PR200 Training & Tutorials
Currently, these short videos have been uploaded without detailed explanations. However, we are in the process of enhancing this section by adding descriptions and instructions under each video. This will provide clearer guidance on their content and help you better understand the steps and procedures shown. Stay tuned for updates!
PR200 How to Troubleshoot
This video explains the troubleshooting process for the PR200. The correct way to troubleshoot is to ensure that all stations are properly configured. It also covers how to disable and reactivate stations. In the following videos, you will find instructions on how to set up each station correctly.
Station 2 - Tray Handling and Pick & Place Robot Calibration
This video covers the handling of trays and the calibration of the pick & place robot. It explains how to remove and refill the tray, ensuring proper alignment for reinsertion. The video also demonstrates how to teach the pick & place robot using the HMI interface to position it correctly for grabbing the first row of cones. If you need to adjust or troubleshoot tray handling and robot calibration, this is the video to watch.
Station 3 - Adjustment
This video explains how to properly adjust Station 3 on the PR200 V5. It begins with important safety steps, including raising the rod to its maximum position before making any adjustments. The video then covers the adjustment process in two main steps:
- Adjusting the Skate – Ensuring proper height and alignment with the shaker.
- Adjusting the Rod – Positioning the rod correctly to ensure it pushes the paper into the cone holder without excessive force.
If you need to fine-tune Station 3 for optimal performance, this is the video to watch.
Station 4 - Dosing & Filling – Component Overview
This video provides an overview of the components involved in the dosing and filling process on the PR200. It explains the role and function of key elements such as:
- Dosing Components: Tumbler and funnel sensors, dosing gate, scale, and turret operation.
- Filling Components: Compaction needle, tri-funnel, air jet system, and vibrators for product flow control.
The video also includes important maintenance and adjustment tips to ensure proper operation. If you're troubleshooting or setting up Station 4, this is the video to watch.
Station 4 - Adjustment: Funnel, Shaker, Fiber Optic Sensor
⚠ Safety Warning ⚠
Some adjustments require bypassing the door protection. Only bypass the safety sensor when necessary for specific adjustments. Never leave it bypassed, as certain moving parts can activate automatically and cause serious injuries.
This video guides you through the adjustment process for Station 4, covering:
- Funnel Adjustment – Setting the correct height for optimal product flow.
- Shaker Adjustment – Ensuring proper cone lifting without interfering with the filling process.
- Fiber Optic Sensor Calibration – Teaching the sensors to detect cones accurately.
- Needle Adjustment – Positioning the needle to avoid compression while ensuring effective filling.
If you need to fine-tune Station 4 for better performance, this video provides step-by-step instructions.
Station 4 - How to Fix Compaction Issues
This video explains how to troubleshoot and resolve compaction issues at Station 4. It covers:
- Re-teaching the Shaker & Needle – Ensuring proper calibration before making adjustments.
- Adjusting Needle & Compaction Parameters – Modifying needle settings and delay times to optimize compaction.
- Checking the Filling Funnel & Product Flow – Ensuring smooth product flow and adjusting the funnel angle if needed.
- Adjusting the Vibrator & Needle Timing – Synchronizing vibration speed with needle movement for consistent filling.
- Checking Tooling & Shaker Adjustments – Verifying the correct tooling and fine-tuning shaker settings based on product type.
- Needle Maintenance & Spring Adjustment – Inspecting the needle for wear and adjusting spring tension for optimal performance.
If you're experiencing compaction inconsistencies, this video provides step-by-step troubleshooting solutions.
Station 4 - Dosing & Filling – Component Overview
This video provides an overview of the components involved in the dosing and filling process on the PR200. It explains the role and function of key elements such as:
- Dosing Components: Tumbler and funnel sensors, dosing gate, scale, and turret operation.
- Filling Components: Compaction needle, tri-funnel, air jet system, and vibrators for product flow control.
The video also includes important maintenance and adjustment tips to ensure proper operation. If you're troubleshooting or setting up Station 4, this is the video to watch.
How to Set Station 5 – Adjustment Steps
This video provides step-by-step instructions to properly adjust Station 5 for optimal performance. It covers:
- Gripper Adjustment – Positioning the grippers close to the upper funnel for stability.
- Lowering the Station – Ensuring the correct gap between the station and cone holder.
- Raising the Rod – Adjusting the lift height to maintain proper cone positioning.
- HMI Settings – Using the Compaction Page to run a Cycle Test.
- Depth Adjustment – Setting the rod depth to achieve consistent 5mm compression.
If you need to fine-tune Station 5, this video provides clear guidance on the necessary adjustments.
Station 5 - Alignment & HMI Settings Overview
This video explains how to properly align the funnel with the Jaw Star Compressor to ensure optimal performance. It also provides an overview of the key settings available on the HMI for Station 5, including:
- Rod Depth Adjustment – Modify how deep the rod descends.
- Second Compaction Option – Add an extra needle for additional compression (may slow production).
- Gripper Tightness Adjustment – Control the pressure applied by the gripper.
- Step-by-Step Mode – Enable manual control for precise adjustments.
If you need to fine-tune the alignment or adjust HMI settings for Station 5, this video provides clear instructions.
Station 6 - Adjustment
This video provides step-by-step instructions on adjusting Station 6 for proper twisting performance. It covers:
- Preparation – Ensuring the correct station height and positioning before making adjustments.
- Adjusting the Grippers – Setting the right pressure to hold the paper securely without being too tight or too loose.
- Adjusting the Vertical Position of the Side Grippers – Fine-tuning the height for optimal grip.
- Adjusting the Up Stroke – Performing a cycle test to ensure smooth operation.
- Twist Parameters on HMI – Modifying the total rotation number to fine-tune the tightness of the twist.
If you need to adjust the twisting mechanism or troubleshoot issues, this video provides clear guidance.
Station 6 - Fixing Twist
This video explains how to properly adjust Station 6 to fix twisting issues. It covers:
- Adjusting the Gripper Pressure – Ensuring the cone does not spin inside the grippers by tightening or loosening the bolt and locking it securely.
- Adjusting the Up Stroke – Preventing cone tearing by carefully setting the gripper height while avoiding damage to the O-rings.
Motion-based guidance helps clearly visualize each step for smoother adjustments. If you need to troubleshoot twisting issues, this video provides the necessary steps.
Station 7 Setup & Adjustment – Cutting Station Setup & Safety
⚠ Important Safety Notice ⚠
Adjusting Station 7 (Cutting Station) can be dangerous if not done correctly or by someone without proper training. Always proceed with caution:
- Seek guidance from an experienced operator before making adjustments.
- Preferably work without the blade and wear protective gloves.
This video covers the following adjustments:
- Adjusting the Cutting Height – Ensuring the blade cuts at the correct level without damaging the pre-roll.
- Adjusting the Flat Top (Crown Effect) – Modifying the rod depth for a uniform crown cut.
- Adjusting the Grippers – Setting the gripping height for stability during cutting.
- Changing the Blade – Safely removing and replacing the cutting blade.
- Replacing the Cutter Block – Removing and installing a new anvil for precise cutting.
- Changing the Flat Top Rod Tip – Adjusting the tip based on the tooling or pre-roll format.
- Final Verification & HMI Adjustments – Ensuring all settings are saved and stored in the Recipe Page.
If you need to adjust or troubleshoot Station 7, this video provides critical safety guidance and step-by-step instructions.
Station 9 – Mechanical Adjustment
This video explains how to make mechanical adjustments to Station 9
If you need to mechanically adjust Station 9, this video provides clear step-by-step instructions.