PEBCO Dustless Loading Spouts User manual

MANUAL
Dustless Loading
&
Self-Contained Dustless
Loading Spouts

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TABLE OF CONTENTS
1MANUAL OVERVIEW.........................................................................................1
1.1 MANUAL CONTENTS ............................................................................................................................1
1.2 PRODUCT OVERVIEW..........................................................................................................................1
1.3 STORAGE RECOMMENDATIONS........................................................................................................1
1.4 GENERAL INSTALLATION ....................................................................................................................1
1.5 OPERATION...........................................................................................................................................1
1.6 MAINTENANCE RECOMMENDATIONS ...............................................................................................1
1.7 WARRANTY............................................................................................................................................2
2PRODUCT OVERVIEW.......................................................................................3
2.1 STANDARD COMPONENTS .................................................................................................................3
2.2 OPTIONAL COMPONENTS...................................................................................................................4
2.3 SCDLS SYSTEMS..................................................................................................................................5
3STORAGE RECOMMENDATIONS.....................................................................7
3.1 GENERAL REQUIREMENTS.................................................................................................................7
3.2 ELECTRICAL EQUIPMENT ...................................................................................................................7
3.3 SCDLS SPECIFIC EQUIPMENT............................................................................................................8
3.4 ADDITIONAL REQUIREMENTS ............................................................................................................8
4GENERAL INSTALLATION................................................................................9
4.1 RECEIVING INSPECTION .....................................................................................................................9
4.2 INSTALLATION WARNING....................................................................................................................9
4.3 MOUNTING AND INSTALLATION.........................................................................................................9
4.3.1 Installation of Assembled Units..................................................................................................9
4.3.2 Installation of Unassembled Units............................................................................................10
4.3.3 Installation of Dust Collection Systems on SCDLS Units ........................................................13
4.3.4 SCDLS Fan Motor Burn-in Instructions....................................................................................13
5OPERATION .....................................................................................................15
6MAINTENANCE RECOMMENDATIONS ..........................................................16
6.1 MAINTENANCE PROGRAM IMPORTANCE.......................................................................................16
6.2 WEAR PARTS ......................................................................................................................................16
6.3 MAINTENANCE SCHEDULE ...............................................................................................................16
6.3.1Suggested Maintenance Schedule..........................................................................................17
6.3.2 Spare Part Installation Log.......................................................................................................17
6.4 SAFETY PRECAUTIONS.....................................................................................................................17
6.5 GENERAL INSPECTION......................................................................................................................18
6.6 LUBRICATION......................................................................................................................................18
6.6.1 Flange Bearings.......................................................................................................................18
6.6.2 Gear reducer............................................................................................................................18
6.6.3 Drive Motor...............................................................................................................................18
6.6.4 Drive Bearings..........................................................................................................................18
6.6.5 Lifting Cables ...........................................................................................................................19
6.7 ROTARY LIMIT SWITCH ADJUSTMENT ............................................................................................19
6.8 INTERNAL CONE INSPECTION AND REPLACEMENT.....................................................................20
6.14.1 Intermediate Cone Replacement/Inspection (Lower Half).......................................................20

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6.14.2 Intermediate Cone Replacement/Inspection (Upper Half).......................................................21
6.9 CABLE INSPECTION AND REPLACEMENT.......................................................................................21
6.9.1 Lift Cable Inspection and Replacement...................................................................................22
6.9.2 Cone Support Cable Inspection and Replacement..................................................................23
6.10 DUST SLEEVE REPLACEMENT .........................................................................................................24
6.11 SHORTENING OF TRAVEL.................................................................................................................25
6.12 MOUNTING BOLT INSPECTION.........................................................................................................26
6.13 SCDLS FILTER INSPECTION AND REPLACEMENT.........................................................................26
6.14 SCDLS VALVE INSPECTION ..............................................................................................................27
6.14.1 Diaphragm Valve Inspection....................................................................................................27
6.14.2 Pilot Valve Inspection...............................................................................................................28
6.14.3 Drain Valve Inspection.............................................................................................................29
6.15 TROUBLESHOOTING..........................................................................................................................29
6.16 HYDRAULIC SYSTEMS.......................................................................................................................31
7WARRANTY......................................................................................................32

