Costa WD7 Series Specification sheet

WD7-WP7 Series
Instruction, use and
maintenance manual
COSTA LEVIGATRICI S.p.A.
Via Venezia, 144 - Po. Box 157- 36015 Schio (VI) Italy
Tel. [phone]  Fax [phone]
Translation of
the original
instructions
eng

WD7-WP7 Series
Revision 01 of 21/11/2018
0 - Index
1
This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
0.1 Reference standards ________________________________________________________________1
1Introduction _________________________________________________________________ 2
1.1 How to read the manual: structure and consultation ______________________________________2
1.1.1 Scope and content of the manual______________________________________________________2
1.1.2 Safety terms and symbols used in this manual ____________________________________________2
1.1.3 Operators to whom the manual is addressed and the language adopted________________________3
1.1.4 Information search and consultation criteria ______________________________________________4
1.1.5 Preservation of the manual ___________________________________________________________4
1.2 How to update the manual____________________________________________________________4
1.3 Manufacturer machine data___________________________________________________________5
1.4 Technical assistance ________________________________________________________________5
1.5 Warranty __________________________________________________________________________5
2Description__________________________________________________________________ 6
2.1 General description of the machine ____________________________________________________6
2.1.1 Conventional terms _________________________________________________________________6
2.1.2 Machine units______________________________________________________________________7
2.1.3 Position and description of motors and safety microswitches _________________________________8
2.2 Foreseen use_______________________________________________________________________9
2.2.1 Foreseen use and surroundings _______________________________________________________9
2.2.2 Operating environmental conditions ___________________________________________________10
2.2.3 Illumination_______________________________________________________________________10
2.2.4 Vibration_________________________________________________________________________10
2.2.5 Noise levels ______________________________________________________________________11
2.2.6 Waste products and pollution_________________________________________________________11
3Safety _____________________________________________________________________ 12
3.1 General information - usage - areas ___________________________________________________12
3.1.1 General safety information and warning ________________________________________________12
3.1.2 Work areas, control areas, danger areas________________________________________________15
3.1.3 Instruction and training of machine conductors ___________________________________________16
3.1.4 Safety and spheres of competence for the operators______________________________________17
3.1.5 Risks present in the room and line in which the machine is installed.__________________________18
3.2 Control and safety systems__________________________________________________________18
3.2.1 Control and signalling systems _______________________________________________________18
3.2.2 Safety during the machine STARTING phase____________________________________________18
3.2.3 Safety during the machine STOPPING phase____________________________________________19
3.3 Accident- prevention and protection measures against residual risks ______________________19
3.3.1 Risk of instability __________________________________________________________________19
3.3.2 Risks of breaking during the operation _________________________________________________20
3.3.3 Risks caused by projecting objects ____________________________________________________20
3.3.4 Risks caused by moving parts ________________________________________________________20
3.3.5 Risks caused by accidental impact against protruding machine parts and corners _______________21
3.3.6 Risks posed by magnetic fields _______________________________________________________21
3.4 Characteristics of the safety guards and other safety devices adopted _____________________22
3.4.1 Fixed safety guards ________________________________________________________________22
3.4.2 Movable safety guards (interlocked) ___________________________________________________22
3.4.3 Safety devices ____________________________________________________________________23
3.5 Safety measures against other risks __________________________________________________27
3.5.1 Protection against risks caused by noise levels___________________________________________27
3.6 Safety during maintenance, adjustment, installation, setting up and cleaning operations ______28
4Transport __________________________________________________________________ 29
4.1 Warning __________________________________________________________________________29
4.2 Machine transport and positioning____________________________________________________30
5Connections________________________________________________________________ 34
5.1 Electric connections________________________________________________________________34

