Novag Spray Equipment NI-3PE User manual

Service Manual
Spray Unit
NI–3PE~400V
Issue 1.130/05/22
Ref. NR-00052-ENG
Before preparing the unit and starting it up, please take the time to read all
the technical and safety instructions in this manual. It is essential that you
follow these instructions carefully so that you can handle and use the unit
properly. These instructions are intended to maximize user safety and
avoid malfunctions deriving from the incorrect use of the unit.

NI–3PE~400V
Service manual
2/56 Issue 1.1 Ref. NR-00052-ENG
http://www.novag.eu
HI-TECH SPRAY EQUIPMENT, S. A. (hereinafter “HI-TECH”) grants this Limited Guarantee to the original
buyer (hereinafter the “Client”) for the unit and the original accessories given with the unit (hereinafter the
“Product”) against any fault in the design, materials or manufacture of the Product at the time of the first
purchase by the user and for a duration of two (2) years thereafter.
If during the guarantee period and under normal conditions of use, the Product should fail to work correctly
due to defects of design, material or manufacture, the authorised distributor of the country where the HI-
TECH Product or technical assistance service has been purchased shall repair or replace the Product in
accordance with what is established in the following:
CONDITIONS
a) The validity of this guarantee will be subject to the presentation of the original invoice issued by
the HI-TECH authorised distributor for the sale of the Product along with the Product handed over
for repair or replacement, which must show the date of purchase and the serial number. HI-TECH
reserves the right to refuse to give the guarantee service when the indicated data fail to appear
on the invoice or have been modified after the purchase of the Product.
b) The repaired or replaced Product will continue to maintain the original guarantee for the time
remaining until the end of the guarantee or for three (3) months from the repair date, if the
remaining period of the original guarantee were shorter.
c) This guarantee will not be applied to the faults in the Product caused by its faulty installation, the
natural wear and tear of the components, any use other than that considered normal for this
Product or which should fail to strictly comply with the instructions of use provided by HI-TECH;
due to accident, carelessness, adjustments, alterations or modifications of the Product not
authorised by HI-TECH or due to the use of accessories, heating devices, pumping equipment
and/or dispensers that have not been approved or manufactured by HI-TECH.
d) The guarantee applicable to the components and accessories forming part of the Product and
which have not been made by HI-TECH will be limited to the guarantee offered by the original
manufacturer thereof.
HI-TECH WILL NOT RECOGNISE ANY EXPRESS ORAL OR WRITTEN GUARANTEES OTHER THAN THIS
PRINTED LIMITED GUARANTEE. ALL IMPLICIT GUARANTEES, INCLUDING, WITHOUT LIMIT, ADAPTATION
FOR A SPECIFIC USE, ARE SUBJECT TO THE DURATION OF THIS WRITTEN GUARANTEE. HI-TECH DOES
NOT ASSUME ANY KIND OF COMMITMENT OR RESPONSIBILITY FOR ALL POSSIBLE DAMAGE OR EXPENSE
CAUSED BY FAULTS IN THE OUTPUT OF THE PRODUCT, ITS WORKING OR THE DISPENSING OF MATERIAL
THROUGH THE PRODUCT, INCLUDING, WITHOUT LIMITATION, ALL EXPENSES CAUSED BY DAMAGE TO
PEOPLE OR PROPERTY. EQUALLY, HI-TECH WILL IN NO CASE ACCEPT LIABILITY FOR THE LOSS OF
SPECULATIVE PROFITS OR COMMERCIAL LOSSES. ALL REPAIRS OR REPLACEMENT OF FAULTY
PRODUCTS WILL CONSTITUTE THE COMPREHENSIVE FULFILMENT OF HI-TECH'S OBLIGATIONS WITH
RESPECT TO THE CLIENT. HI-TECH DOES NOT IN ANY WAY GUARANTEE THE SUITABILITY OR APTITUDE OF
ITS PRODUCT FOR ANY PARTICULAR PURPOSE OR APPLICATION.
All information provided on components which have not been manufactured by HI-TECH and which is
based on reports received from the original manufacturer, though considered precise and reliable, is
provided without any guarantee or responsibility of any explicit or implicit kind.
All concession, sale or financial leasing of the Product by HI-TECH in no case explicitly or implicitly
constitutes any authorisation, acceptance or concession for the use of any rights or patents, nor does it
encourage, nurture or back their infringement.
The restrictions on the guarantee suppose no limitation on the legal rights of the consumer established in
applicable national legislation, nor do they affect any rights derived from the bargain and sale agreement
between the consumer and supplier.
All information provided in this manual has been included in the confidence that it is true, although it does
not constitute any responsibility or implicit or explicit guarantee. HI-TECH reserves the right at any time
and without prior warning to make all improvements and modifications necessary to this manual, in order
to rectify any possible typographical errors, increase the information contained or insert the changes
caused to the characteristics and performance of the unit.
WARRANTY

