Novag III User manual

Service Manual
Proportioning Unit
novaG - III
Issue 2.7 13/02/19
Ref. NR-00002-ENG
Before installing the unit and starting it up, carefully read all the technical
and safety documentation included in this manual. Pay special attention
to the information to know and understand the operation and the
conditions of use of the unit. All of the information is aimed at enhancing
User Safety and avoiding possible breakdowns derived from the incorrect
use of the unit.

novaG - III
Service Manual
2/42 Issue 2.7 Ref. NR-00002-ENG
http://www.novag.eu/
HI-TECH SPRAY EQUIPMENT (hereinafter “HI-TECH”) provides this LIMITED WARRANTY (hereinafter “Warranty”) to
the original purchaser (hereinafter “Customer”) covering this equipment and the original HI-TECH manufactured
accessories delivered with the equipment (hereinafter “Product”) against defects in material or workmanship of the
Product (hereinafter “Defect” or “Defective”) for a period of two (2) years from the date of first purchase as shown on the
original HI-TECH invoice (hereinafter “Warranty Period”).
If during the Warranty Period under normal use, the Product is suspected by Customer to be Defective in material or
workmanship, it is Customer’s responsibility to contact HI-TECH and return the Product to HI-TECH as directed by HI-
TECH, freight prepaid. If HI-TECH determines that the Product is Defective and that such Defect is covered by this
Warranty, HI-TECH will credit Customer for the reasonable freight charges incurred by Customer in returning the
Defective Product to HI-TECH, and HI-TECH (or its authorized agent) will, at HI-TECH’s option, repair or replace the
Product, subject to the following:
Original Invoice: The original invoice must be kept as proof of the date of first sale and the Product serial number. The
Warranty does not cover any Product if the Original Invoice appears to have been modified or altered, or when the serial
number on the Product appears to have been altered or defaced.
Product Maintenance: It is the Customer’s responsibility to maintain the Product properly. See your maintenance
schedule and owner’s manual for details. The Warranty does not cover an improperly maintained Product.
Non-HI-TECH Components and Accessories: Non-HI-TECH manufactured components and accessories that are used
in the operation of the Product are not covered by this Warranty. Such components and accessories shall be subject to
the warranty offered to the Customer, if any, by the original manufacturer of such component or accessory.
Other Warranty Exclusions: The Warranty does not cover any Product that HI-TECH determines has been damaged or
fails to operate properly due to misuse, negligence, abuse, carelessness, neglect, or accident. By way of example only,
this includes:
•Normal wear an tear.
•Improper or unauthorized installation, repair, alteration, adjustment or modification of the Product.
•Use of heating devices, pumping equipment, dispensers, or other parts or accessories with the Product that
have not been approved or manufactured by HI-TECH.
•Failure to follow the operating instructions and recommendations provided by HI-TECH.
•Cosmetic damage.
•Fire, flood, “acts of God,” or other contingencies beyond the control of HI-TECH.
THE WARRANTY DESCRIBED HEREIN IS THE EXCLUSIVE REMEDY FOR THE CUSTOMER AND IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS, IMPLIED, STATUTORY OR OTHERWISE, AND THE IMPLIED WARRANTIES OF MERCHANTABILITY
AND FITNESS FOR A PARTICULAR PURPOSE AND ALL OTHER WARRANTIES ARE HEREBY DISCLAIMED. TO THE FULLEST
EXTENT PERMITTED BY LAW, HI-TECH SHALL NOT BE RESPONSIBLE, WHETHER BASED IN CONTRACT, TORT (INCLUDING,
WITHOUT LIMITATION, NEGLIGENCE), WARRANTY OR ANY OTHER LEGAL OR EQUITABLE GROUNDS, FOR ANY
CONSEQUENTIAL, INDIRECT, INCIDENTAL, LOST PROFITS, SPECIAL, PUNITIVE OR EXEMPLARY DAMAGES, WHETHER TO
PERSON OR PROPERTY, ARISING FROM OR RELATING TO THE PRODUCT, EVEN IF HI-TECH HAS BEEN ADVISED OF THE
POSSIBILITY OF SUCH LOSSES OR DAMAGES.
Non-Warranty Service by HI-TECH: If HI-TECH determines that the suspected Defect of the Product is not covered by
this Warranty, disposition of the Product will be made pursuant to the terms and conditions of HI-TECH’s written
estimate on a time and materials basis.
Continuing Warranty for Products Repaired or Replaced under Warranty: Following the repair or replacement of a
Product covered by this Warranty, such Product will continue to be subject to the original Warranty for the remainder of
original Warranty Period or for three (3) months from the repair or replacement date, whichever is longer.
No Rights Implied: Nothing in the sale, lease or rental of any Product by HI-TECH shall be construed to grant any right,
interest or license in or under any patent, trademark, copyright, trade secret or other proprietary right or material owned
by anyone; nor does HI-TECH encourage the infringement of same.
Exclusive Warranty: This writing is the final, complete, and exclusive expression of the Warranty covering the Product.
Any statements made by HI-TECH, its employees or agents that differ from the terms of this Warranty shall have no
effect. It is expressly understood that Customer’s acceptance of this Warranty, by performance or otherwise, is upon
and subject solely to the terms and conditions hereof, and any additional or different terms and conditions proposed or
expressed by Customer or anyone, whether in writing or otherwise, are null and void unless specifically agreed to in
writing by an Officer of HI-TECH.
WARRANTY

