Troubleshooting the PR200 by Isolating Stations
This procedure explains how to troubleshoot the PR200 by temporarily disabling downstream stations and reactivating them one at a time. This makes it easier to identify which station requires adjustment.
Training Video
Watch the complete troubleshooting procedure before following the detailed steps below.
Troubleshooting Approach
When troubleshooting the PR200, avoid adjusting several stations at the same time. Instead, isolate the machine process and verify each station individually.
The procedure starts by disabling Stations 5, 6 and 7 so that Station 4 can be evaluated independently. Once Station 4 is operating correctly, the remaining stations are reactivated one at a time and tested before moving to the next station.
Isolate and Test Station 4
Begin by disabling the stations located after the filling process. This allows cones to pass through Station 4 without being compacted, twisted or cut by the following stations.
- From the HMI, locate the Compaction, Twist and Cut tabs.
- Open each tab and use the control located in the upper-right corner to change the station from Enable to Disable.
- In the Cut tab, deactivate the three available functions: Cut, Top Crush and Vacuum.
- Go to the Filling tab and verify that Paper Infeed is activated. When active, the control should appear green.
- Start the machine by pressing the blue Reset button, followed by the green Start button.
- Allow approximately three or four cones to enter the machine, then deactivate Paper Infeed to stop additional cones from being distributed.
- Allow the cones already inside the machine to complete the filling process, including bottom compaction with the needle, and collect them at the machine output.
Reactivate and Test Station 5
Once Station 4 has been verified and all required adjustments are complete, Station 5 can be added back into the production sequence.
- Return to the HMI and open the Compaction tab.
- Reactivate the compaction function from the upper-right corner of the screen.
- Start the machine using the blue Reset button, followed by the green Start button.
- Allow a few cones to pass through the machine, then deactivate Paper Infeed.
- Observe the cones as they are compacted at Station 5 and inspect the result.
Reactivate and Test Station 6
After Stations 4 and 5 are operating correctly, the twisting station can be reactivated and tested.
- From the HMI, open the Twist tab.
- Reactivate the required twisting options from the upper-right corner.
- Return to the Filling tab and reactivate Paper Infeed.
- Press the blue Reset button and then the green Start button.
- Allow a few cones to enter the machine, then deactivate Paper Infeed.
- Observe the cones while they are being twisted at Station 6 and inspect the finished twist.
Reactivate and Test Station 7
Station 7 should only be tested after Stations 4, 5 and 6 have been confirmed to operate correctly.
- From the HMI, open the Cut tab.
- Reactivate the required Station 7 functions.
- If necessary, activate Cut first and test it independently. Then activate Top Crush and test again. Vacuum can be activated afterward if required.
- Return to the Filling tab and reactivate Paper Infeed.
- Start the machine using the blue Reset button, followed by the green Start button.
- Allow a few cones to pass through, then deactivate Paper Infeed.
- Observe the cones as they are processed and cut at Station 7.
Recommended Troubleshooting Method
The important principle is to confirm one station before adding the next station back into the process.
If the cones are correct before a station is activated and a problem appears immediately afterward, the newly activated station becomes the primary area to inspect.
Final Verification
Once all required stations have been tested and adjusted, reactivate the normal production configuration and run several complete cones through the PR200.
Verify filling, compaction, twisting and cutting before returning the machine to normal production.