01 - 13

SUPER NOVA
AIRLESS PNEUMATIC PUMP 45:1 / 68:1 / 80:1
A
t e x

Ed. 007

ca

II 2 G c IIB T4

OPERATING AND MAINTENANCE INSTRUCTIONS

PA I N T

S P R AY I N G

EQUIPMENT

ENGLISH

Due to a constant product improvement programme, the factory reserves the right to modify technical details mentioned in this manual without prior notice. This manual is to be considered as an English language translation of the original manual in Italian. The manufacturer shall bear no responsibility for any damages or inconveniences that may arise due to the incorrect translation of the instructions contained within the original manual in Italian.

SUPER NOVA 45:1/68:1/80:1

English

AIRLESS PNEUMATIC PUMPS FOR SPRAY PAINTING

INTRODUCTION........................................................p.1

A B C D E F G H I L M

WORKING PRINCIPLE.......................................p.2 TECHNICAL DATA. ..............................................p.2 DESCRIPTION OF THE EQUIPMENT................p.3 TRANSPORT AND UNPACKING........................p.4 SAFETY RULES..................................................p.4 Conditions of guarantee......................................p.5 TYPICAL INSTALLATION....................................p.6 SETTING UP.......................................................p.6 OPERATION........................................................p.7 CLEANING AT THE END OF THE WORK..........p.7 GENERAL MAINTENANCE................................p.8 ROUTINE MAINTENANCE.................................p.8

N TROUBLESHOOTING.........................................p.9 O DISASSEMBLY OF THE PNEUMATIC MOTOR.....p.10 P DISASSEMBL OF THE PUMPING GROUP........p.15 Q FILTER GROUP..................................................p.20 R STEM GROUP....................................................p.22 S PUMPING GROUP..............................................p.24 T FOOT VALVE BODY............................................p.26 U COMPLETE PUMPING GROUP . ......................p.27 V COMPLETE AIR GROUP....................................p.28 W COMPELTE HANDTRUCK . ...............................p.29 X MOTOR GROUP.................................................p.30 Y ACCESSORIES...................................................p.32 Z ATEX CERTIFICATE............................................p.35

Read this operators manual carefully before using the equipment. An improper use of this machine can cause injuries to people or things.

It indicates an accident risk or serious damage to equipment if this warning is not followed.

It indicates a fire or explosion risk if this warning is not followed.

It indicates wound and finger squashing risk due to movable parts in the equipment.

It is obligatory to wear suitable It indicates imporclothing as gloves, goggles and tant recommendations about dispoface shield. sal andrecycling process of products in accordance with the environmental regulations.

WE ADVISE THE USE OF THIS EQUIPMENT ONLY BY PROFESSIONAL OPERATORS. ONLY USE THIS MACHINE FOR USAGE SPECIFICALLY MENTIONED IN THIS MANUAL. Thank you for choosing a LARIUS S.R.L. product. As well as the product purchased, you will receive a range of support services enabling you to achieve the results desired, quickly and professionally.

SUPER NOVA 45:1/68:1/80:1

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A WORKING PRINCIPLE
SUPER NOVA 45:1 (or 68:1 - 80:1) is a pneumatic pump to be used

in the high pressure painting without air (Airless) or for transferring of fluids in case of more stations of usage. The pump is essentially constituted of an air motor and a structure called material pumping group or simply pumping group. In the pneumatic motor, compressed air causes the vertical recipro-

cating movement of the motor piston; this movement is transmitted through a connecting rod to the material pumping piston. So doing the pump sucks the fluid and pushes it to the outlet. The ratio 45:1 (or 68:1 - 80:1) means that the outlet pressure of fluid is 45 (or 68 or 80) times higher than the pump feed air pressure.

B technical data
SUPER NOVA
FEEDING AIR PRESSURE MAX PRODUCT PRESSURE FEEDING AIR INLET MAX DELIVERY CYCLES PER LITER MX CYCLES PER MINUTE MATERIAL OUTPUT WEIGHT NOISE PRESSURE LEVEL

45:1
3-7 bar (40-90 psi) 270 bar (3900 psi) 3/4" GAS (M) 14 l/min (3,7 gpm) 4 60 1" GAS conico (F) 57 kg <90 dB (A)

68:1
3-7 bar (40-90 psi) 476 bar (6902 psi) 3/4" GAS (M) 11 l/min (2,95 gpm) 5,5 60 1" GAS conico (F) 57 kg <90 dB (A)

80:1
3-7 bar (40-90 psi) 560 bar (8120 psi) 3/4" GAS (M) 8,5 l/min (2,3 gpm) 7 60 1" GAS conico (F) 57 kg <90 dB (A)

Parts of the pump in contact with the material Pumping group: galvanized carbon steel and cast iron or stainless steel AISI 303 and 420B Sealing balls: stainless steel AISI 420B Gaskets: teflon or nitrile or delrin or vulkollan Other parts of the pump Support and cylinder for pneumatic motor: aluminium Covering: sheet FE37 Motor piston and roller pushing mount: cast iron
CODE 65100 65101 68400 65400 65406 68406 65102 65103 68401 65401 65407 68407 65104 65105 68402 65402 65408 68408 AVAILABLE VERSIONS SUPER NOVA 45:1 SUPER NOVA 45:1 INOX SUPER NOVA 45:1 INOX ON CARRIAGE SUPER NOVA 45:1 ON CARRIAGE SUPER NOVA 45:1 WALL-MOUNTED SUPER NOVA 45:1 WALL-MOUNTED INOX SUPER NOVA 68:1 SUPER NOVA 68:1 INOX SUPER NOVA 68:1 INOX ON CARRIAGE SUPER NOVA 68:1 ON CARRIAGE SUPER NOVA 68:1 WALL-MOUNTED SUPER NOVA 68:1 WALL-MOUNTED INOX SUPER NOVA 80:1 SUPER NOVA 80:1 INOX SUPER NOVA 80:1 INOX ON CARRIAGE SUPER NOVA 80:1 ON CARRIAGE SUPER NOVA 80:1 WALL-MOUNTED SUPER NOVA 80:1 WALL-MOUNTED INOX

