Norac FLEXI-COIL 67 Series User manual

FLEXI-COIL Series 67
Installation Manual
Spray Height Controller
Improving the competitiveness o Industry and
Agriculture through Precision Measurement

Printed in Canada
Copyright  2005-08 by NORAC Systems International Inc
Reorder P/N: UC4+BC+FC1-INST REV E (FLEXI-COIL Series 67)
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 GENERAL SYSTEM DESCRIPTION .................................................................................................. 2
3 PARTS LISTS ...................................................................................................................................... 3
4 INSTALLATION PROCEDURE ........................................................................................................... 8
4.1 EXISTING SYSTEM CHECK ............................................................................................................... 8
4.2 BOOM SPEED TEST........................................................................................................................ 8
4.3 WING SENSOR INSTALLATION....................................................................................................... 10
4.4 MAIN LIFT SENSOR INSTALLATION ................................................................................................ 13
4.5 ROLL SENSOR INSTALLATION ....................................................................................................... 14
4.5.1 Boom Roll Sensor Mounting.................................................................................................. 15
4.5.2 Chassis Roll Sensor Mounting .............................................................................................. 15
4.5.3 Inverted Roll Sensor Mounting .............................................................................................. 17
4.5.4 Temperature pro e................................................................................................................ 17
4. HYDRAULIC INSTALLATION ........................................................................................................... 18
4.6.1 Valve Assem ly ..................................................................................................................... 18
4.6.2 Valve Mounting...................................................................................................................... 19
4.6.3 Hydraulic Plum ing ...............................................................................................................20
4.7 ELECTRICAL INSTALLATION .......................................................................................................... 21
4.8 COMPLETING THE INSTALLATION .................................................................................................. 25
5 ELECTRICAL REFERENCE – CABLE DRAWINGS ........................................................................ 2
5.1 ITEM C01: 44 2B-40 – SENSOR TRUNK CABLE ......................................................................... 2
5.2 ITEM C01B: 44 87 – SENSOR EXTENSION CABLE ........................................................................ 2
5.3 ITEM C02: 44 8 – SENSOR BRANCH CABLE ............................................................................... 27
5.4 ITEM C02B: 44 4 – CABLE UC4 CAN NODE DUAL .................................................................... 27
5.5 ITEM C03: 44 5 D – CABLE VALVE VARIABLE RATE DT.............................................................. 28
5. ITEM C04: 44 51 – VALVE EXTENSION CABLE ............................................................................. 28
5.7 ITEM C10: 44 50-09 – POWER CABLE FOR FLEXI-COIL 7 SERIES ............................................ 29

1
1 INTRODUCTION
Congratulations on your purchase of the NORAC UC4+ Spray Height Controller 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 ha e suggestions
regarding the parts list or the installation procedure, please don’t hesitate to contact us ia
the information gi en below:
Phone: [phone] Canada (Toll Free)
1-866-306-6722 United States (Toll Free)
([phone] Europe
1-306-664-6711 all other regions
E-mail: ser [email protected]
Website: www.norac.ca

