Larius NOVA 55:1 EXT Operating instructions

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www.larius.com
ED. 06 - 07/2020
Manuale Cod. 150152
NOVA 55:1 EXT
Airless pneumatic
pump for extrusion
OPERATING AND MAINTENANCE MANUAL
EN

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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.

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WARNINGS ............................................................................................................................................................ P. 4
PRINCIPLE OF OPERATION .................................................................................................................................. P. 5
TECHNICAL DATA .................................................................................................................................................. P. 6
DESCRIPTION OF THE MACHINE......................................................................................................................... P. 7
TRANSPORT AND UNPAC KING ........................................................................................................................... P. 8
CONDITIONS OF GUARANTEE ............................................................................................................................. P. 8
SAFETY REGULATIONS ........................................................................................................................................ P. 8
TYPICAL INSTALLATION........................................................................................................................................ P.10
TUNING .................................................................................................................................................................. P.10
OPERATION............................................................................................................................................................ P.10
END OF WORK CLEANING.................................................................................................................................... P.11
ROUTINE MAINTENANCE ..................................................................................................................................... P.11
TROUBLESHOOTING ............................................................................................................................................ P.12
DISASSEMBLY OF THE PNEUMATIC MOTOR...................................................................................................... P.13
REMOVING THE PUMP UNIT ................................................................................................................................ P.18
EXPLODED PUMPING UNIT VIEW ........................................................................................................................ P.20
EXPLODED MOTOR UNIT VIEW............................................................................................................................ P. 2 2
ACCESSORIES....................................................................................................................................................... P.24
DECLARATION OF CONFORMITY ...................................................................................................................... P.27
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NOVA 55:1 EXT
Airless pneumatic pump for extrusion
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.
INDEX
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A
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.
WARNINGS
A
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 inuence 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 carefully.
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.
FIRE AND EXPLOSION HAZARD
Solvent and paint fumes in work area can ignite or explode.
To help prevent fire and explosion:
- Use equipment ONLY in well ventilated area.
- Eliminate all ignition sources, such as pilot lights, cigarettes and plastic drop cloths (potential static arc).
- Ground equipment and conductive objects.
- Use only grounded hoses.
- Do not use trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or uids containing such solvents in
pressurized aluminium equipment. Such use can cause serious chemical reaction and equipment rupture, and result in death,
serious injury, and property damage.
- Do not form connections or switch light switches on or off if the air contains inammable fumes.
If electrical shocks or discharges are encountered the operation being carried out using the equipment must be stopped immediately.
Keep a re extinguisher at hand in the immediate vicinity of the work area.




any risk of the equipment starting unexpectedly.
Report any risk of chemical reaction or explosion if this warning has not been given.
(IF PROVIDED) There is a risk of injury or serious lesion related to contact with the jet from the spray gun. If this should occur, IMME-
DIATELY contact a doctor, indicating the type of product injected.
(IF PROVIDED) Do not spray before the guard has been placed over the nozzle and the trigger on the spray gun.
(IF PROVIDED) Do not put your ngers in the spray gun nozzle.
Once work has been completed, before carrying out any maintenance, complete the decompression procedure.
It indicates important recommendations about disposal and recycling process of products in accordance with the environmental
regulations.
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 grounded and that it complies with safety standards.
High-pressure uid from gun, hose leaks, or ruptured components will pierce skin.
To help prevent injection, always:
- (IF PROVIDED) Engage trigger lock when not spraying.
- (IF PROVIDED) Do not put your hand over the spray tip. Do not stop or deect leaks with your hand, body or other.
- (IF PROVIDED) Do not point gun at anyone or at any part of the body.
- (IF PROVIDED) Never spray without tip guard.
- Do pressure relief if you stop spraying or being servicing sprayer and before any maintenance operations.
- Do not use components rated less than sprayer Maximum Working Pressure.
- Never allow children to use this unit
- (IF PROVIDED) Brace yourself; gun may recoil when triggered.
If high pressure fluid pierces your skin, the injury might look like “just a cut”, but it is a serious wound!
Get immediate medical attention.
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.

