the outgoing cable and be car ried out returning it to the system One of the two Idler Wheels is spring loaded to act as an automatic tensioning device removing slack from the cable If the slack becomes excessive or if the tension becomes too high a Drive Unit Safety Roller S
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64. veying 2 Manual Start Switch 3 Manual Stop Switch 4 Green Light 5 Clock for Dispensing 6 Manual Dispensing Switch 7 Manual Cleanout Switch DISPENSING PANEL 34 INSTALLATION amp SERVICE MANUAL 7 2 Photo 43 safety eid Roller INMENEE MM Switch for Drive Photo 4 Safety Switch Roller Switch for Drive Tie dames gd e jd Photo 5 Valve Photo 6 Manual Bypass Switches 39 DISPENSING PANEL INSTALLATION amp SERVICE MANUAL 1 Clock for Conveying Item 1 A Ifthe Clock Item 1 will not start the systems but the Manual Start Switch Item 2 will start the systems the Clock Part No 01467TC will need to be replaced Ifthe systems will not run and the Green Light Item 4 is off Ist Check all Safety Switches Roller Switches in Drive Units and reset as necessary Once the Safety Switches are reset it will reset the Control Panel and turn the Green Light Item 4 on The Red Light on the back of the Drive Unit which needs to be reset will be on See Photo 1 2nd If none of the Safety Switches Roller Switches need to be reset you will need to check the Control Drop See Photo 2 to be sure the door is completely closed The system will not run if the door 15 open 3rd If resetting the Drive Units and closing the door on the Control Drop do not resolve the problem you will need to check electrical
65. witch will shut off the Drive Unit INSTALLATION amp SERVICE MANUAL 5 0 5 100 01 00 K P 2 50 9 SY L 50 6 YSTEM 1 HP Wi P M W E L TA L OV CO ER M ER amp 9 we Y a 2 b t 7 A P d IN ST A LL AT IO N amp SE RV IC E M A N UA L C50100TM 2 50 SYSTEM 1 HP W METAL COVER C50100TMK 2 50 SYSTEM 1 HP W METAL COVER amp t i PARTS LIST 15 ITEM PART NUMBER DESCRIPTION 1 froo DRVEFRAME 3 twee CLEANOUTCOVER 1 tomos WASHERADAPIOR 1 4 400006 NULADAPIOR a s 400007 2 roos GuDERoE 2 IkLERWMEL 2 s tw MOUNNGBLOK 2 9 tms CLEARCOVROR 1 1 SPROCKET 1 two MOTORMOUT tms BELTGUARD tms GUARDCUP 1 tms FOAMSEAL Joa 15 400004 SPROCKETADAPTOR 1 16 300 GEARREDUCER 1 ar toosif LOWERMOUNTGEARBOX 1 1s 1000527 UPPER MOUNT GEARBOX 1 19 two i 2 tw PNOTRO 1 twos SPRNGCOVER 2 100070 MOUNNGANGEE 2 25 400108 MOUNT BRACKET TUBE SUPPORT 1 m roomp BAHIDLERBRACKET
66. xt Widm C38113W or caulk it until it stops leaking Use silicone sealant on any seams or metal joints Is there a control drop If proximity switch is on the control drop it should shut off immediately You can adjust the sensitivity Is the proximity switch on an inline switch The timer may be set wrong if the prox switch is on an inline switch this has to be set by length of system and speed of cable Does the proximity switch trip too fast Adjust the switch adjustment screw is by the light Is there a load on the switch Needs FMS time delay delay to keep it from putting load on switch Is the paddle hitting the switch Put holddown before the recycler to keep the cable from jumping up and down causing the paddle to hit the switch Is tubing rusting Puta couple of feet of stainless steel or powder coated feed tube on each side of wall coming into and going out of the building powder coated 15 a less costly method than stainle How many times have you removed stretch You shouldn t have to remove stretch more than three times You get of 1 percent of stretch for the life of the cable Most of the construction stretch should be taken out in the first year V Was the cable pre stretched during installation Cable should always be pre stretched during installations Was the tube in the tube connectors butted against each other during initial installation The tube in the connectors must be butted tog
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