Norac UC4 Total Control User manual

UC 4
Total Control
Automatic Boom Height
System
RHS BestWay 1200/1600
Installation Manual
Canada
NORAC Systems International Inc.
CALL TOLL FREE: 1-800-667-3921
[phone]
SHIPPING ADDRESS:
3702 Kinnear Place
Saskatoon, SK
S7P 0A6
United States
NORAC, Inc.
CALL TOLL FREE: 1-866-306-6722
[phone]
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 2005-07 by NORAC Systems International Inc.
Reorder P/N: UC4-BC-RH1-INST Rev E (Bestway)
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 SENSOR INSTALLATION............................................................................................................ 16
4.5 HYDRAULIC INSTALLATION................................................................................................................ 18
4.5.1 Valve Assembly and Mounting .............................................................................................. 18
4.5.2 Hydraulic Plumbing ............................................................................................................... 21
4.6 ELECTRICAL INSTALLATION .............................................................................................................. 23
4.7 COMPLETING THE INSTALLATION....................................................................................................... 27
5 ELECTRICAL REFERENCE – CABLE DRAWINGS ........................................................................ 28
5.1 ITEM C1: 44662B –SENSOR TRUNK CABLE ..................................................................................... 28
5.2 ITEM C2: 44668 –SENSOR BRANCH CABLE ..................................................................................... 28
5.3 ITEM C3: 44656 –VALVE CABLE VARIABLE RATE ............................................................................ 29
5.4 ITEM C4: 44651 –VALVE EXTENSION CABL E .................................................................................... 29
5.5 ITEM C10: 44650-37 –POWER CABLE RHS 1200/1600................................................................... 30
5.6 ITEM C13: 44687 –SENSOR EXTENSION CABLE ............................................................................... 31

2
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: [phone] in Canada (Toll Free)
1-866-306-6722 in the United States (Toll Free)
1-306-664-6711 all other regions
E-mail: [email protected]
Website: www.norac.ca

3
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.

4
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 – Bestway Sprayer Boom Control System Parts
Item Part Number Description Pcs Len
UC4-BC-RH1 KIT UC4 BOOM CONTROL RHS BESTWAY 1200/1600 1 EA
* BRACKET PARTS *
B10 44704 MOUNTING BRACKET UC3-BC VALVE 1 EA
B11 44695-4 MOUNTING BRACKET UC3 SENSOR 4IN LG 1 EA
B13* 44728 MOUNTING BRACKET COMPLETE UC4 BREAKAWAY
EXTENDED
2 EA
B16 44727 MOUNTING BRACKET ADAPTER 2.5IN TO 4IN 2 EA
* CABLE PARTS *
C1 44662B-40 CABLE UC3 SENSOR TRUNK AMPF TO AMPF BLACK
STANDARD 40FEET
1 EA
C2 44668 CABLE UC3 SENSOR 1 AMP RECEPT 3 AMP PLUG BC 1 EA
C3 44656 CABLE VALVE VARIABLE RATE 1 EA
C4 44651 CABLE VALVE EXTENSION 1 EA
C10 44650-37 CABLE POWER UC4 BOOM CONTROL RHS 1200/1600 1 EA
C13 44687 CABLE UC3 SENSOR TRUNK PT EXTENSTION AMPM
TO AMPF BLACK 14FEET
1 EA
* ELECTRONIC PARTS *
E1 4461BC UC4 BOOM CONTROL PANEL 1 EA
E2 44631 UC4 ULTRASOUND SENSOR 3 EA