2
2 GENERAL SYSTEM DESCRIPTION
Figure 1 depicts the general system layout of the UC4+ Spray Height Controller 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
specially to fit the sprayer to facilitate 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 mo ement 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 LISTS
The parts that come with your UC4+ Spray Height Controller are listed in Table 1. The item number 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 – FLEXI-COIL Spray Height Controller System Parts
Item Part Number Name Quantity
B05 44706-01 KIT CABLE TIE BLACK 10 PCS 21 IN 150 PCS 7 5 IN 1
B10 44700-06 BRACKET VALVE MOUNTING STD 1
B11 44743 MOUNTING BRACKET MAIN LIFT SENSOR UC4 PLUS 1
B13 44728 MOUNTING BRACKET COMPLETE UC4 BREAKAWAY EXTENDED 2
C01 44662B-40 CABLE UC3 SENSOR TRUNK AMPF TO AMPF BLACK STANDARD 40FEET 1
C01B 44687 CABLE UC3 SENSOR TRUNK PT EXTENSTION AMPM TO AMPF BLACK 14FEET 1
C02 44668 CABLE UC3 SENSOR BRANCH 1 AMP RECEPT 3 AMP PLUG BC 1
C02B 44664 CABLE UC4 CAN NODE DUAL 1
C03 44656D CABLE VALVE VARIABLE RATE DT 1
C04 44651 CABLE VALVE EXTENSION 1
C10 44650-09 CABLE POWER FOR FLEXI-COIL 67 SERIES 1
E01 4461BC+ UC4 PLUS BOOM CONTROL PANEL 1
E02 44631 UC4 ULTRASOUND SENSOR 3
E03 44641 UC4 PLUS ROLL SENSOR W TEMPERATURE PROBE 1
E04 44642 UC4 PLUS ROLL SENSOR 1
H04 44863-29 HOSE ASSEMBLY 122R2-06 36 IN L 8FJX90 6FJX 2
H20 44865-07 HYDRAULICS FITTING KIT - FC1 1
M01 446BC+MAN7 OPERATOR MANUAL UC4+ SPRAY HEIGHT CONTROL 1
M10 UC4+BC+FC1-INST MANUAL INSTALLATION UC4+ FLEXI-COIL 67 SERIES 1
V01 44963D VALVE BLOCK ASSEMBLY 2 STATION CC/LS PROP DT 4 BOLT 1

4
Substitution parts will in no way affect the operation of the system pro ided that they are installed
as directed.
Item V01 – 2 Station Val e Block (44963D) may be substituted with:
Item Part Number Name Quantity
V01 44933D VALVE BLOCK ASSEM UC4-BC 2-STATION CC/LS VARIABLE RATE 1
The 44933D is a direct replacement for the 44963D Both valve blocks function the same The blocks
are identifiable by the filter cap shape and by the part number stamped on the side
The A and B ports are opposite on each al e block so erify that the hoses are being connected to
the correct port. The raise lines always go to the “B” port and the lower lines go to the “A” port.
44933D Val e Block Shown Alongside 44963D Val e Block
Filter Cap Part Number
(44933D) Filter Cap Part Number (44963D)

5
Table 2 - 44865-07 - Hydraulics Fittings Kit – FC1
Item Part Number Name Quantity Picture
F02 104369 PLUG - 6MBP 4
F03 104643 FEMALE ADAPTER - 8FP 8FJX 2
F04 104627 TEE ADAPTER - 8MBR 8MJT 2
F05 104929 MALE TO FEMALE ADAPTER - 6MB 8FB 2
F06 103312 MALE ADAPTER - 6MB 6MJ 6
F07 44928 ORIFICE INSERT 047 IN ONE WAY 4
6 M B - 6 M OR X 90
SIZE IN
1/16TH'S
GENDER: MALE
OR FEMALE
90 ° ANGLE
SWIVEL
TYPE
GENDER
SIZE
TYPE:
B - ORB
- IC
OR - FLAT
FACE
P - PIPE
Fitting Name
Example:
The use of dielectric grease is not recommended on any NORAC electrical connections.
To ensure all stainless steel hardware does not gall or seize apply a light coating of the supplied
Permatex Anti-seize grease to all threaded parts upon installation. Permatex Anti-seize lubricant is
preferred, but other similar anti-seize products may be used.

6
The parts that come with your UC4+ System are shown below in their general installation
configuration.
Figure 2 – UC4+ Spray Height Controller Components