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Conjunction
sleeve
Pump supply
air input
Lubricant bucket
Fig. 2B Fig. 4B
Gasket pressing ring nut
Fig. 3B
Fig. 1B
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The NOVA 55:1 EXTpump is a pneumatic high pressure pump
to be used for transferring high viscosity products.
NOVA is essentially comprised of an air motor and a structure
dened as the “material pumping unit” or simply the “pumping unit”.
The compressed air in the pneumatic motor generates vertical
alternative motor piston movement: this movement is transmitted
through a connecting rod to the material pumping piston ending
with a follower plate that allows for the suction of very viscous
products.
The 55:1 ratio indicates that the material output pressure is 55
times the pump supply air pressure.
B
PRINCIPLE OF OPERATION

AIR CONSUMPTION
PUMP FLOW RATE
1110
580530
87
240
0510 15 20
01 2345
0
60
120
180
240
300
BAR
600
1200
1800
2400
3000
3600
4200
4800
0
600
1200
1800
2400
3000
0
15
30
45
60
75
90
105
120
7 bar (100 psi)
5 bar (70 psi)
3 bar (40 psi)
PSI
L/MIN
CFM
GPM
L/MIN
NOVA 55:1 EXT
Pump supply air pressure 3-6 bar
Maximum product pressure 330 bar
Supply air input 3/4” BSPP (M)
Maximum flow rate 12 l/min
Number of cycles per litre 5
Maximum N° of cycles per minute 60
Material outlet 1” BSPP (F)
Weight 57 Kg
Noise pressure level <90 dB (A)
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TECHNICAL DATA
Parts of pump in contact with material
Pumping unit: galvanised carbon steel and cast iron or AISI 303
and 420B stainless steel
Sealing balls: AISI 420B stainless steel
Gaskets: Teon or nitrile, delrin or vulkollan rubber
Other pump parts
Support and pneumatic motor support: aluminium
Cover: FE37 sheet
Motor piston and roller pushing support: cast iron
Always observe these notes when assessing
the compatibility of products to be used and
when eliminating one or more pump components
that are no longer usable in order to
plan the recycling of individual components
in an environmentally safe manner.

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Fig. 1D
Pos. Description
1 Pump supply air inlet
2 Pneumatic motor
3 Material outlet
4 Material input
5 Material pumping unit
Pos. Description
6 Bleed valve
7 Lubricant bucket
8 Gasket pressing ring nut
9 Conjunction sleeve
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DESCRIPTION OF THE MACHINE

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
and markings on the outside of the packing.
          
used is large enough for such purposes, is properly lit and has
a clean, smooth oor surface.
    
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 qualied 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.
        
operations and transport to the workplace of the machine.

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 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,interventionsandmaintenancethat
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.
CONDITIONS OF GUARANTEE
 
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.
       
COMPLY WITH THE ACCIDENT PREVENTION AND ALSO
ENVIRONMENTAL REGULATIONS IN FORCE IN THE COUNTRY
WHERE THE PLANT IS INSTALLED AND USED.
        
WHERE YOU ARE WORKING CREATES A POTENTIAL RISK
OF ACCIDENTS.
      
STANCE.
 -
MAGED PARTS AND THE MACHINE CAN WORK PROPERLY.
 
THE REGULATIONS IN FORCE.
 -
PMENT OUT OF THE WORK AREA.
 NEVER EXCEED THE MAXIMUM WORKING PRESSURE
INDICATED.
 (IF PROVIDED) NEVER POINT THE SPRAY GUN AT YOUR-
SELVES OR AT OTHER PEOPLE. THE CONTACT WITH THE
CASTING CAN CAUSE SERIOUS INJURIES.
 
IMMEDIATE MEDICAL ADVICE SPECIFYING THE TYPE OF
THE PRODUCT INJECTED. NEVER UNDERVALUE A WOUND
CAUSED BY THE INJECTION OF A FLUID.
       
PRESSURE IN THE CIRCUIT BEFORE PERFORMING ANY
CHECK OR PART REPLACEMENT OF THE EQUIPMENT.
        
