POSTPROCESS LEVO User manual

LEVO QuickStart Guide
Automated Surface Finish Machine
PostProcess Technologies, Inc. • www.postprocess.com • REV B

Copyright
Conventions
Copyright © 2018 by PostProcess Technologies Inc. “POSTPROCESS”. All rights reserved. The information
disclosed herein is proprietary information owned by POSTPROCESS. This information shall be used solely and
exclusively by employees and customers of POSTPROCESS as documentation for the safe operation of
processing equipment provided by said company. The information herein shall be used by or disclosed to others
only for this purpose.
Published: February 2018
Disclaimer: The content of this guide is subject to change without prior notice. Please contact POSTPROCESS
for the most current information. Items marked with an asterisk * have been identied as likely to be updated.
Picture on front cover is for illustrative purposes only and does not reect actual dimensions.
WARNING
CAUTION
NOTE
Draws attention to an operating procedure, practice, or condition, etc., that may result in injury or death if not
carefully observed or followed.
Draws attention to an operating procedure, practice, or condition, etc., that may result in damage to equipment if
not carefully observed or followed.
Draws attention to an operating procedure, practice, or condition, etc., that must be emphasized or provides
information to simplify procedures and tasks.
Any time a button is referenced the following formatting will be used.
Buttons – References to a button that can be pressed or activated by an operator will be BOLD AND
CAPITALIZED.
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Table of Contents
1 OPERATION.........................................................................................................................................................................
1.1 Connecting Power to the LEVO.......................................................................................................................
1.1.1 Powering Up the LEVO........................................................................................................................
1.1.2 Emergency Stop Button......................................................................................................................
1.2 Automatic Operation – Setup/Start...............................................................................................................
1.2.1 Speed Control.......................................................................................................................................
1.3 Maintenance Operations..................................................................................................................................
1.3.1 Media Maintenance.............................................................................................................................
1.3.2 Liquids Maintenance...........................................................................................................................
2 TROUBLESHOOTING........................................................................................................................................................
2.1 Thereisadecreaseinwater/detergentow,ortheowhasstopped...................................................
2.2 The spray nozzle is not operating properly...................................................................................................
2.3 Leakage...............................................................................................................................................................
2.4 Liquid build-up in the envelope chamber......................................................................................................
2.5 The LEVO is not stationary...............................................................................................................................
 2.6 WherecanIndtheLEVO Serial Number?.................................................................................................
3 POINT OF CONTACT.........................................................................................................................................................
4 REVISION HISTORY..........................................................................................................................................................
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List of Figures
Figure 1. Location of Master Power Switch...................................................................................................................
Figure 2. Power and Emergency Stop Buttons.............................................................................................................
Figure 3. Detergent Chamber...........................................................................................................................................
FIgure 4. Circular Envelope...............................................................................................................................................
Figure 5. VFD Speed Control............................................................................................................................................
Figure 6. Abrasive / Finishing Media...............................................................................................................................
Figure 7. Reservoir and Drain Bucket..............................................................................................................................
Figure 8. Casters with Ratchet.........................................................................................................................................
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Warnings
Failure to adhere to any of the warnings below could void the warranty. Read thoroughly before operating the
machine. If the machine appears to be malfunctioning in any way, immediately PUSH the EMERGENCY STOP
button and refer to the Troubleshooting section of this guide on page 9. If the issue is not able to be resolved,
call POSTPROCESS for additional support.
• Do not operate the unit without proper grounding.
• Donotallowalcohol,gasolineorotherammablesolutionsnearthemachine.Doingsocouldcausea
 reorexplosion.
• Do not touch the detergent with bare skin. Use nitrile gloves, laboratory-style eyeglasses and other
necessary personal protective equipment when performing any operations including removing parts
where skin could come into contact with the detergent.
• Do not attempt to disassemble or repair the machine.
• Keeptheentirepowercordsuspendedaboveoorsurface.
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Warnings, Cautions and Notes
Cautions
• Connect the unit only to 60 hz single-phase 120v power.
• Use only POSTPROCESS detergents and media. Do not add any other liquid solutions or abrasive media
to the machine.
• Donotoperatethemachinewithoutsufcientdetergentinthetank.
Ventilation
PostProcessTechnologiesdetergentsarespecicallyformulatedchemistryformaximized3Dprintedsupport
removalefciency.Itisrecommendedthattheequipmentbelocatedinawellventilatedroom.Specic
ventilation requirements can vary widely due to size of the install room, existing ventilation (positive or negative)
and differences in individual sensitivities to airborne scents or fragrances. For more information on the safe use
of POSTPROCESSdetergentsrefertotheSDSforthespecicdetergentused.
Electrical Safety
Caution should be used whenever working with industrial-powered equipment. If there is an emergency
situation, it is important to note that hitting the EMERGENCY STOP button does not turn off power to the
LEVO. It turns off the LEVO’s operating cycle only. To shut off power to the LEVO, turn off the MASTER POW-
ER SWITCH,located on the right side, rear panel of the LEVO. (For a visual of the switch location, see Figure 1.
Location of MASTER POWER SWITCH)
NOTE
The EMERGENCY STOP button should only be used in actual emergency situations. For any other situation
requiring the machine to be powered down, use the MASTER POWER SWITCH.