7
Figure 3 – Hydraulic Plumbing Schematic

8
4 INSTALLATION PROCEDURE
4.1 E XISTING SYSTEM CHECK
It is necessary to check the existing system’s
functionality before installing the UC4+
system
1 Drive your sprayer onto a flat piece of
land, with unobstructed boom movement
(e g no power lines)
2 Test that all boom functions operate
correctly As you test each function
check it off in Table 3
It is necessary to test the boom
functions in all directions
Table 3 – Hydraulic System Function
Check Sheet
BOOM
FOLD
IN
FOLD
OUT UP DOWN
LEFT
MAIN
RIGHT
ROLL*
N/A
N/A
* Some sprayers may not have this function
4.2 B OOM S PEED T EST
IMPORTANT:
Raise/lower all boom sections se eral
times to warm up the hydraulic system.
Grease all mo ing 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 4
You will need a stopwatch or a
watch that displays “seconds” for
the next step.
3 Raise the LEFT boom from its extreme
LOW position to the very TOP of its
travel Record the time this takes in
Table 4, “Trial #1” for “Left UP”
4 Lower the LEFT boom from its extreme
HIGH position to the BOTTOM of its
travel Record this time in Table 4,
Trial #1, for “Left DOWN”
Be careful when lowering the
booms so they don’t hit the
ground.
5 Similarly, record two more time trials
(Trial #2 & #3) for the LEFT boom and
record in Table 4
6 Repeat Steps 1 through 5 for the RIGHT,
MAIN and ROLL functions
Your sprayer may not ha e a roll
feature.
7 Average the three trials recorded for
each boom movement and record this
calculation in the “Average Time” slot in
Table 4.
8 These “Average Times” now represent
how quickly your system can react to
manual control In Section 4.8, this
procedure is repeated with the UC4+
System installed for comparison and
troubleshooting purposes

9
Table 4 – Boom Test Record (WITHOUT UC4+ System)
Working RPM:
Boom Trial #1
[Sec]
Trial #2
[Sec]
Trial #3
[Sec]
Avg Time
[Sec]
Left UP
Left DOWN
Right UP
Right Down
Main UP
Main DOWN
Roll CW
Roll CCW
Table 5 – Boom Test Record (WITH UC4+ System)
Working RPM:
Boom Trial #1
[Sec]
Trial #2
[Sec]
Trial #3
[Sec]
Avg Time
[Sec]
Left UP
Left DOWN
Right UP
Right Down
Main UP
Main DOWN
Roll CW
Roll CCW
Some sprayers may not ha e the Roll functions.

10
4.3 W ING S ENSOR I NSTALLATION
1 Assemble the Breakaway Sensor
Mounting Brackets (B11) as show in
Figure 4 and Figure 5
Figure 4 – Breakaway Sensor Bracket
Exploded View
Figure 5 – Breakaway Sensor Mounting
Bracket Assembly
To assemble the breakaway sensor
bracket:
a) Assemble the bolt and nut into the
collar
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) Install the spring between the collar
and the upper ring of the base
e) Insert tube through assembly and
tighten the collar
2 Mount the sensor bracket onto the boom
If possible, mount the sensor
brackets while the booms are in
their folded position to ensure that
they will not interfere with
anything when the boom is folded
for transport.
3 The mounting brackets can be installed
with the mounting base behind (Figure
8) or in front of the tube (Figure 6)
Mounting the sensor bracket to
the break-away section of the
boom may cause the boom to drop
suddenly as a break-away occurs.
This will occur on break-away
sections which lift as they break
away.
For optimal boom tip protection, it
is recommended that the sensor be
mounted within approximately
two feet (60cm) of the boom tip.
Please refer to the UC4+ system
warranty at the end of the UC4+
Sprayer Boom Control Operator’s
Manual (M01) for implications
4 Mount the NORAC UC4+ ultrasonic
sensor (E02) into the sensor brackets
The sensors should be oriented forward
(ahead) of the boom (see Figure 6 and
Figure 8)

11
When installing the UC4+ sensors
(E02), start with the smallest serial
number on the left hand side
proceeding to the largest serial
number on the right hand side
(Figure 9).
5 Sensor cables should run through the
mounting bracket tube 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 (Figure 6)
Figure 6 – Another Acceptable Mounting
A oid mounting sensors in
locations where they may read
from parts of the boom as shown
in Figure 7.
Figure 7 – Poor Mounting
(Sensor Reading off Boom)
General mounting rules for UC4+
ultrasonic wing sensors:
a) In its lowest position, the sensor mouth
must be 9 inches or more from the
ground
b) The bottom of the sensor must be at least
9 inches in front of the spray nozzles
c) The bottom of the sensor must be at least
9 inches above the spray nozzles
d) Ensure that there are no obstructions
within a 12-inch diameter circle
projected directly below the center of the
sensor
e) The sensor should be approximately
vertical at normal operating heights
Figure 8 – Sensor Mounting Guidlines
A
B
B
D
C
Ultrasonic
Acoustic Cone

