PDC KST80-712 User manual

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TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
Steam
Tunnel
KST80-712
Serial Number: 441

Page 2 of 24
TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
Table of Contents
1. INTRODUCTION..................................................................................................................3
1.1 Overview.......................................................................................................................3
1.2 Confidentiality..............................................................................................................3
1.3 Manual Storage.............................................................................................................3
1.4 Warranty Note ..............................................................................................................3
2. SAFETY PRECAUTIONS....................................................................................................4
2.1 Warning Statement .......................................................................................................4
2.2 Danger, Warning, and Caution.....................................................................................4
3. INSTALLATION & SETUP .................................................................................................6
3.1 Regulator Setup ............................................................................................................9
4. CONTROLS.........................................................................................................................10
4.1 Power..........................................................................................................................10
4.2 Exhaust Blower...........................................................................................................10
4.3 Tunnel Temperature Controller..................................................................................11
4.4 TCU Temperature Controller Parameters Default Parameters...................................12
5. ADJUSTING THE TUNNEL..............................................................................................15
5.1 Steam Valve Flow Volume Control ...........................................................................15
5.2 Steam Valve Direction Control ..................................................................................17
6. STEAM VENTING PACKAGE..........................................................................................19
6.1 Adjusting the Vent Valves..........................................................................................19
6.2 Adjusting the Tunnel Stand........................................................................................20
7. SHUTDOWN.......................................................................................................................21
8. GENERAL TROUBLESHOOTING ...................................................................................21
9. BOILER ...............................................................................................................................23
10. TECHNICAL INFORMATION .....................................................................................24
11. CUSTOMER SERVICE CONTACT INFORMATION.................................................24

Page 3 of 24
TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
1. INTRODUCTION
1.1 Overview
The PDC Model KST80-712 is for use in shrink-fitting the labels or neckbands to
consumer product containers, downstream of the label/neckband application point
on a production-line conveyor.
1.2 Confidentiality
This manual and the information contained herein are confidential property of PDC
International Corporation. They may not be reproduced and may only be used in
conjunction with the purchased PDC tunnel.
1.3 Manual Storage
Please keep this manual in a safe and accessible place for all operators and other
parties that may be responsible for this machine.
1.4 Warranty Note
The machine is warranted as per PDC "terms and conditions" to work with the
materials and products with which it was tested.

Page 4 of 24
TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
2. SAFETY PRECAUTIONS
2.1 Warning Statement
Failure to install, service, and operate this tunnel in accordance with the
instructions in this manual, proper training, adherence to warning labels, exercising
common sense, and due caution may result in serious bodily injury.
Please read this manual carefully and understand it before operating this tunnel.
Please contact PDC International directly at [phone] with any questions or
for any problems or conditions that arise that you do not understand.
2.2 Danger, Warning, and Caution
(Danger, Warning, and Cautions are based on definitions in ANSI Z535.4 -2007, Section 4.)
Before any work is to be done on the tunnel, turn off the steam supply and turn the
power ON/OFF switch to the OFF position. Allow the tunnel sufficient time to
cool down properly and then disconnect the main power supply and then follow
proper lockout/tagout procedures.
Danger:Before opening the filter or condensate trap for any reason, be
sure to first relieve all pressure and to wear appropriate protective clothing!
Some components are under pressure and can cause serious bodily injury or
death!
Warning:Do not touch tunnel components (other than the console) until
unit is off and has had time to cool down. Unit is hot and can burn, causing
serious bodily injury.
Caution:Before any work is to be done on the machine, or before reaching
into the machine for any reason, if possible turn all switches to the off position
including the main power fused disconnect switch and then follow proper
lockout/tagout procedures!

Page 5 of 24
TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
Caution:Ensure that all gauges read zero prior to doing any work on the
tunnel system.
© Clarion Safety Systems, LLC
(The safety label above is located on each side of this tunnel and on the overhead
exhaust tubing to the vent blower.)
(This warning label may or may not appear on the filter housing, depending on the
type of filter used for this tunnel. In either case, please make all operators aware
of this danger as the message is applicable in all options.)