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All information provided in this Service Manual is assumed to be correct; although this does not
constitute any implicit or explicit liability or guarantee. HI-TECH reserves the right at any time
and without prior warning to make all improvements and modifications necessary to this Service
Manual, in order to rectify any possible typographical errors, supplement the information
contained or insert changes predicated by the performance or use of the unit.
The novaG - III series metering unit has been designed and manufactured in full compliance to
the provisions of Machine Directive 89/392/CEE in its modified form and the National
Regulations that transpose it. It also meets all European Directives concerning electromagnetic
compatibility and electrical safety and the provisions of the Harmonised Norms that are
applicable.
This chapter contains information on the safety, handling and use of the novaG - III series
metering unit.
Before installing the unit and starting it up, carefully read all the technical
and safety documentation included in this manual. Pay special attention
to the information to know and understand the operation and the
conditions of use of the unit. All of the information is aimed at enhancing
User Safety and avoiding possible breakdowns derived from the incorrect
use of the unit.
WARNING! Establishes information to alert on a situation that might cause serious
injuries if the instructions are not followed.
PRECAUTION! Establishes information that indicates how to avoid damage to the unit
or how to avoid a situation that could cause minor injuries.
NB: is relevant information on a procedure being carried out.
Careful study of this manual will enable the operator to know the characteristics of the unit and
the operating procedures. By following the instructions and recommendations contained herein,
you will reduce the potential risk of accidents in the installation, use or maintenance of the unit;
you will provide a better opportunity for incident-free operation for a longer time, greater output
and the possibility of detecting and resolving problems fast and simply.
Keep this Service Manual for future consultation of useful information at all times. If you lose
this manual, ask for a new copy from your HI-TECH local distributor or directly contact HI-TECH
SPRAY EQUIPMENT.
WARNING! The design of the novaG - III series metering unit does not allow its use in
potentially explosive atmospheres or to exceed the pressure and temperature limits
described in the technical specifications of this manual.
SAFETY AND HANDLING

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When working with the unit, it is recommended that the operator wear suitable clothing and
elements of personal protection, including, without limitation, gloves, protective goggles, safety
footwear and face masks. Use breathing equipment when working with the machine in
enclosed spaces or in areas with insufficient ventilation. The introduction and follow-up of
safety measures must not be limited to those described in this manual. Before starting up the
machine, a comprehensive analysis must be made of the risks derived from the products to be
dispensed, the type of application and the working environment
To prevent all possible bodily harm caused by incorrect handling of the
raw materials and solvents used in the process, carefully read the safety
information provided by your supplier.
Deal with the waste caused according to current regulations.
Disconnect the unit from the power supply before carrying out any
operation inside the electrical console.
The electrical maintenance of the machine must only be performed by a
qualified electrician.
To avoid damage caused by the impact of pressurized fluids, do not open
any connection or perform maintenance work on components subject to
pressure until the pressure has been completely eliminated.
Use suitable protection when operating, maintaining or remaining in the
operating area of the unit. This includes, but is not limited to, the use of
masks, protective goggles, gloves, shoes and safety clothing.
The unit includes components that reach temperatures that are liable to
cause burns. The hot parts of the unit must not be handled until they
have cooled.
To prevent serious harm by crushing or loss of limbs, do not work with
the unit without the safety guards installed on all moving parts. Make
sure that all of the safety protections are correctly reinstalled after all
repair or maintenance work is completed.