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Item Part Number Description Pcs Len
* HYDRAULIC PARTS *
V1** 44933
or
44933S
VALVE PACKAGE CC LS PROP 2 STATION
EXPANDABLE W/FILTER
VALVE BLOCK ASSEM UC4-BC 2-STATION CC/LS
VARIABLE RATE
1 EA
H2 104178 COUPLING HYD QUICK PIONEER MALE TIP 8FB 2 EA
101854 HYD HOSE END 6WC 8MB 2 EA
100655 HYD HOSE 2 WIRE 3/8 IN 2 354 IN
102897 HYD HOSE END 6WC 6FJX 2 EA
H3 100655 HYD HOSE 2 WIRE 3/8 IN 2 228 IN
102897 HYD HOSE END 6WC 6FJX 2 EA
100641 HYD HOSE END 6WC 6MP 2 EA
H4 101775 COUPLING HYD 6FPT 2 EA
H5 102559 COUPLING HYD 6MP 6MP 2 EA
H6 103345 COUPLING HYD 6MJ 6FJX90 2 EA
H7 103192 COUPLING HYD 8MB 6FB 2 EA
H8 42997 COUPLING HYD 6MB-6MJ ORIFICE 1/32 2 EA
H9 104092 COUPLING HYD 6FP 6FJX 2 EA
H50 44928 ORIFICE INSERT .047 IN ONE WAY 2 EA
H51 103312 COUPLING HYD 6MB 6MJ 4 EA
H52 104369 COUPLING HYD 6MBP 2 EA
H53** 44920 SANDWICH BLOCK KIT - SINGLE ACTING
CONVERSION
2 EA
* MISC. PARTS *
M1A 446BC-MAN-1 MANUAL UC4 BOOM CONTROL TECHNICAL LARGE
BOOKLET
1 EA
M1B 446BC-MAN-2 MANUAL UC4 BOOM CONTROL QUICK REFERENCE
SMALL BOOKLET
1 EA
M2 100084 TIE CABLE 21 IN BLACK 10 EA
M3 100091 TIE CABLE 7.5 IN BLACK 150 EA
M4 104409 FOAM DISC 45 PPI CONDUCTIV 1/2 X 2-3/4 DIA 6 EA
M5 105435 CHAIN 1/2 IN PLASTIC 3 42 IN
M6 100660 BOLT HEX NC GR5 PLTD 1/4X1 3 EA

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Item Part Number Description Pcs Len
M7 100853 NUT HEX NC GR5 PLTD 1/4 IN 3 EA
M10 UC4-BC-RH1-INST MANUAL INSTALLATION UC4 RHS 1200/1600 1 EA
M11 100651 BOLT HEX NC GR5 PLTD 3/8X3/4 2 EA
M12 100947 WASHER LOCK SPRING PLTD 3/8 IN 2 EA
M13 100645 BOLT HEX NC GR5 PLTD 3/8X4 2 EA
M14 44942 TUBING PLASTIC CLEAR PETG 2.75 X.028 1 16 IN
* In a kit shipped prior to February 1, 2007, the part number for Item B13 is 44722.
** If the part number for Item V1 (NORAC valve block) is 44933S, Items H53 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.

7
The parts that come with your UC4 System are shown below in their general
installation configuration.
Figure 2 – UC4 Boom Control Components

8
Figure 3 – Hydraulic Plumbing Schematic
NOTE: If the part number of Item V1 is 44933S, Items H53 are not included in the kit.

9
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 the following Function Check and Boom Speed
Test.
4.1 E XISTING H YDRAULIC S YSTEM F UNCTION C HECK
Check all functions of the existing hydraulic system of your sprayer on Table 2.
There may be more functions in the existing hydraulic system. Please refer to the
sprayer’s operation manual and check additional functions, if necessary.
Table 2 – Hydraulic System Function Check Sheet
HYDRAULIC SYSTEM FUNCTION
INNER OUTER TIP* FIELD
OPERATION
FOLD UNFOLD FOLD UNFOLD FOLD UNFOLD UP DOWN
LEFT BOOM
RIGHT BOOM
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.

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4.2 B OOM S PEED T EST
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.
9. These “Average Times” now represent how quickly your system can react to

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manual control of boom functions. In Section 4.7 Completing the
Installation, 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]
LeftUP
Left DOWN
RightUP
Right Down
MainUP
Main DOWN
Roll CW
Roll CCW
Table 4 – Boom Test Record (WITH UC4 System)
Working RPM (Set this the same as in Table 3):
Section: Trial #1
[Seconds]
Trial #2
[Seconds]
Trial #3
[Seconds]
Average
Time
[Seconds]
LeftUP
Left DOWN
RightUP
Right Down
MainUP
Main DOWN
Roll CW
Roll CCW

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4.3 W ING S ENSOR I NSTALLATION
1. Assemble the Breakaway Sensor Mounting Brackets as shown in Figure 4 and
Figure 5.
Figure 4 – Breakaway Sensor Bracket Exploded View
Figure 5 – Breakaway Sensor Mounting Bracket Assembly