NI–3PE~400V
Service Manual
3/56 Issue 1.1 Ref. NR-00052-ENG
http://www.novag.eu/
The equipment described in this manual has been designed and manufactured in compliance
with the following European Directives, following as application guide the harmonized standards
detailed and in conformity with the relevant UK Statutory Instruments (and their amendments):
Directive 2006/42/EC on machinery (UK Supply of Machinery (Safety) Regulations 2008)
UNE EN 12100:2012 (BS EN ISO 12100:2010)
Directive 2014/30/EU on electromagnetic compatibility (UK Electromagnetic Compatibility
Regulations 2016)
UNE EN 55011 (BS UNE EN 55011)
UNE EN 55016-2-1 (BS UNE EN 55016-2-1); UNE EN 55016-2-3 (BS UNE EN 55016-2-3);
UNE EN 55032 (BS UNE EN 55032)
UNE EN 61000-3-2 (BS UNE EN 61000-3-2); UNE EN 61000-3-3 (BS UNE EN 61000-3-3);
UNE EN 61000-4-2 (BS UNE EN 61000-4-2); UNE EN 61000-4-3 (BS UNE EN 61000-4-3);
UNE EN 61000-4-4 (BS UNE EN 61000-4-4); UNE EN 61000-4-5 (BS UNE EN 61000-4-5);
UNE EN 6100-4-6 (BS UNE EN 6100-4-6); UNE EN 61000-4-8 (BS UNE EN 61000-4-8); UNE
EN 61000-4-11 (BS UNE EN 61000-4-11)
Directive 2014/68/EU on pressure equipment (UK Pressure Equipment (Safety)
Regulations 2016)
UNE EN 809:1999 +A1 (BS EN 809:1998 +A1:2009)
Directive 2014/35/EU on electrical safety (UK Electrical Equipment (Safety) Regulations
2016)
UNE EN 60204-1:2019 (BS EN 60204-1:2018)
Directive 2003/10/EC on noise level (UK The Control of Noise at Work Regulations 2005)
UNE EN ISO 3740 (BS EN ISO 3740:2019)
UNE EN ISO 3746 (BS EN ISO 3746:2010)
Directive 2011/65/EU on the restriction of the use of certain hazardous substances in
electrical and electronic equipment with amendment 2015/863/EU (UK The Restriction of
the Use of Certain Hazardous Substances in Electrical and Electronic Equipment
Regulations 2012)
Directive 2012/19/EU on waste electrical and electronic equipment (UK The Waste
Electrical and Electronic Equipment Regulations 2013)
SAFETY AND HANDLING