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This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
5.2 Pneumatic connection______________________________________________________________ 35
6Operation __________________________________________________________________ 38
6.1 Control and signalling systems ______________________________________________________ 38
6.1.1 General Information________________________________________________________________ 38
6.1.2 Electric box ______________________________________________________________________ 38
6.1.3 Control console on the machine ______________________________________________________ 39
6.1.4 Control console built into the electric box _______________________________________________39
6.1.5 PCM-type control console ___________________________________________________________40
6.1.7 PC-type control console ____________________________________________________________41
6.1.7 "PLC-VISION"-type control console ___________________________________________________42
6.2 Water and lubricant/coolant supply ___________________________________________________ 43
6.2.1 Water features for the lubricant/coolant ________________________________________________ 43
6.2.2 Lubricant/coolant liquid synthetic solution –CASTROL SYNTILO 81E ________________________44
6.2.3 Lubricant/coolant liquid mineral solution –RHENUS R-FLEX _______________________________44
6.3 Sand belt procurement _____________________________________________________________ 45
6.3.1 Pieces of advise for an optimal use of the sanding belt ____________________________________46
6.3.2 How to choose the sanding belts and the working cut speeds _______________________________46
6.4 Insertion of sand belts______________________________________________________________ 47
6.4.1 Longitudinal sand belt insertion_______________________________________________________47
6.5 Machine starting___________________________________________________________________ 48
6.5.1 Starting with traditional-type control console_____________________________________________48
6.6 Feed table ________________________________________________________________________ 48
6.6.1 Whole-stiff type ___________________________________________________________________48
6.6.2 Roller table ______________________________________________________________________ 48
6.6.3 Feed table with permanent magnet plates ______________________________________________ 48
6.7 Work thickness adjustment _________________________________________________________ 49
6.8 Feed motor _______________________________________________________________________ 49
6.8.1 Belt return _______________________________________________________________________ 49
6.8.2 Automatic return cycle______________________________________________________________ 49
6.9 Work unit starting__________________________________________________________________ 49
6.9.1 Selection of sand belt and brush units cutting speed ______________________________________ 50
6.9.2 Inversion of rotation direction ________________________________________________________50
6.9.3 Transversal oscillation movement_____________________________________________________50
6.9.4 Cylinder unit work height adjustment __________________________________________________50
6.9.5 Brush unit work height adjustment ____________________________________________________51
6.9.6 Feed belt suction system____________________________________________________________ 51
6.9.7 Sand belt cleaning blowers __________________________________________________________51
6.9.8 Piece cleaning blowers _____________________________________________________________ 51
6.9.9 Feed belt cleaning blowers __________________________________________________________51
6.9.10 Piece drying system _______________________________________________________________ 51
6.9.11 Oil mist filter______________________________________________________________________ 51
6.9.12 Gravity filter for the filtration of the emulsifiable liquid______________________________________51
6.9.13 XVS unit_________________________________________________________________________ 52
6.8.14 XRS unit ________________________________________________________________________ 53
6.10 Electronic control equipment ________________________________________________________ 54
6.10.1 Gefran 4 device___________________________________________________________________54
6.10.2 Qem HB237 device ________________________________________________________________54
6.11 Stopping modes___________________________________________________________________ 55
7Routine maintenance ________________________________________________________ 56
7.1 Safety warnings: precautions and setting the machine in maintenance condition ____________ 56
7.1.1 Setting in maintenance condition _____________________________________________________56
7.1.2 General safety rules _______________________________________________________________ 57
7.1.3 Checks and efficiency tests on safety devices ___________________________________________57
7.1.4 Maintenance of the electrical system __________________________________________________57
7.2 General information on routine maintenance ___________________________________________ 59
7.2.1 Technical warnings for good maintenance ______________________________________________59
7.2.2 Maintenance plan _________________________________________________________________60
7.3 Routine maintenance_______________________________________________________________ 60
7.3.1 Machine cleaning__________________________________________________________________ 60

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This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
7.3.2 Machine washing __________________________________________________________________61
7.3.3 Maintenance and changing of lubricant/coolant___________________________________________62
7.3.4 Routine maintenance_______________________________________________________________63
7.3.5 Comparative lubricant table__________________________________________________________65
7.3.6 Brakes __________________________________________________________________________65
7.3.7 Drive belts _______________________________________________________________________66
7.3.8 Drive belt replacement procedure _____________________________________________________67
7.4 Feed system ______________________________________________________________________67
7.4.1 Feed belt ________________________________________________________________________67
7.4.2 Feed table with permanent magnet plates_______________________________________________67
7.4.3 Demagnetizer with plates____________________________________________________________67
7.5 Pressure roller units________________________________________________________________67
7.6 Electrical power unit________________________________________________________________68
7.7 Electronic digital displays ___________________________________________________________68
7.7.1 Thickness display__________________________________________________________________68
7.7.2 Speed display_____________________________________________________________________68
7.8 Sand belt oscillation________________________________________________________________68
7.9 Sand belt cleaning blowers __________________________________________________________68
7.10 Rubber contact cylinder_____________________________________________________________69
7.11 Brush unit ________________________________________________________________________69
7.12 Emulsified liquid recovery tank_______________________________________________________69
7.13 Adjustment of the pressure units and work units________________________________________69
7.14 XVS Unit__________________________________________________________________________70
7.14.1 Lubrication _______________________________________________________________________70
7.15 XRS Unit__________________________________________________________________________71
7.15.1 Brushes replacement_______________________________________________________________71
7.15.2 Lubrication _______________________________________________________________________71
7.15.3 Replacement the oil of the main gearcase_______________________________________________71
7.15.4 Replacement the oil of the spindle gearcase_____________________________________________71
7.15.5 Top up the oil of the gearcases _______________________________________________________72
7.16 Machine setting examples ___________________________________________________________72
7.16 Trouble-shooting table______________________________________________________________73
8Waste elimination ___________________________________________________________ 76
9Machine scrapping __________________________________________________________ 76
10 Enclosures_________________________________________________________________ 76
11 Photo _____________________________________________________________________ 77

