UC4 Total Control Automatic Boom Height System NITRO (Miller 200 Series 1999+, 120-ft Boom) Installation Manual Canada NORAC Systems International Inc. CALL TOLL FREE: 1-800-667-3921 (306) 664-6711 SHIPPING ADDRESS: 3702 Kinnear Place Saskatoon, SK S7P 0A6 United States NORAC, Inc. CALL TOLL FREE: 1-866-306-6722 (763) 786-3080 SHIPPING ADDRESS: 1290 Osborne Rd. NE, Suite F Fridley, MN 55432-2892 For other service locations please view our website: www.norac.ca Improving the Competitiveness of Industry and Agriculture through Precision Measurement
Printed in Canada Copyright 2006-07 by NORAC Systems International Inc. Reorder P/N: UC4-BC-NT2-INST Rev D (Nitro) NOTICE NORAC Systems International Inc. reserves the right to improve products and their specifications without notice and without the requirement to update products sold previously. Every effort has been made to ensure the accuracy of the information contained in this manual. The technical information in this manual was reviewed at the time of approval for publication.
TABLE OF CONTENTS 1 INTRODUCTION... 2 2 GENERAL SYSTEM DESCRIPTION... 3 3 PARTS LIST... 4 4 INSTALLATION PROCEDURE... 9 4.1 EXISTING HYDRAULIC SYSTEM FUNCTION CHECK... 9 4.2 BOOM SPEED TEST... 10 4.3 WING SENSOR INSTALLATION... 12 4.4 MAIN LIFT SENSOR INSTALLATION... 16 4.5 HYDRAULIC INSTALLATION... 18 4.5.1 Valve Assembly (Single-acting cylinders)... 18 4.5.2 Valve Mounting... 20 4.5.3 Hydraulic Plumbing... 21 4.6 ELECTRICAL INSTALLATION... 22 4.7 COMPLETING THE INSTALLATION... 25 5 APPENDIX A - ELECTRICAL REFERENCE: CABLE DRAWINGS... 26 5.1 ITEM C1: 44662B SENSOR TRUNK CABLE... 26 5.2 ITEM C2: 44668 SENSOR BRANCH CABLE... 26 5.3 ITEM C3: 44656 VALVE CABLE (VARIABLE RATE)... 27 5.4 ITEM C4: 44651 VALVE EXTENSION CABLE... 27 5.5 ITEM C10: 44650-22 POWER CABLE UC3 BC NITRO... 28 5.6 ITEM C11: 44688 VALVE DISCONNECT EXTENSION 4-FT... 29 6 APPENDIX B - MOUNTING A SENSOR IN THE WHEEL TRACK... 31 6.1 MOVING THE ROLL SENSOR... 32 6.2 TURNING THE CENTER (MAIN LIFT SECTION) OFF... 32 6.3 ADJUST THE SENSOR OFFSET... 32 6.4 ADD AN ADDITIONAL SENSOR... 33
1 INTRODUCTION Congratulations on your purchase of the Norac UC4 automated sprayer boom height control system. This system is manufactured with top quality components and is engineered using the latest technology to provide operating features and reliability unmatched for years to come. When properly used the system can provide protection from sprayer boom damage, improve sprayer efficiency, and ensure chemicals are applied correctly. Please take the time to read this manual completely before attempting to install the system. A thorough understanding of this manual will ensure that you receive the maximum benefit from the system. YOUR INPUT CAN HELP MAKE US BETTER! If you find issues or have suggestions regarding the parts list or the installation procedure, please don t hesitate to contact us via the information given below: Phone: 1-800-667-3921 in Canada (Toll Free) 1-866-306-6722 in the United States (Toll Free) 1-306-664-6711 all other regions E-mail: Website: service@norac.ca www.norac.ca 2
2 GENERAL SYSTEM DESCRIPTION Figure 1 depicts the general system layout of the UC4 Sprayer Boom Control system. Figure 1 - System Components and General Location NOTICE: Every effort has been made to ensure the accuracy of the information contained in this manual. All parts supplied are selected to fit the sprayer and supply the customer with a complete installation. However Norac cannot guarantee all parts fit as intended due to the variations of the sprayer by the manufacturer. Please read this manual in its entirety before attempting installation. ATTENTION: When installing the UC4 system please be aware that at a point in the installation your sprayer booms will be inoperative until the installation is complete. Any installation procedure requiring boom movement will need to be done first. Once the hydraulics have been disconnected you must complete the electrical installation before the booms become operative. 3
