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Costa WD7 Series Instruction, Use And Maintenance Manual

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WD7-WP7 Series
Instruction, use and
maintenance manual
COSTA LEVIGATRICI S.p.A.
Via Venezia, 144 - Po. Box 157- 36015 Schio (VI) Italy
eng
Tel. +39-0445-675000
Fax +39-0445-675110

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  • Page 1 WD7-WP7 Series Instruction, use and maintenance manual COSTA LEVIGATRICI S.p.A. Via Venezia, 144 - Po. Box 157- 36015 Schio (VI) Italy  Tel. +39-0445-675000 Fax +39-0445-675110...
  • Page 3 Transport __________________________________________________________________ 29 Warning __________________________________________________________________________ 29 Machine transport and positioning ____________________________________________________ 30 Connections ________________________________________________________________ 34 Electric connections ________________________________________________________________ 34 This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 4 7.2.1 Technical warnings for good maintenance ______________________________________________ 59 7.2.2 Maintenance plan _________________________________________________________________ 60 Routine maintenance _______________________________________________________________ 60 7.3.1 Machine cleaning__________________________________________________________________ 60 This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 5 Trouble-shooting table ______________________________________________________________ 73 Waste elimination ___________________________________________________________ 76 Machine scrapping __________________________________________________________ 76 10 Enclosures _________________________________________________________________ 76 11 Photo _____________________________________________________________________ 77 This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 7: Reference Standards

    Electromagnetic Compatibility (EMC). - Legislative Decrees 81/2008 Safety and health protection on working place. - EEC Directive No. 2006/42/EC Machinery Directive. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 8 REQUIRED: Indicates the conditions required for the operators. PROHIBITED: Indicates the conditions prohibited for the operators. Note: supplies information of particular significance. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 9 In addition to the characteristics above, the maintenance men must possess specific and specialised technical knowledge (mechanical/electrical) required for the tasks prescribed in the manual. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 10 “machine modification form”. d) the Manufacturer must be sent a copy of the “machine modification form” . This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 11: Technical Assistance

    This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 12 - motor side: where the motors are positioned. VACUUM UNIT ELECTRIC BOX MOTOR SIDE BELT INFEED SIDE Fig. 2-1 Conventional terms adopted in descriptions This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 13 Fig. 2-2 Machine units This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 14 Safety min-max XRS unit thickness microswitches (Detail 1-2, Photo 18); Potentiometer for group height sensing (XRS (Detail 3, Photo 18). This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 15: Foreseen Use

    It is therefore the user’s responsibility to provide adequate air filtration systems that prevent the formation of potentially explosive surroundings. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 16 (worn-out bearings, loose belts, etc.). Intervene as described in the chapter entitled “Maintenance” or contact the authorised assistance center indicated in Chapter 1.4. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 17 This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 18 Employer. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 19 This prescription must be placed in clear evidence by the use of the appropriate signs near the machines. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 20 - the use of the machine for any purposes other than those for which it has been expressly designed and constructed is absolutely prohibited. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 21 The machine can be placed in maintenance condition by following the detailed instructions provided at the start of the Chapter entitled “Maintenance”. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 22 Managers must make sure that each worker is provided with adequate training in regard to safety and health, with particular attention on each worker’s work position and tasks. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 23 The dangers involved in machine operation, the risks raised, the safety measures provided, and the warnings for the operators will be described in detail further on in this chapter. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 24: Control And Safety Systems

