UC3 Sprayer Boom Control Operator s Manual 2004 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 (952) 224-4142 SHIPPING ADDRESS: 6667 West Old Shakopee Rd., Suite 111 Bloomington, MN 55438 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 2004 NORAC Systems International Inc. Reorder P/N: 446BC-MAN2 Revision D 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... 1 2 CHECK YOUR SOFTWARE VERSION... 1 3 OPERATOR SAFETY... 2 4 GENERAL SYSTEM DESCRIPTION... 4 4.1 INSTALLATION... 5 4.2 SENSORS... 5 4.3 POWER CABLE... 7 4.4 SENSOR CABLES... 8 4.5 CONTROL PANEL... 8 4.6 REMOTE CONTROLS... 10 5 SYSTEM OPERATION... 11 5.1 TYPICAL OPERATION... 11 5.1.1 Using the Toggle Switches... 13 5.1.2 Change to Automatic or Manual Mode... 13 5.1.3 Adjust the Target Height (Setpoint)... 14 5.1.4 View the Actual Boom Height... 14 5.1.5 Change the Sensitivity of the System (SENSI)... 14 5.1.6 Change Between SOIL and CROP mode... 14 5.2 UNDERSTANDING PERFORMANCE ISSUES... 16 5.3 UNDERSTANDING CROP MODE... 19 5.4 MENU NAVIGATION... 21 5.4.1 Normal Operating Screen... 21 5.4.2 Main Menu Overview... 22 5.4.3 Menu Structure Map... 23 6 SYSTEM CONFIGURATION... 24 6.1 INITIAL POWER UP... 24 6.2 INSTALL... 24 6.3 RETUNE... 25 6.4 AUTOMATIC SYSTEM SETUP... 26 6.5 MANUAL SYSTEM SETUP... 40 6.5.1 Setting Up Sensors... 40 6.5.2 Setting Up Hydraulic Valves... 42 6.5.3 Turning Booms OFF or ON... 46 6.5.4 "Other?" SETUP Options... 46 6.5.5 "Other?" SENSOR Options... 47 7 MAINTENANCE... 49 8 TROUBLE SHOOTING... 51 8.1 POWER SUPPLY... 52 8.2 SENSOR... 52 8.3 REMOTE SWITCH... 54 8.4 HYDRAULIC... 54 8.5 CONTROL PANEL... 55 8.6 OTHER... 55 9 STATEMENT OF LIMITED WARRANTY... 56
1 Introduction Congratulations on your purchase of the Norac UC3 automated sprayer boom height control system. The 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 through before attempting to use the system. Although the UC3 has been designed for easy set up and use, a thorough understanding of this manual will ensure that you receive the maximum benefit from the system. If you have any questions or comments regarding the operation of the UC3 please contact Norac at any of the numbers below. If you require service, phone us or visit our web site for the location of the Norac Service center nearest to you. Phone (toll free): 1-800-667-3921 in Canada 1-866-306-6722 in the United States 1-306-664-6711 all other regions E-mail: service@norac.ca Web Site: www.norac.ca 2 Check Your Software Version The information in this manual applies to systems with Version 3N (version 3 revision N) or later UC3 control panel software. When the panel is turned on, the software version and revision will be displayed for a few seconds. If your panel does not display a version when it is turned on, your software is Version 1 (all revisions). All UC3 panels can have their software upgraded for a nominal fee. It is recommended that all panels with earlier software be updated to the current software version. Contact your local dealer or Norac for more information. 1
3 Operator Safety **************** DANGER **************** 1. Always ensure that the UC3 system is powered down or in Manual Mode: before leaving the operator s seat; while the machine is not moving; or when transporting the machine; 2. Under no circumstances should any service work be performed on the machinery while the UC3 system is in the Automatic Mode. 3. Before working on any part of the booms the following action must be taken: set the UC3 system to Manual Mode using the AUTO/MAN switch; turn the sprayer s engine off. 4. Do not operate this machine before: reading & understanding the operator's manual; gaining a thorough understanding of how to conduct machine operations. 5. To show technical details of the machine some figures in this manual may show safety shields removed. Never operate this machine with any safety devices removed or disconnected. 6. The UC3 system will greatly improve your spraying height accuracy and protect the boom against damage in a wide variety of field conditions. Under some circumstances performance may be limited. The OPERATOR of the sprayer must remain ALERT at all times and override the automatic control when necessary. Refer to the warranty statement in Section 9 for more details. **************** DANGER **************** 2
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4 General System Description Figure 1 shows the general layout of the UC3 Boom Control system. The function of each of the major system components is described in this section. POWER CABLE SENSOR CABLE CONTROL BOX LEFT SENSOR (LO) RIGHT SENSOR (RO) SENSOR BRACKET JUNCTION BOX or BRANCH CONNECTION OPTIONAL SENSOR (LI) OPTIONAL SENSOR (MR) OPTIONAL CENTER SENSOR (ML) OPTIONAL SENSOR (RI) OPTIONAL ROLL SENSOR (MR) OPTIONAL SENSOR (LI) LEFT SENSOR (LO) OPTIONAL CENTER SENSOR (ML) OPTIONAL SENSOR (RI) RIGHT SENSOR (RO) Figure 1. System Components and General Location 4
4.1 Installation For proper installation of the UC3 boom control system please refer to the installation manual for your model of sprayer. 4.2 Sensors Two sensors are provided with your UC3 boom control kit. The sensors use ultrasound to measure the distance to the ground, or the top of the crop. A minimum of two sensors can be used to achieve control of the left and right booms. These sensors are mounted on the outer sections of each boom with the mounting brackets provided (see Figure 2). MOUNTING BRACKET ULTRASONIC SENSOR Figure 2 UC3 Sensor and Mounting Bracket 5