3 PARTS LIST The parts that come with your UC4 Sprayer Boom System are listed in Table 1. In this document, the item number shown on the left side of this table references each part. Please ensure that all parts in your kit are present before proceeding with your installation. Table 1 - Nitro Sprayer Boom Control System Parts Item Part Number Description Pcs Len UC4-BC-NT2 KIT HARDWARE UC4 BOOM CONTROL NITRO 120FT 1 EA * BRACKET PARTS * B10 44700-05 MOUNTING BRACKET VALVE NITRO 1 EA B11 44695-4 MOUNTING BRACKET UC3 SENSOR 4IN LG 1 EA B16 44701 PLATE ACCESS PANEL 1 EA B17 44702 PLATE ACCESS PANEL COVER (POWER) 1 EA B18 44703 PLATE ACCESS PANEL COVER (TRUNK) 1 EA B19 44726 MOUNTING BRACKET NITRO SPRING BREAKAWAY SENSOR UC4 2 EA * CABLE PARTS * C1 44662B-40 CABLE UC3 SENSOR TRUNK AMPF TO AMPF BLACK STANDARD 40FEET C2 44668 CABLE UC3 SENSOR 1 AMP RECEPT 3 AMP PLUG BC 1 EA 1 EA C3 44656 CABLE VALVE VARIABLE RATE 1 EA C4 44651 CABLE VALVE EXTENSION 1 EA C10 44650-22 CABLE POWER UC3 BC NITRO 1 EA C11 44688 CABLE VALVE DISCONNECT EXTENSION 4FT 1 EA * ELECTRONIC PARTS * E1 4461BC UC4 BOOM CONTROL PANEL 1 EA E2 44631 UC4 ULTRASOUND SENSOR 3 EA 4
Item Part Number Description Pcs Len V1* 44933 or 44933S * HYDRAULIC PARTS * VALVE PACKAGE CC LS PROP 2 STATION EXPANDABLE W/FILTER VALVE BLOCK ASSEM UC4-BC 2-STATION CC/LS VARIABLE RATE 1 EA H1 101827 COUPLING HYD 8MBP 2 EA H2 104586 COUPLING HYD 6FORXR 6MORT 1 EA H3 102897 HYD HOSE END 6WC 6FJX 1 EA 100655 HYD HOSE 2 WIRE 3/8 IN 1 60 IN 104928 HYD HOSE END 6WC 8FORX 1 EA H4 102897 HYD HOSE END 6WC 6FJX 1 EA 100655 HYD HOSE 2 WIRE 3/8 IN 1 60 IN 104719 HYD HOSE END 6WC 6FORX 1 EA H11 104719 HYD HOSE END 6WC 6FORX 1 EA 104459 HYD HOSE END 6WC 6FJX90 1 EA 100655 HYD HOSE 2 WIRE 3/8 IN 1 98 IN H12 105327 COUPLING HYD 6MOR 12FORX 2 EA H14 104719 HYD HOSE END 6WC 6FORX 1 EA 104459 HYD HOSE END 6WC 6FJX90 1 EA 100655 HYD HOSE 2 WIRE 3/8 IN 1 101 IN H15 104884 COUPLING HYD 6MOR 8FORX 2 EA H16 104885 COUPLING HYD 8FORXR 8MORT 2 EA H17* 44920 SANDWICH BLOCK KIT SINGLE ACTING CONVERSION 2 EA H18 104634 COUPLING HYD 6FJCN CAP NO 6 FEMALE JIC 2 EA H50 44928 ORIFICE INSERT.047 IN ONE WAY 4 EA H51 103312 COUPLING HYD 6MB 6MJ 6 EA * MISC. PARTS * M1A 446BC-MAN-1 MANUAL UC4 BOOM CONTROL TECHNICAL LARGE BOOKLET M1B 446BC-MAN-2 MANUAL UC4 BOOM CONTROL QUICK REFERENCE SMALL BOOKLET 1 EA 1 EA M2 100084 TIE CABLE 21 IN BLACK 10 EA M3 100091 TIE CABLE 7.5 IN BLACK 150 EA 5
Item Part Number Description Pcs Len M4 104409 FOAM DISC 45 PPI CONDUCTIV 1/2 X 2-5/8 DIA 6 EA M5 105435 CHAIN 1/2 IN PLASTIC 3 42 IN M6 100660 BOLT HEX NC GR5 PLTD 1/4X1 3 EA M7 100853 NUT HEX NC GR5 PLTD 1/4 IN 3 EA M10 UC4-BC-NT2-INST MANUAL INSTALLATION UC4 NITRO 120FT 1 EA M11 100610 BOLT HEX NC GR5 PLTD 3/8X1 2 EA M12 100947 WASHER LOCK SPRING PLTD 3/8 IN 2 EA M13 100823 SCREW TAPPING NO 6 X 3/8 TRUSS 6 EA M14 105436 TUBE CLEAR PLASTIC 2-3/4" ID 1 16 IN M15 103022 BOLT HEX NC GR5 PLTD 5/16X1-1/4 4 EA M16 103025 WASHER FLAT USS 5/16 PLTD 4 EA M17 100870 NUT LOCK NYLON NC PLTD 5/16 IN 4 EA If the part number for Item V1 (NORAC valve block) is 44933S, Items H17 are not included in the kit. The #44933S valve block has solenoid valves whose engraved part number is 105723. Please see Section 4.5.1 for further details. 6
The parts that come with your UC4 System are shown below in their general installation configuration. Figure 2 UC4 Boom Control Components 7
8 Figure 3 Hydraulic Plumbing Schematic (Single-Acting Hydraulics)