13
To assemble the breakaway sensor bracket:
a) Assemble the bolt and nut into the collar of the bracket.
b) Grease the bottom edge of the collar and the angled tube of the base.
c) Place the collar onto the angled tube of the mounting base.
d) Compress and install the spring between the collar and the upper ring of
the base.
e) Install the tube as shown and, for now, lightly tighten collar around the
tube. You will need to aim the sensor bracket later.
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 ensure that the sensor and bracket will
not interfere with anything when the boom is folded for
transport.
NOTE: Please be aware of the maximum length of the sensor branch
cable (Item C2) for each branch. Note that the sensors can not
be mounted outside of this range on each boom. It might be
wise to route the branch cable at this time to ensure that the
cable reaches to the sensors. (Please refer to Section 4.6
Electrical Installation)
IMPORTANT:
Provide enough slack in the sensor branch cable to account for the
movement of the main section, parallel lift, and FOLDING boom
movement.
3. Mount one NORAC UC4 ultrasonic sensor (Item E2) near the tip of each boom
with the brackets provided (Items B13 and B16). Use the 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 9 inches or
more from the ground.
•The bottom of the sensor must be at least 9 inches in front of the spray
nozzles.
•The bottom of the sensor must be at least 9 inches above the spray nozzles.

14
•The sensor should be approximately vertical at normal operating heights.
•Ensure 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 Control Panel to force the boom dangerously close to the
ground. For this reason, 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.
NOTE: When installing the UC4 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 (Figure 6). 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 Control Panel software.
(This feature is typically used by NORAC technical support
staff.)
Figure 6 – Sensor Serial Number Installation Location

15
4. The UC4 sensor bracket is designed to mount to the large square frame member,
as shown below in Figure 7.
Figure 7 – Preferred Mounting
5. 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 (Items M3
and/or M2) the connector in place. The cable must not be allowed to hang below
the boom (Figure 7).

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4.4 M AIN S ENSOR I NSTALLATION
1. Mount the third sensor on the main section with the bracket provided (Item
B11). Mount the sensor so it is pointing ahead of the boom if possible (ensure
you have clearance when the center section is raised and lowered). You may
mount this sensor pointing behind the boom if necessary, but try to keep it
ahead of the spray nozzles (Figure 8).
2. Aim the sensor perpendicular to the ground. Tighten all the sensor bracket
bolts.
Figure 8 – Main Sensor Mounting
NOTE: Please note that the standard UC4 kit will NOT provide main
section automatic control. The main section sensor will ONLY
assist you in monitoring the height visually on the UC4 Control
Panel. You must manually control the main section height.
Check with NORAC for the availability of an upgrade kit that
will provide main section automatic control.
General mounting rules for ultrasonic center sensors:
•The sensor must have a 12-inch diameter clear view of the ground without
any obstructions (e.g. Nozzles, Hoses, Fenders).

17
•The sensor is to be mounted as far outward from the center of the boom as
possible.
•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-inch or more
above the target (e.g. The crop or the ground) and ensure that the sensor is
safely high enough given the terrain and possible obstructions.
•Do not mount the sensor directly behind the tire. If mounted behind
the tire there will be inadequate crop canopy to reflect the unwanted
ultrasonic signal causing an error when using CROP mode.
NOTE: The standard kit will include an alignment fixture (Item M14:
plastic tube). This fixture is NOT required when performing
installations on sprayers that do not support boom roll movement.
Discard or return M14 to NORAC.

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4.5 H YDRAULIC I NSTALLATION
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.
IMPORTANT:
Hydraulic component failure due to oil contamination is not covered
under the warranty of your UC4 system. Therefore, it is strongly
recommended that a qualified technician, using proper installation
techniques, do the hydraulic installation.
4.5.1 Valve Assembly and Mounting
1. On a clean surface
remove the plastic
plugs from the “A”,
“B”, “P”, and “T”
ports of the NORAC
hydraulic valve
(Item V1) (Figure
9).
2. Install the 6MB-
6MJ fittings (Item
H51) on the “P” and
“T” ports and
tighten to 18 ft-lbs.
Figure 9 – NORAC Valve Block
3. Install the orifices (Item H50) with the notch facing outward into the “B”
ports as shown in Figure 10. An O-ring pick can be used to ease installing the
orifices into their locations.
4. Install the 6MB-6MJ fittings (Item H51) into the “B” ports and tighten to 18 ft-
lbs.
5. Install the 6MBP plugs (Item H52) into the “A” ports and tighten to 18 ft-lbs.