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http://www.novag.eu
Electrical products cannot be thrown out with the rubbish. They must be taken to a
dedicated collection point for an environmentally sound disposal in accordance
with local regulations. You must contact your local collective or retailer for
information about recycling. Before leaving WEEE at appropriate collection
facilities, batteries must be removed and disposed of separately for proper
recycling. The packaging materials are recyclable. Dispose of packaging materials
in an environmentally sound manner and place them at the disposal of recycling
sectors.
TRANSPORT AND STORAGE
Proper precautions must be taken so that the equipment can withstand the effects of transport
and storage temperatures between -25°C and +55°C or up to +70°C for short periods that do
not exceed 24 hours. Also, appropriate means to prevent damage from moisture, vibrations or
shocks must be foreseen.
This section contains important information on the safe handling and operation of the novaG - I
proportioning unit.
Before preparing the unit and starting it up, please take the time to read all
the technical and safety instructions in this manual. It is essential that you
follow these instructions carefully so that you can handle and use the unit
properly. These instructions are intended to maximize user safety and
avoid malfunctions deriving from the incorrect use of the unit.
A DANGER! indication alerts you to situations which may result in serious injury if the
instructions are not followed.
A WARNING! indication gives information on how to avoid damaging the unit and
situations likely to cause minor injury.
A NOTE indication provides useful information on the procedure in question.
Read this manual carefully to familiarize yourself with the unit’s characteristics and operating
procedures. By following the instructions and recommendations contained in this manual you
will reduce the risk of accidents in the preparation, use and maintenance of the unit, ensuring
incident-free operation for a longer time, improved performance and the quick and easy
detection of problems.
Keep this Service Manual handy for reference at all times. If you lose this manual, ask for a new
copy from your local HI-TECH distributor or directly contact HI-TECH Spray Equipment, S.A.
WARNING! The novaG - I proportioning unit is not designed for use in potentially
explosive environments. Pressure and temperature must not exceed the limits indicated
in the technical specifications of this manual.

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When working with the unit, it is essential that you wear suitable clothing and personal
protective equipment including but not limited to gloves, protective goggles, safety footwear and
face masks. Use breathing equipment when working with the unit in enclosed spaces or in
areas with insufficient ventilation. The safety measures given in in this manual are part of a
wider safety procedure. Before powering up the unit, you must perform a comprehensive
analysis of the risks associated with the products it dispenses, the type of application, and the
working environment.
To avoid bodily damage caused by the incorrect handling of the
substances and solvents used with this unit, read carefully the safety
information provided by their suppliers.
Dispose of waste as required by applicable legislation.
Disconnect the unit from the power supply before opening the electrical
console.
Electrical maintenance should only be carried out by a qualified
electrician.
To avoid exposure to pressurized fluids, do not release any connectors or
perform maintenance work on parts subjected to pressure until the
pressure has been completely eliminated.
Use suitable protection when using or performing maintenance on the
unit, or when in its vicinity. This protection includes, but is not limited to,
the use of masks, protective goggles, gloves, safety footwear and safety
clothing.
This unit includes parts which reach temperatures likely to cause burns.
Do not touch or handle the hot parts of the unit until they have cooled
down.
To avoid the risk of crushing or amputation, only use this unit when its
moving parts are fitted with correctly installed safety guards. Make sure
all safety guards are correctly mounted after completing repair or
maintenance work.

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Service manual
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The novaG - I proportioning unit is designed for the application of polyurea chemical systems
for polyurethane foaming and certain two-component epoxy systems.
Principal heating system
Consists of two independent heaters without gaskets. Each heater has two 900 W/1500 W
heating elements delivering total power of 1800 W / 3000 W, and the necessary control and
safety mechanisms for the correct operation of the system. Their special configuration permits a
temperature differential (ΔT) of 30º C and application temperatures of 80ºC under normal
ambient temperature conditions.
Hose heating system
Designed with a 3000 W isolation transformer that enables effective heating up to a total hose
length of 93 meters (305 ft) for foam and 78 meters (256 ft) for polyurea. The system includes
an innovative hose heating concept in which the copper heating element is spread evenly
around the circumference of the hose, providing a uniform heating watt density and precise
control of the product application temperature. This hose heating element design is extremely
resistant to fatigue failure.
100% circumferential coverage produces the most homogenous distribution of heat available.
Proportioning pumps
This assembly comprises two positive-displacement piston pumps operated by a dual-piston
hydraulic cylinder.
The parallel piston pump configuration ensures constant volume and guarantees uniformity of
pressure in both directions of pump movement.
CHARACTERISTICS

