--- title: "Station 4: Filling Setup & Calibration" description: "Station 4 • Setup & Calibration # Station 4 – Filling Setup & Calibration Set the funnel, shaker, paper detection sensors and needle working positions for a consistent Station 4 filling process. ## Training Video Watch the complete setup and…" url: "https://www.supportpreroll-er.com/docs/setup-adjustment/station-4-filling-setup-calibration/" updated: "2026-08-16" category: "PreRoll-Er / PR200 V5 / Setup & Adjustment" --- # Station 4: Filling Setup & Calibration Station 4 • Setup & Calibration # Station 4 – Filling Setup & Calibration Set the funnel, shaker, paper detection sensors and needle working positions for a consistent Station 4 filling process. ## Training Video Watch the complete setup and calibration procedure before following the detailed steps below. Your browser does not support the video tag. ## Overview This procedure explains how to set the main working positions used at Station 4 during the filling process. **The setup covers four important areas:** 1. Funnel working position 2. Shaker working position 3. Paper detection sensor calibration 4. Needle working position These adjustments establish the correct relationship between the cone, paper, funnel, shaker and compaction needle before normal filling operation. STEP 1 ## Position a Cone at Station 4 Begin by placing a cone with paper into Station 4. Press **Reset**, run the machine until the paper reaches Station 4, and stop the machine with the paper in position. The remaining adjustments are performed using this cone and paper as the physical reference. STEP 2 ## Open Filling Jog Mode From the HMI, navigate to: **Filling → Initial Setup → Filling Jog Mode**. Activate **Filling Jog Mode**. This mode allows the Station 4 components to be moved individually while establishing their working positions. STEP 3 ## Adjust the Funnel Working Position Use the **Funnel** control on the HMI to move the filling table and establish the gap between the top of the cone and the table/funnel assembly. The technician uses approximately **2 5/8 in.** as his preferred working gap in the demonstrated configuration. This measurement should be treated as a setup reference rather than a universal value because the correct position depends on the product and tooling being used. The objective is to provide enough clearance for the paper to enter and move into position without interference. ## Why the Gap Matters If the gap is too small, the paper may have difficulty entering the correct position. It can interfere with the assembly or become crushed as the mechanism moves upward. If the gap is too large, the station operates higher than necessary and the shaker may approach the upper limit of its working travel. Adjust the table until the cone-to-funnel relationship provides adequate clearance without creating excessive travel. STEP 4 ## Teach the Funnel Position Once the desired funnel working position has been established, use the corresponding **Teach** control on the HMI. Press and hold **Teach for approximately two seconds**. The HMI records the current position as the Funnel Working Position. STEP 5 ## Raise the Shaker Next, use the HMI to raise the **Shaker**. Raising the shaker lifts the cone holder toward the funnel and places the paper in its filling position. Observe the paper carefully as the shaker moves upward. STEP 6 ## Check the Paper Position The video demonstrates two useful ways to verify the paper position. First, observe the **three detection lights**. When all three are active, the sensors are detecting the paper in position. Second, visually inspect the paper through the available gaps in the assembly. The paper should be high enough to reach the correct filling position without being pushed against the top of the assembly. ## ⚠ Avoid Setting the Shaker Too High If the paper reaches too high, it can contact the upper portion of the assembly during shaking. This may crush the top of the paper and negatively affect filling. Adjust the shaker until the paper reaches the desired position while maintaining sufficient clearance. STEP 7 ## Teach the Shaker Position Once the shaker position is correct, use the **Shaker Position Teach** control. Press and hold **Teach for approximately two seconds**. This stores the current shaker position as the working position. The video shows a value around **21** during this setup. This should be considered the value for the demonstrated machine configuration, not a required setting for every product. STEP 8 ## Teach the Paper Detection Sensors With the paper raised into the correct position, verify that all three detection lights are active. Follow the three sensor connections to the rear of the assembly. Each sensor has a **SET** button located below its red indicator light. With the paper present in the detection position, press the **SET button once on each of the three sensors**. This establishes the first detection condition. STEP 9 ## Teach the Sensors Without Paper Lower the shaker so the paper is no longer positioned in front of the sensors. The sensors now have a reference condition with **no paper detected**. Press the **SET button again on each of the three sensors**. After this second calibration step, the sensor indicators should clear and the sensors are ready to distinguish between the paper-present and paper-absent conditions. STEP 10 ## Verify Sensor Detection Raise the shaker again and return the paper to its working position. Verify the three sensor indicators. All **three detection lights should turn on** when the paper is correctly positioned. If all three sensors respond correctly, continue to the needle adjustment. STEP 11 ## Lower the Needle Use the HMI to lower the compaction needle. Watch the cone holder and surrounding assembly carefully as the needle moves downward. Continue lowering the needle until the assembly **just begins to lift**. This indicates that the needle has reached the bottom of the paper and has begun applying upward force through the assembly. STEP 12 ## Back the Needle Off Slightly Once movement or lifting is observed, raise the needle slightly until the affected component returns to its normal flat position. The objective is to establish the bottom working position **without leaving the needle loaded against the paper**. This position becomes the reference used for the needle working position. STEP 13 ## Teach the Needle Position Once the needle is correctly positioned, use the **Needle Teach** control on the HMI. Press and hold **Teach for approximately two seconds**. The current needle position is then stored as its working position. The demonstrated machine shows a taught value of approximately **218**. As with the shaker value, this is specific to the setup shown in the video and should not automatically be applied to another configuration. STEP 14 ## Exit Filling Jog Mode After the funnel, shaker, sensors and needle have all been correctly taught, exit **Filling Jog Mode**. Station 4 is then ready for a controlled operational test. ## Final Verification Before returning Station 4 to normal operation, verify that: - The funnel working position provides adequate clearance above the cone. - The paper enters the filling area without interference or crushing. - The shaker raises the paper to the correct filling position without pushing it too high. - All three paper detection sensors respond when the paper is in position. - The sensors correctly clear when the paper is removed. - The needle reaches the bottom working position without remaining loaded against the paper. - The Funnel, Shaker and Needle working positions have been taught and stored. - Filling Jog Mode has been exited. **Final test:** Run a controlled cycle and observe Station 4 through the complete filling sequence. The paper should enter cleanly, rise into the correct position, be detected by all three sensors, and allow the filling and needle mechanisms to operate without interference.