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The novaG - III metering unit has been designed and built for the application of Polyureas,
chemical systems for polyurethane foaming and some two-component epoxy systems.
Principal Heating System
Consists of two independent heaters without seals. Each heater has four 1500 W heating
elements, that give the unit a total power of 6000 W, and the necessary control and safety
components for precise operation of the system. Its singular configuration allows a temperature
differential (ΔT) of 90º F and application temperatures of up to 194º F under normal conditions
of ambient temperature.
Hose Heating System
Designed with a 3000 W isolation transformer that
enables effective heating up to a total hose length of
305 feet for foam and 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.
Double Acting Opposed Piston Metering Pumps
A pump line driven by a double rod hydraulic cylinder. The in line pump system with opposed
piston pumps provides a constant volume and guarantees uniform pressures in both directions
of pump movement. Different sized pumps allow for various volumetric ratios to be achieved
(1:4 to 4:1) between the chemical components used in the process.
CHARACTERISTICS

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Electrical
Main voltage: ______________________________________________________ 230 V / 400 V
Frequency: ____________________________________________________________50/60 Hz
Electrical consumption: ________________________ 66.5 A @ 3 x 230 V / 38.4 A @ 3 x 400 V
Pre Heater power: _______________________________________________ (2 x 6 kW) 12 kW
Hose Transformer Power (*): _________________________________________________3 kW
Electrical Motor Power: _____________________________________________________4 kW
Total Active Power: _______________________________________________________19 kW
Inside the console, there is a terminal strip for connecting the main power
(wire not supplied) to the unit. The electrical connection of the unit must
only be carried out by a qualified electrician.
Mechanical
Maximum working pressure P1 (with pumps 1.2):___________245 kgf/cm2 (24 MPa) / 3481 psi
Max. Production ratio 1:1 (with pumps 1.2 @ P1):___________________ 8 kg/min / 17.64lb/min
Normal working pressure P2 (with pumps 1.2): ____________163 kgf/cm2 (16 MPa) / 2320 psi
Max. Production ratio 1:1 (with pumps 1.2 @ P2):___________________12 kg/min / 26.5 lb/min
Minimum production: ___________________________________________1 kg/min / 2,2 lb/min
Maximum hose length for foam:_________________________________________ 93 m / 305 ft
Maximum hose length for polyurea:______________________________________ 78 m / 256 ft
Recommended compressor: _________________________________________ 3 HP III phase
Approximate weight (hydraulic tank empty): _____________________________ 250 kg / 551 lb
Approximate weight (hydraulic tank full): ________________________________ 309 kg / 681 lb
Dimensions: ___________________________________________________H: 1352 mm / 53 in
W: 945 mm / 37 in
L: 745 mm / 29 in
(*) For temperatures above 75ºC (167ºF), the maximum hose length will be 78m (256 ft)
TECHNICAL SPECIFICATIONS

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Figure 1. General Description.
GENERAL DESCRIPTION

