Larius ZEFIRO Operating manual

PAINTING EQUIPMENT
OPERATING AND MAINTENANCE INSTRUCTION
ENGLISH
OPERATING AND MAINTENANCE INSTRUCTION
Ed. 001 05 - 11

1
ZEFIRO
English
INTRODUCTION ...........................................................p.1
WARNINGS ........................................................p.2
WORKING PRINCIPLE ........................................ p.3
TECHNICAL DATA ................................................ p.4
DESCRIPTION OF THE EQUIPMENT ................. p.5
Control panel with alarm display ...................... p.7
TRANSPORT AND UNPACKING ......................... p.8
SAFETY RULES ................................................... p.8
Electrical safety precautions ............................ p.9
SETTING-UP ........................................................ p.9
Connection of the flexible hose to the gan ....... p.9
Check on power supply .................................... p.10
Connection of the tooling to the power supply . p.11
Washing of the new equipment ........................ p.11
Preparation of the paint ................................... p.14
WORKING ............................................................ p.14
Start of the painting operations ........................ p.14
Spray adjustment ............................................. p.15
CLEANING AT THE END OF THE WORK ........... p.15
ROUTINE MAINTENANCE .................................. p.18
Check on the packing nut ..................................... p.18
PROBLEMS AND SOLUTIONS ........................... p.19
CORRECT PROCEDURE OF
DECOMPRESSION .............................................. p.20
REPLACEMENT OF THE PUMPING
GROUP'S GASKETS ........................................... p.21
WARNING PLATE ................................................ p.21
CLEANING AND/OR REPLACEMENT OF
THE PRESSURE TRANSMITTER ....................... p.22
Check on the pressure transmitter ................... p.22
SPARE PARTS
COMPLETE PRESSURE CONTROL DEVICE
REF. 16350 .......................................................... p.24
COMPLETE PUMPING REF. 16100 ..................... p.26
FILTER GROUP ................................................... p.28
RECIRCULATING-SAFETY VALVE
GROUP REF. 16400 ............................................. p.29
DRIVE ASSEMBLY ............................................... p.30
ELECTRIC MOTOR .............................................. p.32
COMPLETE FRAME ............................................ p.33
ACCESSORIES .................................................... p.34
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.
ELECTRIC PISTON PUMP
ELECTRIC PISTON PUMP
A
B
C
D
E
F
G
H
L
M
N
O
P
Q
R
S
T
U
V
W
Z
I