12
Figure 9 – Sensor Serial Number Installation Location
3 SENSOR SYSTEM
5 SENSOR SYSTEM

13
4.4 M AIN L IFT S ENSOR I NSTALLATION
1 Assemble the main lift sensor bracket
(B11) as shown in Figure 10
Figure 10 – Main Lift Sensor Bracket
2 The bracket can then be mounted to the
lowest frame member on the center
section of the sprayer The bracket
should be mounted so the sensor
mounting collar is in approximately the
center of the sprayer and ahead of the
boom (Figure 11 and Figure 12)
The sensor mounting collar must
not be behind the sprayer’s wheel.
The General Mounting Rules for
UC4+ Ultrasonic Sensors, from the
pre ious section, must be followed.
Figure 11 – Main Lift Sensor Bracket
Mounting Position
3 Mount the sensor onto the sensor
mounting collar (Figure 11)
Figure 12 – Main Lift Sensor Mounted in
the Correct Location
Bracket Tube
Sensor
Mounting Tab
Sensor Mounting
Collar
Bracket Base

14
4.5 R OLL S ENSOR I NSTALLATION
Mount the roll sensors to the included
roll sensor brackets using the machine
screws and nylon lock nuts, as illustrated
in Figure 13.
The roll sensors must be mounted
tightly to the brackets.
Figure 13 – Mounting the Roll Sensor to
the Roll Sensor Mounting Bracket
When mounting the roll sensors use the
following guidelines and refer to Figure
14
a) The smaller the distance between A
and B in Figure 14, the better the
performance will be
Distance A can not be more than
12”.
b) The roll sensors must not be
mounted below the pivot point
c) Ensure the roll sensors are sitting
relatively level when the sprayer
chassis and boom are level
d) Both roll sensors must be mounted
with the circular AMP connector
facing towards the Right-Hand Wing
(when looking from the rear of the
sprayer)
Figure 14 – Mounting Guidelines for Center Pi ot Sprayers
Connectors towards
Right-hand Wing 

15
Figure 15 – Roll Sensor Mounting with Respect to Sprayer Orientation
4.5.1 Boom Roll Sensor Mounting
The boom roll sensor (E04) must be
mounted to the rotating part of the boom
Follow these guidelines and refer to Figure
16, 17 and Figure 18 to mount the sensor
a) Make sure you are using the roll
sensor that does NOT have a
temperature probe (only one cable)
(E04)
b) The boom roll sensor must be
mounted to the rotating part of the
boom suspension
c) Use cable-ties to secure the bracket
to a square edge feature (square
tube)
d) Ensure the AMP (circular) connector
exits towards the Right Hand Wing
(when looking from the rear of the
sprayer)
e) Securely cable-tie the connector to
the frame
4.5.2 Chassis Roll Sensor Mounting
The chassis roll sensor must be mounted to a
non-rotating part of the boom To mount the
chassis roll sensor, follow the following
guidelines and refer to Figure 16, 17 and
Figure 18
a) Make sure you are mounting the roll
sensor that does have a temperature
probe (2 cables) (E03)
b) Mount the chassis roll sensor (E03)
to a non-rotating part of the boom
c) Cable-tie the bracket to a square
edge feature (square tube)
d) The AMP (circular) connector
MUST exit towards the Right Hand
Wing (when looking from the rear)
e) Securely cable-tie the connector to
the frame
* The boom frame
roll sensor does not
ha e a temperature
probe

16
Figure 16 – Roll Sensor Mounting (Viewed from Rear of Sprayer)
Figure 17 – Roll Sensor Mounting (Viewed from Front of Sprayer)
Figure 18 – Boom and Chassis Roll Sensors Correctly Mounted
E04
E03
E03
E04
E03
E04

17
4.5.3 Inverted Roll Sensor Mounting
If desired, the Roll sensor may be mounted
inverted, so long as the connector exits
towards the right-hand boom Inverted
mounting may be used to optimize the
mounting criteria as explained at the
beginning of Section 4.5
Figure 19 – In erted Roll Sensor Mounting may be Applicable for Optimal Performance
4.5.4 Temperature probe
Fasten the temperature probe (E03) to the
UC4 valve block using the included
3/8x1/2” bolt as illustrated in Figure 20
Figure 20 – UC4+ Val e block with
Temperature Probe Installed