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Revision 01 of 21/11/2018
0.1 - Reference standards
1
This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
0.1 Reference standards
The indications provided in the following Standards were used in the preparation of this manual.
-UNI EN 12100-1:2005
Standard that defines the basic terminology and specifies the general design methods to be used.
- UNI EN 12100-2:2005
Standard that defines the technical specifications and principles.
- UNI 10653
Standard that defines the essential criteria to ensure the quality of the information in the technical
documentation.
- UNI 10893
Standard that provides the criteria for the structure and expository order of the contents of the
instructions for use.
- Presidential Decree No. 303 dated 27.04.1956
General rules for hygiene requirements in the workplace.
- Legislative Decree No. 277 dated 12.08.1991 for the assimilation of EEC Directives No. 80/605;
No. 83/477; No. 86/188; and No. 88/642
Protection of employees against the risks derived by exposure to chemical, physical and biological
agents during work.
- Directive 2006/95/CE
Low Voltage (LVD).
- EEC Directive No. 89/336
Electromagnetic Compatibility (EMC).
- Legislative Decrees 81/2008
Safety and health protection on working place.
- EEC Directive No. 2006/42/EC
Machinery Directive.

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This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
1 Introduction
1.1 How to read the manual: structure and consultation
1.1.1 Scope and content of the manual
This manual describes the WD7-WP7 Series machine.
Each machine is manufactured according to the customer specific requirements, his working
standards and experience; each single device is described and illustrated, although the pictures and
the machine assembly diagrams showed in the handbook are different from your machine in their
configuration.
In this manual, the WD7-WP7 Series machine will be referred to simply as the “machine” for reasons
of brevity.
This manual has been written to fully acquaint the operators with the machine and to operate in
conditions of safety.
This manual will provide the operators with all the instructions and information required for the use and
for the correct maintenance of the machine, together with safety and accident-prevention rules.
1.1.2 Safety terms and symbols used in this manual
- EXPOSED PERSON: any person who is partially or totally within the limits of a danger area.
- DANGER AREA: an area inside or near machines where the presence of an exposed person
creates a risk for the safety and the health of the person.
- QUALIFIED TECHNICIAN: a specialised person employed by the Manufacturer or an authorised
assistance center who has been duly instructed and authorised to perform routine or extraordinary
maintenance or repairs that require a particular knowledge of the machine, its operation, and safety
devices and their operation.
- OPERATORS: persons in charge of installing, operating, and adjusting the machine, performing
routine maintenance and cleaning the machine, each within the limits of the responsibilities
assigned.
Symbols used in the safety warnings for a better reading and understanding of the text:
IMPORTANT: Indicates risk situations for personnel and accident-prevention rules for
the operators.
10
WARNING: Indicates risk situations for the machine and/or the components and/or the
product being worked.
PRECAUTIONS: Further information and/or prescriptions to ensure safety during the
operation in progress.
REQUIRED: Indicates the conditions required for the operators.
PROHIBITED: Indicates the conditions prohibited for the operators.
Note: supplies information of particular significance.