2
ZEFIRO
English
Read this operator’s manual carefully before using the equipment.
An improper use of this machine can cause injuries to people or things.
Do not use this machine when under the influence of drugs or alcohol.
Do not modify the equipment under any circumstances.
Use products and solvents that are compatible with the various parts of the equipment, and read the manufacturer’s warnings care-
fully.
See the Technical Details for the equipment given in the Manual.
Check the equipment for worn parts once a day. If any worn parts are found, replace them using ONLY original spare parts.
Keep children and animals away from work area.
Comply with all safety standards.
It indicates an accident risk or serious damage to equipment if this warning is not followed.
It indicates important recommendations about disposal and recycling process of products in accordance with the environmental
regulations.
WARNINGS The table below provides the meaning of the symbols used in this manual in relation to using, earthing,
operating, maintaining, and repairing of this equipment.
It indicates a fire or explosion risk if this warning is not followed.
Eliminate all ignition sources such as pilot lights, cigarettes, portable electric lamps and plastic drop cloths.
Keep work area free of debris.
ONLY use this equipment in a well ventilated area.
EARTH ALL THE EQUIPMENT LOCATED IN THE WORK AREA.
Do not form connections or switch light switches on or off if the air contains inflammable fumes.
If electrical shocks or discharges are encountered the operation being carried out using the equipment must be stopped immedia-
tely.
Keep a fire extinguisher at hand in the immediate vicinity of the work area.
It indicates wound and finger squashing risk due to movable parts in the equipment.
Tenersi lontano dalle parti in movimento.
Do not use the equipment without the proper protection.
Before any inspection or maintenance of the equipment, carry out the decompression procedure explained in this manual, and prevent
any risk of the equipment starting unexpectedly.
Report any risk of chemical reaction or explosion if this warning has not been given.
There is a risk of injury or serious lesion related to contact with the jet from the spray gun. If this should occur, IMMEDIATELY contact
a doctor, indicating the type of product injected.
Do not spray before the guard has been placed over the nozzle and the trigger on the spray gun.
Do not put your fingers in the spray gun nozzle.
Once work has been completed, before carrying out any maintenance, complete the decompression procedure explained in this
manual.
Report any danger of electric shock if the warning and presence of live electrical parts has not been indicated.
Store in a dry place and do not expose to the rain.
Check that the cables are in good condition.
Switch off the equipment and discharge any electricity before cleaning or maintaining the equipment.
Mark any clamps attached to earth cables.
Use ONLY 3-wire extension cords and grounded electrical outlets.
Before starting work make sure that the electrical system is earthed and that it complies with safety standards.
It is obligatory to wear suitable clothing as gloves, goggles and face shield.
Wear clothing that complies with the safety standards in force in the country in which the equipment is used.
Do not wear bracelets, earrings, rings, chains, or anything else that may hinder the operator’s work.
Do not wear clothing with wide sleeves, scarves, ties, or any other piece of clothing that could get tangled up in moving parts of the
equipment during the work, inspection, or maintenance cycles.

3
ZEFIRO
English
A
WORKING PRINCIPLE
The LARIUS ZEFIRO unit is defined “electric piston pump”.
An electric piston pump is used for high pressure painting without
air (from this process derives the term ”airless”).
The pump is controlled by an electric motor coupled with a
reduction gear.
A cam shaft and a connecting rod allow to obtain the reciprocating
motion necessary to the working of the “pumping group” piston.
The piston movement produces a “vacuum”.
The product is sucked, pushed towards the pump outlet and then
sent to the gun through the flexible hose.
An electronic device located next to the reduction box, is used
to regulate and control the pressure of the material leaving the
pump. When the pump reaches the set value, the motor stops and
starts again when the value decreases.
A safety valve avoiding overpressure, guarantees the total reliability
of the equipment.
Indoor
Outdoor
Industrial buildings
Industrial constructions
Redeveloping
Roofing
Fields of application
Lacquer
Waterborne
Acrylic
Enamels
Fixative
Applications materials
Paints
Emulsions
Fillers
Primer

4
ZEFIRO
English
*Available on request with special voltages
PARTS OF THE PUMP IN CONTACT WITH THE MATERIAL Stainless Steel AISI 420B, Teflon; Aluminium
ZEFIRO
SUPPLY (single-phase)*
SUPPLY WITH RUN GENERATOR
MOTOR POWER
MAX. WORKING PRESSURE
MAX. DELIVERY
MATERIAL OUTLET
WEIGHT
LEVEL OF THE SOUND PRESSURE
LENGTH
WIDTH
TOTAL HEIGHT
230Vac 50H
minimum 4Kw asynchronous
1,1 kW
210 bar
2,5 L/min
M16 x 1,5 (M)
20 Kg
≥80dB(A)
(A) 620 mm
(B) 560 mm
(C) 995 mm
B
TECHNICAL DATA
C
A
B

5
ZEFIRO
English
C
POS.
1
2
3
DESCRIPTION OF THE EQUIPMENT
ON/OFF switch
Pressure control knob
Reduction casting
Description POS.
4
5
6
Pumping group
High pressure flexible hose of compensation
Suction filter
Description
6
1
3
4
3 2
54
2
1
5

6
ZEFIRO
English
POS.
7
8
9
10
Recirculation tube
Recirculating-safety valve
Filter unit
Airless manual gun
Description POS.
11
12
13
Trigger safety clamp
Product flexible pipe connection
Electronic control panel
Description
13
9
1312
8
9
1011
8
12
7

