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PEBCO®

DUSTLESS LOADING/SELF-CONTAINED DUSTLESS LOADING SPOUTS

MANUAL OVERVIEW

1

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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®

(270) 442-1996 or FAX (270) 442-5214.

2.0 PRODUCT OVERVIEW

Section 2

details both standard and optional components for

PEBCO®

Dustless Loading Spout

(DLS) and Self-Contained Dustless Loading Spout (SCDLS) units.

3.0 STORAGE RECOMMENDATIONS

Section 3

covers 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 4

covers 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 5

is designed to familiarize you with the operation of the

PEBCO®

Dustless Loading Spout.

6.0 MAINTENANCE RECOMMENDATIONS

Section 6

covers 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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Summary of Contents for Dustless Loading Spouts

Page 1: ...MANUAL Dustless Loading Self Contained Dustless Loading Spouts ...

Page 2: ...LLATION 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 5 OPERATION 15 6 MAINTENANCE RECOMMENDATIONS 16 6 1 MAINTENANCE PROGRAM IMPORTANCE 16 6 2 WEAR PARTS 16 6 3 MAINTENANCE SCHEDULE 16 6 3 1 Suggested Maintenance Schedule 17 6 3 2 Spare Part Installa...

Page 3: ...able 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 7 WARRANTY 32 ...

Page 4: ...s 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 4 covers installation an...

Page 5: ...PEBCO DUSTLESS LOADING SELF CONTAINED DUSTLESS LOADING SPOUTS MANUAL OVERVIEW 2 7 0 WARRANTY Section 7 is PEBCO s Warranty to the purchaser of Dustless Loading Self Contained Dustless Loading Spouts ...

Page 6: ...iled 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 ...

Page 7: ...e 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...

Page 8: ...dard 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 au...

Page 9: ...ach 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...

Page 10: ...ve 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 moi...

Page 11: ...nit is installed Filters should be stored in an area protected from pests and excess humidity Temperature should not exceed 100 F 38 C Do not stack Storing filters mounted inside the assembly is acceptable so long as all these conditions are satisfied by the storage area for the assembly Hose assemblies must be removed capped plugged 3 4 ADDITIONAL REQUIREMENTS Prior to long term storage and start...

Page 12: ...Follow all local fall protection falling object protection requirements whenever working aloft Anchor all large equipment that is to be installed BEFORE lifting If a Loading Spout Positioner system is present this system should be fully isolated from all power sources before any lifting systems are positioned Moving the unit while lifting systems are in place may result in equipment damage or tipp...

Page 13: ... pipe to the side outlet of the housing using an appropriate gasket material Not necessary for SCDLS units 8 Electrical connections to the drive motor rotary limit switch and optional equipment can now be made Refer to the provided wiring diagrams for more information WARNING Until the Rotary Limit Switch has been checked to ensure proper adjustment DO NOT FULLY RETRACT THE SPOUT as over retractin...

Page 14: ...uipment lift the housing assembly to the mating flange 5 Install nuts and washers Use only a high grade hex head bolt with an equal grade of nut flat and lock washer Lock washers and or a thread locking material should be used Angle supports on top of the housing assembly must be utilized for additional support to the hopper or other rigid steel structure to ensure that the housing assembly is ins...

Page 15: ... or his representative is responsible for terminations at the various components according to the drawing provided Connections for the tilt switch are located within a small terminal box located on the outlet assembly The rotary limit switch and slack cable limit switch are located on the housing assembly and should be wired through conduit suitable for the expected environment The motor and brake...

Page 16: ... a signal to the operator 20 For SCDLS units continue to Section 4 3 3 NOTE After one week of service it is recommended that a complete check of all fasteners be made to ensure tightness 4 3 3 Installation of Dust Collection Systems on SCDLS Units 1 Check all air tubing for any signs of damage and tool check each connection to ensure tightness Connections are tightened at the factory but can becom...

Page 17: ... way from the fully closed position Fully opening the damper will cause overload and may damage the system Once burn in is complete the damper may be adjusted as necessary to obtain the desired volume flow rate by measuring the static pressure at the outlet and referencing that measurement to the fan curve provided in the manufacturer s component data Use care when adjusting the volume flow rate t...

Page 18: ...directly below the spout open the vehicle container hatch 2 Once the hatch has been opened begin lowering the loading spout to the vehicle or container opening 3 The dust extractor should be turned on at this point 4 Continue to lower the outlet assembly until it is firmly seated in the vehicle container hatch 5 Start the product feed The vehicle or container should be properly filled with little ...

Page 19: ...formance while holding down maintenance costs 6 2 WEAR PARTS Parts exposed to high frictional forces whether due to the sliding of two parts against each other or due to exposure to the product flow are expected to wear and may need to be replaced PEBCO does not consider the wearing of Seals Cones Lift Cables Cone Suspension Cables Dust Sleeves or SCDLS Filters due to friction to be a defect as co...

Page 20: ... Gear Reducer Oil Level Inspect Mounting Bolts Check Chains Grease Drive Bearings Check Electric Motors Check Limit Switch es 6 3 2 Spare Part Installation Log Date Part Qty Comments 6 4 SAFETY PRECAUTIONS WARNING Before conducting any maintenance on or around the system it should be fully isolated from all power sources Failure to do so may result in injury or death Follow all local fall protecti...