    This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 25 All lift trucks and other vehicles must be barred from the installation area to prevent accidental impact with the protruding parts of the machine. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 26 The machine must be set in safe maintenance condition before proceeding to maintenance, setting or cleaning operations. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 27 2 meters. The demagnetizer can never be used in areas where the use of explosion-proof equipment is prescribed. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 28 All the safety guards must be re-assembled after every maintenance or repair operations in order to permit re-enabling of machine functions. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 29 (Detail H5, see wiring diagrams). This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 30 29. Wearers of pace-makers devices are absolutely prohibited from coming any closer than 2 meters 30. Danger of fire 31. caution compressed air This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 31 Revision 01 of 21/11/2018 3 - Safety 32. fulguration danger 33. standing in this area is prohibited Fig.3-4 Safety device configuration This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 32 WD7-WP7 Series Revision 01 of 21/11/2018 3 - Safety Fig.3-5 Safety device configuration Fig.3-6 Safety device configuration This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 33 Bear in mind that above the level of 75 dB(A), the following measures must be adopted: - personal protective equipment (such as headsets or ear-plugs); - sound absorption screens (if necessary). This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 34 - The appropriate means and equipment MUST be used during installation. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 35 The failure to observe the precautions above can create risk of serious injury and accident with consequent damage to the machines and injury to the operators. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 36 (including the instruction manual inserted in the electric box) are present. Note: the weight of the machine is listed in the “Technical Data Enclosure”. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 37 - Position the respective support plates contained in the box above the 4 or more adjustment screws. - Lower the machine into its final position slowly. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 38 Make the ground connection using the holes near the support and adjustment screws. For any problems or clarification, the Costa Levigatrici S.p.A. Assistance Service is always available. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 39 WD7-WP7 Series Revision 01 of 21/11/2018 4 - Transport Fig.4-3 Electric box lifting Fig.4-4 Vacuum lifting Fig.4-5 Roller system lifting This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 40: Electric Connections

    Failure to observe these instructions is considered as unauthorised tampering with the machine. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 41: Pneumatic Connection

    This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 42 25 drops fall approximately each air cubic meter. Fig. 5-2 Filter regulator lubricator This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 43 2 Manometer of 1 sand belt tightness; 3 Pressure regulator of 2 sand belt tightness; 4 Manometer of 2 sand belt tightness. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 44: Operation

    The conductor is authorised to operate on the main power switch only for the starting and stopping of the machine; all the other operations must be performed by the maintenance men. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 45 Fig. 6-2 Electric box with control console See the drawing and the specific description provided in the "Wiring diagram manual". This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 46 8. Power on indicator lamp. Fig. 6-3 PCM control console For more detailed information, consult the respective manual enclosed with the machine’s documentation. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 47 14. Monitor on/off key. Fig. 6-4 PC control console For more detailed information, consult the respective manual enclosed with the machine’s documentation. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 48 "PLC-VISION"-type control console Fig. 6-5 control console For more detailed information, consult the respective manual enclosed with the machine’s documentation. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 49 We suggest that you keep these parameters constantly checked, by making the oil controlled by skilled technicians (CASTROL or other certificated companies) every month. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 50 Using a lubricant/coolant other than the one indicated may cause the premature decay of the paint, the oxidation of unprotected metal parts, or other damage to the machine and connected systems. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 51 Belt thickness 2,30 1,80 1,20 0,85 0,75 0,65 0,55 0,52 0,48 0,45 0,43 0,40 Fig. 6-5 Sand belt thickness table This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 52 Grits 100 - 120 - 150 - 180 cut speed 18 m/s 220 - 240 - 260 - 280 - 320 This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 53 8 Set the Grit-Set using the respective buttons (on the control console) to the thickness value corresponding to the type of belt inserted (see paragraph 6.8.4). This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 54: Machine Starting

    The plates operating temperature must be within -10 and +40°C. It is forbidden to use the magnet plates with warm materials. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 55: Feed Motor

    Detail S11-H11 for starting, Detail S12 for stopping, and Detail P11 for current absorption. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 56 -0.45, for example, if a pre-loading value of 2 tenths is required. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 57 The cloth filter (Detail 2, Photo 2) advances automatically and the sludge collecting is separated Consult the respective manual inserted in the machine documentation. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 58 Depending on the machine's work conditions, we discourage using the XVS unit together with the cylinder unit because the low feed speed might cause the overheating of the workpiece. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 59 The unit can be accessed by opening the door positioned on the sanding belt insertion side. Minimum thickness that can be worked: 1 mm New brushes must not collide with the feed belt. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 60 This position programmer/display offers the possibility to memorise up to fifteen different work programs. See the specific Manual provided with the machine's documentation for further details. Fig. 6-8 Qem HB 237 This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 61: Stopping Modes