4 INSTALLATION PROCEDURE Before installing the NORAC UC4 Boom Control System to your sprayer, it is necessary to check that all functions of the existing hydraulic system are working properly. Furthermore, it is informative to determine how quickly your sprayer booms and main (center) section are able to change their position without the UC4 System installed. Doing so may illustrate the design strengths and constraints of your sprayer s mechanical and hydraulic configuration. This information may also prove valuable when troubleshooting the installation, and if you need to contact NORAC for installation support. For example, NORAC support staff may use this information to determine if there are unwanted orifices (or backwards orifices) remaining in the hydraulic system when the UC4 System is installed. Drive your sprayer onto a flat piece of land, without any obstructions in the way of boom movement (e.g. power lines). Try to gain the best view of the booms and involved cylinders as you can. This may be best done with two people: one in the cab, and one outside. Perform following Function Check and Boom Speed Test. 4.1 EXISTING HYDRAULIC SYSTEM FUNCTION CHECK Check that all functions of the existing hydraulic system of your sprayer by using Table 2. There may be more functions in the existing hydraulic system. Please refer to the sprayer s operation manual and ensure checking all functions. LEFT BOOM RIGHT BOOM Table 2 Hydraulic System Function Check Sheet HYDRAULIC SYSTEM FUNCTION INNER OUTER TIP* FIELD OPERATION FOLD UNFOLD FOLD UNFOLD FOLD UNFOLD UP DOWN MAIN BOOM N/A N/A N/A N/A N/A N/A ROLL* N/A N/A N/A N/A N/A N/A * Some sprayers may not have this function/section. 9
4.2 BOOM SPEED TEST IMPORTANT: Let the sprayer run for several minutes to heat up the hydraulic oil. Raise/lower the left and right booms, main and hydraulic roll sections several times to help get the system (hydraulic oil, valve solenoids) warmed up. This will simulate field conditions and makes QUITE a difference in some cases. Grease all moving parts for consistent results. 1. Lower each boom and main section as close to the ground as possible. 2. Set your sprayer at field working RPM on the throttle and mark this value in Table 3. NOTE: You will need a stopwatch or a watch that displays seconds for the next step. 3. Individually raise the LEFT boom from its extreme LOW position to the very TOP of its travel. Note the length of time it takes for this and record this in Table 3, Trial #1 for Left UP. 4. Individually lower the LEFT boom from its extreme HIGH position to the BOTTOM of its travel. Note the length of time it takes for this and record this in Table 3, Trial #1, for Left DOWN. NOTE: You will need to be careful when lowering the booms at full speed to the bottom of their travel so that they don t hit the ground. You may want to mark positions on the cylinder pistons at which to stop the test while using another person as a spotter. Raising your main section will give you more working height to do this test. Please use common sense to avoid damage! 5. Similarly, record two more time trials (Trial #2 & #3) for the LEFT boom and record in Table 3. 6. Repeat Steps 3 through 5 for the RIGHT boom and the MAIN section. 7. Repeat a similar procedure for the hydraulic (active) roll feature (if your sprayer supports this) for the clockwise (CW) and counter-clockwise (CCW) rotations. 8. Average the times of the three trials recorded for each boom movement function (e.g. LEFT, RIGHT, etc.) and record this calculation in the appropriate Average Time slot in Table 3. 10
9. These Average Times now represent how quickly your system can react to manual control of boom functions. In Section 4.7, this procedure is repeated with the UC4 System installed for comparison and troubleshooting purposes. Table 3 Boom Test Record (WITHOUT UC4 System) Working RPM: Section: Trial #1 [Seconds] Trial #2 [Seconds] Trial #3 [Seconds] Average Time [Seconds] Left UP Left DOWN Right UP Right Down Main UP Main DOWN Roll CW Roll CCW Table 4 Boom Test Record (WITH UC4 System) Working RPM (Set this the same as in Table 3): Trial #1 Trial #2 Trial #3 Section: [Seconds] [Seconds] [Seconds] Left UP Left DOWN Right UP Right DOWN Average Time [Seconds] Main UP Main DOWN Roll CW Roll CCW 11
