Station 5 – Alignment & HMI Settings
Align the Station 5 funnel, adjust compaction settings from the HMI, and use Step-by-Step Mode to inspect the complete compaction sequence.
Training Video
Watch the complete Station 5 alignment and HMI procedure before following the detailed steps below.
Overview
This procedure covers the main Station 5 adjustments available during setup and daily operation.
It explains how to align the funnel after a changeover, adjust the compaction rod depth from the HMI, add an additional compaction cycle when necessary, adjust gripping pressure, and use Step-by-Step Mode to observe the complete Station 5 sequence.
Main areas covered:
- Funnel alignment after changeover
- Compaction rod depth
- Additional compaction cycle
- Gripper pressure
- Step-by-Step Mode
- Station troubleshooting using the HMI
Check the Funnel After a Changeover
During a changeover, the Station 5 funnel must be replaced along with the appropriate grippers.
After installing the new funnel, verify its alignment before operating the station.
Correct alignment helps the pre-roll move through Station 5 without interference.
Align the Funnel
If the funnel is not centered, use the two adjustment screws located behind the assembly.
Loosen both screws enough to allow the funnel assembly to move from side to side.
Move the funnel until its opening is centered over the plastic center piece.
While holding the funnel in the correct position, tighten both screws to secure the alignment.
Recheck the center position after tightening to make sure the assembly did not move.
Adjust the Compaction Rod Depth
The Station 5 HMI allows the operator to control how far the compaction rod travels downward.
When additional or reduced compaction is required, adjust the rod depth gradually.
The technician recommends making changes in approximately 5-unit increments and observing the result after each adjustment.
Add an Additional Compaction Cycle
The HMI also allows an additional compaction cycle to be added when the product requires more compaction.
This can be useful depending on the characteristics of the material being processed.
The effect can be more noticeable with products that are difficult or sticky.
Use an additional cycle only when it provides a meaningful improvement in the finished pre-roll.
Adjust the Gripper Pressure
Station 5 also allows the operator to adjust the gripping pressure.
The grippers need to hold the pre-roll securely while compaction takes place.
The appropriate pressure can vary depending on the product, paper, and amount of compaction required.
Adjust the gripping pressure while observing how the pre-roll behaves during the compaction cycle.
Use Step-by-Step Mode
One of the most useful troubleshooting tools available for Station 5 is Step-by-Step Mode.
When this mode is enabled, the machine does not automatically complete the entire Station 5 sequence.
Instead, the operator advances the process one step at a time.
This makes it possible to observe what the station is doing during each stage of its sequence.
Start a Step-by-Step Test
With a pre-roll available at the station:
- Enable Step-by-Step Mode.
- Press Reset.
- Press Start.
- Allow the station to complete its first movement.
- Use the Step-by-Step control to advance to the next action.
- Continue advancing through the sequence while observing Station 5.
Each press advances the station through another step controlled by the PLC.
Observe Each Station Movement
As the station advances, watch the mechanical components and the pre-roll carefully.
Step-by-Step Mode is especially useful when a problem happens too quickly to identify during normal automatic operation.
Use it to investigate:
- Compaction not occurring correctly
- The pre-roll not entering the correct position
- A component moving at the wrong point in the sequence
- The pre-roll changing position during compaction
Because the sequence waits for the operator before advancing, each movement can be inspected individually.
Use Step-by-Step Mode for Troubleshooting
If Station 5 produces inconsistent results, use Step-by-Step Mode before making multiple adjustments.
Observe the complete sequence and identify where the problem first appears.
Once the problematic step has been identified, inspect the related mechanical adjustment or HMI parameter.
Final Verification
After adjusting or troubleshooting Station 5, verify that:
- The correct funnel and grippers are installed for the current setup.
- The funnel opening is centered with the plastic center piece.
- Both funnel alignment screws are securely tightened.
- Compaction rod depth is appropriate for the product.
- Rod depth changes have been made gradually.
- Additional compaction cycles are only being used when necessary.
- Gripper pressure holds the pre-roll securely during compaction.
- Step-by-Step Mode can advance through the complete Station 5 sequence correctly.
- The pre-roll enters and remains in the correct position throughout the sequence.