Page 6 of 24
TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
3. INSTALLATION & SETUP
This procedure should only be performed by qualified technicians. Incoming steam
lines should be isolated from the steam generator and all lockout/tagout procedures
should be followed.
Connect the drain lines from the steam filter canister and condensation trap to a
suitable drain or condensate return line. Be sure the adjustment knob on the
Armstrong pressure reducing valve is turned to the maximum counterclockwise
position (zero pressure). Connect the steam hose from the output of the steam
regulator to the inlet on top of the tunnel (if shipped separately). Connect a steam
input line from the steam generator to the ball valve located at the steam supply
inlet on the steam tunnel. Connect air line for electronic regulator.
Refer to the installation drawing (in the Assembly Drawings tab of this binder) for
details.
OUTPUT OF
STEAM
REGULATOR
INLET ON TOP
OF TUNNEL

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TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
** Please read carefully the entire manual before operating this machinery or
performing the checklist that follows.** After reading this manual, the following
is a useful checklist to refer back to, for startup of the tunnel and associated
equipment.
1.) Install. Connect the power and air (as discussed above).
2.) Power up the conveyor (and vent blower, if one exists).
3.) Check the setup sheet. Adjust the steam valves, blower speed,
and vents, accordingly.
4.) Check temperature settings on the controller.
5.) Adjust pneumatic regulator, to 18-22 psi (see below).
6.) Open the steam valve.
ARMSTRONG
PRESSURE
REDUCING
VALVE
PALL STEAM
FILTER
CONDENSATION
TRAP
STEAM FILTER
CONDENSATION
TRAP (NOT
SHOWN, ON
BOTTOM OF
FILTER)
BALL VALVE
(STEAM
SUPPLY INLET)

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TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
The pneumatic precision regulator adjusts the
flow for steam going inside the tunnel. The
air pressure setting at the pneumatic
transducer should be targeted at 20 psi
initially –range 18-22 psi.
The thermodynamic steam trap opens to
release condensate. It is normal for it to
exhaust intermittently, but if it exhausts
continually, then there may be debris on the
seat that may be causing it to stay open.
Please see the Troubleshooting Section below, for more details, before taking
any corrective action, and do not attempt to fix any part of this unit if you are not
trained and comfortable doing so, as the discharge can
be sudden and hot!
PNEUMATIC
TRANSDUCER
GAUGE
CONDENSATION
TRAP

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TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
3.1 Regulator Setup
Slowly open the ball valve at the steam inlet to allow steam to flow into the steam
tunnel manifold. Turn the knob on the Armstrong pressure reducing valve to adjust
until of reading of 75 PSI is achieved on the filter inlet gauge.
Maintenance notes:
When the pressure differential between the filter inlet gauge an
the filter outlet gauge is greater than 5 PSI, the filter needs to be
replaced.
Replacing the filter approximately every 3 months will
minimize other issues such as those that could occur that might
not be as noticeable as a pressure change in the line.
Old filters can be cleaned and reused.
For assistance with this, please contact Anthony Caccamo or
Todd Smith at PDC at [phone].
BALL
VALVE
(STEAM
SUPPLY
INLET)
ARMSTRONG
PRESSURE
REDUCING
VALVE
PALL STEAM
FILTER
FILTER INLET
GAUGE
FILTER OUTLET
GAUGE

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TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
4. CONTROLS
4.1 Power
The electrical power for this tunnel may vary. Please refer to the installation
drawing of your particular unit (in the Assembly Drawings tab of this binder) for
details.
4.2 Exhaust Blower
To turn on the exhaust blower, locate the Lenze VFD on the blower that is located
downstream from the tunnel, and press the green button on it.
The Lenze Operating Manual is included in the Literature section that accompanies
this manual. Please see pages 22-24 of that operating manual especially, as it
shows the basic keypad functions.
Lenze AC Tech SMVector Control Box
BLOWER ON
SWITCH
(GREEN)
BLOWER OFF
SWITCH
(RED)

Page 11 of 24
TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
4.3 Tunnel Temperature Controller
At the front of the tunnel, turn the tunnel electronic temperature control power
switch (green) to “on”. This green switch turns on the KST80-712 tunnel.
After turning this switch, the tunnel temperature will rise to the temperature setting
on the controller. To change the temperature, push either of the buttons, marked
with the up or down arrow, to raise or lower the temperature, respectively.
Read the supplied temperature controller manual (blue manual from Red Lion) in
the Literature section that accompanies this manual, before making any other
changes to the temperature controller settings.