4.3 WING SENSOR INSTALLATION 1. For reference, an exploded view of the Breakaway Sensor Mounting Brackets is as shown in Figure 4. Figure 4 Breakaway Sensor Bracket Exploded View NOTE: When installing the Sensors, (Item E2) start with the smallest serial number on the left hand side proceeding to the largest serial number on the right hand side. This will allow for a more intuitive setup when tuning the system. This arrangement is also REQUIRED when using the QUICK SETUP feature available via the UC4 Panel software. This feature is typically used by NORAC technical support staff. 12
Figure 5 - Sensor Serial Number Installation Location 2. In order the to reduce the chance of problems, inspect the booms in their folded position. Mark the locations where the Sensor Brackets can be mounted without contacting the sprayer. Then the booms can be unfolded and the sensors mounted without having any mechanical interference. NOTE: If possible, mount the sensor brackets while the booms are in their folded position to reduce the chance of clearance errors and to ensure that the sensor and bracket will not interfere with anything when the boom is folded for transport. NOTE: Please note the maximum length of the Sensor Branch Cable (Item C2) for each branch. Note that the sensors will not be able to be mounted outside of this range on each boom and consider that some length will be taken up due to routing the cable. It might be wise to route the Sensor Branch Cable (Item C2) at this time to prevent problems. (See 4.6 Electrical Installation) IMPORTANT: Provide enough slack in the Sensor Branch Cable to account for the movement of the center section, parallel lift, and FOLDING boom movement. 13
3. Mount one ultrasonic sensor (Item E2) near the tip of each boom with the brackets provided (Item B19). Using the 8-mm nuts and lock washers provided with the sensor to attach the sensor to the bracket. The sensors should be oriented forward (ahead) of the boom. General mounting rules for ultrasonic wing sensors: When the boom is in its lowest position, the sensor mouth must be nine inches or more from the ground. The bottom of the sensor must be at least 9 inches in front the spray nozzles. The bottom of the sensor must be at least 9 inches above the spray nozzles. The sensor should be approximately vertical at normal operating heights. Insure that there are no obstructions within a 12-inch diameter circle projected directly below the center of the sensor. Improved boom tip protection and control may be obtained by mounting the sensor as close to the end of the boom as possible. However, if the sensors are mounted to the breakaway portion of the boom, the operator must be aware that due to boom geometry a breakaway action may cause the UC4 controller to force the boom dangerously close to the ground. If your particular boom breaks away in an upward direction, the sensor may read a large height and force your boom to the ground when the system is in automatic mode. Please consider this situation when mounting wing sensors. If this is your case, you may want to avoid mounting on a breakaway section. Please refer to the UC4 system warranty at the end of the UC4 Sprayer Boom Control Operator s Manual (Item M1) for implications. 14
Figure 6 - Sensor Mounting Figure 7 Cable Routing (Bracket shown is not the Nitro Bracket) The sensor cable should be run down through the tube of the mounting bracket and then behind the member the bracket is mounted onto. Cable-tie the connector in place. The cable must not be allowed to hang below the boom. (See Figure 7). 15
4. Once the sensor brackets are mounted to the boom you can make adjustments to fine-tune your particular sprayer installation. You may wish to mount the sensors starting at a small angle to allow for easier "breakaway". This will allow the sensor to "breakaway" more easily if contact is made directly to the front of the bracket. The following are typical reasons for mounting the bracket at an angle. If the bracket must make contact with another boom section when folded. If you spray in fields with many obstructions, such as beehives. Figure 8 - Sensor Angular Adjustment 4.4 MAIN LIFT SENSOR INSTALLATION 1. Mount the third sensor on the center section with the bracket provided (Item B10). Ensure you have clearance when the center section is raised and lowered. Mount this sensor pointing behind the boom, but try to keep it ahead of the spray nozzles. (See Figure 9) 2. Aim the sensor perpendicular to the ground. Tighten all the sensor bracket bolts. 16