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1. Control Panel
Controls and regulates the operation of the unit.
2. Isocyanate Metering Pump
Meters the Isocyanate.
3. Polyol Metering Pump
Meters the Polyol.
4. Isocyanate Pre Heater
Heats the Isocyanate to the pre-set temperature.
5. Polyol Pre Heater
Heats the Polyol to the pre-set temperature.
6. Hose Heating Transformer
Supplies the required voltage for heating the hoses.
7. Hydraulic Pressure Gage
Indicates the pressure in the hydraulic drive system.
8. Isocyanate Pressure Gage
Indicates the pressure in the Isocyanate system.
9. Isocyanate Safety Pressure Switch
Deactivates the directional valve in the event of excessive pressure in the Isocyanate system.
10. Isocyanate Temperature probe
Provides information on the temperature of the Isocyanate.
11. Polyol Pressure Gage
Indicates the pressure in the Polyol system.
12. Polyol Safety Pressure Switch
Deactivates the directional valve in the event of excessive pressure in the Polyol system.
13. Polyol Temperature Probe
Provides information on the temperature of the Polyol.
14. Recirculation Kit
15. Hydraulic Pressure Regulator
Allows the pressure of the hydraulic system to
be increased or decreased. Turn clockwise
to increase the pressure and
counterclockwise to reduce it. In order to
regulate the pressure of the hydraulic system,
the NORMAL or RETRACT key must be
activated.
Regulate the hydraulic system so that the output pressure of the unit
never exceeds the pressure of work of the installed product hoses.

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16. DIP S1 Selector TPC Probes
This sets the hose heating control mode
to be selected, depending on whether
the system includes a single
Temperature Control Sensor (TCS) for
automatic temperature control or no
TCS for manual temperature control.
Please be aware that after
manipulating the DIP selector you
should switch off the unit so the
change. (in detected buy the board).
17. DIP S2 Selector Control Units
This sets the pressure and temperature
units that will be shown on the control
panel displays to Metric or English. Set
to EU for the pressure to be shown in
bar and the temperature to be shown in
degrees Celsius. Set to USA for the
pressure to be shown in psi and the
temperature to be shown in degrees
Fahrenheit. Please be aware that after
manipulating the DIP selector you
should switch off the unit so the
change. (in detected buy the board).
18. DIP S3 selector –Input Voltage selector
It allows selecting the input voltage. Moving the 1 switch to ON for 230V with neutral and to OFF
for 400V without neutral. Selection is factory set and cannot be modified without HI-TECH
technical service authorization. Please be aware that after manipulating the DIP selector
you should switch off the unit so the change (in detected buy the board).

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Figure 2. Control Panel
The Control Panel allows the optimum working conditions to be selected and set, depending on
the characteristics and requirements of the products to be dispensed. Using the MODE key, the
different control parameters may be entered. The parameter display will flash for a few seconds
to allow the change of this value by pressing the UP / DOWN keys. Once the change is made,
press the MODE key once more for the new value to be entered into memory and to select the
next parameter for setting.
The modification mode will be interrupted automatically after 3 seconds without activity on the
keyboard.
The parameters that may be selected and displayed are the following:
•Hose temperature in automatic control mode (maximum 80º C / 176º F)
•Hose heating power (maximum 50 Amps)
•Isocyanate heater temperature (maximum 90ºC / 194º F)
•Polyol heater temperature (maximum 90ºC / 194º F)
•Total number of cycles to be made
•Number of cycles made
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
The display shows the temperature of the Isocyanate hose
(ISO) and the temperature of the Polyol hose (RESIN).
The hose heating control may be automatic (optional) if using
a Temperature Control Sensor (TCS) or manual. The control
mode must be established with the two DIP selectors on the printed circuit board (S1).
If the TCS is located in the ISO hose (the recommended placement), then set the Isocyanate
DIP selector to ON and the Polyol DIP selector to OFF. In this setup, the Isocyanate
temperature will show on the indicator and the Polyol indicator will be blank. If the hose heat
system does not include a TCS or the sensor is inoperative, then set both DIP selectors to OFF.
In this setup, both temperature indicators will be blank. In the units equipped with two hose
transformer power, locate the DIP “Hose ISO” and the DIP “Hose RESIN” to ON position if the
hoses have TCS for the temperature control system, or OFF position if the hoses not have TCS.
Please be aware that after manipulating the DIP selector you should switch off the unit so
the change. (In detected by the board).
ISO on / RESIN off
w/TCS
ISO off / RESIN off
manual control
Dual Hose Heat
(optional)
To select the temperature when the unit is working in automatic control mode, press the MODE
key until the temperature flashes,select the required temperature by pressing the UP/DOWN
keys and press the MODE key once more to enter the selected value into memory. Repeat the
process to select the Amps. When the unit is in automatic mode, the value of the power must
be set between 45 and 50 Amps.
Hose temperature settings that are higher than the temperature settings of the heaters cannot
be programmed.
If only one temperature control system is working (ISO or POL), the limiting temperature value
will be the highest set in the heaters.
If both temperature control systems are working (ISO and POL), the limiting value will be related
to each of their corresponding heaters.
Temperature settings are restricted to 80ºC maximum for hoses and 90ºC maximum for
heaters.

