Intraco CABLEVEY Manual
2
INSTALLATION & SERVICE MANUAL
3INSTALLATION & SERVICE MANAUL
GENERAL INFORMATION 5
Warranty
Length, Capabilities and Material Recommendations
V-Belt Tension
Cable Speed
Installation Guide
LARGE DRIVE UNIT 13
C50100TM - 2” (50 System) 1 HP w/ METAL COVER
C50100TMK - 2” (50 System) 1 HP w/ METAL COVER & LIGHT KIT
MOTORIZED HOPPER 18
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
PROXIMITY RECYCLER 22
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)
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INSTALLATION & SERVICE MANUAL
3INSTALLATION & SERVICE MANAUL
CONTROL HOPPER / AUGER CAP & ASSEMBLY 26
C00161 - Control Hopper / Auger Cap
C00155 - Hopper / Auger Cap Assembly
CORNERS 31
C50300TWPS - 2” Bi-Directional Mechanical Corner
CABLE 33
C38201 - Galvanized Cable w/ 1 1/4” Discs
ACCUDIAL FEED DROP 36
C50605PCL - Contact Clear Volumetric Drop
C50606PCL - Clear Volumetric Drop
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INSTALLATION & SERVICE MANUAL
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DISPENSING PANEL 38
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)
TRIPPING SYSTEM (COMPONENTS) 51
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
Buttons Broken
Cable
Cable Connector Breaking
Cable Jerks and Pulls Extremely Hard
Corners
Drop Doors Sticking Open
Drops/Fill Bafe 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 & Disc
System Plugs
Tripping System
Cablevey Feeding System Start Up
Cablevey Feeding System Start Up For Tripping
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SERVICE MANUAL
5GENERAL INFORMATION
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 ef ciency - the feeding system. Intraco, Inc. decided to manufacture and
market its own line of feed conveying equipment with the trade name CABLEVEY.
The rst 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 in 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
manufacture, assembly, packing, crating, shipping, sales, service, of ce 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 “E” Award, a certi cate 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
& 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 rst installation of the 4” diameter tubular conveyor now being used for a
wide variety of materials and installed in various applications.
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.
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GENERAL INFORMATION 6
7GENERAL INFORMATION
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,
Iowa. Any defective part must be returned to INTRACO prepaid for examination and inspection.
INTRACO’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 damages are
claimed; and failure to give notice of claim within (30) days from date of delivery or the date xed 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 specied, but will not be liable for any loss, damage, detention or delay caused
by accident, strike, walkout, re, explosion, theft, lightning, windstorm, earthquake, ood, riot, civil
commotion, malicious mischief, act of God or any other cause beyond its reasonable control, whether
or not the same is herein specied 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 tness for a particular purpose.
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SYSTEM GROUND (MASH) MAXIMUM PELLETS MAXIMUM
1 1/2” (38) System Up to 900’ (275m) 4 Corners Up to 900’ (275m) 4 Corners
Up to 800’ (245m) 8 Corners Up to 800’ (245m) 8 Corners
Up to 600’ (185m) 14 Corners Up to 600’ (185m) 12 Corners
2” (50) System Up to 900’ (275m) 4 Corners Up to 900’ (275m) 4 Corners
Up to 800’ (245m) 10 Corners Up to 800’ (245m) 8 Corners
Up to 500’ (185m) 16 Corners Up to 500’ (185m) 10 Corners
Up to 300’ (90m) 18 Corners Up to 300’ (90m) 12 Corners
GENERAL INFORMATION 6
7GENERAL INFORMATION
LENGTH, CAPABILITIES AND
MATERIAL RECOMMENDATIONS
Maximum recommendations vary with the conguration of the system, cable speed and the
material being transported. As noted below, the numbers of corners inuences the maximum
recommended length of the system. In most cases, the lower the bulk 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 per cubic foot.
Air Trippers can open maximum 200 Drops.
Hand Trippers can open maximum 100 Drops.
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CABLE SPEED MOTOR PULLEY BELT
FT./MIN METER/MIN
63 19.2 01291C (AK27) 01259 (4L280)
69 21 01292C (AK30) 01259 (4L280)
82 25 01293C (AK34) 01259 (4L280)
88 26.8 01294C (AK39) 01260 (4L290)
101 30.8 01295C (AK44) 01260 (4L290)
GENERAL INFORMATION 8
9GENERAL INFORMATION
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 is a question
should be sent to us in an adequate amount for testing. MSDS sheets must be provided for
materials to be tested.
CAPACITIES
The capacity of a CABLEVEY 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, it may be necessary to use a lower cable speed to reduce carryover of
material past the intended drop. The cable speed is 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.
PROPER V-BELT TENSION
Push on belt between the sheaves. The force required to deect the belt 1/8” (3mm) should be
between 4 lbs. (1.81 kg.) and 8 lbs. (3.62 kg.).
A new belt should be tensioned to require near 8 lbs. (3.62 kg.), force for 1/8” deection.
A 4 lb. (1.81 kg.) force is adequate for a belt that has operated over 50 hours.
OVERTENSIONING CAN CAUSE GEAR REDUCER BEARING DAMAGE.
LENGTH, CAPABILITIES AND
MATERIAL RECOMMENDATIONS
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GENERAL INFORMATION 8
9GENERAL INFORMATION
THE NEW CABLEVEY FEEDING AND CONVEYING SYSTEM
CABLEVEY is a registered trademark of a feeding 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 exibility of the cable enables it to be installed in almost any conguration, with the use of
corner assemblies having an idler to reduce friction, wear and pull requirements.
The material is introduced into the system by means of a hopper which helps keep the material
owing.
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 in 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: All electrical connections are to be made by a qualied 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
CABLEVEY feeding system.
1. Conference 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 if necessary to recess ceilings.
c) Determine height at which tubing will be installed.
d) Location of bulk bin and/or feed container source or ll auger system.
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GENERAL INFORMATION 10
11 GENERAL INFORMATION
e) Determine direction of feed ow.
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 the best system layout. If not using
ll 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:
1. 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 all tubes -- make
sure there are no burrs or rough edges.
2. Hang the 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.
c) 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, but if 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.
c) 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.
e) 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 the drive unit frame.
Snap into place, insert two #10 x 3/8” sheet metal screws into belt guard through drive unit
frame.
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GENERAL INFORMATION 10
11 GENERAL INFORMATION
g) Electrical Connection: Have qualied electrician wire power supply to drive safety switch and
motor. Check direction of motor, sprocket must turn counterclockwise.
h) Attach Cover: Slip cover into place behind spring-covers.
i) Provide good, secure support for unit - either suspended from ceiling or place on oor or drive
unit stand.
5. Proximity Recycler Feed Sensor: Never install on return side of drive unit.
6. 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 is level and the
holddowns are on each side of the hopper.
c) The slide gate under the hopper must be opened to let feed ow out. 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.
e) 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.
7. Install Cable:
a) Block Idler Wheel on tension take-up assembly in Large Drive Unit forward 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.
c) 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.
e) 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. This 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 is too high, feed can accumulate on the
tue bottom. If adjustment is required, slightly loosen the bolts holding the mount bracket
to the frame, adjust as necessary and retighten.
8. Install Drops:
a) Mount the drops in proper position over holes.
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