Overview

This procedure explains how to set up and adjust Station 7, the cutting station.

Station 7 receives the pre-roll after twisting and performs the final cutting and crown-forming operations. Correct setup is especially important because the pre-roll must remain stable and straight while the blade and grippers operate.

Bring the Pre-Roll Into Station 7

Begin with a pre-roll that has already completed the twisting process.

Move it into Station 7 and position it where the cutting operation will take place.

Before making adjustments, inspect where the blade will contact the pre-roll. This gives you the initial reference for determining whether the cutting position needs to move higher or lower.

Set the Cutting Height

The Station 7 height can be adjusted to change where the cut occurs on the pre-roll.

If additional downward adjustment is available, the station itself can be lowered.

In the setup demonstrated in the video, the station is already at its lowest position. To move the cutting point higher on the pre-roll, the technician instead raises the pre-roll from underneath.

Use the working-position adjustment to establish the required cutting height.

Keep the Pre-Roll as Low as Practical

Do not raise the pre-roll higher than necessary.

When too much of the pre-roll extends outside the holder, it develops additional lateral movement or play.

This allows the pre-roll to move from side to side while the cutting grippers operate. Excessive movement increases the risk of the grippers contacting or damaging the pre-roll instead of holding it consistently.

Lock the Working Position

Once the correct pre-roll height has been established, secure the working-position adjustment.

Lock the mechanism in place before continuing with the remaining Station 7 setup.

Recheck the cutting location after locking the adjustment to confirm that the position has not changed.

Adjust the Crown Position

Station 7 includes an adjustable rod used to control the top or crown of the finished pre-roll.

The video recommends using the grippers as a visual reference.

Fine-tuning should then be performed by running product and inspecting the resulting crown.

Avoid Bottoming Out the Crown Rod

Pay close attention to the rod depth while adjusting the crown.

Adjust the rod gradually and inspect the result after running product. The objective is to create the desired crown without mechanically loading the grippers.

Lock the Crown Adjustment

Once the correct crown position has been established, lock the adjustment securely.

If the adjustment is left loose, vibration and machine movement can cause the setting to gradually move downward during production, resulting in inconsistent or poor crown formation.

Adjust the Gripper Height

The Station 7 grippers can also be moved vertically to change where they hold the pre-roll during cutting.

Loosen the gripper adjustment points and move the gripper assembly higher or lower depending on the required gripping position.

Once the desired position is reached, tighten the adjustment securely.

This adjustment can be especially useful when fine-tuning the relationship between the cutting position and crown formation.

Replace the Cutting Blade

On the PR200 V5 shown in the video, the blade block can slide downward to provide easier access.

Two screws on the underside secure the blade. Remove the screws, remove the existing blade, and install the replacement blade.

The blade mounting system is magnetic, so use caution when bringing the replacement blade into position.

The blade should slide into its locating channel and seat correctly before the screws are tightened.

Replace the Cutter Block

The cutter block can also be replaced when required.

Access the retaining fastener from the top using an Allen wrench. Loosen the fastener, remove the cutter block, and install the replacement into the same locating groove.

When reinstalling the block, make sure it is positioned correctly relative to the blade.

Inspect or Replace the Strippers

Station 7 also contains two stripper components associated with the cutting assembly.

Inspect them whenever servicing the cutting area and replace them if they show excessive wear or damage.

Change the Compaction Tip During Changeover

When changing between certain pre-roll formats, the Station 7 compaction tip must also be changed.

The video specifically demonstrates a changeover between 0.5 g and 1 g configurations.

The tip pulls downward and slides out of its mounting position.

Install the correct replacement tip by sliding it into the same slot until it is fully seated and clicks into position.

The tip can also be removed using the same procedure when cleaning is required.

Inspect the Station Before Testing

Before running a Cycle Test or Step-by-Step sequence, inspect the Station 7 hardware.

Verify that the adjustment points and fasteners are properly tightened.

Pay particular attention to any component that was loosened during setup or changeover.

Record the Station Reference

The Cutter screen on the HMI contains a Station Dial Adjustment value.

This value acts as a reference for the mechanical station position.

Once Station 7 has been mechanically adjusted and is producing the desired result, read the physical station setting and enter that same reference into the HMI.

In the video, the demonstrated station is positioned at approximately 41.

Save the Reference to the Recipe

The Station Dial Adjustment is not electronically connected to the mechanical dial.

Changing the physical adjustment does not automatically update the HMI value.

The operator must manually enter the mechanical reference into the Cutter screen.

Once the correct value has been entered, save it to the appropriate recipe so the reference is stored in the PLC.