Figure 9 Center Sensor Mounting General mounting rules for ultrasonic main lift sensors: The sensor must have a 12-inch diameter clear view of the ground without any obstructions. The sensor is to be mounted as far outward from the center of the boom as possible. Do not mount the sensor and target directly behind the tire. If mounted behind the tire there will be inadequate crop canopy to reflect the signal when using CROP mode. Ensure that there will be no contact between the sensor and the booms when folding and unfolding. Mount the sensor as low as possible while maintaining about 12-in or more above the target (i.e. The crop or the ground) and ensure that the sensor is safely high enough given the terrain and possible obstructions. NOTE: The standard kit will include an alignment fixture (Item M14). This fixture is NOT required when performing installations on sprayers that do not support boom roll movement. Discard or return M14 to NORAC. 17
4.5 HYDRAULIC INSTALLATION WARNING! The hydraulic system creates very high pressure that can injure. Before disconnecting any hydraulic lines ensure that all pressure has been bled from the system. When changing the boom hydraulic hoses leave the booms in the TRANSPORT POSITION. 4.5.1 Valve Assembly (Single-acting cylinders) 1. On a clean surface remove the plastic plugs from the "A", "B", "P", and "T" ports of the Hydraulic Valve (Item V1). 2. Install the 6MB-6MJ (Item H51) fittings on the "P" and "T" ports and tighten to 18 ft-lbs. 3. Install the orifices (Item H50) into the A and B ports as shown. An O-ring pick can be used to ease installing the orifices into their locations. Install the "B" port orifices with the notch facing outwards and the A orifices with the notch facing inwards. 4. Install the 6MB-6MJ fittings (H51) into the A and "B" ports and tighten to 18 ft-lbs. 5. Install the 6FJCN caps (Item H18) on each A fitting and tighten to 18 ft-lbs. Figure 10 Valve Block Port Assembly (Single-Acting Cylinders) 18
IMPORTANT: Check the engraved part number on the top plate of the solenoid valves (Figure 10). If the number is 105723, proceed to Section 4.5.2 (page 20). STEP 6 through STEP 13 are required for all other part numbers. 6. Assemble the Single Acting Sandwich Block Kit (Item H17). 7. Remove the 2 solenoid valves from the top of the valve block by removing the 4 Hex Socket Cap Screws from each valve and discard these 2-in long bolts. See Figure 11. 8. Coat the top and bottom of the sandwich block in clean hydraulic oil. 9. Install the 4 O-rings into the bottom of the sandwich block. 10. Place the sandwich onto the valve block with the O-rings facing downward. 11. Align the sandwich with the alignment holes. The "A" stamped into the sandwich faces the Port side of the valve block. See Figure 11. 12. Place the solenoid valves on top of each sandwich and install the 2-1/2" long bolts supplied with the sandwich. Tighten the bolts in a corner to corner pattern to 31 inlbs. 13. Finish tightening the bolts in a circular pattern and torque the bolts to 62 in-lbs. Figure 11 Sandwich Block Installation 19
4.5.2 Valve Mounting 1. A valve mounting plate (Item B10) is provided with 5/16 NC bolts. Mount the valve plate directly under the spray nozzle valves. (See Figure 12) Figure 12 Mounting Plate and Valve installation NOTE: You must ensure the valve manifold, solenoids, and hoses will not interfere with any moving parts of the sprayer. Also, you must ensure proper routing of the hoses such that they will not be pulled tight at any time. 2. Mount the valve using the bolts (Item M11) and washers (Item M12) in the location shown in Figure 12. The bolts should thread into the valve block at least 3/8". The valve mounting holes are drilled and tapped 3/8 NC-1" deep. 20