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This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
General warnings
BEFORE PERFORMING ANY OPERATION ON THE MACHINE, THE OPERATORS AND
THE QUALIFIED TECHNICIANS MUST CAREFULLY READ THE INSTRUCTIONS
CONTAINED IN THIS DOCUMENT (and respective enclosures) AND RESPECT THE
SAME DURING THE EXECUTION OF THE OPERATIONS.
THE OPERATION OF THE MACHINE WHEN DOUBTS ARISE ON THE CORRECT
INTERPRETATION OF THE INSTRUCTIONS IS PROHIBITED, AND IN SUCH CASES THE
MANUFACTURER OR THE AUTHORISED ASSISTANCE CENTER MUST BE CONTACTED
FOR CLARIFICATION.
PLEASE PAY PARTICULAR IMPORTANCE TO CHAPTER 3 “SAFETY” THAT CONTAINS
IMPORTANT AND DETAILED INFORMATION AND WARNINGS REGARDING SAFETY.
Note: The Manufacturer offers to organise personnel training courses at his own premises or
those of the client. The request, times, costs, and methods to be adopted must be
previously agreed upon.
1.1.3 Operators to whom the manual is addressed and the language adopted
- the operators in charge of operating the machine will be referred to as “conductors” for reasons of
brevity;
- the technical operators in charge of routine maintenance will be referred to as “maintenance men” for
reasons of brevity, and each will be responsible for the mechanical or electrical responsibilities
assigned;
- mechanical maintenance men: operators instructed and authorised for the maintenance of the
mechanical parts, and pneumatic and hydraulic systems;
- electrical maintenance men: operators instructed and authorised for the maintenance of electrical
and/or electronic parts and systems;
- qualified technicians are specialised persons employed by the Manufacturer or the authorised
assistance center that have been duly instructed and authorised to perform routine or extraordinary
maintenance or repairs that require a particular knowledge of the machine, its operation, and safety
devices and their operation.
Note: The tasks, responsibilities, and limits on intervention by the various operators will be
illustrated as follows.
The conductors must not perform operations reserved to the maintenance men or
qualified technicians, and the Manufacturer declines all liability for damages derived as
a result.
In order to understand the instructions (text and illustrations) the conductors of the machine must have
(or acquire through adequate instruction and training) the following characteristics:
- adequate education to read and understand the contents of the manual in the parts that regard
them specifically and for the correct interpretation of the drawings and diagrams;
- ability to understand and interpret the symbols, pictograms and video messages;
- awareness of the principal health, accident-prevention, and technological standards;
- awareness of the positioning of the machine inside the factory;
- awareness of the procedures to follow in case of emergency, and how to procure and use the
personal protective equipment correctly.
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.

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This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
We provide some of the important prescriptions contained in the European Directives
that regulate safety in the workplace.
The factory’s SAFETY MANAGER must:
-make sure that this knowledge is sufficient for the reading and thorough understanding
of this manual;
-provide the conductors with adequate practical training and make sure through the use
of tests that the conductors are capable of operating the machine correctly and safely
both under standard operating conditions and in emergency situations.
1.1.4 Information search and consultation criteria
The documentation for the machine includes:
- Use and maintenance instruction manual;
- Wiring diagram manual;
- Pneumatic diagram manual;
- Enclosed technical data (lay-out, technical data sheet, rating plate, CE conformity declaration and
spare parts list);
- Respective manuals for the other equipment installed in the machine.
The information and instructions in the manual are organised by chapters and paragraphs that can be
easily identified by consulting the systematic table of contents.
The chapter of each respective page is listed at the top.
The pages are numbered progressively.
The paragraphs are numbered by two or more numbers separated by dots. The first number indicates
the chapter, the following numbers indicate the paragraphs and the sub-paragraphs in logical order
(example: 1.1.5 indicates Chapter 1, Paragraph 1, Sub-paragraph 5).
The figures are numbered by two numbers separated by hyphen. The first number indicates the
chapter, the second number indicates the figure (example: Fig. 2-23 indicates figure 23 of chapter 2).
1.1.5 Preservation of the manual
This manual and all enclosed documents must be kept in accessible place near the machine and
known to all the users for a rapid consultation. This manual is an integral part of the machine for safety
purposes and therefore:
- it must be preserved in integral condition (in all of its parts);
- it must follow the machine wherever it goes until the machine is finally dismantled (even in case of
movement, sale, or rent, etc.);
- it must be kept up to date and include any and all modifications made to the machine..
1.2 How to update the manual
Whenever following repairs and/or modifications (authorised in written form by the Manufacturer) the
manual must be updated:
a) the authorised operator (an employee of the Manufacturer or of an authorised assistance center)
must fill out a “machine modification form” that bears:
- all the operations performed;
- the date of execution;
- the operators authorised.
b) the “machine modification form” must be inserted in the manual.
c) the parts of the manual involved in the modification must be marked by a note that invites
consultation of the “machine modification form”.
d) the Manufacturer must be sent a copy of the “machine modification form” .