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For the data input, the order will be as follows:
•Temperature set-point for A (ISO) heater and B or R (POL).
•Temperature set-point for A (ISO) hose and B or R (POL).
•Amps set-point for A (ISO) and B or R (POL).
•Ratio adjustment.
•Cycles pre-selection.
•Date input
If the TCS stops working, the temperature display will show the symbol (---)and the heating will
be automatically turned off.
AT start-up, the hose heat set point is not maintained in memory and must be reset after each
activation of the CONTROL POWER key.
To select the hose power when the unit is working in manual heating control mode, press the
MODE key until the amperage flashes,press the UP / DOWN keys to enter the number of amps
required and press the MODE key once more to enter the value into memory.
Refer to the table shown below to select the power that is required to reach the 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
Select the required amps for a quick pre-heating.
N.B.:
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 settings programmed by the machine operator will be stored for the next time the
heating is switched on.

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3. Heaters
The display shows the temperature in the Isocyanate heater (ISO) and the temperature in the
Polyol heater (RESIN). To enter new temperature values, press the MODE key until the
respective temperature flashes;select the required temperature by pressing the UP/DOWN
keys and press the MODE key to enter the value into memory.
The pushbuttons turn on or off the heater of each product. Each pushbutton has a led that lights
steady when the heater is on; if the led flashes, it indicates that the heater is at the preset
temperature.
If the temperature control probe stops working, the temperature display will show the symbol
(---)and the heater will automatically be turned off.
AT start-up, the heater set point is not maintained in memory and must be reset after each
activation of the CONTROL POWER key.
4. Mode Key
Allows access to change the different control parameters.
5. Up / Down Keys
Allows the value of each of the parameters to be increased or decreased.
6. Pressure
Indicator displays the Isocyanate pressure (ISO) and the Polyol (RESIN)
Using the DIP S2 selector labeled USA and EU, the units of
pressure and temperature can be set. Set the switch 1 of DIP
S2 selector to EU (ON) for the pressure to be displayed in bar
and the temperature in degrees Celsius; set the switch 1 of DIP
S2 selector to USA (OFF) for the pressure to be displayed in psi and the temperature in
degrees Fahrenheit. Please be aware that after manipulating the DIP selector you should
switch off the unit so the change. (In detected by the board).
7. Counter
Indicator displays the cycles used and the cycles remaining from the preset. The cycle counter
is incremental and may be reset by simultaneously pressing the UP / DOWN keys.
The system allows pre-selecting the required number of working cycles so that the unit will
automatically stop when it reaches this number. To enter the number of cycles to reach
automatic shutdown, press the MODE key until the cycle meter flashes, select the number of
cycles with the UP / DOWN keys and press the MODE key to enter the value into memory.
When the unit starts, the cycles used will be deducted from the pre-selected cycles until the
total number of cycles requested is completed. Once completed, the display will show zero and
the unit will automatically stop.
The cycle meter display will alternate every two or three seconds to show the cycles used
(totalizer) and the cycles remaining (pre-set). The cycles remaining will be shown by the
Minus sign (-XXXXX). The counter display will also show any alarm warnings resulting from
faults.
8. Power Control Key
Pushbutton turns on and off the control voltage to the electrical circuit of the heaters and hoses.
When the key is on, the led in its center will come on. It may be turned off at will by pressing the
key once more, or automatically if an alarm is caused due to excessive temperature in the
heaters (alarms 6 and 7) or due to excessive current in the heating system of the hoses (alarm
9).