Page 12 of 24
TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
4.4 TCU Temperature Controller Parameters Default Parameters
UNIT NUMBER
MNEMONIC
PARAMETER
USER SETTING
SP
Temperature Setpoint
Per product setup
sheet
OPOF
Output Power Offset
0
OP
Output Power
100
ProP
Proportional Band
12
Intt
Integral Time
10
dErt
Derivative Time
0
P-2
Proportional Band#2 (secondary)
-
It-2
Integral Time #2 (secondary)
-
dt-2
Derivative Time #2 (secondary)
-
rtio
Remote Setpoint Ratio
-
bIAs
Remote Setpoint Bias
-
AL-1
Alarm 1
10
AL-2
Alarm 2
10
CONFIGURE INPUT
MNEMONIC
PARAMETER
USER SETTING
tYPE
Input Sensor Type
T
SCAL
Temperature Scale Units
°F
dCPt
Temperature Resolution
0
FLtr
Digital Filtering
1
SPAN
Input Slope
1000
SHFt
Input Offset
0
SPLO
Setpoint Lower Limit
0
SPHI
Setpoint Upper Limit
250
SPrP
Ramp Rate
60
InPt
User Input
PLOC
HCur
Heater Current Scaling
50
CONFIGURE OUTPUT
MNEMONIC
PARAMETER
USER SETTING
CYCt
Cycle Time
2
OPAC
Control Action
REV
OPLO
Output Power Lower Limit Range
0
OPHI
Output Power Upper Limit Range
100
OPFL
Sensor Fail Power Preset
0
OPdP
Output Power Dampening
3
CHYS
ON/OFF Control Hysteresis
1
Tcod
Auto-Tune Dampening Code
2
ANAS
Linear Output Assignment
OP
ANLO
Linear Output Scale Value
0
ANHI
Linear Output Scale Value
100
ANdb
Linear Output Deadband
0

Page 13 of 24
TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
ANut
Linear Output Update Time
0
CONFIGURE LOCKOUTS
MNEMONIC
PARAMETER
USER SETTING
SP
Setpoint Access
ENT
OP
Output Power
ENT
dEv
Access Deviation Display
RED
HCur
Access Heater Current Display
RED
IN-2
Access Second Analog Input
RED
UdSP
Access Display Units
RED
Code
Access Code Number
O
PID
Access Primary PID Values
ENT
PID2
Access Secondary PID Values
LOC
Rtbs
Access Ratio and Bias Values
LOC
AL
Access Alarm(s) Values
ENT
ALrS
Enable Reset Alarm (s)
ENBI
SPSL
Enable Local/Remote Setpoint
Selection
LOL
trnF
Enable Auto/Man Transfer
ENBL
tUNE
Enable Auto-Tune
ENBL
CONFIGURE ALARMS
MNEMONIC
PARAMETER
USER SETTING
Act1
Alarm 1 Operation Mode
B-IN
rSt1
Alarm 1 Reset Mode
AUTO
Stb1
Alarm 1 Standby Enabled
NO
AL-1
Alarm 1 Value
10
Act2
Alarm 2 Operation Mode
B-IN
rSt2
Alarm 2 Reset Mode
AUTO
Stb2
Alarm 2 Standby Enabled
NO
AL-2
Alarm 2 Value
10
AHYS
Alarm Hysteresis Value
1
CONFIGURE COOLING
MNEMONIC
PARAMETER
USER SETTING
CYC2
OP2 Output Cycle Time
2
GAN2
Relative Cooling Fan
1
db-2
Heat-Cool Overlap/Deadband
0
CONFIGURE SERIAL COMMUNICATIONS
MNEMONIC
PARAMETER
USER SETTING
bAUd
Baud Rate
1200
PArb
Parity Bit
ODD
Addr
Unit Address
0
Abrv
Abbrev. Or Full Transmission
NO
PrAt
Automatic Print Rate
0
PoPt
Print Options
NO