7
ZEFIRO
English
PAINT SPRAYING EQUIPMENT
SW HEAD CONTROL
ON
OFF
1
6
5
4
3
2
CORRENTE MASSIMA SUPERATA - MAXIMUM CURRENT EXCEEDED
MAX STROM UBERSCHRITTEN - MAXIMUM COURANT DÉPASSÉ
MANCANZA CONNESSIONE A TERRA - NO EARTHING
KEINE ERDUNG - PAS DE MISE À TERRE
TENSIONE DI ALIMENTAZIONE BASSA -
LOW VOLTAGE FEEDING CURRENT
NIEDRIGE VERSORGUNGSSPANNUNG - TENSION D'ALIMENTATION A L'ENTRÉE TROP FAIBLE
TENSIONE DI ALIMENTAZIONE ALTA - HIGH VOLTAGE FEEDING CURRENT
HOHE VERSORGUNGSSPANNUNG - TENSION D'ALIMENTATION A L'ENTRÉE TROP ÉLEVÉE
SURRISCALDAMENTO MOTORE - OVERHEATING MOTOR
UBERHITZUNG MOTOR - SURCHAUFFAGE MOTOR
SURRISCALDAMENTO HEAD CONTROL -
OVERHEATING HEAD CONTROL
UBERHITZUNG HEAD CONTROL - SURCHAUFFAGE HEAD CONTROL
LED ALLARMI-ALARMS-WARNMELDUNGEN-ALARME
www.larius.com
ITALY
CONTROL PANEL WITH ALARM DISPLAY
This machine has a control panel (C1) that uses LED signals
(C2) to display any alarms that are activated while the machine
is operating .
The type of alarm is indicated by the number of
times the LED flashes.
To determine the type of alarm see the instructions
on the sticker (C3).
®
C3
C1
C2

8
ZEFIRO
English
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.
• 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 equi-
pment. 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 user is responsible for the operations of unloa-
ding 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 disposal of packaging materials is a customer’s
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 packa-
ging materials in an environment-friendly manner
as much as possible.
• 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.
Read carefully and entirely the following instruc-
tions 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, expendable materials other than
those recommended by the manufacturer can be
a danger of accident.
The manufacturer will be relieved from tort and
criminal 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 PRO-
PERLY.
• 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 MEDI-
CAL 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. RE-
PLACE THE PARTS DAMAGED OR WORN.
ESAFETY 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.

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ZEFIRO
English
FSETTING-UP
CONNECTION OF THE FLEXIBLE HOSE TO THE GUN
• Connect the high pressure flexible hose (F1) to the pump
(F2) and to the gun (F3) , ensuring to tighten the fittings (the
use of two wrenches is suggested) .
NEVER use sealants on fittings’ threads .
It is ADVISED to mount a high pressure manometer at the
pump outlet (see on page “Accessories”) to read the product
pressure .
• It is recommended to use the hose provided with the standard
kit (ref. 18036).
NEVER use a damaged or a repaired flexible hose.
• TIGHTEN AND CHECK ALL THE FITTINGS FOR CONNEC-
TION 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
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.
• NEVER SPRAY OVER FLAMMABLE PRODUCTS OR
SOLVENTS IN CLOSED PLACES.
• NEVER USE THE TOOLING IN PRESENCE OF POTEN-
TIALLY EXPLOSIVE GAS.
The high speed of travel of the product 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.
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 sol-
vents 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.
IF THE PRODUCT TO BE USED IS TOXIC, AVOID
INHALATION AND CONTACT BY USING PROTEC-
TION GLOVES, GOGGLES AND PROPER FACE
SHIELDS.
TAKE PROPER SAFETY MEASURES FOR THE
PROTECTION OF HEARING IN CASE OF WORK
NEAR THE PLANT.
Electrical safety precautions
• Check the switch is on the "OFF" position before connecting
the cable to the mains.
• Never carry a plugged-in equipment.
• Disconnect the equipment before storing it and before
performing any maintenance operation or replacing of ac-
cessories.
• Do not carry the equipment neither unplug it by pulling the
electric cable.
• Protect the cable from heat, oil and sharp edges.
• When the tool is used outdoors, use only an extension cable
suited for outdoor use and so marked.
• Take care when the pumping rod is moving.
Stop the machine whenever someone is within its vicinity.
• Repairs of the electrical equipment should only be carried
out by skilled personnel, otherwise considerabledanger to
the user may result.
Never attempt to tamper with the calibre of
instruments.