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Electrical
Voltage: ________________________________________________________________ 400V
Frequency: ____________________________________________________________ 50/60Hz
Connections:_________________________________________________________3PE~400 V
Motor power:______________________________________________________________3 kW
Heater power: _____________________________________________________3.6 kW / 6 kW
Hoses power: ________________________________________________ 3 kW / 1,6 kW / - kW
Max. Total Active power: ___________________________________________________12 kW
Max. Consumption: _____________________________________________23 A @ 3PE~400V
Mechanical
Maximum working pressure (#7.6 size pumps):_________________________140 bar (14 MPa)
Maximum working pressure (#4.5 size pumps):_______________________ 175 bar (17.5 MPa)
Maximum output at 1:1 ratio (#7.6 size pumps): _______________________________ 9 kg/min
Maximum output at 1:1 ratio (#4.5 size pumps): _______________________________ 4 kg/min
Minimum output:________________________________________________________ 1 kg/min
Maximum length of heated hose with 3 kW transformer (for foam): ___________________ 93 m
Maximum length of heated hose with 3 kW transformer (for polyurea) (*): ______________ 78 m
Maximum length of heated hose with 1,6 kW transformer (for foam):__________________ 48 m
Recommended compressor: ______________________________________ 3 HP single-phase
Approximate weight:_______________________________________________________190 kg
Dimensions: ___________________________________ H: 1165 mm / W: 605 mm / D: 744 mm
Acoustic
A-weighted sound pressure level: _______________________________________ 79,2 dB (A)
A-weighted sound power level: _________________________________________ 94,0 dB (A)
Values obtained according to UNE-EN ISO 3746:1995 standard.
(*) For temperatures above 75ºC (167ºF), the maximum
hose length will be 78m (256ft).
Cable Section 6 mm2
TECHNICAL SPECIFICATIONS

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MODEL VARIANTS
MÁX. POWER (SECTION) & N.B.
9,6kW 19,1A (6 mm2)
9,6kW 19,1A (6 mm2)
9,6kW 19,1A (6 mm2) RED
12kW 23A (6 mm2)
12kW 23A (6 mm2)
8,2kW 16,3A (2,5 mm2)
10,6kW 21A (6 mm2)
6,6kW 13A (2,5 mm2)
9kW 18A (6 mm2)
TCS
YES
YES
YES
YES
YES
NO
NO
NO
NO
HOSES
HEATED TRAFO
HEATED TRAFO.
HEATED TRAFO.
HEATED TRAFO
HEATED TRAFO
HEATED TRAFO.
HEATED TRAFO.
RECIRCULATION
RECIRCULATION
TRANSF.
3Kw 400v
3Kw 400v
3Kw 400v
3Kw 400v
3Kw 400v
1,6Kw 230v
1,6Kw 230v
-
-
INTEGRAT ED TANKS
NO
NO
NO
NO
NO
YES
YES
YES
YES
PUMPS
#7,6 - #7,6
#4,5 - #4,5
#4,5 - #4,5
#7,6 - #7,6
#4,5 - #4,5
#4,5 - #4,5
#4,5 - #4,5
#4,5 - #4,5
#4,5 - #4,5
HEATERS
2x 1,8 kW
2x 1,8 kW
2x 1,8 kW
2x 3 kW
2x 3 kW
2x 1,8 kW
2x 3 kW
2x 1,8 kW
2x 3 kW
MOTOR
3kW 400V
3kW 400V
3kW 400V
3kW 400V
3kW 400V
3kW 400V
3kW 400V
3kW 400V
3kW 400V
CONNEC.
3PE~400V
3PE~400V
3PE~400V
3PE~400V
3PE~400V
3PE~400V
3PE~400V
3PE~400V
3PE~400V
VERSION
NI-SP2
NI-SP3
NI-SP4
To order suitable spare parts, check the correct elements that equip your machine.