Always observe these instructions carefully when evaluating the product compatibility and in case of disposal of some parts of the pump no more usable, in order to meet the environmental regulations on recycling process. WARNING! ALWAYS USE ORIGINAL HYDRAULIC SPARE PARTS CERTIFIED BY LARIUS, SUITABLE FOR PRESSURE VALUES HIGHER THAN 500 bar. THE COMPANY LARIUS ASSUMES NO LIABILITY FOR DAMAGE TO PROPERTY AND / OR PERSONS.
410

1300

720

580

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C DESCRIPTION OF THE EQUIPMENT

6 1

13

6 9 ANTI-FREEZE SYSTEM 2 1
8 5 3

8 10 7 4 3 5

11 12 POS. 1 2 3 4 5 6 7 DESCRIPTION Pump feeding air inlet Pneumatic motor Material output Material entry Material pumping group Eyebolt for pump transport Material recirculation hose POS. 8 9 10 11 12 13 Filter Grounding cable Suction filter Spraying gun High pressure hose Air treatment group DESCRIPTION

10

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D TRANSPORT AND UNPACKING

The packed parts should be handled as indicated in the symbols and markings on the outside of the packing. Before installing the equipment, ensure that the area to be used is large enough for such purposes, is properly lit and has a clean, smooth floor surface.

Read carefully and entirely the following instructions before using the product. Please save these instructions in a safe place. The unauthorised tampering/replacement of one or more parts composing the machine, the use of accessories, tools, consumables other than those recommended by the Manufacturer might represent a danger of accident. The Manufacturer will be relieved from any civil and penal liability. KEEP YOUR WORK PLACE CLEAN AND TIDY. DISORDER WHERE YOU ARE WORKING CREATES A POTENTIAL RISK OF ACCIDENTS. ALWAYS KEEP PROPER BALANCE AVOIDING UNUSUAL STANCE. BEFORE USING THE TOOL, ENSURE THERE ARE NOT DAMAGED PARTS AND THE MACHINE CAN WORK PROPERLY. ALWAYS FOLLOW THE INSTRUCTIONS ABOUT SAFETY AND THE REGULATIONS IN FORCE. Keep those who are not responsible for the equipment out of the work area. NEVER exceed the maximum working pressure indicated. NEVER point the spray gun at yourselves or at other people.THE CONTACT WITH THE CASTING CAN CAUSE SERIOUS INJURIES. In case of injuries caused by the gun casting, seek immediate medical advice specifying the type of the product injected. Never undervalue a wound caused by the injection of a fluid. Always DISCONNECT THE SUPPLY AND release the pressure in the circuit before performing any check or part replacement of the equipment. NEVER MODIFY ANY PART IN THE EQUIPMENT. CHECK REGULARLY THE COMPONENTS OF THE SYSTEM. REPLACE THE PARTS DAMAGED OR WORN. Tighten and check all the fittings for connection between pump, flexible hose and spray gun before using the equipment. Always use the flexible hose supplied with standard kit. THE USE OF ANY ACCESSORIES OR TOOLING OTHER THAN THOSE RECOMMENDED IN THIS MANUAL, MAY CAUSE DAMAGE OR INJURE THE OPERATOR. The fluid contained in the flexible hose can

The user is responsible for the operations of unloading and handling and should use the maximum care so as not to damage the individual parts or injure anyone. To perform the unloading operation, use only qualified and trained personnel (truck and crane operators, etc.) and also suitable hoisting equipment for the weight of the installation or its parts. Follow carefully all the safety rules. The personnel must be equipped with the necessary safety clothing. The manufacturer will not be responsible for the unloading operations and transport to the workplace of the machine. Check the packing is undamaged on receipt of the equipment. Unpack the machine and verify if there has been any damage due to transportation. In case of damage, call immediately LARIUS and the Shipping Agent. All the notices about possible damage or anomalies must arrive timely within 8 days at least from the date of receipt of the plant through Registered Letter to the Shipping Agent and to LARIUS. The disposal of packaging materials is a customers competence and must be performed in accordance with the regulations in force in the country where the plant is installed and used.It is nevertheless sound practice to recycle packaging materials in an environment-friendly manner as much as possible.

E SAFETY RULES
The employer shall train its employees about all those risks stemming from accidents, about the use of safety devices for their own safety and about the general rules for accident prevention in compliance with international regulations and with the laws of the country where the plant is used. The behaviour of the employees shall strictly comply with the Accident prevention AND ALSO ENVIRONMENTAL regulations in force in the country where the plant is installed and used.

SUPER NOVA 45:1/68:1/80:1

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be very dangerous. Handle the flexible hose carefully. Do not pull the flexible hose to move the equipment. Never use a damaged or a repaired flexible HOSE. The high speed of the product flowing in the hose can create static electricity through discharges and sparks. It is suggested to earth the equipment. The pump is earthed through the earth cable of the supply. The gun is earthed through the high pressure flexible hose. All the conductors near the work area must be earthed. NEVER SPRAY OVER FLAMMABLE PRODUCTS OR SOLVENTS IN CLOSED PLACES. NEVER USE THE TOOLING IN PRESENCE OF POTENTIALLY EXPLOSIVE GAS. The machine is equipped with an anti-freeze system that allows it to work even at very low temperatures. However, after a few minutes of operation, the upper metal outer surface cools dramatically. Avoid touching the area indicated. Contact of the skin with the low-temperature area may cause frostbite. Common working clothes and leather gloves provide adequate protection.