PEBCO® DUSTLESS LOADING/SELF-CONTAINED DUSTLESS LOADING SPOUTS MANUAL OVERVIEW
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1 MANUAL OVERVIEW
1.0 MANUAL CONTENTS
This Section of the manual will familiarize you with the contents of the other manual sections. This
manual is general in approach and may not include everything you want to know about the specifics
of your particular application. Specific technical information can be found on the drawings which are
a part of this manual.
If you have any questions, which cannot be answered by the written material provided, call PEBCO®
[phone] or FAX [phone].
2.0 PRODUCT OVERVIEW
Section 2details both standard and optional components for PEBCO®Dustless Loading Spout
(DLS) and Self-Contained Dustless Loading Spout (SCDLS) units.
3.0 STORAGE RECOMMENDATIONS
Section 3covers recommendations for proper storage. In some cases, scheduling requirements or
construction delays result in the equipment being stored prior to installation. The guidelines
suggested in this section are to aid the installer in selection of proper storage conditions. Because of
variability in site conditions/facilities, proper equipment storage/protection is the responsibility of the
purchaser or his agent.
PEBCO® is not responsible for any equipment damage which results from inadequate
storage/protection efforts.
4.0 GENERAL INSTALLATION
Section 4covers installation and start-up procedures. Pay special attention to the !!! WARNING !!!
in Section 4.2. Generally, installation of DLS systems requires working aloft, and may require
applying power to the unit to move between the retracted and extended positions of the spout.
Extreme care and good safety procedures should be used whenever working at height or around
moving equipment.
5.0 OPERATION
Section 5is designed to familiarize you with the operation of the PEBCO®Dustless Loading Spout.
6.0 MAINTENANCE RECOMMENDATIONS
Section 6covers recommendations for maintenance procedures. Information is presented on
lubrication, rotary limit switch adjustment, internal cone inspection, cable inspection, and outer sleeve
replacement. Maintenance specific to SCDLS units is also presented.

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7.0 WARRANTY
Section 7is PEBCO®’s Warranty to the purchaser of Dustless Loading/Self-Contained Dustless
Loading Spouts.

PEBCO® DUSTLESS LOADING/SELF-CONTAINED DUSTLESS LOADING SPOUTS PRODUCT OVERVIEW
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2 PRODUCT OVERVIEW
The PEBCO®Dustless Loading Spout (DLS) is a device of two or more conical sections that bridges the gap
between a load-out controls device such as a cutoff gate, conveyor, etc. and a hopper, truck, railcar or barge. The
DLS is retracted to allow the moveable transport device to be positioned and then it is lowered to facilitate dust-
free loading of the bulk solid product. Product is dropped into the inlet cone and travels down the cone assembly,
out of the outlet cone, and into the container being loaded. As product moves down the spout, dust is contained in
the dust sleeve encasing the cone assembly, and routed to a dust collection system through an outlet in the tub.
2.1 STANDARD COMPONENTS
The following components can be found on all PEBCO®DLS units:
DRIVE MOTOR AND GEAR REDUCER
The motor and gear reducer are mounted to the outside of the housing assembly to provide easy
access. The motor is powered by a three phase power source and is engaged by a command from
the operator. Motor and gear reducer combinations vary depending on the application; see the
manufacturer’s component data in the associated cut sheet for detailed manufacturer data.
DRIVE SHAFT AND LIFT CABLES
The drive shaft is supported by flange bearings mounted on either side of the housing assembly and
raises and lowers the spout by way of three lifting cables which run from cable drums on the shaft to
the outlet assembly. For lifting cable inspection and replacement, refer to Section 6.9.1.
ROTARY LIMIT SWITCH
The rotary limit switch is connected to the shaft by a chain drive. The rotary limit switch dictates the
limits of travel for the DLS by dropping out the motor contactor to stop the motor when the adjustable
cams within the switch reach positions which correspond to the upper and lower limits of travel.
These limits can be changed as desired by adjusting the switch; for more information on rotary limit
switch adjustment, see Section 6.7. Refer to the associated cut sheet for manufacturer data.
INLET CONE
The inlet cone is contained within the housing, and connects the spout to the equipment above by
way of a sealed flange. Material enters through the inlet cone and is passed down either to the
outlet assembly or an intermediate cone assembly.
CONE SUPPORT CABLES
The cone support cables ensure that each cone is suspended level and at the correct height. The
cable runs from the housing assembly to the outlet assembly with intermediate cones connected
to the cable via U-bolt cable clamps. For cone suspension cable inspection and replacement, see
Section 6.9.2.