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This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
1.3 Manufacturer machine data
Manufacturer: Costa Levigatrici S.p.A.
Via Venezia,144
36015 Schio (VI) Italy
Tel.: [phone]
Fax: [phone]
e-mail:[email protected]
http:www.CostaLev.com
1.4 Technical assistance
Technical assistance provides the Clients with:
- clarification and information;
- operations at the Client’s premises by specialised technicians;
- spare parts transmission.
Requests for assistance can be sent directly to the Manufacturer or the authorised assistance center.
Bear in mind that:
-the Client is obliged to purchase only original spare parts or those authorised in written
form by the Manufacturer;
-the disassembly and re-assembly operations required for worn-out and/or damaged
parts must be entrusted to qualified technicians and performed as prescribed in the
instructions provided by the Manufacturer;
-the use of non-original spare parts and/or the defective or incorrect assembly of the
same release the Manufacturer from all liability.
Authorised assistance center: Costa Levigatrici S.p.A.
Via G. Galilei, 5
36066 Sandrigo (VI) Italy
Tel.: [phone]
Fax: [phone]
e-mail: [email protected]
1.5 Warranty
1. Barring specific contract stipulations otherwise, the terms of warranty provided with the purchase of
the machine are those prescribed by UCIMU (Italian Machine Tool Manufactures' Association).
Warranty coverage will not be provided in the following cases:
- the failure to respect the safety rules (see Chapter 3 “Safety”)
- the inappropriate use of the machine
- modifications not authorised by the Manufacturer in written form have been made to the machine.
During the period of warranty coverage, all parts that malfunction due to evident defects in
manufacture will be replaced free of charge; consumable materials and parts subject to normal wear
will not be replaced under warranty.
2. Technical interventions performed during the period of warranty coverage for routine
maintenance operations (belt grinding, replacement of parts subject to normal wear, work unit
alignment and sand belt oscillation adjustment) or extraordinary maintenance (for damages
caused by the failure to respect the rules provided in the instruction manual, negligent or erroneous
machine use or treatment) will be billed according to the common prices for such services in
force at the time.

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This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
2 Description
2.1 General description of the machine
Overview
We provide a brief description of the machine in order for the machine conductors and maintenance
men to acquire:
- an initial awareness of the machine and its composite parts;
- the terminology and names that will be adopted in this manual.
This knowledge is indispensable for a better comprehension of the instructions and warnings provided
in the following paragraphs.
2.1.1 Conventional terms
The following conventional terms have been used in the descriptions below:
-workpiece infeed side: the side of the machine where the operators for the loading of the product to
be worked stand;
-workpiece outfeed side: the side of the machine where the operators for the unloading of the product
worked stand;
-belt infeed side: the side of the machine where the operator for sand belt insertion stand;
-motor side: where the motors are positioned.
Fig. 2-1 Conventional terms adopted in descriptions
ELECTRIC BOX
VACUUM UNIT
WORKPIECE
INFEED SIDE
WORKPIECE
OUTFEED SIDE
BELT INFEED SIDE
MOTOR SIDE

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This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
2.1.2 Machine units
We provide a schematic example of a machine’s principal units below (see Fig. 2-2):
1) feed table unit;
2) cylinder unit;
3) brush unit;
4) control console;
5) electric box with or without control console;
6) gravity filter;
7) workpiece drying system fan;
8) oil mist filter;
9) vacuum unit.
Fig. 2-2 Machine units
4
5
1
8
2
7
1
9
3
6