Norac ultrasonic sensors are designed to work best in the brackets provided (shown above). If you decide to use a different style of sensor mount you may limit the performance of the sensor and/or void your warranty. Further, it is important to follow the guidelines in the Installation Manual provided with your kit for mounting the sensors. The sensors should be at least 9 inches above and 9 inches in front of the spray nozzles. The optional center sensor is very useful for setting your initial spray height when you begin a field. It is true that the center height will not change much, in consistent soil conditions, since both ends of the main boom follow the height of the power unit. However, it is extremely difficult to accurately judge the boom s actual height from the cab. It is also normally quite difficult for the operator to see the center section nozzles. It is common for operators to be in error from 8 to 12 inches or more. How often does your operator check nozzle height with a tape measure? The UC3 panel will give you an actual height reading in the cab, and allow active control to the desired height. Another good reason for the main boom sensor is that soil conditions change along with the weight of the machine. As the level of fluid in the tank of the sprayer changes throughout the day and soil conditions vary, the height of the center boom will change because of the amount the tires sink into the soil. To ensure proper chemical application, a center sensor may be mounted as in Figure 3 to control the main boom (center mast) height. OPTIONAL CENTER SENSOR Figure 3 Soft Conditions Center Sensor Required For large boom or severe terrain applications, an additional sensor may be mounted near the midpoint of each boom to obtain an average height reading. The average height reading will provide improved height control over the length of the boom, and protect the boom in severe terrain conditions (see Figure 4). 6
POSSIBLE CRASH WITHOUT ADDITIONAL SENSORS CRASH AVOIDED WITH ADDITIONAL SENSORS Figure 4 Severe Terrain Additional Sensors Required On sprayer models with center frame roll capability, an optional sensor can be added to automatically adjust the amount of roll of the entire boom. Addition of this sensor to the UC3 system can greatly improve the speed and stability of the control action. Contact Norac for more information on the availability of roll control for your sprayer model. 4.3 Power Cable Figure 5 Roll Control of the Center Frame The power cable supplies 12 volt D.C. negative ground power to the control panel and the sensors. The system will function properly with a supply between 11 and 28 volts and may draw up to 10 amperes during normal operation. The control panel contains intelligent valve drive circuitry that helps to protect the system against short circuits and other wiring problems. However, it is still recommended to connect the UC3 power cable to a fused supply, that turns on and off with the ignition key of the sprayer/tractor. 7
4.4 Sensor Cables The ultrasound sensors are connected to the control panel via sensor cables. A "trunk" cable runs from the panel to the sprayer boom. There, a standard "branch" cable allows for connection of the two standard boom sensors and an optional center sensor (refer to Figure 6). Another optional branch cable is required to connect additional sensors. CONNECTS TO SENSOR TRUNK CABLE WING SENSOR (LO OR RO) OPTIONAL CENTER SENSOR (ML) WING SENSOR (LO OR RO) Figure 6 Branch Cable 4.5 Control Panel The control panel is the main component of the UC3 system because it regulates the operation of the entire system. The panel uses the readings from the ultrasonic sensors to control solenoid operated valves (usually hydraulic), that in turn adjust the boom height. The control panel will: (1) indicate when the system is in automatic or manual mode, (2) indicate any hydraulic action which is underway, and (3) accept input to adjust all control system settings. The front face of the control panel is shown in Figure 7. This section gives a general description of each item shown on the control panel. 8
UC3 BOOM CONTROL LCD SCREEN SENSOR DISPLAY /SETUP SWITCH SENSOR DISPLAY (YES) + AUTO +/- SWITCH POWER SWITCH SETUP (NO) MANUAL AUTO/MANUAL SWITCH 4.5.1 LCD Screen Figure 7 UC3 Control Panel During normal operation, the LCD screen will show the status of the system and allow you to examine or change settings. All settings for the UC3 system are stored in cyclic menus. This type of menu allows the user to access each menu entry by progressively toggling the appropriate switch. For example, each toggle of the SETUP switch will advance the user to the next item in the SETUP menu. 4.5.2 SENSOR DISPLAY/SETUP Switch (NO) Pressing UP on the SENSOR DISPLAY / SETUP switch will access the SENSOR DISPLAY menu. This menu provides information about the sensors. Pressing DOWN on the SENSOR DISPLAY / SETUP switch will access the SETUP menu. This menu provides options and settings regarding the UC3 system parameters. Toggling this switch in the SETUP direction also provides the alternate function "NO". In some instances the control panel may prompt the operator with a question that requires a yes or no response. To answer no in these situations toggle the switch toward the word "NO". For a more detailed description of the SENSOR DISPLAY / SETUP menus, see Section 5.4 - Menu Navigation. 4.5.3 The +/- switch Use the +/- switch to change various settings in each of the SETUP and SENSOR DISPLAY menus. For a numeric entry, each click of the switch towards the + direction will increase the setting while each click towards 9
the direction will decrease the setting. If the switch is held, the number will continue to automatically increase or decrease. The rate of change will increase with the time you are holding the switch. If the selections for the menu item are to be picked from a list, this switch will present the next selection in the list. When in AUTO mode use this switch to modify the control height set point. Not all menus allow the user to change the setting with the +/- toggle switch. Some screens are only for informational purposes. In a menu where a setting cannot be changed, the +/- toggle switch is ignored. 4.5.4 AUTO/MANUAL switch (YES) The UC3 boom control system has two operational modes automatic and manual. This switch changes the operational mode of the system. In automatic mode (AUTO), the control panel will regulate the height of each boom to a predetermined set point. In manual mode (MANUAL), the sprayer functions as if no automatic control system is present. When the system is in AUTO the operator can override automatic control by operating the manual switches on the sprayer's boom controls (usually a joystick or multifunction handgrip). If the operator activates the left boom switch (either up or down) the system will put the left boom into manual mode. The AUTO switch also provides the alternate function "YES". In some instances the control panel may prompt the operator with a question that requires a yes or no response. To answer yes in these situations toggle the switch toward the word "YES". 