Always check the product is compatible with the materials composing the equipment (pump, spray gun, flexible hose and accessories) with which it can come into contact. Never use paints or solvents containing Halogen Hydrocarbons (as the Methylene Chloride). If these products come into contact with aluminium parts can provoke dangerous chemical reactions with risk of corrosion and explosion. Avoid approaching too much to the pump piston rod when the pump is working or under pressure. A sudden movement of the piston rod can cause wounds or finger squashing.

condiTIONS OF GUARANTEE
IF THE PRODUCT TO BE USED IS TOXIC, AVOID INHALATION AND CONTACT BY USING PROTECTION GLOVES, GOGGLES AND PROPER FACE SHIELDS. The conditions of guarantee do not apply in the following situations: - improper washing and cleaning of components causing malfunction, wear or damage to the equipment or any of its parts; - improper use of the equipment; - use that does not conform with applicable national legislation; - incorrect or faulty installation; - modifications, interventions and maintenance that have not been authorised by the manufacturer; - use of non-original spare parts or parts that do not correspond to the specific model; - total or partial non-compliance with the instructions provided.

TAKE PROPER SAFETY MEASURES FOR THE PROTECTION OF HEARING IN CASE OF WORK NEAR THE PLANT.
WARNING! ALWAYS USE ORIGINAL HYDRAULIC SPARE PARTS CERTIFIED BY LARIUS, SUITABLE FOR PRESSURE VALUES HIGHER THAN 500 bar. THE COMPANY LARIUS ASSUMES NO LIABILITY FOR DAMAGE TO PROPERTY AND / OR PERSONS.

SUPER NOVA 45:1/68:1/80:1

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F TYPICAL INSTALLATION
The SUPER NOVA pump is generally supplied on support for wall fastening or on trolley or on air host. For the correct fastening of the pump on other structures use the 4 holes placed at the base of the pneumatic motor (see the illustration for dimensions).
* 266

G2 G1

45

45

CONNECTION OF THE PRODUCT HOSE Connect the product suction hose (G3) to the pump coupling (G4).

11

G4
240

*Int. holes

G3

G SETTING-UP
PUMP FASTENING ON THE HOIST For the correct fastening of the pump on the hoist, follow the procedure described in the manual for use and maintenance of the air hoist. CONNECTION TO THE FEED AIR For pump feed use a hose with an internal diameter higher than 20 mm. Install at the pump inlet an air pressure regulator (it is suggested complete with condensate filter and lubricator). The outlet pressure of the material is 45 times (SUPER NOVA 45:1) or 68 times (SUPER NOVA 68:1) or 80 times (SUPER NOVA 80:1) the inlet pressure of the pump feed air. Therefore, it is extremely important to adjust the value of the feed air pressure. CONNECTION OF THE RECIRCULATION HOSE Connect the recirculation hose (G1) to the coupling (G2).

CONNECTON OF THE PRODUCT FEEDING HOSE Connect the gun hose (G5) to the coupling (G6).

G6 G5

CONNECTION OF THE SPRAYING GUN Connect the spraying gun (G7) to the prodcut feeding hose (G8).

G8

G7

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H OPERATION
Check all the fittings for connection of the different components (pump, flexible hose, spray gun, etc.) before using the equipment. Dip the material pumping hose (H1) into the product tank (H2) (if the pump is fixed on the air hoist, follow the procedure described in the manual of use and maintenance of the air hoist)

Always avoid pump idling: this operation could damage the pneumatic motor and the sealing gaskets.

In case of long downtime during the use with the plant (for example, all night long at the end of the working day), ensure the product you are using can be left inside the pump and the different pipes without drying. In this case, it is enough to stop the air supply to the pump and drain the residual pressure in the circuit acting on the delivery valve or on the pump bleeder valve.

H1 H2

Make the compressed air flow into the pump. It is advisable to adjust air pressure to minimum necessary for its continuous working. When the product chamber is full, pump will start working and stopping. Pump will start working again any time the trigger of the spray gun is pressed or the delivery valve is open. The pump has been adjusted at our factory with light mineral oil and a part of it could be left inside the pumping element. Point the spray gun (H3) or the delivery valve at the collecting tank (H4) and drain the product left inside the pump till the material to be used has come out.

I CLEANING AT THE END OF THE WORK

By "cleaning at the end of the work" we mean the cleaning to carry out in case of use with a different product or if a long period of downtime is foreseen. Stop the air supply to the pump. Dip the material pumping hose into the washing solvent tank (check its chemical compatibility with the product being used). Make compressed air flow into the pump. It is advisable to adjust the air pressure to minimum necessary to its continuous working. Point the spray gun or the delivery valve at a container and drain all the product left inside the pump till a clean solvent comes out. Now, stop the air supply to the pump and drain the residual pressure. In case of long downtime, we suggest to duly suck and leave light mineral oil inside the pumping unit.

H3 H4

Store possible dangerous fluids in proper containers. Their disposal must be performed in accordance with the regulations in force about the industrial waste goods.

SUPER NOVA 45:1/68:1/80:1

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L GENERAL MAINTENANCE
Discharge the pump pressure (opening the discharging valves) before any maintenance operation.

M ROUTINE MAINTENANCE
Controllo della ghiera premiguarnizioni Always close the compressed air supply and release the pressure in the plant before performing any check or maintenance of the pump. Check periodically (and each time the pump is operated after a long downtime) that the packing nut is not loosened, causing otherwise the coming out of the product. To tighten the packing nut, use the clamping wrench (ref. 20144). The packing nut must be tightened so as to avoid wastes of product, but not excessively to provoke pumping piston seizure and seals wear. In case of persistent coming out of product, replace the seals. To prevent the product from drying up on the piston rod, refill the cup with lubricant (compatible with the product used). Check periodically the air supply to the pump. Ensure the air is always clean and lubricated. In case of installation of a lubricator on the air supply to the pump, it is advisable to keep its cup full of a mixture of water and antifreeze liquid (dilution ratio 4:1).

DAILY Clean the filters; Clean the nozzles; Clean all the paint circuit with a specific product; PERIODICALLY Check the pump gaskets tightening (replace the gaskets, if necessary). Clean the movable parts from the paint deposits (spray guns, etc.); Check that the tubes and all the fittings are correctly tightened.