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This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
2.1.3 Position and description of motors and safety microswitches
This manual provides a general listing of all the devices that may or may not be
installed in the machine in question.
We provide a detailed list of the parts that compose the machine for the purpose of easier
understanding.
A. Sand belt motors (Photo 4);
B. Electronic grit set contact cylinder motor (Photo 4);
C. Internal brush motor (Photo 4);
D. Brush working height adjustment motor (Photo 4);
E. Brush oscillation motor (Photo 4);
F. Work thickness adjustment motor (found beneath the feed table Photo 1);
G. Suction unit motor;
H. Feed motor (Photo 2);
I. Drying system fan motor (Photo 3);
J. Oil mist filter motor (Photo 3);
K. Delivery pump motor (Photo 1);
L. Brush rotation motor to unit XVS (Photo 12B);
M. Brush oscillation motor to unit XVS (Photo 12B);
N. Brush lifting motor to unit XVS (Photo 12B).
O. Brush rotation motor to unit XRS (Photo 17);
P. Brush oscillation motor to unit XRS (Photo 17)
Q. Brush lifting motor to unit XVS XRS (Photo 19).
1 Door opening safety microswitch (Part 1, Photo 3 and Part 1, Photo 9C);
2 Sand belt exit safety pneumatic microswitch (Part 3, Photo 6);
3 Over-thickness microswitches (see Paragraph 3.4.3, point 4);
4 Automatic return cycle control microswitches (see Paragraph 6.7);
5 Min-max thickness adjustment safety microswitches (Part 9, Photo 9B);
6 Sand belt breakage safety microswitches (Part 3, Photo 7);
7 Brush height adjustment safety microswitch (Part 1, Photo 8C);
8 Electronic Grit-Set min-max thickness safety microswitches (Part 3, Photo 8A-B);
9 Mushroom-head emergency button (Part 6, Photo 1 and Part 1, Photo 2);
10 Pressure-sensitive movable safety guard (Part 2, Photo 1);
11 Line pressure-switch (Part 5; photo 5);
12 Pressure-switch for 1st work unit sand belt exit safety microswitches (Part 3-4, Photo 5);
13 Pressure-switch for 2nd work unit sand belt exit safety microswitches (Part 3-4, Photo 5);
14 Flow switch (Part 5, Photo 5);
15 Ground probe (Part 1, Photo 10B);
16 Minimum level probe (Part 2, Photo 10B);
17 Maximum level probe (Part 3, Photo 10B)
18 Emergency level probe (Part 4 photo 10B);
19 Sand belt oscillation photocell (Part 1, Photo 6).
20. Safety min-max XVS unit thickness microswitches (Detail 1-2, Photo 12B);
21. Potentiometer for group height sensing XVS (Detail 3, Picture 12B).
22. Safety min-max XRS unit thickness microswitches (Detail 1-2, Photo 18);
23. Potentiometer for group height sensing (XRS (Detail 3, Photo 18).

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This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
2.2 Foreseen use
2.2.1 Foreseen use and surroundings
Appropriate use
The WD7-WP7 Series machines are automatic or semi-automatic depending on whether or not they
are inserted in a production line, and are used for deburring, polishing and brushing of plain surfaces
of ferrous materials or similar material having the “Technical Characteristics” described in the
”Technical Data Enclosure”.
Whenever the machine is used with the manual loading and unloading of the pieces, 2 operators at
least must be employed for the purpose.
Deburring: necessary operation to removal the bur of plates of various thermic cutting, punching,
shearing or other.
Polishing: necessary operation to modify the superficial aspect of plates by regular and constant
material removal.
Brushing: necessary operation to polish the surface and/or to make round with elimination of burr.
The machine and the accessories have been designed and constructed for operation in safety under
the following conditions:
-the operators follow the procedures in the instruction manual;
-the operators respect the technical characteristics of the machine (see “Technical Data Enclosure”),
with particular regard to:
-operating speed limits;
-workable thicknesses;
-maximum width permissible;
-service coefficient (hours worked per shift);
-surrounding conditions, such as the dust level, temperature, and humidity of the installation rooms).
Any other use of the machine must be previously authorised by the Manufacturer in written form.
Without such written consent, such use will be considered “inappropriate” and the Manufacturer will be
released from any and all liability for damage and injury, and all form of warranty coverage for the
machine and the devices supplied with it will be invalidated.
This manual describes the machine.
The machine can be inserted in a production line that includes other machines both
upstream and downstream.
Costa Levigatrici declines all liability for the identification of the risks and the
prescription of safety warnings regarding the connection areas to these other machines.
UNFORESEEN AND/OR INAPPROPRIATE AND/OR INCORRECT USE OF THE MACHINE
Any use of the machine and of its units for the working of other materials or the
achievement of higher production values than those established will be considered
“INAPPROPRIATE USE”.
EXPLOSIVE SURROUNDINGS
Unless otherwise expressly requested and inserted in the purchase contract, this
machine is constructed standard, and not flameproof version.
Installation and operation in rooms where explosive gases may be present is therefore
strictly prohibited.
It is therefore the user’s responsibility to provide adequate air filtration systems that
prevent the formation of potentially explosive surroundings.