REGULARLY THE COMPONENTS OF THE SYSTEM.
REPLACE THE PARTS DAMAGED OR WORN.
 (IF PROVIDED) TIGHTEN AND CHECK ALL THE FITTINGS
TRANSPORT AND
UNPACKING
SAFETY RULES
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 packaging materials in an
environment-friendly manner as much as possible.
Readcarefullyand entirelythe followinginstructions
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 materialsother than
those recommended by the manufacturer can be a
danger of accident.
The manufacturer will be relieved from tort and
criminal liability.
E
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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.
FOR CONNECTION BETWEEN PUMP, FLEXIBLE HOSE AND
SPRAY GUN BEFORE USING THE EQUIPMENT.
 -
DARD KIT.
 
THOSE RECOMMENDED IN THIS MANUAL, MAY CAUSE
DAMAGE OR INJURE THE OPERATOR.
 
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 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.
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.
Never spray over flammable products or solvents
in closed places.
Never use the tooling in presence of potentially
explosive gas.
Always check that 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.
If the product to be used is toxic, avoid inhalation
and contact by using protection gloves, goggles
and proper face shields.
Take proper safety measures for the protection
of hearing in case of work near the plant.

21
Fig. 1H
CONNECTING THE MATERIAL OUTPUT HOSE
Connect the high pressure hose to pump output.
Thoroughly tighten ttings.

all night at the end of a working day), ensure that the product
you are using and different hoses can be left inside the pump
without drying.
If this risk does not exist, then simply cut off pump air supply
and discharge circuit pressure on the dispensing valve or the
pump bleed valve before an operating pause.
Pos. Code Description
1 510000 200-litre pneumatic extrusion ram
2 510100 Castiron followerplate completewith dualgasket
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nova 55:1 ext
ED. 06 - 07/2020 - Cod. 150152
TYPICAL INSTALLATION
TUNING
OPERATION
H
I
J
The NOVA 55:1 pump can be installed on the pneumatic extrusion
ram with follower plate (see figure).
Pneumatic extrusion rams allow for the product to be suctioned
directly by the drum and allow for quick replacement of the drum
itself. The plate, fastened to the pump base, compresses the
material, ensuring a constant ow or product. Furthermore, it
protects material that has not yet been suctioned from contact
with dust and humidity and from drying caused by contact with air.
SECURING THE PUMP TO THE EXTRUSION RAM
For correct pump securing on the extrusion ram, follow the
procedure described in the pneumatic extrusion ram use and
maintenance manual.

pump is secured on the pneumatic extrusion ram, follow the
procedure described in the pneumatic extrusion ram use and
maintenance manual).

means of the electric/pneumatic valve. Have compressed air ow
to the pump. Adjust air pressure to minimum value necessary
for continuous operation.
   
product chamber is full. The pump will re-start operation every
time the dispensing valve opens.
          
oil which may remain somewhat inside the pump. Direct the
dispensing valve against a container and drain all product left
inside the pump until the material to be used comes out.
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 55 times the inlet pressure of the pump feed
air. Therefore, it is extremely important to adjust
the value of the feed air pressure.
Check all connection fittings on the different com-
ponents (pump, flexible hose, etc.) before using
the machine.
Never operate the pump without a load. This could
cause serious damage to the pneumatic motor
and ruin sealing gaskets.
CONNECTING SUPPLY AIR
Use a hose with an internal diameter of no less than 20 mm for
pump supply.

Lubricant oil
Cod. 16340
Pin
Cod. 20144
L2
L1
Fig. 2LFig. 1L
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END OF WORK CLEANING
ROUTINE MAINTENANCE
K
L
End of work cleaning is intended as the cleaning to be carried out whenever you wish to use a different product or when a long period
of machine inactivity is foreseen.