Lubricating oil Ref. 16325 Wrench Ref. 20144 Oil topping up ring

SUPER NOVA 45:1/68:1/80:1

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N TROUBLESHOOTING
PROBLEM CAUSE SOLUTION

The pump does not start

Feeding air is not enough; Outlet product line clogged;

Check the air supply. Increase the diameter of the feeding hose; Clean. Disconnect the outlet product pipe. Feed pump at minimum pressure and check if the pump starts without the outlet pipe; Disassemble the pumping group and clean; Turn the plug counterclockwise and push downwards the valve body. Use a metal rod and a mallet; Disassemble the motor and check;

Dried product inside the pumping element; Pneumatic motor blocked in the cycle reversal position; Parts failure of the pneumatic motor;

Accelerated working and no pressure of the pump

There is no product; The pump sucks air;

Add product; Open the exhausting valve. For the version on air hoist, follow the instructions in the relevant manual; Increase the feeding air pressure; Disassemble the suction valve. Clean and/or replace if necessary the worn parts; Disassemble the outlet valve. Clean and/or replace if necessary the worn parts;

Feeding air is not enough; Suction valve worn or partially clogged;

Outlet valve worn or partially clogged;

The pump works, but the product is not flowing enough

Suction valve worn or partially clogged; Outlet product line clogged;

Disassemble the suction valve. Clean and/or replace the worn parts; Clean. Disconnect the outlet product pipe. Feed pump at minimum pressure and check if delivery increases without the outlet pipe; Increase air pressure;

The feed air pressure is too low;

Leakage of product from the lubricating cup

Upper gaskets worn.

Tighten the packing nut. In case of persistent waste of product, replace the upper gaskets of the pumping unit.

Always close the compressed air supply and release the pressure in the plant before performing any check or replacement of parts of the pump.

SUPER NOVA 45:1/68:1/80:1

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O DISASSEMBLY OF THE PNEUMATIC MOTOR

Always close the compressed air supply and release the pressure in the plant before disassembling the pneumatic motor of the pump. Unscrew the coupling sleeve so as to disconnect the pumping group from the motor. Disconnect the air feeding pipe to the pump. Unscrew the fitting (O1) and the sleeve (O2). Turn counterclockwise the screws (O3) [take care to the washers (O4)] and remove the covering (O5). Unscrew the two ring nuts (06) from the support (07). Turn counterclockwise the screws (O8) [take care to the washers (O9)] and remove the support (O7) together with the rollers (O10) and the pins (O11). Extract the spring (O12), the spring guide rod (O13) and the roller pushing piston (O14). Ensure the spring slides freely on the guide rod, the guide rod slides into the roller pushing piston and this last slides into the mount hole. Check the roller (O10) and the pin (O11) are undamaged. Replace them if damaged. Remove and check the rubber pad (O15) and the washer (O16).
O1 O2 O3 O4 O5

Coupling sleeve

O8 O9 O7 O14 O13 O12 O6 O6 O12 O13 O14 O10 O15 O10 O11 O11

O16

10

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Pull upwards the seat (O17) so as to take out the valves (O18) and the springs (O19) (clean and/or replace the worn parts). Unscrew the lock nut (O20) [take care of the washer (O21)] by keeping the bush (O22) blocked using a wrench. Remove the seat (O17) from the rod (O23). Unscrew the bush (O22) (if necessary, keep the rod (O23) blocked on the threaded part using pliers with the bits wrapped in rags to avoid damage to thread).
O18 O19 O17 O19 O18 O20 O21 O17

O22

O23

Remove the screws (O24) [take care to the washers (O25)], a manifold (O26) and the gasket (O27). Handle with care the manifold. The edges of its plate are very sharp. Important: do not remove the other manifold if not necessary (it will facilitate the fastening of the manifold removed).

O28 O29

Using a screwdriver, remove the washer (O28) and the rubber pad (O29).

O24 O25

O26

O27

11

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Turn counterclockwise the rod guiding screw (O30) [take care to the washer (O31)] and check the seal inside the screw (O30) is undamaged. Take out the screws (O32) [take care of the washers (O33)] and remove carefully the cylinder (O34) (do not bend it during extraction in order to avoid that motor piston may damage the internal surface of the cylinder).

O32

O30

O33 O34

O31

Extract the motor piston from the motor support (O35). Verify the O-ring (O36) is undamaged. Tighten the lower edge of the piston rod using pliers (see illustration) and unscrew the fitting (O37) with a wrench. Remove the motor rod (O38) and check it is undamaged. Rub the motor rod (O38) with vaseline grease before inserting it into the housing of the piston rod. Tighten again with pliers the lower edge of the piston rod and screw the fitting (O37) (application of a sealant on the thread is advisable). Warning: tighten here
O36

O38

O35

O37

12

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Check the gas ring inside the support (O39) is undamaged. Check the gasket (O40) is undamaged and correctly positioned. Coat the inner walls of the cylinder (O41) with a thin layer of vaseline grease. Insert the motor piston (O42) into the cylinder (O41) carefully. Fasten the cylinder (O41) on the support (N39) (respect the position) and at the same time insert the piston rod into the support. Turn clockwise the screws (O43).

O43

O41

Check gas ring

O40

O42

O39

Insert into the motor rod (O44) the washer (O45). Carefully insert the rod guiding screw (O46) into the motor rod (turn it slowly following the direction of the thread) and screw it on the cylinder (O41). Insert the rubber pad (O47) and the washer (O48) into the support. Screw the bush (O49) on the motor rod (O44). Insert the seat (O50), the washer (O51) and screw the lock nut (O52).

O52

O51

O50

Adjust bush and lock nut so as the rod (O44) just out of about 1 mm from the lock nut (see illustration).
O48 O47 O46 O45 O44
1 mm

O49

O44

13

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Insert the springs (O54) and the valves (O55) into the seat (O53). Position the seat on the pump support and lay the manifold (O56) on the seat [do not forget the gasket (O57)]. Fasten the manifold with screws (do not tighten) ensuring it is perfectly parallel to the other manifold and the distance between them is 46 mm (see illustration). The distance between the walls of the manifold and the edge of the seat must be about 0,8 mm.