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Figure 1.General view
OVERVIEW

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1. Isocyanate intake
3/4"BSP Threaded Inlet connection chemical component “A”.
2. Polyol intake
3/4"BSP Threaded Inlet connection chemical component “R”.
3. Isocyanate output manifold
Distributor Iso hose connection.
4. Polyol output manifold
Distributor Pol hose connection.
5. Heated Hoses with transformers
Keeps spray products at the right temperature in hoses.
6. Hose temperature sensor
Monitors the temperature of the spray products.
7. Control panel
Controls the correct operation of the unit.
8. Isocyanate proportioning pump
Delivers metered quantities of isocyanate to the system.
9. Polyol proportioning pump
Delivers metered quantities of polyol to the system.
10. Isocyanate heater
Heats the isocyanate to the pre-set temperature.
11. Polyol heater
Heats the polyol to the pre-set temperature.
12. Isocyanate pressure gauge
Indicates the pressure in the isocyanate circuit.
13. Polyol pressure gauge
Indicates the pressure in the polyol circuit.
14. Isocyanate heater sensor
Provides information on the temperature of the isocyanate heater.
15. Polyol heater sensor
Provides information on the temperature of the polyol heater.
16. Isocyanate intake filters
Prevent solid particles from the entering the unit’s isocyanate pump.
17. Polyol intake filters
Prevent solid particles from the entering the unit’s polyol pump.
18. Hydraulic pressure gauge
Indicates the pressure of the hydraulic circuit.
19. Isocyanate circuit safety pressure switch
Shuts off the solenoid valve in the event of excess pressure in the isocyanate circuit.
20. Polyol circuit safety pressure switch
Shuts off the solenoid valve in the event of excess pressure in the polyol circuit.

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21. Hydraulic pressure regulator
Enables the pressure of the hydraulic circuit to be
increased or reduced.
To increase pressure, turn the tap clockwise; to reduce
pressure, turn the tap anti-clockwise.
NORMAL or RETRACT commands must be active
before you can adjust the pressure of the hydraulic
circuit.
The hydraulic circuit should be regulated to ensure that the unit’s output
pressure never exceeds the working pressure of the product hoses fitted
to the unit.
22. Hydraulic oil tank
Contains the oil used by the unit’s hydraulic system.
23. Hydraulic cylinder
Drives the pumps.
24. Oil level and thermometer
Displays the fluid level and temperature of the hydraulic oil tank.
25. Electric motor
Drives the hydraulic pump.
26. Hydraulic pump
Axial piston pumps are swash plate design variable displacement pumps.
The flow and pressure compensator control, also known as a load sensing control, matches
pump output flow and pressure to the system demand.
Pumps oil to the hydraulic cylinder.
27. Hydraulic return filter
Filters impurities from the hydraulic oil.
28. Hydraulic oil fill cap
For topping up the oil tank.
29. Male connector hose heating
Allows temperature control in the hoses.
30. Transformer hose
Provides the necessary voltage for heating the hoses.
31. Reversing switch
Actuate to change of direction of the hydraulic cylinder.

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32. Isocyanate tank (OPTIONAL)
Contains chemical component “A”. Capacity 30 litres.
33. Polyol tank (OPTIONAL)
Contains chemical component “R”. Capacity 30 litres.
34. Isocyanate recirculation valve (OPTIONAL recirculation hoses only)
Enables selection between recirculation and spray for the isocyanate circuit.
35. Polyol recirculation valve (OPTIONAL recirculation hoses only)
Enables selection between recirculation and spray for the polyol circuit.
36. TCS DIP switches
Enables selection of the hose heater control mode depending on
whether hoses incorporate a temperature control sensor (TCS).
See page 14 point 2 of this manual for instructions on selecting the
correct control mode. The unit must be disconnected before
operating the DIP switch.
37. Temperature units DIP switch
Enables selection of temperature units on the control panel
displays. Set this switch to the “EU” position to display the
temperature in degrees Celsius (ºC), or “USA” to display the
temperature in degrees Fahrenheit. The unit must be disconnected before operating the
DIP switch.
38. Motor DIP switch
Activates/deactivates the hydraulic drive. Factory settings depend
on the model. The “Motor DIP” selector function is only active
in units with hydraulic drive. The unit must be disconnected
before operating the DIP switch.