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Warnings, Cautions and Notes
Overview
This QuickStart Guide is intended to explain the basic setup and operation of the LEVO Surface Finish machine.
Read this guide thoroughly before operating the LEVO to ensure safe and efcient operation.If a question is
not answered in this guide, contact POSTPROCESS for additional support.
The LEVO applies patent-pending technology, including optimized energy with circular motion in combination
withproprietary,eco-friendlyconsumablemediatoachievethedesiredsurfacenishon3Dprinted parts or
components. The LEVOisidealfornishingsmallpartsbecauseofitscircularenvelopecapacity.TheLEVO,
likeallofoursurfacenishingproducts,hasbeendesignedandmanufacturedwithnoise-reductionfeaturesand
functionality to reduce excess noise in your production environment.
While the LEVO is robust, care should be used during operation. When accessing the chamber, gently open and
closetheenvelopeaccessdoor.Becarefulwhenextractingnishedpartstolimittheamountofconsumable
media that is lost during the part removal process. Ensure no heavy materials are stored above the LEVO that
may fall and damage it.
Detergent Safety
As noted in the safety warnings above, it is important that operators do not come into contact with any form of
detergent with bare or uncovered skin.
• When working with or near detergents, always wear nitrile gloves.
• Wear laboratory-style protective glasses.
• If bare skin comes in contact with detergent, thoroughly wash the
body part with soap and warm, clean water.
• It is recommended that an eyewash station is near the LEVO
and any detergent storage areas.

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1. OPERATION
1.1 Connecting Power to the LEVO
The LEVO is delivered with an industrial power cord. Use only the power cord supplied by POSTPROCESS with
the LEVO. Connect the LEVO only to 60 hz single-phase 120v power.
The MASTER POWER SWITCH is located on the lower left rear panel of the LEVO. Before connecting or
disconnecting the LEVO to power, ensure the MASTER POWER SWITCH is in the bottom “O” or OFF position
(refer to Figure 1. Location of Master Power Switch).
When the power cord is connected to the LEVO and plugged into a single-phase 120v power outlet, press the
POWER switch to the “I” or ON position. The LEVO is now ready to be powered up.
WARNING
Do not place the power cord in a location where it could come into contact with water or other liquid substances.
Itisrecommendedtokeeptheentirepowercordsuspendedabovetheoorsurface.
Figure 1. Location of Master Power Switch Figure 2. Power and Emergency Stop Buttons
1.1.1 Powering Up the LEVO
The POWER button for the LEVO is located to the left of the right side access panel, below the handle. To power
up (or down) the LEVO , press the POWER button. If the POWERbuttonisashing,the LEVO is on and ready for
use. The POWER button will be continuously running when the SF MICRO C is running. (refer to Figure 2. Power
and Emergency Stop Buttons).

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1. OPERATION
1.1.2 Emergency Stop Button
Opposite the POWER button, beneath the right-side access panel is the large EMERGENCY STOP button (shown
in Figure 2. Power and Emergency Stop Buttons).
1.2 Automatic Operation - Setup/Start
The LEVOisdesignedtobefullyautomaticandconguredforany3Dprinttechnology.Thetypeofabrasive/
polishing media and the necessary concentration of POLYGONE 3™ detergent is predetermined for each
customer’sspecicoperation.
The left side of the LEVO houses the circular envelope or chamber. The envelope is roughly 12” in diameter x 10”
deepandislledwithabrasive/polishingmediacarefullyselectedtomaximizeaspecicoperationalneed.As
the name suggests, the envelope creates energy and abrasive/polishing action through rotational energy, causing
the media to spin. The LEVOenvelopealsohasaspraynozzlethatinjectsuidintothesurfacenishingprocess.
See the next section 1.2.1 LEVO Speed Control for more information.
Beneath the right-side panel is where an operator can access the detergent chamber to add more PG3 and water
as per the designated recipe provided for the application. For more information about maintaining liquid levels
for the LEVO, please see the Maintenance section of this Quick Start Guide.
CAUTION
If the LEVO appears to be malfunctioning in any way, immediately PUSH the EMERGENCY STOP button and
refer to the Troubleshooting section of this QuickStart Guide.
If the issue is not able to be resolved, contact POSTPROCESS support.
Figure 3. Detergent Chamber
NOTE
WheneveranoperatorisllinguptheLEVOwithwaterandPG3,nitrileglovesshouldbeworn,anditishighly
recommended that a funnel be used to avoid spillage.
Tobeginthenishingcycle,press
the POWER button to ON.