Store possible dangerous fluids in suitable containers. They must be disposed of in accordance with regulations
regarding the disposal of industrial waste.
Always close the compressed air supply and discharge the pressure in the system before inspecting or carrying
out any maintenance work on the pump.
and check whenever re-starting the pump after a long period of inactivity) that the gasket pressing ring nut (L2)
has not become loose, causing product to leak out. To tighten the ring nut, lift the lubricant bucket (L1).
The ring nut (L2) must be tightened so as to avoid leaks but not excessively to cause the seizure of the pumping piston and gasket
wear. If product leaking persists, replace gaskets.
L1) full (compatible with the product being used) n order to prevent the product from drying on the piston
shaft.

installed on the air supply line to the pump, it is recommended that its cup be kept full with a mixture of water and anti-freeze liquid
(dilution ratio 4:1).

Problem Possible cause Solution
The pump does not start Feeding air is not enough; Check the air supply. Increase the
diameter of the feeding hose;
Outlet product line clogged; Clean. Disconnect the outlet product
pipe. Feed pump at minimum pressure
and check if the pump starts without
the outlet pipe;
Dried product inside the pumping element; Disassemble the pumping group and
clean;
Pneumatic motor blocked in the cycle
reversal position;
Turn the plug counterclockwise and
push downwards the valve body. Use
a metal rod and a mallet;
Parts failure of the pneumatic motor; Disassemble the motor and check;
Accelerated working and no pressure
of the pump
There is no product; Add product;
The pump sucks air; Open the exhausting valve. For
the version on air hoist, follow the
instructions in the relevant manual;
Feeding air is not enough; Increase the feeding air pressure;
Suction valve worn or partially clogged; Disassemble the suction valve. Clean
and/or replace if necessary the worn
parts;
Outlet valve worn or partially clogged; Disassemble the outlet valve. Clean and/
or replace if necessary the worn parts;
The pump works, but the product is
not flowing enough
Suction valve worn or partially clogged; Disassemble the suction valve. Clean
and/or replace the worn parts;
Outlet product line clogged; Clean. Disconnect the outlet product
pipe. Feed pump at minimum pressure
and check if delivery increases without
the outlet pipe;
The feed air pressure is too low; Increase air pressure;
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.
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TROUBLESHOOTING
M
Always close the compressed air supply and release the pressure in the plant before performing any check or
replacement of parts of the pump.

Conjunction sleeve
N8
N9
N6
N12
N13
N14
N7
N14
N13
N12
N6
N15
N16
N10
N11
N11
N10
N3
N2
N1
N4
N5
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DISASSEMBLY OF THE PNEUMATIC MOTOR
N
Always close compressed air supply and dischar-
gepressure before dismantling the pneumatic
motor from the pump.

the motor.

N1) and the sleeve (N2).
    N3) [be careful of washers (N4)] and
remove the cover (N5).
N6) from the support (N7).
Unscrew the screws(N8) [be careful of washers (N9)] and remove
the support (N7)together with the rollers (N10) and the pins (N11).
Remove the spring (N12), the spring guide rod (N13)and the
roller pushing piston (N14). Make sure that the spring slides
freely on the guide rod, that the guide rod slides freely on the
roller pushing piston and that the latter slides freely inside the
support hole.
Check conditions on the roller (N10)and the pin (N11). Replace
if damaged.
Remove and check the shock absorber (N15)and the washer
(N16).

N18 N19 N17 N19 N18
N20
N21
N17
N22
N23
N24
N25
N26
N27
N28
N29
Remove screws (N24)[careful of washers (N25)] and remove a
collector (N26)and the gasket (N27).
With the help of a screwdriver, remove the washer (N28)and
the shock absorber (N29).
Fig. 2N
Fig. 3N
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Handle the collector with care. The edges of the
plate secured to it are very sharp.
Important: do not remove the other collector
unless strictly necessary(this will facilitate sub-
sequent securing of the removed collector).
(N17)in order to remove valves (N18)and
springs (N19) (clean and/or replace worn components).
(N20)[being careful of the washer (N21)]
and keeping the bush locked with a wrench (N22).
(N23) from the rod (N17).
(N22)(if necessary, keep the rod locked (N23)
on the threaded part with pliers whose grippers are wrapped in
a rag to avoid damaging threading).

