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

WD7-WP7 Series
Revision 01 of 21/11/2018
0 - Index
2
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

WD7-WP7 Series
Revision 01 of 21/11/2018
0 - Index
3
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

WD7-WP7 Series
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.

WD7-WP7 Series
Revision 01 of 21/11/2018
1 - Introduction
2
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.

WD7-WP7 Series
Revision 01 of 21/11/2018
1 - Introduction
3
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.

WD7-WP7 Series
Revision 01 of 21/11/2018
1 - Introduction
4
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” .