10
ZEFIRO
English
ZEFIRO
MADE IN ITALY WWW.LARIUS.COM
Code Serial
number
Year
PRESSIONE MASSIMA 230 bar
MAX PRESSURE 3335 PSI
16910 3073
230Vac 50Hz 1.8Kw
115Vac 50Hz 1.8Kw
CHECK ON POWER SUPPLY
• Check the mains voltage corresponds to the equipment’s
rating.
Make sure that the electrical system is earthed and
complies with regulations.
Voltage
F1
F2
F3

11
ZEFIRO
English
CONNECTION OF THE TOOLING TO THE POWER SUPPLY
• Check the switch (F4) is on the "OFF" (0) position before
connecting the cable to the mains.
• The supply cable is provided without plug.
Use a plug which guarantees the plant earthing.
Only a technician or a skilled person should perform the
connection of the plug to the electric cable.
Should anyone use an extension cable between
the tooling and the socket, it must have the same
characteristics as the cable supplied (minimum
diameter of the wire 2,5 mm2) with a maximum
length of 50 mt. Higher lengths and lower diameters
can provoke excessive voltage falls and also an
anomalous working of the equipment.
• Place the pressure control knob (F5) on the “MIN” position
(turn counterclockwise).
WASHING OF THE NEW EQUIPMENT
• The equipment has already been adjusted at our factory with
light mineral oil left inside the pumping group as protection.
Therefore, wash with diluent before sucking the product.
F4
OFF
F5

12
ZEFIRO
English
• Lift the suction pipe and dip it into the solvent tank.
• Connect the clamp to an earthing point.
• Ensure the gun is without nozzle (F3).
• Press the switch (F4) of the equipment ON (I).
• Turn clockwise the pressure control knob (F5) so as the
machine works at idle speed.
F3
F4
ON
F5

13
ZEFIRO
English
• Now the machine is ready. Should you use water paints,
besides the solvent wash, a wash with soapy and then clean
water is suggested.
• Insert the gun trigger lock and assemble the nozzle.
• Remove the suction pipe (F8) and take away the solvent tank
(F9).
• Point the gun at the solvent tank and press the trigger so as
to recover the residual solvent.
• As the pump idles, press the OFF (0) switch to stop the tooling
(F4).
Absolutely avoid to spray solvents indoors. In
addition, it is recommended to keep away from
the pump in order to avoid the contact between
the solvent fumes and the electric motor.
• Point the gun (F6) at a container (F7) keeping the trigger
pressed (so as to drain the oil inside) till a clean solvent
comes out. Now, release the trigger.
F7
F6
F4
OFF
F8 F9

14
ZEFIRO
English
GWORKING
START OF THE PAINTING OPERATIONS
• Use the tooling after performing all the SETTING UP ope-
rations above described.
• Dip the suction pipe (G1) into the product tank.
• Open the safety- relief valve (G2) (turn clockwise so as the
pin slides on the cam track).
• Press the switch ON (I) of the equipment and turn a little the
pressure control knob (G3) clockwise, so as the machine
works at the idle speed.
PREPARATION OF THE PAINT
• Make sure the product is suitable to be used with a spray
gun.
• Mix and filter the product before using it. For filtration, use
CLOSE-MESH (ref. 214) and LARGE-MESH (ref.215) LA-
RIUS METEX braids.
Never use products containing halogen hydrocarbons (as methy-
lene chloride). If these products come into contact with aluminium
parts of the equipment, can provoke dangerous chemical reactions
with risk of explosion.
Make sure the product to be used is compatible with the
materials employed for manufacturing the equipment
(stainless steel and aluminium). Because of that, please
contact the supplier of the product .
Delivery pipe connection
G2
G3
ON
G1