Figure 13 - Valve Mounting and Valve Cable Connections 4.5.3 Hydraulic Plumbing NOTE: After this point in the installation the booms will be inoperative until the electronics are fully installed. 1. After the NORAC valves are mounted to the sprayer, the hydraulic hoses and fittings can be installed (plumbed). The plumbing for the hydraulic circuit is shown schematically in Figure 3. Follow the schematics for routing the hoses that connect to the cylinders. 2. Connect the two remaining hoses (Items H4 and H3) to the Pressure (P) and Tank (T) ports on the NORAC valve block (V1). Connect hoses H3 and H4 to the Nitro valve block using T fittings (Items H2 and H16) provided. See Figure 3. 21
NOTE: You must also ensure there are no other orifices present in the circuit between the Norac valve block and the boom cylinders. 4.6 ELECTRICAL INSTALLATION 1. Install the UC4 control panel (Item E1) in the cab of the sprayer with the supplied mounting bracket. Mount the panel where it will be clearly visible and within easy reach of the operator. The location must facilitate connecting the power and sensor cables to the bottom of the control panel. Generally, a good spot to mount the UC4 control panel is on the right hand side of the cab to the ROP (Roll Over Protection) Bar. Four pilot holes for the screws provided need to be drilled to facilitate the mounting of the control panel. ROP Figure 14 Control Panel Mounting Figure 15 - Mounting the Control Panel with a Bracket 22
2. Locate the 16-pin AMP connector in the cable from the joystick in the cab. Connect the UC4 power cable (Item C10) between this connection. Connect the 3-pin power connector from the UC4 power cable to the power bar on the right hand side of the cab. Figure 16 UC4 Joystick Connection 3. Connect the remaining 16-pin AMP connector to the UC4 Control Panel. 4. There is an access hole located in the front right corner of the cab floor that may be seen when the floor mat is lifted. Access plates (Items B16, B17 and B18) which maintain the cab seal are provided in the UC4 kit. Route the Sensor Trunk Cable (Item C1) through the smaller hole in the access plate and attach to the UC4 control panel mounted in the cab. 5. Using the Valve Extension Cable (Item C4), connect the 6 pin GP connector from the UC4 Power Cable (C10) to the 6 pin GP connector on the Valve Cable (C3) attached to the NORAC valves. When routing this cable use the larger hole in the access plate provided. The cover plates provided may now be screwed onto the access plate to seal the cab. If your sprayer has the quick disconnect option also install the Valve Disconnect cable (C11) between the Valve Cable (C3) and Valve Extension Cable (C4). This will allow for a connection to be made at the same location as the Nitro wiring. 23
Figure 17 - Access Plates 6. Route the Valve Extension Cable (C4) and the Sensor Trunk Cable (C1) from the cab to the front of the sprayer to the area where the NORAC hydraulic valves are located. Use cable ties to fasten the Valve Extension and Sensor Trunk Cables to the sprayer. 7. Connect the UC4 Valve Cable (C3) to the Valve Extension Cable (C4) at the front of the sprayer. NOTE: The Valve Extension Cable (C4) may be packaged with one GP end not installed. This is normal; it helps installations for other sprayer types. Pin this connector on (connector included) as per drawing in section 5.4. TAKE EXTRA CARE! These pins require a special tool to remove them if you make an error! 8. Install the Valve Cable (C3) onto each NORAC valve as shown in Figure 13. The connectors on the valve cable are marked RIGHT UP, LEFT UP, RIGHT PORT ( right down ), and LEFT PORT ( left down ). Fasten with the included rubber seals and screws. Ensure that the cables are oriented as shown, with the cable labels RIGHT PORT and LEFT PORT on the SAME side as the hydraulic hoses (the port-side of the block). 9. Connect the Sensor Branch Cable (C2) to the Sensor Trunk Cable. If not done already, route the Sensor Branch Cable out to the wing sensors and center sensor and connect using the amp connectors. Follow existing cables and/or hydraulic lines along the boom to avoid movement problems when the boom is folded. Cable-tie the Sensor Branch Cable (C2) every 12 inches. 24