46 mm 0,8 mm 0,8 mm

O53 O56

O54

O55

O56

O57

O68 O53 O67

Rub the rollers (O58) and the pins (O59) with vaseline grease and insert them into the mount (O60). Rub the rubber pad (O61) and the washer (O62) with vaseline grease and insert them into the mount (O60). Grease the roller pushing pistons (O63), the spring guide rods (O64), the springs (O65) and insert them into the mount (O60). Fasten without tightening the ring nuts (O66) on the mount (O60). Fasten the mount on the manifolds and tighten the screws (O68) [do not forget of washer (O67)]. Tighten the ring nuts (O66) and the screws (O69). Assemble again the covering and all the fittings of the air supply line.

O66

O69

O60

O66 O65 O64 O63 O58 O61 O62 O59

14

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P DISASSEMBLY OF THE PUMPING GROUP

GASKETS REPLACEMENT
Always close the compressed air supply and release the pressure in the plant before disassembling the pumping group. If the product being used is toxic, it is suggested to follow the cleaning procedure on page 7 to avoid the contact with the product during the disassembling of the pumping unit. Disconnect the suction hose (P1), the product exhausting tube (P2) and the recirculation hose (P3) from the pumping unit.
P2

P3

P1

Unscrew the coupling sleeve (P4) so as to disconnect the pumping group rod (P5) from the motor.

P5

P4 P5

15

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Loosen the packing gland (P6) without removing it, by means of the suitable clamping wrench (P7).

P7

Wrench Ref. 20144

P6

Unscrew and remove the gaskets stuffing pack (P8) by means of a the suitable clamping wrench (P9).

P8

P8

P9

P8

16

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Remove the packing gland (P10) to reach the upper sealing gaskets (P11).

P10

P11

Closed gaskets pack

Insert the new gaskets pack (P12) in the slot (P13).

ATTENTION!

FOLLOW THE GASKETS ASSEMBLY AS DESCRIBED.

P12

P13

Open gasket pack

CORRECT ASSEMBLY upper gaskets pack

17

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Unscrew and remove the foot valve (P14).

P14

Remove the stem (P15) and the sleeve (P16) from the pumping unit, and extract the sleeve (P16) from the stem (P15).
P16 P15

P16 P15

P16 P15

18

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Unscrew and remove the gaskets stuffing pack (P17) to loose the worn lower sealing gaskets (P18).

P17

P18

P18

Insert the new gaskets pack (P19) as shown.

P19

Assembly according to the following picture.

ATTENTION!

FOLLOW THE GASKETS ASSEMBLY AS DESCRIBED.

CORRECT ASSEMBLY upper gaskets pack

19

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Q FILTER GROUP
WARNING: always indicate code and quantity for each part required. 0
13

2 14

4 7

11

10

9 15 8 12

20

SUPER NOVA 45:1/68:1/80:1

English FILTER GROUP for SUPER NOVA 45:1 - SUPER NOVA 68:1 - SUPER NOVA 80:1
Pos. 0 0 1 1 2 3 4 5 5 6 Code 65021 65022 65180 65080 95218 65078 65095 65177 65077 95214 Description Complete stainless steel filter Complete steel filter Stainless steel filter container Steel filter container Filter sieve Sieve support OR Stainless steel filter base Steel filter base Plug Pos. 7 8 9 9 10 11 11 12 13 Code 6149/1 33010 33037 33034 6148 65176 65076 3385 10107 Description Fitting Sealing washer Ball cock Ball cock Fitting Filter inlet fitting stainless steel Filter inlet fitting steel Fitting Label

LABELS for SUPER NOVA 45:1

Pos. 14 15 Code 95069 7176 Description Filter label Technical data label

LABELS for SUPER NOVA 68:1

Pos. 14 15 Code 95183 7178 Description Filter label Technical data label

LABELS for SUPER NOVA 80:1

Pos. 14 15 Code 65322 7174 Description Filter label Technical data label

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R STEM GROUP
WARNING: always indicate code and quantity for each part required.

1 2

LOWER SEALING GASKETS PACCO DI PACK TENUTA INFERIORE

11/C 4 3

11

11/B

11/A

7 8

9 10

NOTE
THE ORIENTATION OF THE LOWER SEALING GASKETS PACK IS OPPOSITE IN RESPECT TO THE UPPER SEALING GASKETS PACK.

11

12

CORRETTO CORRECT MONTAGGIO ASSEMBLY

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English SUPER NOVA 45:1 STEM GROUP
Pos. N. pcs. Code 1 1 2 1 3 1 4 1 5 1 6 1 7 inox 1 7 steel 1 65023 65024 65068 65067 65066 65065 65064 65063 65162 65062 Description Stainless steel complete stem Steel complete stem Fitting Fitting Coupling ring Coupling bush Pumping stem Pumping stem gasket Stainless sleel gaskets stuffing stem Sleel gaskets stuffing stem Pos. N. pcs. Code 8 9 10 11 11A 11B 11C 12 inox 12 steel 1 1 1 2 1 3 2 1 1 1 91010 95021 65161 65041 98209 95010 95138 98212 65144 65145 Description Pin UNI 6873 5x14 Ball 7/8" Gaskets stuffing nut Complete gaskets pack Gaskets stuffing female nut Gasket PTFE Gasket Polyethylene Gaskets stuffing male nut Stainless steel stem ass. ball housing Steel stem ass. ball housing