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9. Motor Key
Pushbutton turns on and off the hydraulic motor. When the key is active, the led in its centre will
come on. This may be turned off at will by pressing the key once more, or automatically in the
event of overload in the hydraulic motor (alarm 8).
10. Ratio Key
Controls that the pressure difference between the two components will not be higher than the
programmed (between a 5 and a 25%), if the difference is greater than, the alarm number 10
will be activated. The system to monitor the pressure differential is activated five seconds after
pressing the NORMAL key and allows the differential to be exceeded for two seconds before
the alarm is set off. The ratio control parameters are factory set. When the key is active, the led
in its center will come on.
11. Normal Key
Activates the normal operation of the machine. When the key is active, the led in its center will
come on.
12. Retract Key
Sets the piston rod of the Isocyanate metering pump to the retract position and prevents the
crystallization of Isocyanate on the piston rod. Press the RETRACT key every time the unit is
stopped by the operator. When the key is active, the led in its center will come on.
13. Direction Indicator Pilot Lights
Indicates the direction of movement of the metering pumps. If excessive pressure is caused in
the system, the pilot lights will be turned off and alarms 3 and 4 will be set off. The functions of
the NORMAL and RETRACT keys will remain active
14. USB Port
Connector to insert device of massive storage for capture of data.
Only installed in Units provided with Logger (standard Units).

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When the unit has faults caused by conditions affecting its correct operation, an audible alarm
will sound and a fault number will show on the COUNTER display. The system does not allow
an alarm to be reset until the fault causing the alarm has been corrected. After resetting, the
MODE key must be pressed.
The procedures recommended to determine the possible causes activating the alarms are
indicated in the following:
1. Maneuvering Voltage under 170 V
•Check the electrical supply connections.
•Check the transformer thermal limit switch.
2. Maneuvering Voltage over 270 V
•Check the electrical supply connections.
3. Excessive ISO Pressure (deactivates the directional valve and the heating system)
•Check the product pressure.
•Check the number 10 led of the printed circuit: it must be lit.
•Check the over pressure safety switch.
4. Excessive POL Pressure (deactivates the directional valve and the heating system)
•Check the product pressure.
•Check the number 11 led of the printed circuit: it must be lit.
•Check the over pressure safety switch.
5. Excessive ISO temperature (deactivates the POWER CONTROL)
•Check the heater heating system.
•Check the connections of the safety thermostat and allow it to cool so that it makes an
automatic reset.
•Check the number 12 led of the printed circuit: it must be lit.
6. Excessive POL temperature (deactivates the POWER CONTROL)
•Check the heater heating system.
•Check the connections of the safety thermostat and allow it to cool so that it makes an
automatic reset.
•Check the number 13 led of the printed circuit: it must be lit.
7. Fault key (it only turns on when the machine is connected to the mains)
•Check the keyboard.
8. Motor fault (the motor stops)
•Check the amperage draw on the hydraulic motor.
•Check the electrical connection of the hydraulic motor.
•Check the number 15 led of the printed circuit: it must be turned off.
9. Fault in Hose Heating System (deactivates the POWER CONTROL)
•Replace the faulty triac.
ALARMS

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10. Fault Ratio Off Tolerance (deactivates the directional valve)
•Check the product pressures.
•Replace the pressure transducer if there is no reading.
•Press the ratio key to cancel the function.
11. 000000 Cycle Pre-selection made (deactivates the directional valve)
•Press the MODE key to reset the counter
•Set the cycle selector to zero.
Disconnect the unit from the main power supply before working on the
inside of the electrical console. The electrical maintenance of the
machine must only be performed by a qualified electrician.