IMPORTANT: Provide enough slack in the Sensor Trunk Cable and the Sensor Branch Cable to account for the movement of the center section, parallel lift, and FOLDING boom movement. 10. Start up your sprayer and test the functionality of the original manufacturer s boom controls. The NORAC control panel does not need to be powered up for the original switches to function. Unfold the booms and raise/lower each boom and center section. Again confirm that the cabling/hoses are agreeable to the entire range of motion. 11. If one or more of these functions do not work, review the hydraulic and electrical portions of this manual to check for proper installation. Also refer to Section 5 in this manual for the electrical pin-outs of the NORAC cables. You can use this information to try to pinpoint where the problem is occurring. If you still have trouble, contact NORAC for assistance. 4.7 COMPLETING THE INSTALLATION 1. Turn on the power for the UC4 Control Panel using the switch on the side of its chassis. Ensure that the display lights up to confirm that the panel has proper +12 Volt power. 2. Repeat the Boom Speed Test as described in Section 4.2 Boom Speed Test with the NORAC UC4 System installed. Record the results for comparison in Table 4. 3. The procedure for the installation of the UC4 system is now complete. Begin the AUTOMATIC SYSTEM SETUP procedure as described in the UC4 Total Control Automatic Boom Height Technical Manual (M1A). 25
5 APPENDIX A - ELECTRICAL REFERENCE: CABLE DRAWINGS 5.1 ITEM C1: 44662B SENSOR TRUNK CABLE 5.2 ITEM C2: 44668 SENSOR BRANCH CABLE 26
5.3 ITEM C3: 44656 VALVE CABLE (VARIABLE RATE) 5.4 ITEM C4: 44651 VALVE EXTENSION CABLE 27
5.5 ITEM C10: 44650-22 POWER CABLE UC3 BC NITRO 28
5.6 ITEM C11: 44688 VALVE DISCONNECT EXTENSION 4-FT 29
6 APPENDIX B - MOUNTING A SENSOR IN THE WHEEL TRACK A word of caution is necessary when considering the mounting location for the center roll (OR main lift) sensor. Mounting the center roll sensor directly behind a sprayer tire can impair main lift control when spraying in CROP MODE. SOIL MODE performance will not be inhibited. Consider the following: when the sprayer tire travels over crop it will trample the crop into the ground to some degree. In this discussion, this crop depression is referred to as the wheel track. The NORAC Sprayer Boom Control System is designed to read the top of the crop when in CROP MODE. Figure 18 - Center Roll Sensor Mounted Behind a Tire Therefore when the roll sensor is in crop mode and positioned in the wheel track, there is insufficient amount of actual crop to measure. This would cause the main lift section to lower (when running in AUTOMATIC mode) because it will read off of the soil. This does NOT represent a control system deficiency, but unfortunately this could cause the center section to lower uncomfortably close to standing crop. "Wheel Track" Operation Normal Operation Figure 19 - Boom Behavior while in the Wheel Track There are four options: 1. Move the roll sensor to a new location that is outside of the wheel track. This is the preferred fix, but not always feasible. 30
