Norac UC4 Total Control User manual

UC 4
Total Control
Automatic Boom Height
System
NITRO (Miller 3200 Series 2006+, 90/120 ft Boom)
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 2006-07 by NORAC Systems International Inc.
Reorder P/N: UC4-BC-NT3-INST Rev E (NITRO 90/120FT)
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................................................................................................................ 17
4.5.1 Valve Assembly ..................................................................................................................... 17
4.5.2 Valve Mounting...................................................................................................................... 20
4.5.3 Hydraulic Plumbing ............................................................................................................... 21
4.6 ELECTRICAL INSTALLATION .............................................................................................................. 22
4.7 COMPLETING THE INSTALLATION....................................................................................................... 27
5 ELECTRICAL REFERENCE – CABLE DRAWINGS ........................................................................ 28
5.1 ITEM C1: 44662B-40 –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 CABLE.................................................................................... 29
5.5 ITEM C10: 44650-22 –CABLE POWER NITRO ................................................................................. 30
5.6 ITEM C11: 44688 –VALVE DISCONNECT EXTENSION 4-FT CABLE...................................................... 31
APPENDIX A .............................................................................................................................................. 32

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 – NITRO Sprayer Boom Control System Parts
Item Part Number Description Pcs Len
UC4-BC-NT3KIT HARDWARE UC4 BOOM CONTROL NITRO
90/120FT
1 EA
* BRACKET PARTS *
B10 44700-05 MOUNTING BRACKET VALVE NITRO 1 EA
B11 44695-4 MOUNTING BRACKET UC3 SENSOR 6IN 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 44729 MOUNTING BRACKET NITRO UNIVARSAL SPRING
BREAKAWAY
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 44650-22 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

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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
H1 101827 COUPLING HYD 8MBP 2 EA
H3 102897 HYD HOSE END 6WC 6FJX 1 EA
100655 HYD HOSE 2 WIRE 3/8 IN 1 80 IN
103771 HYD HOSE END 6WC 8MBX90 1 EA
103345 COUPLING HYD 6MJ 6FJX90 1 EA
H4 102897 HYD HOSE END 6WC 6FJX 1 EA
100655 HYD HOSE 2 WIRE 3/8 IN 1 80 IN
103771 HYD HOSE END 6WC 8MBX90 1 EA
103345 COUPLING HYD 6MJ 6FJX90 1 EA
H5 104459 HYD HOSE END 6WC 6FJX90 1 EA
100655 HYD HOSE 2 WIRE 3/8 IN 1 110 IN
104719 HYD HOSE END 6WC 6FORX 1 EA
H6 104459 HYD HOSE END 6WC 6FJX90 1 EA
100655 HYD HOSE 2 WIRE 3/8 IN 1 144 IN
104928 HYD HOSE END 6WC 8FORX 1 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 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 2-5/8
DIA
6 EA

6
Item Part Number Description Pcs Len
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-NT3-INST MANUAL INSTALLATION UC4 NITRO 90/120FT 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 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 serial number of the sprayer is prior to 21.12733, you need a
Hydraulic Adapter Kit (UC4-BC-NT4H). Please refer to Appendix
A on page 32 for more information.
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

11
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]
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. For reference, an exploded view of the Breakaway Sensor Mounting Brackets is
as shown in Figure 4.
Figure 4 – Breakaway Sensor Bracket Exploded View
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 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)

13
IMPORTANT:
Provide enough slack in the sensor branch cable (C2) to account for the
movement of the main section, parallel lift, and FOLDING boom
movement.
3. Mount one NORAC 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 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.
•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 controller to force the boom dangerously close to the ground.
Because of this, 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 (Items E2), start with the
smallest serial number on the left hand side proceeding to the
largest serial number on the right hand side (Figure 5). 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).

14
Figure 5 – Sensor Serial Number Installation Location
4. Mount the sensor mounting brackets (Item B19) on to the booms as shown in
Figure 6.
Figure 6 – Sensor Bracket Mounting
FRONT

15
Figure 7 – Sensor Cable Routing
5. The sensor cable should be run down through the tube of the mounting bracket
and then along 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).

16
4.4 M AIN L IFT S ENSOR I NSTALLATION
1. Mount the third sensor on the main section with the bracket provided (Item
B11). Ensure you have clearance when the main section is raised and lowered.
Mount this sensor pointing behind the boom, but try to keep it ahead of the
spray nozzles.
2. Aim the sensor perpendicular to the ground. Tighten all the sensor bracket
bolts.
General mounting rules for ultrasonic main lift sensor:
•Mount the sensor at the midpoint of the main lift section.
•The sensor must have a 12-inch diameter clear view of the ground without any
obstructions.
•Ensure that there will be no contact between the sensor and the booms when
folding and unfolding, or raising and lowering.
•The bottom of the sensor must be at least 9 inch in front of the spray nozzles.
•The bottom of the sensor must be at least 9 inch above the spray nozzles.
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.

17
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
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 8).
2. Install the 6MB-6MJ fittings (Item H51) on the “P” and “T” ports and tighten to
18 ft-lbs.
Figure 8 – NORAC Valve Block

3. Install the orifices (Item H50) into the “B” ports with the notch facing
outwards as shown in Figure 9. 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.
Figure 9 – Valve Block Port Assembly
IMPORTANT:
Check the engraved part number on the top plate of the solenoid valves
(Figure 9). If the number is “105723”, proceed to Section 4.5.2 (page 20).
STEP 6 through STEP 12 are required for all other part numbers.
6. Assemble the Single Acting Sandwich Block Kit (Item H53). 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 (Figure 10).
7. Coat the top and bottom of the sandwich block in clean hydraulic oil.