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Figure 2.Control panel
The control panel enables you to set the optimum operating conditions for the characteristics
and requirements of the products dispensed. Press the MODE button to enter the desired
settings for temperature, intensity and number of cycles to run. The selected parameter remains
flashing for a few seconds, allowing you to change the values by touching the UP / DOWN
buttons. After changing the value, press the MODE button again to confirm your selection.
The parameter modification function automatically cancels after a few seconds if there is no
further activity on the buttons.
The parameters that can be selected and viewed are:
•Hose temperature in automatic control mode (maximum 80ºC)
•Hose heating intensity in manual control mode (maximum 50 A)
•Isocyanate heater temperature (maximum 90ºC)
•Polyol heater temperature (maximum 90ºC)
•Number of cycles to run.
•Number of cycles completed.
CONTROL PANEL

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1. Main Power switch
Turns the electric supply to the control panel on and off. It must be turned ON for any operation
to be performed with the unit. When turned ON, the green pilot at the top of the switch will come
on.
2. Hoses
Hose heating control can be automatic when a temperature control
sensor is used for direct temperature control, or manual where no
temperature control sensor is used. The control mode is selected
via a DIP switch on the printed circuit board. Set the “HOSE
TEMP” DIP to ON if the isocyanate hose incorporates a temperature control sensor. If the
isocyanate hose does not incorporate a temperature control sensor, or if it is not working due to
malfunction or other reasons, set the DIP to OFF.
In automatic control mode, the temperature in the isocyanate (ISO) hose is shown on the
corresponding display. In manual control mode, only the selected amperage value is shown.
The unit must be disconnected before operating the DIP selector.
HOSE TEMP ON
with temperature control sensor in ISO
hose
HOSE TEMP OFF
manual control
To select the temperature when the unit is working in automatic heating control mode, touch the
MODE button, select the desired temperature using the UP/DOWN buttons and touch the
MODE button again to confirm the setting. Follow the same procedure to select the amperage.
When the unit is operating in automatic control mode, this value should be set to between 45
and 50 A.
The temperature setting of the hoses cannot be higher than the temperature setting of the
heaters.
In cases where only one automatic temperature control system is working (ISO or POL), the
limit temperature value is the higher of the two heater settings.
Maximum temperature settings are 80ºC for hoses and 90ºC for heaters.

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The sequence for entering commands is as follows:
•First we set the temperature of the ISO and POL heaters.
•Next, we set the temperature of the ISO hoses.
•Then we set the hose current consumption in amps.
•Finally, we enter the cycle preselector setting.
If the temperature control sensor is not active, the symbol (---)
appears on the display and the heating switches off.
The standard unit incorporate an integrated transformer. The
temperature of the hoses is controlled directly with the
corresponding keyboard on the front panel (if it has TCS) or
by programming the current intensity (see point 2 on page
14).
Select the temperature or intensity using the UP arrow button
to increase or DOWN arrow button to decrease amps and
temperature. Adjustment intensity ranges from 0 to 50 amps,
and temperature range up to 80ºC or 176ºF.
Take the values below as an approximate reference to select
the intensity that allows reaching the requested application
temperature.
30 A 38º C 100º F
35 A 48º C 118º F
40 A 60º C 140º F
45 A 75º C 167º F
50 A 80º C 176º F
NOTE: The circuit breaker software of the
transformer has a safety system to prevent
the hoses from being exposed to high
temperatures during long periods of time.
If you have selected a potential over 35 amperes, after 20 minutes, the potential will
automatically regulate to 35 amperes.
This potential cannot be set above 35 amperes until the heater is disconnected from the
hoses and reconnected.
The setpoint programmed by the machine operator will be memorized for the next
heating start-up.
In optional versions the hoses transformer can be
independent. In this case, the temperature of the hoses is
controlled by acting on a potentiometer integrated in the front
of the transformer.
The lower pushbutton on the transformer switches the hose
heating on and off. This pushbutton incorporates an LED
which lights up when the heating is operating; a flashing LED
indicates that the heater is on but is not heating up.
Turn the potentiometer clockwise to increase amps, and anti-
clockwise if you wish to decrease amps. Adjustment ranges
from 0 to 50 amps. Turn the potentiometer clockwise until the
screen shows the required amps for a quick pre-heating.