15
ZEFIRO
English
• Close the recirculation - safety valve (G2) (turn clockwise the
knob to close the valve).
• Make sure the product recycles from the return tube (G4).
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.
The drain valve is a safety valve too. When working
at the maximum pressure available, releasing the
gun trigger sudden increases of pressure can occur.
In this case, the drain valve opens automatically
eliminating part of the product from the recirculating
tube. Then it closes so as to go back to the first
working conditions.
HCLEANING AT THE END
OF THE WORK
• Reduce pressure to the minimum (turn counterclockwise the
pressure control knob (H1)).
• Now the machine carries on sucking the product till the flexible
hose is full, up to the gun. Then it will stop automatically.
SPRAY ADJUSTMENT
• Slowly turn clockwise the pressure control knob to reach the
pressure value in order to ensure a good atomization of the
product.
• An irregular and marked spray on the sides indicates a low
working pressure. On the contrary, a too high pressure causes
a high fog (“overspray”) and waste of product.
• In order to avoid overthickness of paint, let the gun advance
sideways (right-left) when spraying.
• Always paint with regular parallel bands coats.
• Keep a safety and constant distance between the gun and the
support to be painted and also keep yourselves perpendicular
to it.
G4
G2

16
ZEFIRO
English
• Open the recirculation - safety valve (H3) to release the
pressure in the circuit.
• Press the switch (H2) placed on the box of the electric motor,
to stop the equipment.
• Lift the suction pipe and replace the product tank (H4) con
with that of the solvent (H5) (ensure it is compatible with the
product being used).
H2
H3
OFF
H1
Solvent tank
Product tank
H4
H5

17
ZEFIRO
English
• Unscrew the gun (H7) nozzle (H6) (do not forget to clean it
with solvent).
• Press the switch (H2) ON (I) and turn a little the pressure
control knob (H1) clockwise so as the machine works till
the motor starts.
• Make sure the solvent recycles the washing fluid from the
return tube.
• Close the recirculation - safety valve (H3).
• Point the spray gun (H7) into the receptacle used to collect
the product (H4) and hold the trigger down to expel any re-
maining product until clean solvent sprays out. Then release
the trigger.
• Lift again the suction pipe (H8) and remove the solvent tank
(H5).
H1
ON
H2
H3
H7H6
H4
H7
H8 H5

18
ZEFIRO
English
I2
Ref. 16325
ROUTINE MAINTENANCE
CHECK ON THE PACKING NUT
Daily check the packing nut is tight in order to avoid wastes but
not excessively to prevent the piston from seizing and the
gaskets from wearing.
• For tightening, use the wrench (I1) supplied (ref. 11503).
• Now point the gun at the solvent tank and press the trigger
so as to recover the residual solvent.
• As the pump starts idling, press the switch (H2) OFF (0)
to stop the equipment.
Follow the washing procedure before using again
the equipment.
• Use the lubricant (I2) supplied (rif. 16325) to allow an easy
sliding of the piston inside the gasket group.
Daily top up the packing nut.
ALWAYS DISCONNECT THE POWER SUPPLY
AND RELEASE THE PRESSURE IN THE PUMPING
GROUP (open the drain valve) BEFORE TIGHTE-
NING THE PACKING NUT.
I
• In case of long storage, we recommend you to suck and
to leave light mineral oil inside the pumping group and the
flexible hose.
Oil ring
I1
Ref. 11503
H2
OFF
H2