N30
N31
N32
N33
N34
N36
N35
N38
N37
Attention: tighten here
Fig. 4N
Fig. 5N
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Remove the piston from the motor support (N35).
(N36).
see figure)
and use a wrench to loosen the fittings (N37).
(N38)and make sure it is not damaged.
Spread Vaseline grease on the motor rod (N38) before inserting
it in the piston rod cavity.

tighten the fitting (N37) (apply a liquid sealant on the threads).
(N30)[careful of the washer (N31)]
and make sure that the sealing gasket inside the screw (N30) has
not become ruined.
(N32) [careful of the washers (N33)] and
carefully remove the cylinder (N34) (do not tilt it excessively during
extraction to avoid the motor piston from damaging the internal
surface of the cylinder).

1 mm
N39).
N40).

cylinder (N41).
N42) in the cylinder (N41).
N41) on the support (N39) (comply with po-
sitioning) and simultaneously insert the motor rod in the support.
N43).
N44)on the motor rod (N45).
N46)
(having it slowly turn following the direction of the rod threading)
and tighten it on the cylinder (N41).
N47) and the washer (N48).
N49) on the motor rod (N44), insert the hou-
sing (N50), the washer (N50) and tighten the counter-nut (N52).
N52
N48
N43
N41
N42
N40
N39
N47
N46
N45
N44
N51
N50
N49
N44
Check the seal ring
Fig. 6N
Fig. 7N
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Adjust the bush and the counter-nut so that the
rod (N44) pushes out about 1 mm from the
counter-nut (see figure).

46 mm
0,8 mm 0,8 mm
  N53) and the valves (N54) in the housing
(N55), position the housing on the pump support and rest the
collector against the housing (N56) [remember the gasket (N57)].
do not tighten for now) ensuring
it is perfectly parallel to the other collector and that the distance
between the two collectors is 46 mm(see figure).
The distance between the collector walls and the edge of the
housing must be about 0.8 mm.
N58) and pins (N59) and
insert them in the support (N60).
N61) and on the
washer (N62) and insert them in the support (N60).
N63), the spring guide (N64)
and the spring (N65) and insert them in the support (N60).
       N66) on the
support (N60).

(N68) [remember the washers (N67)].
N66) and the screws (N69).

N68
N63
N60
N58
N56 N57
N64
N65
N66
N59
N61
N62
N67
N66
N69
N53 N54 N55
N56
N53
Fig. 9N
Fig. 8N
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Fig. 1O
O8
O9
O5
O33
Conjunction Sleeve
Conjunction tie rod
O35
O37
O36
O34
O20
O32
O33
Fig. 2O
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ED. 06 - 07/2020 - Cod. 150152
REMOVING THE PUMP UNIT
O
Always close compressed air supply and dischar-
gepressure in the system before dismantling the
pumping unit.
 
from the motor.
O33) and disconnect the pumping unit.
O5) and remove the conjunction tie rod.
O8) and unscrew the gasket pressing ring
nut (O9).
Push the motor piston rod downward until the follower plate
comes out from the housing. Unscrew the nut (O37), the plates
(O36) e (O35) and the bush (O34).
Remove the nuts (O33) and disconnect the housing (O32)
[careful of the washer (O20).

Fig. 3O
Fig. 4O
O21
O20
O27
O39
O22
O24
O23
O13
O25
O11
O10
O13
O11
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ED. 06 - 07/2020 - Cod. 150152
Remove the complete shutter unit, the stop (O27) the washer
(O20) and the cylinder (O21) from the shutter unit.

(see also the exploded spare parts view).
Remove the conjunction tie rods from above (O39).
O25) and remove the ball (O24), the ring
(O23), the gaskets (O11), the ring (O13) and the washer (O22)
(replace worn parts).
Remove the upper gaskets pack: the ring (O10), the gaskets
(O11) and the ring (O13). Replace worn components.
For correct reassembly of various components and of the
complete pumping unit, see the exploded spare parts view.

16
17
19
40
39
42
41
22
15
14
13
11
10
9
8
7
6
5
4
3
18
20
21
38
37
36
35
20
34
33
32
31
30
23
23
2
1
29
28
5
27
26
11
13
25
24
23
12
12
Fig. 1P1
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EXPLODED PUMPING UNIT VIEW
P
WARNING:always indicate code and quantity for each part required.