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3. Heaters
This display shows the temperatures in the isocyanate (ISO) and polyol (RESIN) heaters. To
enter new temperature settings, press the MODE button,select the desired temperature by
pressing the UP/DOWN buttons and press the MODE button again to confirm the selected
value.
The lower pushbuttons switch the heater of each product “on”and “off”. Each pushbutton
incorporates an LED which lights up when the heater is operating; a flashing LED indicates that
the heater is “on”but is not heating up.
The heater will temporarily stop working in the event of excess pressure in either of the heating
circuits and will switch “on”again once the problem has disappeared.
If the temperature control sensor is not active, the symbol (---) will appear on the display and the
heater will switch “off”.
The hose heating command is not memorized by the unit and therefore it must be activated “on”
every power-up.
4. Mode button
Press this button to modify the different control parameters.
5. Up / Down buttons
Increase or decrease the value of each parameter.
6. Counter
This display indicates the number of cycles completed, and the number of cycles remaining.
The cycle counter is incremental and can be reset to zero by pressing the UP and DOWN
buttons simultaneously.
The system offers a certain number of work cycle pre-selects. When the unit completes the pre-
selected number of cycles, it stops dispensing product.
To enter the desired number of cycles, press and hold the MODE button until the cycle counter
starts flashing, then select the number of cycles by pressing the UP / DOWN buttons as
required. Then press the MODE button again to confirm the number of cycles.
When the unit starts, the number of completed cycles is deducted from the number of pre-set
cycles. When all the pre-set cycles have completed, the counter displays zero and the unit
stops.
The counter display alternately shows (at intervals of two or three seconds) the number of
cycles completed (totalizer) and cycles remaining (preselector). The remaining cycles are
displayed with a minus sign (-) in front (-XXXXX).
The cycle counter display also shows alerts in the event of malfunction.
You can use the cycle counter remaining as a minimum level indicator in the tanks (integrated
or external). To do this, you must calculate the cycles to program so that the machine stops
warning that you must fill the product tanks. It is recommended to perform the calculation on
93% of the real capacity of the product tank. For this calculation, you must divide 93% of the
liters of said tank by the capacity in cubic decimeters of the corresponding product pump.
For example, if you have a 240 liters isocyanate tank and the machine is equipped with #7.6
isocyanate pump:
93% of 240 l = 223,2 l
#7,6 = 0,076 dm3
223,2 l / 0,076 dm3 = 2937 cycles
In case for integrated 30l tanks and #4.5 product pumps:
93% of 30 l = 27,9 l
#4,5 = 0,045 dm3
27,9 l / 0,045 dm3 = 620 cycles

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For machines with different product tanks or pumps, you must perform the calculation for each
product and program the most unfavorable result (the result with the least number of cycles).
When the counter reaches zero the machine stops in order not to pump air from the tanks into
the system and alerting the lack of product in the tanks. Once the programmed cycles have
been consumed, you must reset the counter and fill the tank if you want to reuse as a low
product level tanks.
7. Control / Power button
This button controls the power switch providing electrical power to the heating circuits of the
heaters and hoses (if applicable). When pressed, this button lights up. To disconnect the power
supply, press this button again. The power supply automatically cuts out in the event of an
alarm for excess temperature in the heaters (alarms 6 and 7) or an alarm for excess intensity in
the hose heating (alarm 9).
8. Motor button
This button starts and stops the hydraulic motor. When pressed, this button lights up. To switch
off the hydraulic motor, press this button again. The hydraulic motor switches off automatically
in the event of hydraulic motor overload (alarm 8). The “Motor” function is only available on
units with hydraulic drive.
9. Normal button
Press this button to activate normal operation. When pressed, this button lights up.
10. Retract button
Pressing this button sets the piston of the isocyanate proportioning pump to the retracted
position to prevent product residue from crystallizing on the piston. Press the RETRACT button
every time you stop the unit. When pressed, this button lights up.
11. Direction indicator lights
These lights indicate the direction of movement of the proportioning pumps (left light for
downward movement, and right light upward movement). When there is excess pressure in the
system, both these lights go out and alarms 3 and 4 are activated. The NORMAL and
RETRACT buttons remain active.