Page 21: ...age to equipment or injury to operating personnel during loading 6 6 LUBRICATION General recommendation is for lubrication 6 6 1 Flange Bearings Flange bearing s that support the drive shaft s and idler shaft s should be greased every 100 hours of operation using NLGI 2 Lithium based grease if the particular bearing has a grease fitting 6 6 2 Gear reducer Gear reducer lubrication level must be vis...

Page 22: ... it is properly wired to the motor starter b If a micro switch has not been actuated but is just about to continue the operation of the drive unit until the sequence described in a occurs If this causes the retracted height of the DLS to be different then specified on the certified drawing this condition is acceptable if the difference in height is no more than plus or minus 1 1 2 inches c If at t...

Page 23: ...duct flow into the vehicle container or air flow up through the spout is not restricted due to damaged components If bent damaged or worn components are discovered these components can be easily and economically replaced Special attention should be paid when loading hydroscopic or sticky material through loading spout Periodically check internal cones for product build up if build up is found stri...

Page 24: ... given to the dust sleeve when performing this maintenance 1 Raise the spout to its retracted full up position Loosen the bolts retaining the dust sleeve NOTE AT THIS POINT THE DUST SLEEVE AND STIFFENING RINGS WILL DROP IT IS IMPORTANT THAT DUE CONSIDERATION BE GIVEN TO THIS FOR SAFETY 2 Lower the spout to expose the cones in the upper section of the DLS 3 To replace a cone disconnect the U bolt c...

Page 25: ...nt the cable must be replaced 3 To replace the cable lift the spout so that a work platform can be placed under the outlet assembly 4 Lower the outlet assembly onto the platform 5 Disconnect the cable from the outlet assembly by unscrewing the lifting eyebolt 6 Remove the cable from the drum by loosening the retention bolt on the drum Figure 4 7 Thread the new cable through the turning sheave Figu...

Page 26: ...nd the cable must be replaced 4 To replace the cable raise the spout to a position about 12 inches from fully retracted and disconnect cone support cables from the attachment points inside the tub Allow the cones to nest within the outlet assembly 5 Lower the outlet assembly to a position that allows easy access to the cone assembly 6 Disconnect the cable from the outlet assembly 7 Mark the cable ...

Page 27: ...s and disconnect the three cone support cables from the attachment points inside the tub Allow the cones to nest within the outlet assembly 3 Lower the spout until it rests on a work platform or some type of support approximately halfway through its travel Do not work on the spout while the weight of the unit is supported on the three lift cables Also do not lower the spout to its full extended po...

Page 28: ...ust be given to the dust sleeve when performing this maintenance 2 Reach inside the housing assembly and remove the three cone support cables by disconnecting the cone shackle from the lug This will allow the cones to rest on the outlet assembly 3 Lower the spout until it rests on a work platform or some type of support approximately halfway through its travel Do not work on the spout while the we...

Page 29: ...t switch full up full down positions as needed Refer to Section 6 7 for rotary limit switch adjustment 6 12 MOUNTING BOLT INSPECTION Check the mounting bolts Replace and or tighten any loose or missing bolts Use the same quality of bolts used in installation This should be done annually 6 13 SCDLS FILTER INSPECTION AND REPLACEMENT Filters on SCDLS units should be inspected monthly to insure they a...

Page 30: ... from the SCDLS by sliding it up off the blow tube 2 Open the valve casing by removing the bolts from the top of the valve 3 Look for signs of moisture in the valve which could indicate that the drain valve is faulty or that the supply air is not being properly conditioned The presence of moisture can drastically reduce performance and life of the diaphragm valves filters and headers 4 Visually in...

Page 31: ...electrical and air supplies Figure 6 Diaphragm Valve Cutaway Illustrative purposes only Goyen model RCAC25FS4 depicted if different model is installed see the manufacturer s component data in the associated cut sheet for manufacturer details 6 14 2 Pilot Valve Inspection 1 Disconnect the unit from all air and electrical sources 2 Purge the remaining air from the headers This can be done by activat...

Page 32: ...i of air 6 14 3 Drain Valve Inspection 1 Disconnect the unit from all air and electrical sources 2 Purge the remaining air from the headers by activating the drain valve 3 Disconnect all tubing and electrical connections 4 Remove the valve and inspect all interior surfaces of the valve Clean using a brush or damp cloth and remove any remaining debris using compressed air 5 Inspect the internal wor...

Page 33: ...ected to power Wiring frayed or loose Upper limit of the rotary limit switch set too low Rotary limit switch not operational Motor not operational Spout over extends Lower limit of the rotary limit switch set too low Rotary limit switch not operational Motor break not operational Dust in exhaust SCDLS Torn filters Worn inlet cone Dust coming from the outlet SCDLS Fan dampener improperly adjusted C...

Page 34: ...properly charged with air should be at 70 80 psi Diaphragm valves damaged or incorrectly connected Pilot valves damaged or incorrectly connected 6 16 HYDRAULIC SYSTEMS Refer to manufacturer s data sheets on items furnished on this order If Hydraulic Power Unit is supplied on this order by PEBCO refer to the Hydraulic System Manual for detailed operation ...

Page 35: ...ion or installation if executed by other than PEBCO misuse unauthorized alteration substitutions repairs or modifications neglect or accident or damage to the equipment caused by improper storage abrasion corrosion and or operation outside the rated load limitations for use of the equipment PEBCO shall not be liable for any repairs replacements or adjustments to the equipment or any cost of labor ...

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