4.5.5 POWER switch This switch is located on the left side of the panel and is used to turn the power to the system on or off. For safety reasons, the system always powers up in manual mode. Consequently it is important to make sure that the power switch cannot be accidentally bumped during field operation. 4.6 Remote Controls Remote control of several functions on the UC3 panel is possible. Remote AUTO and remote MANUAL switches can be wired to the control panel. This feature allows the operator to control the mode of the UC3 system from an external switch or controller. A motion inhibit wire is also available that will stop automatic control actions unless the sprayer indicates that it is in motion. See Section 6.5.4.1 for more information on remote control settings. 10
5 System Operation This section outlines the system s features and controls during basic field operation. Before you can operate your UC3 system in automatic, it needs to be configured either automatically or manually. If your panel will allow automatic mode as shown below, it has been configured. If your panel will not allow automatic mode, it will attempt to begin or resume automatic setup. Refer to Section 6 for configuration instructions. 5.1 Typical Operation The operating screen provides information pertaining to the height and mode of both booms. Figure 8 shows a typical operating screen. LEFT BOOM TARGET HEIGHT LEFT BOOM VALVE COMMAND (DOWN) LEFT BOOM CONTROL MODE (AUTOMATIC) RIGHT BOOM ACTUAL HEIGHT RIGHT BOOM CONTROL MODE (MANUAL) Figure 8 Normal Operating Screen When a boom is in automatic mode, indicated by an "A" in the control mode portion of the screen, the UC3 panel shows the target boom height. In manual mode, indicted by an "M" in the control mode portion of the screen, the UC3 panel shows the current boom height reading. In both automatic and manual modes the screen will also show arrows to indicate that the boom is being commanded to move. Table 1 explains some examples of typical operating screens. 11
Screen Table 1 Example Operating Screens Meaning 36 A A 3 6 Both sides in automatic control, the target boom height is 36 inches. 36 A A 3 6 As above, but now the left side is taking corrective action, upwards. 36 A A 3 6 As above, but now the right side is taking corrective action, downwards. 36 3 6As above, but now the main lift (center) is taking corrective action, downwards. Control mode temporarily disappears while center is active. 34 M A 3 6 Left boom is in manual control, current actual boom height is 34 inches. Right boom is in automatic control, the target boom height is 36 inches. 34 M M 3 6 Left boom is in manual control, the current actual height is 34 inches. The operator is manually lowering the right boom, the current actual height is 36 inches. Table 2 - Special Screens Minimum Override This screen indicates that an attempt has been made to adjust the target height below the minimum height allowed. Refer to Section 6.5.5.1 for more information. SafteyOn This screen means that the system is inhibiting automatic mode because the sprayer indicates that it is not ready (not in motion or operator seat switch is invalid etc). Your system must be wired properly and the sprayer must have the proper sensors to take advantage of this feature see Section 6.5.4.1 for more information. >>>>>>>> >>>> The control panel is busy with a task that may take a few seconds. Wait for the arrows to disappear before activating any UC3 toggle switches. 12
5.1.1 Using the Toggle Switches All functions on the UC3 panel are activated using its three toggle switches. To access either the SENSOR DISPLAY or SETUP menus, make sure you are at the Normal Operating Screen. Toggle toward the word describing the menu you wish to access. To adjust the setting of individual menu items use the +/- switch while the item is displayed. UC3 UC3 BOOM BOOM CONTROL CONTROL SENSOR DISPLAY SENSOR DISPLAY + AUTO SENSOR DISPLAY + AUTO SETUP MANUAL SETUP SETUP MANUAL Menu items will time out and return to the Normal Operating Screen after 30 seconds. If you wish to return to the operating screen sooner, press and hold the SETUP switch for two seconds. Any new settings will take affect once the Normal Operating Screen is displayed. If you wish to lock the sensor height readings on the screen indefinitely, press the + switch once while viewing the desired sensors. This will override the timeout feature. 5.1.2 Change to Automatic or Manual Mode Change the mode from manual to automatic with the AUTO/MANUAL toggle switch on the UC3 control panel. Make sure you are at the Normal Operating Screen. When the system is in manual mode the boom may be controlled as usual with the boom control switches on the sprayers multifunction handgrip. In automatic mode, the control system automatically adjusts the height of the booms to maintain a constant working height. Further, when the system is in automatic mode, operating the sprayer's left or right boom control switches will immediately cause that boom to revert to manual mode. That is, the by using the switches on the sprayer s multifunction hand grip the operator overrides automatic boom height control on either the left or right side. The AUTO switch must be activated to return that boom to automatic mode. The sprayer's main lift switches provide a target height adjustment feature (see Section 5.1.3). If you press and hold the main up or main down 13