NI–3PE~400V
Service manual
18/56 Issue 1.1 Ref. NR-00052-ENG
http://www.novag.eu
In the event of a malfunction affecting the operation of the unit, it emits an audio signal and
shows an alarm code on the COUNTER/CONTADOR display. An alarm cannot be cleared until
the problem which caused it has been resolved. After clearing the alarm, press the MODE
button.
Procedures for determining the causes of alarms are given below:
1. Operating voltage under 170V
•Check the electrical power connection.
•Check the transformer’s thermomagnetic protection.
2. Operating voltage above 270V
•Check the electrical power connection.
3. Excess pressure ISO (solenoid valve and heating system cut-out)
•Check product pressure.
•Check LED no. 10 on the printed circuit board: it should be on.
•Check the safety pressure switch.
4. Excess pressure POL (solenoid valve and heating system cut-out)
•Check product pressure.
•Check LED no. 11 on the printed circuit board: it should be on.
•Check the safety pressure switch.
5. Excess temperature ISO (CONTROL/POWER cut-out)
•Check the heater heating system.
•Check the safety pressure switch connection and allow it to cool down so it can
automatically reset.
•Check LED no. 12 on the printed circuit board: it should be on.
6. Excess temperature POL (CONTROL/POWER cut-out)
•Check the heater heating system.
•Check the safety pressure switch connection and allow it to cool down so it can
automatically reset.
•Check LED no. 13 on the printed circuit board: it should be on.
7. Button malfunction (only active when machine is connected to the power supply)
•Check the buttons.
8. Motor malfunction (motor stoppage)
•Check the consumption of the hydraulic motor.
•Check the electrical connections of the hydraulic motor.
•Check LED no. 15 on the printed circuit board: it should be off.
ALARMS

NI–3PE~400V
Service Manual
19/56 Issue 1.1 Ref. NR-00052-ENG
http://www.novag.eu/
9. Hose heating system malfunction (CONTROL/POWER cut-out)
•Replace the faulty triac.
000000 Preselected cycles completed (solenoid valve cut-out)
•Press the MODE button to reset the counter.
•Set the cycle selector to zero.
Disconnect the unit from the power supply before opening the electrical
console. Electrical maintenance of the machine should only be carried out
by a qualified electrician.

NI–3PE~400V
Service manual
20/56 Issue 1.1 Ref. NR-00052-ENG
http://www.novag.eu
Follow the torques for threaded joints listed in Table 1
according to thread sizes of hose fittings to ensure their
proper assembly.
There is also an alternative procedure to obtain an
equivalent torque without using special tools: joint both
ends of the hoses to be connected, tighten a swivel nut
by hand (without using spanner) until there is resistance
on the nut. Fit two spanners (1) on the fixed ends of the
hoses and turn the swivel nut with a third spanner (2) as
many flats from wrench resistance (FFWR) as indicated
in Table 1.
Table 1. Tightening Threaded Joints
THREAD
SIZE
TORQUE
Nm
FFWR
1/2”-20
23
2 (or 120º)
9/16”-18
30
1-1/2 (or 90º)
NOTE: 1 FFWR corresponds to one complete shear of a flat marked with red between
swivel and fitting or else 60º.
METHOD OF THREADED UNION OF THE HOSES