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This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
2.2.2 Operating environmental conditions
It is the client’s responsibility to provide rooms in compliance with EU Directive requisites for the
prevention of accident in the workplace.
Make sure that the floor is strong enough to support the weight of the machine.
Demarcate the work areas to eliminate risks caused by the transit and presence of people in the
machine’s danger areas.
The rooms must be:
-equipped with emergency exits;
-easily cleaned, in order to ensure adequate health conditions;
-well-aerated (with sufficient air circulation);
-equipped with both natural and artificial illumination sufficient to maintain the safety, health and well-
being of the workers;
-arranged with special attention to the work and control positions.
The machine has been designed and constructed for operation under the following environmental
conditions:
Room temperature: +5° to +40 °C.
Max. relative humidity: 80 %.
The installation room and work area must never present concentrations of dust such to
create the risk of fire because unless otherwise indicated the machine has not been
supplied in flameproof version.
2.2.3 Illumination
The work rooms must be provided with sufficient natural light or devices that ensure adequate artificial
illumination for health and safety.
Work room illumination must comply with the laws in force in the nation where the machine is installed
and must be sufficiently uniform to ensure good visibility in every point, clear reading of the control
panels and the rapid identification of the positions of the emergency buttons and must not create
dangerous glare.
Work room illumination must ensure the safe execution of all the maintenance operations prescribed in
this manual. For operations in special areas (such as maintenance operations inside the machine), the
use of movable illumination systems may be required.
Such movable illumination devices must not constitute a source of risk.
2.2.4 Vibration
The machine does not transmit to the ground any vibration that might compromise its stability or the
precision of any other equipment installed nearby. Unusual machine vibration is a sign of machine
mechanical malfunction (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.

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2.2.5 Noise levels
The machine has been designed and constructed to permit the reduction of sound power at the
source. The noise levels values indicated in ”Technical data Enclosure” are the emission levels and do
not necessarily indicate safe operational levels. Although a relationship exists between emission levels
and exposure levels, such relationship cannot be necessarily be considered in determining whether
other precautions are required or not.
The factors that permit the determination of exposure levels for the operators include the values for
duration of exposure, the characteristics of the work room, and other noise sources present (in terms
of the number of machines and adjacent processes, etc.). The permissible exposure levels prescribed
vary from nation to nation.
The information provided will permit the user of the machine to make a better assessment of the
problem and the degree of risk in question.
Unusual noise levels often indicate mechanical malfunctions (worn-out bearings, loose belts, etc.).
Intervene by following the instructions provided in the Chapter entitled “Maintenance” or contact the
local assistance center indicated in Chapter 1.4.
2.2.6 Waste products and pollution
The working for which the machine has been designed and constructed involves
material that might be toxic or harmful (such as dust, glues, paints, etc.), and therefore
the Employer or the Safety Manager must:
-assess the risk and danger on the basis of the information provided by the producer of
the material;
-instruct the operators in the necessary operating procedures;
-oblige the operators to adopt the necessary personal protective equipment (such as
gloves, goggles, masks, etc.) for the materials being worked.
Organisational and procedural measures must be adopted to make all operations regarding the
shipping, handling, storage and use of any and all toxic or harmful substances used in the production
process absolutely safe.
For the management and elimination of waste, the user is required to respect the laws in force in the
nation of use.
Maintenance phase
The waste materials obtained after changing the lubricants, sand belts, graphite cloths, and belts, etc.
must be collected and sent to the respective differentiated waste elimination centers or treated and
disposed of as required by law.

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This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
3 Safety
3.1 General information - usage - areas
3.1.1 General safety information and warning
The purpose of this chapter is to inform the machine’s conductors and maintenance men of all the
most significant risks and dangers, and both the general and specific precautions to be taken for their
elimination.
This chapter contains information and instructions regarding:
-situations of danger that might arise during the use and maintenance of the machine;
-the protections, safety guards and safety devices adopted and their correct use;
-the residual risks and the operational procedures to adopt (general and specific precautions for their
elimination or reduction).
This chapter provides detailed information and illustrations.
These instructions will be provided in summarised form further on in the manual when the specific
situation is described.
Some of the illustrations in the manual depict the machine or parts of the same without
safety guards or with the protections removed purely to provide better understanding.
THE OPERATION OF THE MACHINE WITHOUT ITS SAFETY GUARDS OR WITH THE
PROTECTIONS DISABLED IS STRICTLY PROHIBITED.
The employer must instruct the operators in the risks of accident present, the devices
provided for their safety, the risks to their hearing, and the general accident-prevention
rules prescribed by European Directives and the local laws in force.
The instructions and safety warnings in this manual have been written on the assumption that
Directive 89/391/EEC and the accessory directives (regarding accident-prevention at the workplace)
have been duly respected.
These directives prescribe general measures for the protection of the health and safety of the
operators, such as:
-hygiene measures;
-collective and individual protection measures;
-measures for first aid emergency, fire prevention, and worker evacuation in case of fire or immediate
and serious risk;
-the use of warning and safety signs;
-the regular performance of the necessary maintenance operations on the rooms, equipment,
machines, and systems, with special attention on the safety devices in conformity with the
instructions provided by the producers;
-correct instruction and training of the operators.
The Employer, Manager and Safety Manager must:
-consider the skills and physical conditions of each individual worker during the
assignment of the tasks to be performed and their possible effect on the individual’s
health and safety;
-provide adequate personal protective equipment;
-oblige single operators to respect the company’s safety rules and devices and to use
the collective and personal protective equipment placed at their disposal.
Each worker must give personal attention to his own safety and health and those of the
workers in the area who might also be involved by his actions or failure to act as befits
his own level of training and the materials and instructions provided by the Employer.