switches for more than two seconds, your panel will switch ALL booms (left, right, main, and roll) to manual mode. This feature provides a convenient method of switching to manual mode when folding the sprayer for transport. 5.1.3 Adjust the Target Height (Setpoint) Adjust the target height setting with the +/- switch while in AUTOMATIC MODE. The smallest target height setting allowed is called the minimum height override. By default the minimum height settings are 25 inches in soil mode, and 25 inches in crop mode. See Section 6.5.5.1 to adjust these settings. You can also adjust your target height by pressing the sprayer's main lift control switches. Each press of the up switch will increase the target height by one inch. Each press of the down switch will decrease the target height by one inch. 5.1.4 View the Actual Boom Height Toggle SENSOR DISPLAY to view the actual boom heights. This screen will show you the left, main (center), and right boom heights. Toggle SENSOR DISPLAY again to view additional sensors if they are installed. You can view the height screens in both automatic and manual modes. See Section 5.4.2 for more information on the sensor height screens. 5.1.5 Change the Sensitivity of the System (SENSI) The SENSI setting can be adjusted in both manual and automatic modes. Toggle SETUP to view the current SENSI setting. While viewing this screen toggle the +/- switch to adjust the value. A lower number will reduce the system sensitivity and improve stability. Increasing the number will speed up the response. Five is the normal setting. At the start of operation, before the sprayer is warmed up, a lower SENSI setting may be required for stable control. As the sprayer warms up, increase the SENSI up until the performance reaches an optimum level. Changes in terrain that include driving through ditches and over terraces are special performance cases. This type of terrain can cause the sprayer to pitch and roll significantly. See Section 5.2 for a discussion of performance issues. 5.1.6 Change Between SOIL and CROP mode The SOIL or CROP setting can be adjusted in both manual and automatic modes. Toggle the SETUP twice to view the current setting. While viewing this screen use the +/- switch to change between SOIL and CROP mode. 14
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5.2 Understanding Performance Issues Your UC3 height control system will work well in most situations. However, as with any equipment, it is important that the operator remains alert at all times. There may be some field and terrain situations where performance is diminished. In these situations the operator must resume height control of the booms manually. A discussion of performance issues is given below to help clarify these situations. Sensitivity Setting Your system is configured to work well in most conditions, with warm hydraulic oil, at a sensitivity of five. When you first begin operation at the start of a day, it may be necessary to operate at a lower sensitivity until the oil has reached normal temperature. Keep increasing the SENSI setting until the performance is optimized. Different types of terrain may require different SENSI settings. The SENSI setting controls more than just response time. It also determines how accurately the system will try to correct for height errors. The higher the sensitivity the higher the accuracy. At low sensitivity a few inches of error will be tolerated. At high sensitivity, virtually no error will be tolerated. Therefore, the system will be much more active at high sensitivity than at low sensitivity. Field conditions and operator preference determine the appropriate SENSI setting. On some sprayer models, it may be difficult to reach an optimum level of sensitivity while maintaining good boom stability. This could be an indication that the boom is mechanically under-damped for control purposes. Additional shock absorbers/dampers can dramatically improve automatic control performance. Some UC3 sprayer kits come complete with additional damper kits. Other sprayer models have damper kits available from the sprayer manufacturer or from Norac as optional equipment. Contact Norac or your sprayer dealer for more assistance. Boom Reaction Time There are two key factors that determine how quickly your boom can react to changes in terrain. The first factor is the available hydraulic speed. The maximum hydraulic speed of your boom was designed by the sprayer manufacturer and is not improved or diminished with the addition of the UC3 height controller. The second factor is the mechanical design of the sprayer. The SENSI setting does affect the reaction time of your boom - the higher the number the quicker the response. However, how high you can run the SENSI setting is determined to large extent by mechanical issues related to the boom and sprayer. 16
Important design issues include the style of main boom mount (for example, center pivot or nonparallel links), the amount of mechanical damping and spring centering on the main boom mount, and whether a main boom roll system is available on the sprayer. All of these factors together determine the maximum sensitivity setting you can run on your UC3 system. This in turn will set the reaction time of the boom in a given situation. The UC3 electronics are rarely the limiting factor in determining overall automatic height control performance. Sensor Reading Over Ditches, Waterways and Outside Rounds Many situations exist where one sensor may be reading over terrain that does not accurately reflect the situation for the rest of the boom. For example, if you are spraying along a waterway, it may be necessary to run the outer boom sensor out into the waterway itself. This situation is similar to the one picture in Figure 4. In this example the outer sensor will bring the boom lower than desired and may put the mid-point of the boom at risk. Outside rounds adjacent to very weedy areas or tall thick grass are examples of the opposite situation. In this situation the outer sensor may bring the boom higher than desired (if the sensor cannot read through the thick grass). In these situations the operator must remain alert and override automatic control when necessary. Addition of the optional severe terrain sensors will greatly improve performance in these situations. Driving Through Ditches and Over Terraces Changes in terrain that include driving over terraces or through ditching are special performance cases. This type of terrain can cause the sprayer or spray cart to pitch and roll significantly. For most boom designs, these changes are instantaneous at the boom tip. No wing