SUPER NOVA 68:1 STEM GROUP

Pos. N. pcs. Code 1 1 2 1 3 1 4 1 5 1 6 1 7 inox 1 7 steel 1 65026 65025 65068 65067 65066 65065 65264 65263 65362 65262 Description Stainless steel complete stem Steel complete stem Fitting Fitting Coupling ring Coupling bush Pumping stem Pumping stem gasket Stainless sleel gaskets stuffing stem Steel gaskets stuffing stem Pos. N. pcs. Code 8 9 10 11 11A 11B 11C 12 inox 12 steel 1 1 1 2 1 3 2 1 1 1 91010 91641 65361 65043 98213 95515 95516 98221 65146 65147 Description Pin UNI 6873 5x14 Ball 3/4" Gaskets stuffing nut Complete gaskets pack Gaskets stuffing female nut Gasket PTFE Gasket Polyethylene Gaskets stuffing male nut Stainless steel stem ass. ball housing Steel stem ass. ball housing

SUPER NOVA 80:1 STEM GROUP

Pos. N. pcs. Code 1 1 2 1 3 1 4 1 5 1 6 1 7 inox 1 7 steel 1 65028 65027 65068 65067 65066 65065 65464 65463 65562 65462 Description Stainless steel complete stem Steel complete stem Fitting Fitting Coupling ring Coupling bush Pumping stem Pumping stem gasket Stainless sleel gaskets stuffing stem Steel gaskets stuffing stem Pos. N. pcs. Code 8 9 10 11 11A 11B 11C 12 inox 12 steel 1 1 1 2 1 3 2 1 1 1 91010 16305 65561 65045 65049 65047/2 65047 65050 65148 65149 Description Pin UNI 6873 5x14 Ball 7/8" Gaskets stuffing nut Complete gaskets pack Gaskets stuffing female nut Gasket PTFE Gasket Polyethylene Gaskets stuffing male nut Stainless steel stem ass. ball housing Steel stem ass. ball housing

23

SUPER NOVA 45:1/68:1/80:1

English

S PUMPING GROUP
WARNING: always indicate code and quantity for each part required.

UPPER SEALING GASKETS PACK PACCO DI TENUTA

SUPERIORE
3/A

1 2 3 3/B 3 4 5 6 3/C 7

CORRETTO CORRECT MONTAGGIO

ASSEMBLY

PERNO DI CHIUSURA

WRENCH

14

10

5 11

NOTE
THE ORIENTATION OF THE UPPER SEALING GASKETS PACK IS OPPOSITE IN RESPECT TO THE LOWER SEALING GASKETS PACK.

12

13

24

SUPER NOVA 45:1/68:1/80:1

English SUPER NOVA 45:1 PUMPING GROUP
Pos. N. pcs. Code 1 3 2 1 3 2 3A 1 3B 3 2 3C 1 4 inox 1 4 steel 1 5 2 65029 65030 65072 65069 65041 98209 95010 95138 98212 65170 65070 65091 Description Stainless steel pumping group Steel pumping group Tie rod Packing gland Complete gasket pack Gaskets stuffing female nut Gasket PTFE Gasket Polyethylene Gaskets stuffing male nut Stainless steel packing gland Steel packing gland OR 162 Pos. N. pcs. Code 6 7 8 9 inox 9 steel 10 11 inox 11 steel 12 13 14 1 1 1 1 1 1 1 1 1 1 1 65094 65093 95013 65171 65071 65092 65158 65058 65090 68090 20144 Description Locking ring Clamping plate Self-locking nut M16 Stainless steel main body Steel main body Anello controdado Stainless steel pumping unit body Steel pumping unit body Pumping sleeve gasket Pumping sleeve Wrench

SUPER NOVA 68:1 PUMPING GROUP

Pos. N. pcs. Code 1 3 2 1 3 2 3A 1 3B 3 2 3C 1 4 inox 1 4 steel 1 5 2 65034 65033 65072 65269 65043 98213 95515 95516 98221 65370 65270 65091 Description Stainless steel pumping group Steel pumping group Tie rod Packing gland Complete gasket pack Gaskets stuffing female nut Gasket PTFE Gasket Polyethylene Gaskets stuffing male nut Stainless steel packing gland Steel packing gland OR 162 Pos. N. pcs. Code 6 7 8 9 inox 9 steel 10 11 inox 11 steel 12 13 14 1 1 1 1 1 1 1 1 1 1 1 65094 65093 95013 65171 65071 65092 65158 65058 65090 68091 20144 Description Locking ring Clamping plate Self-locking nut M16 Stainless steel main body Steel main body Anello controdado Stainless steel pumping unit body Steel pumping unit body Pumping sleeve gasket Pumping sleeve Wrench

SUPER NOVA 80:1 PUMPING GROUP

Pos. N. pcs. 1 3 2 1 3 2 3A 1 3B 3 2 3C 1 4 inox 1 4 steel 1 5 2 Code 65036 65035 65072 65469 65045 65049 65047/2 65047 65050 65570 65470 65091 Description Stainless steel pumping group Steel pumping group Tie rod Packing gland Complete gasket pack Gaskets stuffing female nut Gasket PTFE Gasket Polyethylene Gaskets stuffing male nut Stainless steel packing gland Steel packing gland OR 162 Pos. N. pcs. 6 1 7 1 8 1 9 inox 1 9 steel 1 10 1 11 inox 1 11 steel 1 12 1 13 1 14 1 Code 65094 65093 95013 65171 65071 65092 65158 65058 65090 65458 20144 Description Locking ring Clamping plate Self-locking nut M16 Stainless steel main body Steel main body Anello controdado Stainless steel pumping unit body Steel pumping unit body Pumping sleeve gasket Pumping sleeve Wrench

25

SUPER NOVA 45:1/68:1/80:1

English

T FOOT VALVE BODY

WARNING: always indicate code and quantity for each part required.