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is prohibited.
In particular, the workers must:
-respect the directives and instructions provided by the Employer, Managers and Safety Managers for
collective and individual safety;
-correctly use the machinery, the equipment, the tools, the dangerous substances and preparations,
transport vehicles, and all the other work equipment and safety devices;
-use the protection devices placed at their disposal correctly
-immediately inform the Employer, Manager, or Safety Manager of any defects or
shortcomings in such equipment and devices;
-refrain from removing or modifying the safety devices or signal and control equipment
without authorisation;
-refrain from taking initiatives or performing operations beyond their sphere of competence
that might compromise their own safety or the safety of the other workers.
-Contribute, together with the Employer, Managers, and Safety Managers to the achievement of all
the obligations imposed by the competent authorities or those necessary for the safety and health of
the workers themselves during work.
The following points will provide important warnings for the implementation of the general prescriptions
provided above.
BEFORE STARTING THE PRODUCTIVE CYCLE, the operators (conductors and
maintenance men) must be perfectly aware of:
-the position, function and use of all the controls;
-the position, function and use of all the safety devices;
-the characteristics of the machine;
-this manual and the way in which it must be consulted.
The Manufacturer declines all liability whenever these prescriptions are not respected.
The unauthorised tampering with/replacement of one or more parts of the machine, or the use
of accessories, tools, consumable materials other than those prescribed by manufacturer, can
also pose risk of accident and release the manufacturer from any and all civil and penal liability
derived.
CLOTHING
The operators assigned to the operation and/or maintenance of the machine must wear
work clothes (with tight-fitting sleeves and cuffs) and any personal protective equipment
(gloves, goggles, masks, headsets, etc.) in compliance with the laws and safety rules in
force in the nation of installation as per Directive 89/391/EEC and its accessory
directives.
WORK AREA.
-The work area must NEVER be occupied by boxes, tools, or other objects that might create
obstacles and cause falls. Nothing must limit the freedom of movement of the operators, who in case
of emergency must be able to move freely and quickly. The work area must be kept clean in order to
prevent the work surfaces and floors from becoming slippery and create risk of slipping and falling.
-The work area must be provided with adequate illumination and must be free of all areas of shadow
or dangerous glare that might create additional risks.
-Access to the work area by persons not directly involved in operation and/or maintenance is
prohibited. This prescription must be placed in clear evidence by the use of the appropriate signs
near the machines.

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This manual is the property of COSTA LEVIGATRICI, the partial and/or total reproduction of the same in any form
is prohibited.
It is the responsibility of the operators to respect this prescription and to notify the Safety Managers of
any failures or shortcomings in regard.
The operators must wear the appropriate heat protective gloves when performing operations in areas
where heat is emitted.
The operators must never wear loose bracelets, wristwatches, rings, or chains that swing or hinder
their movements.
Operators with long hair must tie their hair up, and all operators must refrain from wearing scarves or
other garments that might get caught up in the belts and other moving parts of the machine.
Fig. 3-1 Use of gloves
Fig. 3-2 Do not wear jewellery
General safety warnings for the safe operation of the machine
We provide a list of the general safety rules to be used in the most common operative conditions:
-respect the indications provided in the identification plates attached to the machine;
-make sure that there are no persons performing cleaning or maintenance operations or standing in
any of the machine’s danger areas before starting to work;
-never abandon the machine unsupervised when in operation;
-never attempt to lubricate, repair or adjust moving parts;
-maintenance operations must be performed exclusively by authorised personnel and only after first
placing the machine in the maintenance condition (see Chap. 7 ”Maintenance”);
-never open the fixed safety guards or protections with the machine in movement under any
circumstances;
-the use of the machine for any purposes other than those for which it has been expressly
designed and constructed is absolutely prohibited.