cylinder or hydraulic system will be fast enough to correct for the error induced. There are two solutions to this problem. The first solution is for the operator to recognize these situations before they occur and manually raise the boom section(s) to a safe height. Overriding automatic control is made intentionally easy. As soon as the sprayer s boom switch is operated the system will switch that boom to manual control. To return to automatic, use the AUTO/MANUAL switch. This solution is no different than what would occur with no control system present. The second solution is to add a roll control system to your sprayer (if one is available). This type of system will compensate for the sprayer roll in this situation and also add stability to your boom in normal operating conditions. Sensing Further Ahead of the Boom Moving the sensor farther ahead of the boom is not an acceptable solution to any performance issues. The reason is that as the sensor is moved further 17
ahead, there will be an increasing height error at the nozzles. In other words, the sensor and nozzle are at two different points in space thus introducing an error for all but most level terrain. One of the biggest paybacks of a UC3 height control system is maintaining the desired height at the nozzles. Height accuracy should not be sacrificed to maintain a particular spraying speed. Slow down and spray at the proper height. Interestingly enough, moving the sensor farther ahead will likely not solve the problem anyway and may make the situation worse. In severe terrain, this height error can bring the nozzles close to the ground as the sensor reads over the crest of a hill, or down into a ditch. Sensor Capabilities In order for the UC3 system to work at its maximum level of performance, your sensors must be returning accurate height readings at the designed frequency. Under typical conditions, Norac s ultrasonic sensors can provide accurate height readings from 9 inches to over 120 inches, and return many height readings in one second. The SOIL target can be identified through stubble, young crops, row crops, and normal trash. The CROP target can be identified over cereal grains, specialty crops, and row crops. See the next section for more information on CROP mode guidelines There are two main steps to ensure sensor performance. The first step is proper mounting. See Section 4.2 for more information on sensor mounting. The second step is to ensure that the protective foam covers on the sensors are kept clean, and that the ultrasonic transducer behind the foam does not become corroded or excessively dirty. Extra foams are shipped with your kit. The transducer is a maintenance item and can be replaced at Norac Service locations. Transducers can last from three to ten years, depending on conditions. Refer to Section 8.2 for more maintenance information. If the mouth of the sensor becomes wet, it is normal for the sensor to return error messages until the transducer has dried off. This could include rain or excessive overspray. Material can build up on the transducer if the sensor is mounted too close to the spray nozzles. This is the reason the sensor must be mounted at least 9 inches in front of the nozzles. It keeps the sensor housing out of the normal region of overspray. In the sprayer boom application, Norac s ultrasonic sensors ignore any target that is closer than 9 inches from the bottom of the sensor housing. This region is called the blanking range. Operating the sensor at heights near the blanking range is dangerous and will affect performance because height readings can be very intermittent. This is the reason that each sensor must be mounted at least 9 inches above the spray nozzles. The total height to the target is then guaranteed to be 9 inches plus the minimum height setting (15 or 22 inches by default). No control action can take place when sensor heights are invalid or not available to the UC3 panel. 18
5.3 Understanding Crop Mode A unique feature of Norac s ultrasonic sensors are their ability to operate in CROP mode. In this mode the sensor will track the first available sonic target. That is, when positioned over standing crop, the sensor will return the average height of the heads in a circular area below the sensor. In the same situation in SOIL mode, the sensor will track the last available sonic target. That is, signals from the heads, leaves, and trash will be ignored in favor of the ground. It is important to note that the targets must be available and of sufficient strength for the sensor to "see" them. There may be some crop and terrain situations that do not work well for CROP mode or SOIL mode. In these situations the operator must resume height control of the booms manually. Areas of "No Crop" in Crop Mode If, while operating in crop mode, the sensor encounters an area where there is no crop the system will behave as follows. The sensor will track the soil because only one target is available. The boom will lower as shown below. Areas like this may include missed areas during seeding, alkaline areas and so on. When the problem area ends, it may not be possible for the sensor to see the crop again unless the operator raises the boom manually. The sensor may be closer than required nine inches from heads of the crop, thus blanking out the desired target. Boom Stability in Crop "No Crop Area" In general the top of the crop is a more inherently variable target than soil. Put simply, given identical control settings, your height control would be more active when operating in crop than in soil. To allow for this, many settings are customized automatically when you change modes on the UC3 panel. This is designed to provide a more stable response in crop mode. The tradeoff is that the system will also be slightly slower to respond in crop mode than in soil mode. 19