2. Turn the center (main lift) section OFF via the control panel and set the main lift manually. The wings will still adjust when in auto mode. 3. Adjust the sensor offset (for the center sensor) via the control panel in order to compensate for the height difference between soil and crop. 4. Add an additional sensor, away from the wheel track, to handle the main lift height measurement. 6.1 MOVING THE ROLL SENSOR This is self-explanatory. Try to mount the roll sensor in a location away from the wheel track while still allowing a 12-inch diameter clear view of the ground. 6.2 TURNING THE CENTER (MAIN LIFT SECTION) OFF This workaround will disable the center section s AUTOMATIC control; manual control will still be possible. Manually set the height for the center section based on the crop height. The disadvantage is clear, AUTOMATIC center (main lift) control will be lost, but the right/left booms will still adjust automatically. Carry out the following procedure using the UC4 Control Panel: 1. Make sure you are in manual mode, at the operating screen. 35 MM 35 2. Navigate to the "More?" item in the SETUP menu. Press AUTO (YES). 3. Navigate to the "Main?" item in the SETUP menu. Press AUTO (YES). 4. At the "Main On" prompt, toggle the +/- switch to change to Main Off. Main Off 5. Press and hold SETUP for two seconds to return to the operational screen. 6.3 ADJUST THE SENSOR OFFSET To compensate for the lack of crop in the wheel track, adjust the main lift sensor s height reading offset (Zero Height) so that the sensor will read higher to match the average height of your crop. Carry out the following procedure using the UC4 Control Panel: 1. Make sure you are in manual mode, at the operating screen. 35 MM 35 31
2. Navigate to the "More?" item in the SENSOR DISPLAY menu. Press AUTO (YES). 3. Navigate to the "Main?" item in the SENSOR DISPLAY menu. Press AUTO (YES). 4. Toggle SENSOR DISPLAY to display the MLht menu item. MLht 47 5. The + switch will increase the reading, the switch will decrease the reading. DECREASE the reading by the difference in height between standing crop and trampled crop in the wheel track. Adjust this until ALL three sections (right, left, main) are level in the field while in AUTOMATIC mode. This may take some experimentation in field conditions. 6. To return to the operating screen, press and hold SETUP for two seconds. Note that this is subject to a trial and error approach to getting this set adequately. The advantage is that AUTOMATIC control will be retained for the center section. Depending on the crop, the depression caused by the wheel might vary. Note that when turning the implement, the wheel track will follow a different path. If the roll sensor detects standing crop in this situation, the center section will lift momentarily. NOTE: The zero height (for the main lift sensor) will need to be reset when using SOIL MODE operation. 6.4 ADD AN ADDITIONAL SENSOR The final option would be to add a fourth sensor to your system to handle the main lift measuring duties. This sensor would need to be mounted on the center section such that it will NOT read in the wheel track. This would not be a reasonable option for those sprayer types that do NOT provide roll control. In these cases the kit includes a main lift sensor ONLY, and the sensor should be moved to a new location. NOTE: If you use this option, ensure that the roll sensor and the added sensor are located at least 36-in apart to avoid crosstalk. Call NORAC Systems and describe your situation to get pricing for an additional sensor, cabling, and mounting brackets/hardware. Once you have your sensor in place and electrically connected, carry out the following steps via the control panel to configure your system for four-sensor operation. 32
1. Make sure you are in manual mode, at the operating screen. 35 MM 35 2. Navigate to the "More?" item in the SENSOR DISPLAY menu. Press AUTO (YES). 3. Navigate to the "Main?" item in the SENSOR DISPLAY menu. Press AUTO (YES). 4. At the "ML" prompt, it will likely show the following: ML proxy Toggle the + switch to search for sensors. Then use the + switch to scroll through the list of sensor serial numbers. When the serial number (that matches the new main sensor that you have installed) is shown, press AUTO (YES) to confirm. Toggle SENSOR DISPLAY once to display the MLht menu item to check/calibrate the new sensor s height. 5. Press and hold SETUP for two seconds to return to the operational screen. 33
NOTES: 34
NOTES: 35
NOTES: 36