Norac UC4 Total Control User manual

UC 4
Total Control
Automatic Boom Height
System
NITRO (Miller 200 Series 1999+, 120-ft Boom)
Installation Manual
Canada
NORAC Systems International Inc.
CALL TOLL FREE: 1-800-667-3921
[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-NT2-INST Rev D (Nitro)
NOTICE
NORAC Systems International Inc. reserves the right to improve products and their specifications without notice and without
the requirement to update products sold previously. Every effort has been made to ensure the accuracy of the information
contained in this manual. The technical information in this manual was reviewed at the time of approval for publication.

TABLE OF CONTENTS
1 INTRODUCTION .................................................................................................................................. 2
2 GENERAL SYSTEM DESCRIPTION .................................................................................................. 3
3 PARTS LIST......................................................................................................................................... 4
4 INSTALLATION PROCEDURE ........................................................................................................... 9
4.1 EXISTING HYDRAULIC SYSTEM FUNCTION CHECK ................................................................................ 9
4.2 BOOM SPEED TEST .......................................................................................................................... 10
4.3 WING SENSOR INSTALLATION ........................................................................................................... 12
4.4 MAIN LIFT SENSOR INSTALLATION .................................................................................................... 16
4.5 HYDRAULIC INSTALLATION................................................................................................................ 18
4
4. .5 5. .1 1 Valve Assembly (Single-acting cylinders) .............................................................................18
4
4. .5 5. .2 2 Valve Mounting...................................................................................................................... 20
4
4. .5 5. .3 3 Hydraulic Plumbing ............................................................................................................... 21
4.6 ELECTRICAL INSTALLATION .............................................................................................................. 22
4.7 COMPLETING THE INSTALLATION....................................................................................................... 25
5 APPENDIX A - ELECTRICAL REFERENCE: CABLE DRAWINGS ................................................ 26
5.1 ITEM C1: 44662B –SENSOR TRUNK CABLE ..................................................................................... 26
5.2 ITEM C2: 44668 –SENSOR BRANCH CABLE ..................................................................................... 26
5.3 ITEM C3: 44656 –VALVE CABLE (VARIABLE RATE) .......................................................................... 27
5.4 ITEM C4: 44651 –VALVE EXTENSION CABLE.................................................................................... 27
5.5 ITEM C10: 44650-22 –POWER CABLE UC3 BC NITRO ................................................................... 28
5.6 ITEM C11: 44688 –VALVE DISCONNECT EXTENSION 4-FT................................................................. 29
6 APPENDIX B - MOUNTING A SENSOR IN THE “WHEEL TRACK”............................................... 31
6.1 MOVING THE ROLL SENSOR.............................................................................................................. 32
6.2 TURNING THE CENTER (MAIN LIFT SECTION)OFF ............................................................................... 32
6.3 ADJUST THE SENSOR OFFSET .......................................................................................................... 32
6.4 ADD AN ADDITIONAL SENSOR........................................................................................................... 33

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: [e-mail]
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-NT2 KIT HARDWARE UC4 BOOM CONTROL NITRO
120FT
1 EA
* BRACKET PARTS *
B10 44700-05 MOUNTING BRACKET VALVE NITRO 1 EA
B11 44695-4 MOUNTING BRACKET UC3 SENSOR 4IN LG 1 EA
B16 44701 PLATE ACCESS PANEL 1 EA
B17 44702 PLATE ACCESS PANEL COVER (POWER) 1 EA
B18 44703 PLATE ACCESS PANEL COVER (TRUNK) 1 EA
B19 44726 MOUNTING BRACKET NITRO SPRING BREAKAWAY
SENSOR UC4
2 EA
* CABLE PARTS *
C1 44662B-40 CABLE UC3 SENSOR TRUNK AMPF TO AMPF
BLACK STANDARD 40FEET
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

5
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
H2 104586 COUPLING HYD 6FORXR 6MORT 1 EA
H3 102897 HYD HOSE END 6WC 6FJX 1 EA
100655 HYD HOSE 2 WIRE 3/8 IN 1 60 IN
104928 HYD HOSE END 6WC 8FORX 1 EA
H4 102897 HYD HOSE END 6WC 6FJX 1 EA
100655 HYD HOSE 2 WIRE 3/8 IN 1 60 IN
104719 HYD HOSE END 6WC 6FORX 1 EA
H11 104719 HYD HOSE END 6WC 6FORX 1 EA
104459 HYD HOSE END 6WC 6FJX90 1 EA
100655 HYD HOSE 2 WIRE 3/8 IN 1 98 IN
H12 105327 COUPLING HYD 6MOR 12FORX 2 EA
H14 104719 HYD HOSE END 6WC 6FORX 1 EA
104459 HYD HOSE END 6WC 6FJX90 1 EA
100655 HYD HOSE 2 WIRE 3/8 IN 1 101 IN
H15 104884 COUPLING HYD 6MOR 8FORX 2 EA
H16 104885 COUPLING HYD 8FORXR 8MORT 2 EA
H17* 44920 SANDWICH BLOCK KIT – SINGLE ACTING
CONVERSION
2 EA
H18 104634 COUPLING HYD 6FJCN CAP NO 6 FEMALE JIC 2 EA
H50 44928 ORIFICE INSERT .047 IN ONE WAY 4 EA
H51 103312 COUPLING HYD 6MB 6MJ 6 EA
* MISC. PARTS *
M1A 446BC-MAN-1 MANUAL UC4 BOOM CONTROL TECHNICAL LARGE
BOOKLET
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