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PRECAUTION! Use suitable protection and follow the recommendations in the safety
information provided by product suppliers when installing or working with the unit.
HI-TECH provides a series of tools and accessories necessary for assembling the machine. The
kit is made up of the following elements:
BI-00009
Tube of grease Lubriplate 1.75 oz./ 49 gr
1x
NEL-00051-00
TCS for ISO hose & longer RESIN hose
1x
EM-00006
CD with Manuals
1x
HT-00001
Magnet holder tools
1x
HT-00003
Pin extractor
1x
KT-00040-PKG
Kit adaptation Fast-Lock
1x
Inside the console there is a terminal strip for connecting the principal
electrical wire (not supplied) to the unit. The electrical connection of the
unit must only be carried out by a qualified electrician.
NB: To ensure that the unit works correctly, the electrical supply must meet the
specifications indicated on page six of this manual and appearing on the machine
specifications plate.
Follow the recommended procedure in the indicated order to install the unit:
a) Insert the main power cable by passing it through the wire stop at the bottom of the
electrical console and connect as shown in the diagram.
INSTALLATION

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Make sure the power cable is disconnected from the mains source before connecting it
to the terminal strip in the console.
b) Load 63 liters (16.6 gal)
of hydraulic fluid into the
tank of the unit. The oil
must be of the
characteristics and
specifications of DIN
51524 standard, sections
1 and 2 (for example. ISO
VG 46).
PRECAUTION! Do not fill the tank to maximum capacity (81 Lts –
21.4 gal); make sure the amount of oil is not more than 78% of its
maximum capacity (63 Lts. –16.6 gal). Use the visual level indicator
of temperature on the tank as a reference, because the maximum
temperature limit (80ºC –176ºF) coincides with the advised
capacity.
c) Fill the lube reservoir of the Isocyanate pump with DOTP. It is
not necessary to prime the system.
d) Connect the hoses of the products to the outlets of the
respective heaters (the Isocyanate hose to the Isocyanate
heater and the Polyol hose to the Polyol heater).

novaG - III
Service Manual
19/42 Issue 2.7 Ref. NR-00002-ENG
http://www.novag.eu/
NB: The product hoses have been identified with red (Isocyanate) and blue (Polyol),
enabling them to be rapidly distinguished. To avoid errors in connecting the coupling
connectors of the Isocyanate and Polyol hoses, the connectors are of different sizes to
make it impossible for connections to be swapped.
Figure 3. Method of Assembling the Hoses
WARNING! To join the hoses together or to connect them to the heaters or the gun,
use two spanners to hold the parts to be joined (1) and a third spanner to tighten or
loosen the connecting nut (2) as shown the illustrations. The connections must be
tightened to a torque of 20 Nm.

novaG - III
Service Manual
20/42 Issue 2.7 Ref. NR-00002-ENG
http://www.novag.eu/
The hoses receive vacuum drying treatment and are supplied interconnected at the ends to
prevent them from absorbing moisture. Do not separate them until they are going to be installed
in the unit.
The hose connection
system includes special
terminals (fast lock) to
facilitate the electrical
connection to the
transformer and between
the different sections
installed in the unit.
The transformer offers
the option of connecting
to a 40 V output voltage
valid for a total hose
length of up to 48 meters
(158 ft), or an output
voltage of 75 V, for hose
lengths exceeding 48
meters (158 ft) to 93
meters (305 ft). Connect
to one output voltage or
the other depending on
the total hose length
installed. Before starting up the unit, make sure that the connection made in the factory adapts
to the total length of hose installed. If you add or eliminate sections of hose, make sure the
output voltage of the transformer to which it is connected is suitable for the resulting total length.
Otherwise, change the connection.
e) Connect the heated hoses wires to the “fast lock” connector coming out of the hose
transformers as follow:.
a. Unscrew the Nylon Safety
Plug from the “fast lock”
connector body.
b. Unscrew partially the Socket
Head Set Screw from
electrical wires.
c. Insert the heated hose
electrical wire with terminals
into the “fast lock” connector
body.
d. Tighten the Socket Head Set
Screw of the terminals and
place the Nylon Safety Plugs
NB: A good practice is to add some dielectric grease to the ID of the connector.
Repeat the same steps to connect the “fast lock” that you will find in the middle hose
connections
f) Connect the rest of the product hoses to complete the required length. Remember that
the hoses are identified with red (Isocyanate) and blue (Polyol).
NB: Assure the proper mechanical and electrical connection of the hoses to avoid
possible product leakage and hose heat problems.