Thin Crop Ultrasonic sensors operate by bouncing sound waves off of the desired target. A minimum signal level is required from the crop in order to use it for control purposes. This is no different than the fact that your radio must be at a certain minimum volume level before you can physically hear it. Different types of crop, and crops at different stages of development return varying levels of sound. The following are some general guidelines. Crops in growing stages are relatively good sonic targets. Bearded crops are relatively poor sonic targets. In row crops the sensor must be positioned over the row to use the crop signal or between the rows to use the ground signal. The desired target must cover roughly 60 percent of the area to be tracked consistently. That is, when looking at the ground, the heads should cover about 60 percent of the ground. Otherwise, you can use SOIL mode. If the sensor runs too close to the heads, they may not return enough signal to be seen, or they may be blanked out. The nozzles must be at least 22 inches from the crop. Slightly higher target height settings will work better in thin crop 20
5.4 Menu Navigation 5.4.1 Normal Operating Screen When the control panel is turned on the screen will flash the current setup type, followed by the panel software version. The Normal Operating Screen will then be displayed, pictured below. The operating screen provides information pertaining to the height and mode of the booms. A more detailed description of operating screens is given in Section 5.1 Typical Operation. The operating screen is the starting point, and ending point for navigation through the menu structure. 30 MM 35 Figure 9 Normal Operating Screen The following pages describe the screens that are shown as you proceed through the SENSOR DISPLAY and SETUP menus. To navigate through these menus, use the SENSOR DISPLAY/SETUP switch. The table in the following section shows the structure of the main menu. The start of the main menu is the operating screen, shown in bold at the center of the table. UC3 UC3 BOOM BOOM CONTROL CONTROL SENSOR DISPLAY SENSOR DISPLAY + AUTO SENSOR DISPLAY + AUTO SETUP MANUAL SETUP SETUP MANUAL The menu is organized in a cyclic fashion, where the SENSOR DISPLAY/SETUP switch advances you through the menu. Pressing up on the switch toward SENSOR DISPLAY will change the screen to the next higher row shown in the table. Pressing down on the switch toward SETUP will change the screen to the next lower row shown in the table. If at any time, you wish to return to the operating screen, hold the SETUP switch down for two seconds. Also, if you remain in a menu item for 30 seconds, the menu item will time out and return to the Normal Operating Screen. 21
5.4.2 Main Menu Overview Navigating past the end of the menu will return the panel to the operating screen More? Roll 0.5 25 29 31 31 32 30 MM 35 Press YES (Auto) to edit or view more sensor settings. To locate more information on this menu item, refer to Section 5.4.3 Displays reading of the main roll sensor. Depending on sprayer type this menu item may not be displayed. Displays readings from optional boom sensors (left inner and right inner). This menu item may not be displayed. Displays the current boom heights, in inches, from left to right. The heights are adjusted for the offset between the sensor and nozzles. If any sensor errors are detected the type of error will be displayed here. Sensor Display Menu SENSOR DISPLAY / SETUP Switch Setup Menu The operating screen is normally displayed. While at other menu items, if no switch has been pressed for 30 seconds the panel will revert to this screen. Also, from any screen, if you press and hold the Setup switch for two seconds the panel will return to this screen. To navigate to the other screens in this table push the SENSOR DISPLAY/SETUP switch in the indicated direction Sensi 5 Displays the current control sensitivity setting. A higher number means a higher sensitivity resulting in more control actions and quicker response. A lower number will tend stabilize the boom and make it less active. Range is from 1 to 10. Soil ON Or Crop ON ReTune? Install? More? Use the +/- switch to set the sensor target to Soil or Crop. Use the Auto (YES) switch to initiate the automatic hydraulic evaluation of your system. The system will optimize your system for the best performance possible. The evaluation will take from one to three minutes. For a description of the ReTune menu item refer to Section 6.3 Use the Auto (YES) switch to initiate the complete installation process. The System Configuration Assistant will lead you through the setup of your multifunction hand grip, sensors and hydraulic valves. For a description of the Install menu item refer to Section 6.2 Press YES (Auto) to edit or view more control settings To locate more information on this menu item, refer to Section 5.4.3. Navigating past the end of the menu will return the panel to the operating screen 22
5.4.3 Menu Structure Map Section 6.5.5 Avg 2 MHS 18 Section 6.5.1.3 MHC 25 Sht 0 Cht 5 Section 6.5.1 Other? MRht 15 Section 6.5.1 RIht 30 Roll? MR 1290 MLht 27 RI 3571 SENSOR DISPLAY Main? Right? Left? YES ML 3567 Section 6.5.1 LIht 28 ROht 32 RO 3570 More? Roll 0.5 30 32 32 28 27 YES Section 5.1.4 LI 3569 LOht 31 LO 3568 31 MM 29 Section 5.1 Sensi 5 Section 5.1.5 Soil On Section 5.1.6 ReTune? Section 6.3 Install? Section 6.2 More? YES SETUP Left? Right? YES Main? Roll? Roll Off Other? DZ 3 KP 175 RemS Off DZ 4 Section 6.5.4 KP 150 Section 6.5.2 Left On DZ- 100 KP- 50 DZ- 105 KP- 37 Section 6.5.2 Main On DZ 10 KP 50 DZ 5 KP 50 Section 6.5.2 Rght On -DZ 103 -KP 49 -DZ 99 -KP 35 Section 6.5.2 23