6 7

11

10

26

SUPER NOVA 45:1/68:1/80:1

English FOOT VALVE GROUP SUPER NOVA 45:1/ 68:1 /80:1
Pos. 0 0 1 2 3 4 5 6 Code 65031 65032 65174 65074 65155 65154 95027 65142 Description Stainless steel complete foot valve group Steel complete foot valve group OR 4300 OR 4237 Spacer Ball guide Ball 1" 1/4 Ball housing assembly Pos. 7 8 8 9 9 10 10 11 Code 65271 65140 65141 65183 20833 98232 95032 96099 Description Ball housing gasket Stainless steel compl. foot valve body ass. Steel compl. foot valve body ass.o Elbow F-F 1" - 1" 1/2 Stainless steel Elbow F-F 1" - 1" 1/2 Steel Stainless steel suction hose fitting Steel suction hose fitting Sealing sleeve

U COMPLETE PUMPING GROUP

WARNING: always indicate code and quantity for each part required.

SUPER NOVA 45:1

Code

Description Stainless steel complete pumping group Steel complete pumping group Steel complete gasket pack Stainless steel complete gasket pack

65001 65002 65120 68120

SUPER NOVA 68:1

Code

Description Stainless steel complete pumping group Steel complete pumping group Steel complete gasket pack Stainless steel complete gasket pack

65004 65003 65121 68121

SUPER NOVA 80:1

Code Description Stainless steel complete pumping group Steel complete pumping group Steel complete gasket pack Stainless steel complete gasket pack 65006 65005 65122 68122

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SUPER NOVA 45:1/68:1/80:1

English

V COMPLETE AIR GROUP

13 11 10 2 5 6

5 2 7

12

Pos. 1 2 3 4 5 6 7

Code 95145 95031 95090 95301 95302 95308 95309 95313

Description Complete air treatment group Elbow M.F. 1" -MF92 Adapter 3/4 (NGE 3/4) Quick coupling C/for rubber hose skg 25 Quick coupling 1"male Femal fitting (FB 3/4X19) Hose tor/20NL 71N 19x29 Reduction 1" -3/4" MF

Pos. 8 9 10 11 12 13

Code 95318 95319 95323 95350 96259 95089

Description Quick coupling 8x17 Quick coupling m. 1/4" Valvea 1" Group F.R.L. Manometer Elbow F-F 3/4"

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SUPER NOVA 45:1/68:1/80:1

English

W COMPLETE HANDTRUCK COD. 65380

3 1 8

5 6 7 8

Pos. 0 1 2 3 4

Code 65380 65380 20304 18902 65382

Description Complete handtruck Handtruck Plug Split pin Handle

Pos. 5 6 7 8

Code 4461 4492 8371 18914 Wheel Cover Screw Bushing

Description

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SUPER NOVA 45:1/68:1/80:1

English

X MOTOR GROUP
WARNING: always indicate code and quantity for each part required.
1 2 3 40 41 6 50 34 51 34 4 5 10 11 12 13

35 36 37 42 43 44 28 27 38 29 30

7 14 15 16 17

8 9
23 24 25 26 27 28 33 32

45

46A 46B

26 25 24 18 15 14 19 20 21 22 39

31 29

30

46 47 48 49 52 54 53

30

SUPER NOVA 45:1/68:1/80:1

English
Pos. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20* 21* 22* 23 24 25* 26 27 28 Code 95062 95063 95064 95065 95066 95061 95109 95092 95091 95084 95085 95086 95087 95093 95094 95095 95096 95098 95078 95079 95080 33031 95097 95077 95075 95076 95073 95071 Screw Washer Cover Screw Washer Eyebolt Support Roller Pin Roller piston Spring guide Spring Ring nut Schock absorber Washer Lock nut Washer Bush Rod guide screw Leather ring Sealing gasket Copper washer Valve housing Spring O-ring Travese reverse valve Manifold plate Plate gasket Description Pos. 29 30* 31 32 33 34 35 36 37 38 39 40* 41 42 43 44 45 46 46A* 46B* 47 48 49 50 51 52 53 54 Code 95070 95072 95096 95068 95067 95090 95089 95088 95099 95074 95100 95101 95102 95103 95104 95105 95106 95107 3314 95082 95114 95083 95159 510040 95944 95002 95013 95229 Manifold Manifold gasket Washer Screw Plug 3/4" GAS conical Fitting Elbow 3/4" GAS Extention Gas ring Screw Motor cylinder O-ring Motor piston Motor rod Fitting Gasket O-ring Complete motor support Gas ring leather ring Washer Screw Plug Plug Sleeve 3/4" GAS Tie rod Nut Plug Description

*Motor gasket kit for pump NOVA Rif. 40065

31

SUPER NOVA 45:1/68:1/80:1

English

Y ACCESSORIES

Code 11250: AT 250 1/4" Code 11200: AT 250 M16x1,5

Code 11000: AT 300 1/4" Code 11090: AT 300 M16x1,5

Code 11180: L91X 1/4" Code 11120: L91X M16x1,5

PISTON GUNSTOCK FILTERS Code 11039: Green (30M) Code 11038: White (60M) Code 11037: Yellow (100M) Code 11019: Red (200M)

FILTER Code 95218: MESH 30M Code 95219: MESH 60M Code 95220: MESH 100M Code 95221: MESH 200M

Code 65021: LINE FILTER st. steel Code 65022: LINE FILTER steel

FITTING WITH MANOMETER Code 147: M16x1,5 Code 150: 1/4"

Code 91044: PNEUMATIC MIXER

Code 7030: HIGH PRES. FLOW REGULATOR

Code 6099: PREHEATER

32

SUPER NOVA 45:1/68:1/80:1

English
NOZZLES CODES
SFC07-20 SFC07-40 SFC09-20 SFC09-40 SFC11-20 SFC11-40 SFC13-20 SFC13-40 SFC13-60 SFC15-20 SFC15-40 SFC15-60 SFC17-20 SFC17-40 SFC17-60 SFC19-20 SFC19-40 SFC19-60 SFC21-20 SFC21-40 SFC21-60 SFC23-20 SFC23-40 SFC23-60 SFC25-20 SFC25-40 SFC25-60 SFC27-20 SFC27-40 SFC27-60 SFC27-80 SFC29-20 SFC29-40 SFC29-60 SFC29-80 SFC31-40 SFC31-60 SFC31-80 SFC33-40 SFC33-60 SFC33-80 SFC39-40 SFC39-60 SFC39-80 SFC43-40 SFC43-60 SFC43-80 SFC51-40 SFC51-60 SFC51-80