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TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
INP
YES
SEt
YES
OPr
YES
Pdb
NO
INt
NO
dEr
NO
AL1
NO
AL2
NO
dEv
NO
OFP
NO
r_P
NO
Crg
NO
Cdb
NO
OSt
NO
rAt
NO
bIA
NO
RSP
NO
IN2
NO
Pb2
NO
It2
NO
Dt2
NO
SP2
NO
HCr
NO

Page 15 of 24
TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
5. ADJUSTING THE TUNNEL
5.1 Steam Valve Flow Volume Control
The tunnel valve tools (Steam Tunnel Key
and Steam Tunnel Wrench) are located at
the top of the tunnel in a sheet metal box.
Using the steam tunnel key (T wrench),
adjust the flow control valves to the
indicated settings on the product set up
sheet.
The top portion of the T (shown below) may be used as a screwdriver to turn the
slotted pin that fastens the door panel, to access the flow control valves that are
behind the panel.
Caution: If opening panel doors for any reason after tunnel has been turned
on or before it has cooled off after use, exercise caution and stand back as
steam may escape rapidly as soon as door is opened.
The bottom portion of the T contains a cutout that is used to turn the control valve
dials (as shown at left).
Steam Tunnel Key (T Wrench)
PDC Part # PDC-231-00

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TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
There are five (5) steam control valves on each side of the steam tunnel for a total
of ten (10) steam control valves on the entire tunnel.
Each of the steam control valves has a flow control scale as indicated by the valve
indicators. An operator can select a setting of “0” (fully closed), “1/4”, “1/2” ,
“3/4”, or “OPEN” (fully open).
Be sure to reseal each door panel with the top end of the T wrench (or a
screwdriver) when finished (turn screwdriver, or T wrench, a half turn to secure
door).

Page 17 of 24
TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
5.2 Steam Valve Direction Control
The spray pipes can be rotated to direct the steam where it is required for the
shrink process. Loosen the pipe union with the supplied 1-1/8” open-end wrench
and then use the steam tunnel wrench (shown below) to rotate the spray pipe to
position (see following page).
Loosening the Union Steam Tunnel Wrench
PDC Part # PDC-231A00
1-1/8”
OPEN-END
WRENCH
STEAM
TUNNEL
WRENCH

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TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
Record the position number that is aligned to each pointer indicator.

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TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
6. STEAM VENTING PACKAGE
6.1 Adjusting the Vent Valves
Refer to the setup form and adjust each vent according to the amount of shut/open
needed. For each valve handle, 12 o’clock (upward) position is full open, and
9 o’clock (pointed left) position is full shut, and dial indicates increments of shut
between these two points. (For example, “3/4” indicates 3/4 shut).
Loosen wingnut to adjust valve. Retighten wingnut after adjustment.
FULL SHUT
FULL OPEN
WINGNUT

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TAMPER EVIDENT NECK BANDING AND SHRINKSLEEVE LABELING MACHINERY
8 Sheehan Avenue, South Norwalk, CT 06854 USA 203-853-1516 F 203-854-0834 www.pdc-corp.com
6.2 Adjusting the Tunnel Stand
Loosen the clamp that connects the tunnel tubing to the vent blower (see below).
Adjust the tunnel to the desired height with the ratchet handle, located centrally at
the back of the tunnel. Once at the desired height, remove fallen containers and/or
perform maintenance. Once completed, make sure that the O-ring is in place in the
clamp joint before retightening the tubing clamp.
RATCHET HANDLE
CLAMP