6 System Configuration Before the UC3 boom control system will function properly some information about the sprayer and connected sensors is necessary. When the panel is turned on for the first time, the UC3 panel guides the user through the Automatic System Setup. This procedure is described in Section 6.4. Normally the system will automatically configure and calibrate itself to the sprayer. If this process does not produce the desired results, refer to Section 6.5 for details on Manual Setup. 6.1 Initial Power Up The first time the system is powered up it will guide you through the Automatic System Setup. If you wish to restart this procedure after an initial setup has been completed, navigate to the "Install?" item in the Setup menu and confirm the action with the YES (Auto) switch. At any point during the setup procedure you can exit by pressing the NO (Setup) switch. However, if you exit without completing the configuration you may not be able to use your system in automatic mode. The entire "Install" procedure on the UC3 control panel should take approximately two to seven minutes. 6.2 Install You can rerun the automatic system configuration after the panel has gone through it s initial power up procedure. This is useful if a previously configured UC3 system is being moved to a different sprayer. To do this, navigate to the "Install?" item in the setup menu and confirm with the AUTO (YES) switch. The procedure described in Section 6.4 will begin. If you confirm this menu item by accident, you can exit by pressing NO (Setup) before confirming a sprayer type. No settings will be lost. As soon as you confirm a sprayer type and see the "Dfalting" message at step 8 in Section 6.4, all previous system settings will be lost. 24
6.3 ReTune From time to time it may be necessary to recalibrate the UC3 electronics to your sprayer s hydraulics. Examples of such times are: when a hydraulic solenoid valve is changed; when the hydraulic pump is changed or adjusted; and when the normal working temperature of the hydraulic oil has shifted significantly from when the system was previously calibrated. If you are running a pull type sprayer and use different tractors to operate the sprayer, you should run the Retune procedure each time the tractor is changed. To do this, navigate to the "Retune?" item in the setup menu and confirm with the YES (Auto) switch. The procedure described in Section 6.4, starting at Step 13 will begin. Follow the guidelines listed in Section 6.4 Steps 1 to 7 before proceeding at Step 13 (check weather caps, level booms, working RPM etc.). 25
6.4 AUTOMATIC SYSTEM SETUP Step 1 Make sure the UC3 equipment has been installed on your sprayer as per the installation manual for your UC3 system. Step 2 Find a location for the sprayer that is relatively level, and has fairly clean targets for the sensors. For example, position the sensors over bare soil or gravel. Do not conduct the following procedure over standing crop or tall weeds/grass. Step 3 Have the sprayer in the field position with all booms at a normal working height. The main (center) boom should be between 30 and 50 inches in height. The wing tips should be between 30 and 70 inches in height. Step 4 Remove the sensor weather caps on all sensors. Step 5 If you have main boom roll control, the roll frame should be level and the main boom and wing tips should be high enough such that the boom can be rolled about 2 degrees in either direction. It is useful at this point to note which direction on your manual roll control switch will move the boom clockwise, and which switch direction will move the boom counter-clockwise. Clockwise is defined as the left boom moving up when viewed from behind the sprayer. Step 6 Power up the UC3 Control Panel. Make sure the panel is in SOIL mode. Step 7 Start the solution pump and run the sprayer s engine at a normal working rpm for the entire test. For best results, the hydraulic oil must be at a normal working temperature. This may require you to actually operate the sprayer for 5 to 20 minutes to warm up the oil (longer warm up times are required in cold weather). WARNING - AT POINTS DURING THE SYSTEM CONFIGURATION THE BOOMS MAY NEED TO MOVE AUTOMATICALLY AND/OR MANUALLY. Make sure that all personnel and equipment are clear of the left, right, and main booms. 26
Step 8 Select Sprayer Type+/- Use the +/- switch to toggle through a list of available types. Confirm selection with the YES switch (AUTO). Types are listed on page 35 Dfalting Control panel is loading all the settings for your sprayer. Step 9 Scanning Control panel is reading serial numbers of all connected sensors. 3 Sensrs Number of sensors found is displayed. Do not continue if number is incorrect. The number of sensors reported here should match the actual number of sensors on your system. If it does not, ensure that all sensors are plugged in and operating. Power down and power up the control panel to restart the procedure. 27
Of the following two prompts, only the ones that apply to your sprayer type will be displayed. Step 10 Auto Main Control? Answer YES (AUTO) to turn on main boom (center) control. Answer NO (SETUP) to turn off main boom control. Step 11 Auto Roll Control? Answer YES (AUTO) to turn on roll control. Answer NO (SETUP) to turn off roll control. 28
Step 12 Manually Move Left Up Use the sprayer's manual controls to move the left boom up. Do not continue if the wrong boom moves. Use the multifunction hand-grip or joystick to move the boom up at least two feet in one continuous motion. If the wrong boom moves, or no boom is moving, exit the configuration by powering down the control panel. Consult the installation manual for your system to check the hydraulic plumbing and electrical wiring of your system. When you power up the panel again the automatic configuration will resume. Left XX Control panel confirms the proper wiring. Left 52 Height reading is inserted when sensors are detected. If a problem is detected an appropriate error message will appear. For a list of error messages see Table 4. 29
All other relevant boom directions are prompted in the order below. Manually move the appropriate boom as indicated. Manually Move Left Dn Move Left Boom Down Manually Move Rght Up Move Right Boom Up Manually Move Rght Dn Move Right Boom Down Manually Move Main Up Move Main Boom Up Manually Move Main Dn Move Main Boom Down Manually Move Roll CW Move Roll Clockwise Manually Move Roll CCW Move Roll Counter- Clockwise 30
If a different prompt than below appears, refer to information on page 39. Step 13 Manually Level Booms at Working Height Proceed? Reset the position of the booms, if necessary, before proceeding. Toggle YES to continue. The main (center) boom should be between 30 and 50 inches in height. The wing tips should be between 30 and 70 inches in height. If you have roll control, the roll frame should be level. Step 14 Hold Auto Until Done Hold the AUTO Switch to begin the valve tuning sequence. During the hydraulic tuning procedure you must hold the AUTO switch. If AUTO is released before "Done" is displayed, refer to page 36 for more information. DZ STP1 Panel indicates the tuning stage as it progresses. This is an example of one of the progress messages. They are displayed for informational and troubleshooting purposes only. If your sprayer is a John Deere 4710 you may need to step on the brake pedal when the main lift is being tuned to provide enough pressure for the main lift to raise. 31