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1. OPERATION
1.2.1 Speed Control
As mentioned, the LEVOhasacircularenvelopethatnishestheprod-
ucttospecicationsusingacombinationofenergycreatedby
rotation, abrasive/polishing media, and patented PG3 formulation.
See Figure 4. Circular Envelope.
The rotational energy for the LEVO is controlled by a Variable Frequency
Drive (VFD) allowing the envelope to vibrate from zero to 427.5 RPM.
The VFD is located in the right-side cabinet to the right of the Drain
Bucket. As shown in Figure 5. VFD Speed Control, the black dial is
set as a percentage of maximum speed (0 to 100%).
The LED Display will show the operator the actual RPM’s of the
envelope rotational energy.
Figure 6. Abrasive / Finishing
Media
Figure 7. Reservoir and
Drain Bucket
Figure 4. Circular Envelope
Figure 5. VFD Speed Control

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1. OPERATION
1.3 Maintenance Operations
1.3.1 Media Maintenance
1.3.2 Liquids Maintenance
As shown in Figure 6. Abrasive / Finishing Media, the LEVO has a
chamberthatislledwithspeciallyformulatedabrasiveorpolishing
media.Duringthesurfacenishingoperation,theprintedpartis
immersed in this media and the combination of rotational energy,
the abrasive qualities of the media, and the patented PG3 liquids
allactonthepartuntilthedesirednishinglevelisachieved.The
media has a useful life based on the application it is being used in
and the amount of processing that is occurring.
Once the media has degraded to one-third of its original size, it is
time to change out the media.
To change the media, carefully scoop out all of the media particles, and dispose of them according to local
regulations. Next, with a damp cloth and mild cleaning solution, clean out the envelope and wipe down the spray
nozzle to remove any sediment build-up. Also, wipe down the grate that covers the drain inside the chamber
withaplasticbristlebrush.Finally,rellthechamberwithfreshmediasuppliedbyPOSTPROCESS. NEVER use
media other than POSTPROCESS supplied abrasive and polishing media or risk damaging the machine.
The appropriate ratio of PG3 to water is designated for each
customer application but most typically the ratio is 99 parts of
water to 1 part of PG3. The LEVO has a 1.5-gallon tank, so the
correctformulawouldbe2oz.ofPG3andlltheremainderofthe
tank with fresh water. The operator using the SF MICRO C should
always ensure that the correct levels of liquid are being utilized
duringthenishingprocess.Behindtheright-sidepanel(belowthe
PG3 access opening) is the liquids tank and the LEVO drain bucket,
as shown in Figure 7. Reservoir and Drain Bucket.
The Liquids Reservoir is translucent allowing the operator to see
how much liquid remains in the tank. It is important to note that
whenever the tank is empty, the correct recipe of PG3 and water
should be added to the reservoir before operation. Never run the
LEVO without liquids.
Figure 6. Abrasive / Finishing
Media
Figure 7. Reservoir and
Drain Bucket
NOTE
WhenthereservoirisrelledwithPG3andwater,thedrainbucketshouldbeemptied.Ifitisnotemptiedevery
timeliquidisaddedtotheLEVO,theDrainBucketcanoverow.

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2. TROUBLESHOOTING
2.1 There is a decrease in water/detergent ow, or the ow has stopped.
Step 1) Check the liquid reservoir to ensure there is liquid in the tank.
Step 2) Inspect the LEVO spray nozzle. Clear away any buildup or blockages with a wet cloth and mild
detergent.
2.2 The spray nozzle is not operating properly.
Whenthespraynozzleisnotworkingproperlyitisprobablyduetosedimentbuildupfromthesurfacenishing
process. Check the spray nozzle for excess buildup and clean it with a light detergent and a soft cloth to remove
the debris that has built up around the discharge area. For stubborn blockages, the buildup can be removed with a
stiff,newireorbrush.
2.3 Leakage
During manufacturing, all the LEVO plumbingxtureswereafxedandsealedusingconstructiongradematerials.
If any of the plumbing connections, pipes, or tubes begin to leak, shut down the LEVO and contact PostProcess
Support for further instruction.
2.4 Liquid build-up in the envelope chamber
The LEVO is designed to allow liquids to spray into the envelope to moisten the abrasive/polishing media and
enhancethesurfacenishingprocess.Theenvelopecontainsadrainthatallowsexcessliquidstodripoutofthe
envelope and into the Drain Bucket as described in the 1.3.2 Liquids Maintenance section of this guide. If
excessive sediment and materials have clogged the grate, it may cause the liquids to remain in the chamber. If
this occurs, empty all of the media out of the envelope, clean the envelope and the drain to clear away any build
up.
2.5 The LEVO is not stationary
The LEVO was designed with special casters with integral feet that can be adjusted and locked into place. To
prevent unwanted movement, pull out the metal ratchet on each caster, adjust them to engage the foot and lock
the caster into place by pushing in the ratchet. (See Figure 8. Casters with Ratchet)
Most instances where the LEVO is not performing to expectations can be easily resolved by simple
troubleshooting procedures. Below is a list of issues that may arise during post-processing operations.
Figure 8. Casters with Ratchet