PEBCO® DUSTLESS LOADING/SELF-CONTAINED DUSTLESS LOADING SPOUTS PRODUCT OVERVIEW
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OUTLET ASSEMBLY
The outlet assembly is held at the desired height by the lifting cables, and consists of a housing,
outlet cone, a hatch adapter for loading sealed containers or an outlet skirt for loading open
containers, along with optional equipment.
FABRIC REINFORCED DUST SLEEVE AND RINGS
The fabric reinforced dust sleeve serves to contain dust and connects from the housing assembly to
the outlet assembly. Depending on the application, it may be constructed from Coverlight, neoprene
coated nylon, or silicone coated fiberglass. Reinforcing rings are spaced along the sleeve, allowing it
to maintain shape. For dust sleeve replacement, see Section 6.10.
DUST COLLECTOR OUTLET
The dust collector outlet may be located on the side or the top of the housing assembly, and serves to
route dust from the spout to a dust collection system.
2.2 OPTIONAL COMPONENTS
In addition to the standard components mentioned in Section 2.1, PEBCO®DLS units are also
available with the following:
INTERMEDIATE CONE ASSEMBLY
Depending on the length of travel, the DLS unit may contain an intermediate cone assembly between
the inlet and outlet cones. Intermediate cones are attached to the cone support cables using U-bolt
cable clamps. When the spout is retracted, these cones compactly nest inside one another. When
the spout is extended, the cones telescope to direct the product into the container being loaded. For
cone inspection and replacement, refer to Section 6.8.
SLACK CABLE SWITCHES
Slack cable switches are mounted inside the housing assembly and are held in a closed position
when the cable is taut. When the cable becomes loose due to the outlet assembly hitting an
obstruction, the slack cable switch will move to an open position, which will either stop the motor or
send a signal to the operator. See the associated cut sheet for manufacturer data.
AIR VIBRATOR
An air vibrator may be installed on the outlet assembly to assist in material flow. Air vibrators must be
connected to filtered, regulated, and lubricated air with pressure not to exceed 80 psi. Air is supplied
via a coil hose which stretches between the housing assembly and the outlet assembly. DO NOT
connect air vibrators to the same air supply as SCDLS headers; vibrator air must be lubricated, while
header air must be dry. For more information, see the manufacturer’s data provided in the associated
cut sheet.

PEBCO® DUSTLESS LOADING/SELF-CONTAINED DUSTLESS LOADING SPOUTS PRODUCT OVERVIEW
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TILT SWITCH AND JUNCTION BOX
Tilt switches are used to indicate the height of the material or a choked loading condition, and are
mounted on a chain beneath the outlet assembly. When the switch is pushed away from the vertical
position by the material pile, the switch sends a signal to the operator, indicating the spout should be
raised until the switch resets. Tilt switches are available in carbon steel, stainless steel, and PVC,
with an optional float ball for liquid applications. For specific manufacturer data, see the associated
cut sheet.
PENDANT CONTROL (WIRED OR UNWIRED)
PEBCO® can provide a pendant control for the unit if desired. Controls are engineered to meet
the needs of the customer, and vary in configuration depending on the application. See the
associated cut sheet for specific manufacturer data.
MOTOR BRAKE
Motor brakes are used to assist in stopping of the spout. DLS units without motor breaks rely on
friction in the gear reducer to stop the spout. If more precision is required, motor brakes are used so
that when the motor is not receiving a signal to operate, the brake engages.
2.3 SCDLS SYSTEMS
Unlike standard DLS systems, Self-Contained Dustless Loading System (SCDLS) are manufactured
with a dust collection system installed directly onto the housing assembly. This eliminates the need
for a stand-alone dust collection system, and also provides an easy way to put material back into the
product stream.
During the loading process, the dust filters, which are positioned within the spout, are periodically and
automatically purged by air blasts from the diaphragm valves. This forces product collected on the
filters back into the product stream and into the vehicle or container being loaded.
In addition to the components of the standard DLS system, the SCDLS contains the following:
AIR PLENUM
The Air plenum is a sealed chamber located directly above the housing assembly. Air is drawn into
the plenum through the filters, and expelled through the exhaust fan. The plenum also contains
inspection panels for easy access to the filters for inspection and replacement.
HEADERS FOR COMPRESSED AIR
The headers on an SCDLS serve as an air reservoir for the diaphragm valves. Air is supplied to the
headers through one of the fittings located on each header. Use 70-80 psi of clean dry air to charge
the headers.
DIAPHRAGM VALVES
Diaphragm valves pulse air onto the filters during operation to remove product buildup and force it
back into the product stream. The valves are located on top of the plenum to allow for easy access,