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Step 15 Done Release the AUTO switch, the tuning is complete. 55 MM 47 Normal Operating Display is shown. Step 16 30 AA 30 Toggle AUTO to start automatic mode. Observe the behavior of the booms while correcting to the 30 inch target height. The boom actions should be relatively smooth and stable. Boom corrections should stop after a few seconds, under normal conditions (excessive wind may cause small corrections to continue). If the boom corrections are not done in an optimum manner put the system into manual immediately. Retry the entire installation process by navigating to the "Install?" menu item and pressing AUTO (YES) to confirm. If after three attempts the system is not working acceptably, proceed to Section 6.5, Manual Configuration. Step 17 35 AA 35 Increase the target height to 35 inches with the +/- switch. Observe the behavior of the booms. 33
Step 18 34 MM 37 Press the MANUAL switch to return to manual mode. AUTOMATIC SETUP PROCEDURE COMPLETE. If your boom does not appear to be level at the desired height read on. Otherwise your system is ready to use. In manual mode, the control panel shows the nozzle heights of your sprayer, for each boom section. The actual displayed heights may not be exactly the same as your target height. The sensitivity setting determines the degree of acceptable error between the two. See the description of SENSI in Section 5.4.2 for more information. When you selected a particular type of sprayer during the configuration process, typical mounting positions for the sensors were assumed. If your boom is not level at the proper height, confirm sensor height readings by following the procedure in Section 6.5.1.2. 34
Table 3: Sprayer Types TYPE Sprayer Models AN1 Generic sprayer boom AN2 Generic sprayer boom AND Andros Eng. on/off sprayer AP1 Apache 852 AS2 Ag-Shield pull type BT1 Brandt pull type 3 sensor BT2 Brandt pull type year>2002 CS1 Case 4260 CS2 Case 3150, 3185, 3200 FC1 Flexi-Coil 67 series pull type FT1 Fast 7400 pull type FT2 Fast OEM version GM1 Gregson Maverick HG1 Hagie STS12 JD4 JD 4700/4710 SN <6000 JD5 JD 4700/4710 SN >6000 NH1 New Holland 550 NT1 Nitro OM1 Original Equipment Manufacturer wing control only OM2 Original Equipment Manufacturer wing and main lift control OM3 Original Equipment Manufacturer wing, main, c/w severe terrain PT1 (Case) Tyler Patriot RG1 Rogator 854 year<1996 RG2 Rogator 1254 RG3 Rogator 854 year>1996 RG4 Rogator 864/1064 SM1 Summers pull type WR1 Wilmar 8100 WR2 Wilmar 8400 The sprayer type setting tells the panel some basic setup information about your sprayer. When you purchased your system the three-letter suffix on the part number indicates the type of your system. For example, if you purchased a UC3-BC-JD4, you should select the "JD4 " type. 35
Table 4: Automatic System Setup Error Messages In the event of an error condition, the system will immediately halt any valve action and wait for operator acknowledgement. If you are at the point in the tuning procedure where you are asked to hold the AUTO switch, you will be required to release the switch to continue. Once this is done one of the following prompts will appear. At this point you can attempt to resume by pressing the YES (AUTO) switch, or exit the procedure by pressing the NO (SETUP) switch TimeOut! Retry? Explanation Possible Causes Required Action The auto valve test has taken too long to complete. a. There is not enough hydraulic pressure to move the boom. b. The booms are moving too slowly. c. A hydraulic cylinder has reached the end of its stroke but the system is still trying to move in that direction. a. Make sure the solution pump is running, and that all UC3 wiring is connected as per the install manual. On some sprayers in may be necessary to manually stroke the hydraulic pump to complete the test. For example, on the John Deere 4710 you can do this by pressing on the brake pedal. b. Make sure the hydraulic oil is at working temperature. c. Manually reposition the booms into the middle of the cylinder stroke and resume the test with the YES (AUTO) switch. For left and right booms that do not adjust below the level of the main boom, you must make sure that the main boom is below 50 inches before running the auto valve test. SNR 2521 Retry? Explanation Possible Causes Required Action A test cannot proceed because the appropriate sensor is not returning a valid height reading. a. Make sure the sensor is positioned over a good soil target without too much trash. b. Faulty sensor. a. Resume the test with the YES (AUTO) switch. b. Replace sensor 36
Table 4 Continued TooHigh! Retry? Explanation Possible Causes Required Action The boom is positioned higher than 70 " a. The automatic valve test was started with the boom positioned too high a. Manually reposition the booms into the middle of the cylinder stroke and resume the test with the YES (AUTO) switch. For left and right booms that do not adjust below the level of the main boom, you must make sure that the main boom is below 50 inches before running the auto valve test (RETUNE OR INSTALL). b. Resume the test with the YES (AUTO) switch. TooLow! Retry? Explanation Possible Causes Required Action The boom is positioned lower than 30 " a. The automatic valve test was started with the boom positioned too low a. Manually reposition the booms into the middle of the cylinder stroke and resume the test with the YES (AUTO) switch. b. Resume the test with the YES (AUTO) switch. Too Many Retry? Explanation Possible Causes Required Action The system has detected that too many sensors are connected. a. Too many sensors have been connected to the system. a. Remove sensors, or setup the system manually. 37