SUPER FAST-CLEAN

SUPER FAST-CLEAN NOZZLE

Code 18280: GASKET Code18270: SUPER FAST-CLEAN base UE 11/16x16

EXTENTION Code 153: cm 30 Code 154: cm 40 Code 155: cm 60 Code 156: cm 100

HIGH PRESSURE HOSE 3/8" - M16x1,5 for SUPER NOVA 45:1 and SUPER NOVA 68:1 Code 18063: 7,5 mt Code 18064: 10 mt Code 18065: 15 mt HIGH PRESSURE HOSE 1/4" w/fitting 1/4" for SUPER NOVA 80:1 Code 18068: 10 mt

Code 95055: SUCTION SYSTEM Code 98055: SUCTION SYSTEM stainless steel

33

SUPER NOVA 45:1/68:1/80:1

English

Z ATEX CERTIFICATE
DESCRIPTION
These safety instructions refer to the installation, use and maintenance of LARIUS SUPER NOVA series pneumatic piston transfer pumps in high risk environments where potentially explosive gasses or vapours are present.

These instructions, along with the indications provided in the user and maintenance manual, must be fully respected. LARIUS SUPER NOVA series pneumatic piston pumps are group II mechanical devices for use in areas where gasses classified as IIb (category 2 G) are present. They are designed and built in accordance with the 94/9/EC ATEX directive, based on the following European standards: EN 1127-1, EN 13463-1 and EN 13463-5.

TECHNICAL CHARACTERISTICS
The main characteristics of the SUPER NOVA series pneumatic piston pumps are provided in the table below:
Ratio Feeding pressure Air Inlet material Inlet Material output Max operating pressure Max Delivery

45:1 68:1 80:1

3 7 bar 3 7 bar 3 7 bar

CG 3/4" CG 3/4" CG 3/4"

Ball valve Ball valve Ball valve

CG 1. 1/2" CG 3/4" CG 3/4"

270 bar 476 bar 560 bar

14 l/min 11 l/min 8,5 l/min

Room temperature: -20C +60C Fluid max. temperature: 60C Max nr. cycles /minute: 60

MARKING
3
X

II 2 G c IIB T6 II = 2= G= c= T6 = - 20C + 60C 60C xxxx/AA

Tamb: -20C + 60C

Tmax. fluid: 60C

Tech. File: NOVA/ATX/08

Group II (surfaces) Category 2 (zone 1) Explosive atmosphere containing gas, vapours or mists Design safety c Temperature class T6 Room temperature Maximum process fluid temperature Serial number or lot number (xxxxx=PROGRESSIVE/Year = AA)

Correspondence between hazardous areas, substances and categories HAZARDOUS AREAS HAZARDOUS AREA Gas, vapours or mists Gas, vapours or mists Gas, vapours or mists Area 0 Area 1 Area 2 CATEGORIES ACCORDING TO 94/9/CE DIRECTIVE 1G 2G or 1G 3G, 2G or 1G

34

SUPER NOVA 45:1/68:1/80:1

English SAFETY INSTRUCTIONS FOR INSTALLATION IN HAZARDOUS AREA
Read the indications provided in the user and maintenance manual carefully prior to installation. All of the maintenance operations must be performed according to the indications provided in the manual. The grounding wire for the pumps indicated above must be grounded using an appropriate anti-loosening connection. The tubes used to connect the delivery and suction lines must be either metallic, plastic with metallic braid, or plastic with fabric braid and a suitable grounding conductor. The pumps must be installed on properly grounded metallic or antistatic drums. The gases or vapours of any flammable liquids present must belong to group IIB. Based on the type of use and the substances employed, the user must periodically check for any encrustations and must verify the cleanliness, the wear status and the correct functionality of the pump on a regular basis. The user must periodically clean the suction filter in order to prevent any solid materials from entering the pump.The air used to power the pump must be filtered and must come from a SAFE AREA.

EXAMPLE OF DECLARATION OF CONFORMITY

We

Larius S.r.l. Via Antonio Stoppani, 21 23801 Calolziocorte (LC)

declare under our sole responsability that the product: NOVA series pneumatic piston transfer pumps to which this declaration relates complies with the following directives: - Directive 94/9/EC (ATEX)

Compliance has been verified according to the following standards requirements or standards documents: - EN 1127-1 - EN 13463-1 - EN 13463-5

SUPER NOVA series pneumatic piston transfer pump cannot work idle. All of the installation and maintenance operations must be performed by qualified personnel.

Markings II 2 G c IIB T6 Tenv.: - 20C 60C Tmax. fluid: 60C Tech. File: NOVA/ATX/08 Technical dossier kept on file by: INERIS (0080)

EXAMPLE OF INSTALLATION

Calolziocorte- LC Signature (LARIUS)

The picture shows a typical example of the installation of LARIUS pneumatic piston transfer pumps.

35

AIRLESS PNEUMATIC PUMPS

VEGA AIRLESS Rif. 91500 VEGA MISTLESS Rif. 91400

OMEGA AIRLESS Rif. 7300 OMEGA MISTLESS Rif. 7340

NOVA 45:1 Rif. 95000 NOVA 60:1 Rif. 95040 NOVA 68:1 Rif. 95191

GHIBLI 30:1 Rif. 96000

Manufacturer:

23801 CALOLZIOCORTE - LECCO - ITALY - Via Antonio Stoppani, 21 Tel. (39) 0341/62.11.52 - Fax (39) 0341/62.12.43 E-mail: larius@larius.com - Internet http://www.larius.com
DIRECT LINE

CUSTOMERS TECHNICAL SERVICE

Tel. (39) 0341/621256 Fax (39) 0341/621234

OMEGA ZINC Rif. 7430

GHIBLI ZINC Rif. 96900

GHIBLI MIX 2K 40:1 INOX: Rif. 24561