    Remove the cause of stopping as soon as possible. The search for the cause of stopping and its removal must be performed exclusively by the maintenance men. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 62: Routine Maintenance

    - The key to the lock must be removed by the maintenance man in charge and kept in his custody for the entire duration of the maintenance operation. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 63 Chapter entitled “Operation”. The conductor is prohibited from performing any other operation on the electrical equipment. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 64 This operator must be continually updated through courses held at the manufacturer’s premises, and must possess the knowledge and documentation necessary to perform complex interventions on the systems. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 65 When performing maintenance, always consult the enclosed documentation, such as the functional diagrams of the systems and equipment (electrical, pneumatic, etc.; see Chapter 10). This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 66 A specially tested product for the cleaning of rubber can be ordered from the Costa Levigatrici S.p.A. spare parts office. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 67 NOTE: When starting the machine again, verify that the max. delivery head of the lubricant- cooling liquid system is 2,5 Bar (see the manometer – Detail 1, Photo 10C). This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 68 Using a lubricant/coolant other than the one indicated may cause the premature decay of the paint, the oxidation of unprotected metal parts, or other damage to the machine and connected systems. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 69 Molykote Greasing the sliding guides of the XRS unit 180 working hours BR 2 PLUS Continued on next page This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 70 180 working hours and if necessary top up. BLASIA 220 TOTAL Greasing by the automatic centralized device ---------------------- MULTIS 0 This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 71 (Detail 5, Photo 7). This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 72 23÷34 160÷265 38÷56 32÷50 28÷42 above 266 57÷72 51÷64 43÷58 224÷355 72÷102 60÷90 50÷80 above 356 103÷132 91÷120 81÷110 This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 73: Feed System

    Another screw (Detail 4, Photo 10A) adjusts the pressure of the roller and the height limit of the end-of-stroke. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 74 - disconnect the emulsified liquid supply hose by uncoupling the quick coupling (Detail 5, Photo 10A); - remove the bar from the machine. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 75 In order to adjust the parallelism and height of the pressure rollers, adjust the screws on both sides of the machine as described in paragraph 7.5. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 76 - Grease the unit using the respective greasers (Detail 1, Photo 13A); - return the unit to work position and then lock it in place as described above. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 77 - insert the new oil (0,2 liters every gearcase) by using the hole for the oil window (or until that the oil does not tend to leak out of the hole) and closing immediately the oil window. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 78 7.16 Machine setting examples A = REFERENCE VALUE K1 = A - 1,00mm K2 = A + 0,50mm This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 79: Troubleshooting Table

    The H6 pilot light is on correct operation - The flow switch is miscalibrated or - Replace or re-calibrate the flow not working switch This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 80 - Reduce removal and check the - The sand belt slips respective gauge (Fig. 5-3) excessive removal or insufficient belt tightness This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 81 - The belt is too smooth - Grind the belt - The alignment of the work units is - Restore correct alignment incorrect This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

  • Page 82: Machine Scrapping

    - Technical data enclosure (lay-out, technical data sheet, identification plate, CE conformity declaration, and spare parts list); - Manuals for the other equipment installed. This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 83 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo Photo 1 Machine front side This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 84 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 2 Rear side of machine This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 85 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 3 Introduction belt side This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 86 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 4 Service side upper section This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 87 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 5 Pneumatic plant This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 88 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 6 Belt oscillation by photocell This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 89 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 7 This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 90 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 8 This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 91 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 9 This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 92 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 10 This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 93 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 11 Vacuum unit This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 94 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 12 XVS unit This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 95 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 13 XVS unit This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 96 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 14 XRS unit Service side This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 97 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 15 XRS unit Service side This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 98 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 16 XRS unit Service side This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 99 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 17 XRS unit Motor side This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 100 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 18 XRS unit Motor side This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.
  • Page 101 WD7-WP7 Series Revision 01 of 21/11/2018 11 - Photo Photo 19 XRS unit Motor side - upper section This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form is prohibited.

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