PEBCO® DUSTLESS LOADING/SELF-CONTAINED DUSTLESS LOADING SPOUTS PRODUCT OVERVIEW
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and are pulsed automatically by the dust collector timer controller during operation. For more
information on diaphragm valves, refer to the manufacturer data in the associated cut sheet. For
maintenance, see Section 6.14.1.
MULTI PLEATED DUST COLLECTION FILTER PACK
The dust collection filters are mounted between the tub and the plenum and can be reached via the
access panels on the plenum. Filters remove product from the airstream before it enters the plenum,
allowing air to be routed directly out of the plenum into the atmosphere without further need for
processing. Each filter can accommodate a volume flow rate of 500 CFM. Manufacturer data can be
found in the associated cut sheet; for filter inspection and replacement, see Section 6.13.
ENCLOSURE CONTAINING THE DUST COLLECTOR TIMER CONTROLLER
The dust collector timer controller is located inside an enclosure on the side of the unit. The timer
controller regulates the purge sequence by signaling the pilot valve connected to each diaphragm
valve, controlling both the time between each purge and the duration of each purge. The controller
also monitors the pressure differential across the filters for maintenance purposes. Manufacturer
data can be found in the associated cut sheet.
SOLENOID DRAIN VALVE
The drain valve is connected to each header and serves to remove condensation accumulated in the
headers. After each purge cycle, the dust collector timer controller opens the drain valve, which
evacuates the water from the system. Manufacturer data can be found in the associated cut sheet.
For maintenance, see Section 6.14.3.
EXHAUST FAN
The exhaust fan is mounted to the top of the plenum and serves to drive air from the spout and the
container being loaded through the filters and out into the atmosphere. In some cases, air may be
ducted from the outlet of the exhaust fan; however, this is usually not necessary. Do not duct the
outlet air unless the system was originally designed with this specification in mind, as ducting the
outlet air induces a higher load on the exhaust fan. The volume flow rate is controlled by means of a
damper on the outlet of the fan. Use care when adjusting the volume flow rate to ensure that the
maximum flow rate for the filters and the maximum load on the exhaust fan motor is not exceeded.
See the manufacturer’s component data in the associated cut sheet for more information; for
exhaust fan burn-in instructions, see Section 4.3.4.

PEBCO® DUSTLESS LOADING/SELF-CONTAINED DUSTLESS LOADING SPOUTS STORAGE RECOMMENDATIONS
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3 STORAGE RECOMMENDATIONS
3.1 GENERAL REQUIREMENTS
If PEBCO®equipment is to be stored for a period of time longer than three weeks prior to installation,
the following procedures are recommended:
•Equipment should be stored in enclosed areas. Indoor storage area should be clean and dry.
Storage should be off of the floor, preferably on skids or pallets.
•Storage area should be free from rapid temperature changes. If necessary, an additional heat
source should be used.
•Storage area should not subject equipment to vibration.
•All interior and exterior surfaces of the spout must be thoroughly coated with Cosmoline. Any
unpainted surfaces, such as shafts, rollers, bearings, and pins should be given special
attention to ensure a thorough covering of Cosmoline.
•Storage must be above any possible water or snow line.
•All bearings must be fully charged with grease.
•Periodic inspections should be made, checking the covering, any moisture present,
cleanliness and general appearance to ensure the absence of corrosion and the integrity of
the Cosmoline coating.
•If outdoor storage is necessary, the equipment should be fully covered with weather-proof
material, vented so as not to trap moisture, but drip-proof so the water cannot enter or splash
up into it.
3.2 ELECTRICAL EQUIPMENT
•All electrical device enclosures must be opened and coated with CRC Stor & Lube.
•All electrical connections (terminations) must be coated with CRC Stor & Lube.
•All electrical openings must be capped or plugged as necessary to be sealed to atmosphere.
•Minimum Field Wiring 16ga AWG.
•Electrical junction boxes included with the equipment should be opened and any exposed
wire and terminations should be coated with CRC Stor & Lube. Open conduit connections
should be plugged or capped to atmosphere and the enclosure door should be securely
tightened to ensure sealing integrity.