6
Item Part Number Description Pcs Len
M4 104409 FOAM DISC 45 PPI CONDUCTIV 1/2 X 2-5/8
DIA
6 EA
M5 105435 CHAIN 1/2 IN PLASTIC 3 42 IN
M6 100660 BOLT HEX NC GR5 PLTD 1/4X1 3 EA
M7 100853 NUT HEX NC GR5 PLTD 1/4 IN 3 EA
M10 UC4-BC-NT2-INST MANUAL INSTALLATION UC4 NITRO 120FT 1 EA
M11 100610 BOLT HEX NC GR5 PLTD 3/8X1 2 EA
M12 100947 WASHER LOCK SPRING PLTD 3/8 IN 2 EA
M13 100823 SCREW TAPPING NO 6 X 3/8 TRUSS 6 EA
M14 105436 TUBE CLEAR PLASTIC 2-3/4" ID 1 16 IN
M15 103022 BOLT HEX NC GR5 PLTD 5/16X1-1/4 4 EA
M16 103025 WASHER FLAT USS 5/16 PLTD 4 EA
M17 100870 NUT LOCK NYLON NC PLTD 5/16 IN 4 EA
If the part number for Item V1 (NORAC valve block) is 44933S, Items H17 are not included
in the kit. The #44933S valve block has solenoid valves whose engraved part number is
“105723”. Please see Section 4.5.1 for further details.

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 (Single-Acting Hydraulics)

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 following Function Check and Boom Speed
Test.
4.1 E XISTING H YDRAULIC S YSTEM F UNCTION C HECK
Check that all functions of the existing hydraulic system of your sprayer by using
Table 2. There may be more functions in the existing hydraulic system. Please refer
to the sprayer’s operation manual and ensure checking all functions.
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.

10
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.

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9. These “Average Times” now represent how quickly your system can react to
manual control of boom functions. In Section 4.7, this procedure is repeated
with the UC4 System installed for comparison and troubleshooting purposes.
Table 3 – Boom Test Record (WITHOUT UC4 System)
Working RPM:
Section: Trial #1
[Seconds]
Trial #2
[Seconds]
Trial #3
[Seconds]
Average
Time
[Seconds]
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
NOTE: When installing the Sensors, (Item E2) start with the smallest serial
number on the left hand side proceeding to the largest serial
number on the right hand side. This will allow for a more intuitive
setup when tuning the system. This arrangement is also
REQUIRED when using the “QUICK SETUP” feature available via
the UC4 Panel software. This feature is typically used by NORAC
technical support staff.

13
Figure 5 - Sensor Serial Number Installation Location
2. In order the to reduce the chance of problems, inspect the booms in their folded
position. Mark the locations where the Sensor Brackets can be mounted
without contacting the sprayer. Then the booms can be unfolded and the
sensors mounted without having any mechanical interference.
NOTE: If possible, mount the sensor brackets while the booms are in their
folded position to reduce the chance of clearance errors and to
ensure that the sensor and bracket will not interfere with
anything when the boom is folded for transport.
NOTE: Please note the maximum length of the Sensor Branch Cable (Item
C2) for each branch. Note that the sensors will not be able to be
mounted outside of this range on each boom and consider that
some length will be taken up due to routing the cable. It might be
wise to route the Sensor Branch Cable (Item C2) at this time to
prevent problems. (See 4.6 Electrical Installation)
IMPORTANT:
Provide enough slack in the Sensor Branch Cable to account for the
movement of the center section, parallel lift, and FOLDING boom
movement.

14
3. Mount one ultrasonic sensor (Item E2) near the tip of each boom with the
brackets provided (Item B19). Using the 8-mm nuts and lock washers provided
with the sensor to attach the sensor to the bracket. The sensors should be
oriented forward (ahead) of the boom.
General mounting rules for ultrasonic wing sensors:
•When the boom is in its lowest position, the sensor mouth must be nine
inches or more from the ground.
•The bottom of the sensor must be at least 9 inches in front the spray
nozzles.
•The bottom of the sensor must be at least 9 inches above the spray
nozzles.
•The sensor should be approximately vertical at normal operating
heights.
•Insure that there are no obstructions within a 12-inch diameter circle
projected directly below the center of the sensor.
Improved boom tip protection and control may be obtained by mounting the sensor
as close to the end of the boom as possible. However, if the sensors are
mounted to the breakaway portion of the boom, the operator must be
aware that due to boom geometry a breakaway action may cause the UC4
controller to force the boom dangerously close to the ground.
If your particular boom “breaks away” in an upward direction, the sensor may read
a large height and force your boom to the ground when the system is in automatic
mode. Please consider this situation when mounting wing sensors. If this is your
case, you may want to avoid mounting on a breakaway section.
Please refer to the UC4 system warranty at the end of the UC4 Sprayer Boom
Control Operator’s Manual (Item M1) for implications.

15
Figure 6 - Sensor Mounting
Figure 7 – Cable Routing (Bracket shown is not the Nitro Bracket)
The sensor cable should be run down through the tube of the mounting bracket and
then behind the member the bracket is mounted onto. Cable-tie the connector in
place. The cable must not be allowed to hang below the boom. (See Figure 7).

16
4. Once the sensor brackets are mounted to the boom you can make adjustments to
fine-tune your particular sprayer installation. You may wish to mount the
sensors starting at a small angle to allow for easier "breakaway". This will allow
the sensor to "breakaway" more easily if contact is made directly to the front of
the bracket. The following are typical reasons for mounting the bracket at an
angle.
•If the bracket must make contact with another boom section when folded.
•If you spray in fields with many obstructions, such as beehives.
Figure 8 - Sensor Angular Adjustment
4.4 M
AIN L IFT S ENSOR I NSTALLATION
1. Mount the third sensor on the center section with the bracket provided (Item
B10). Ensure you have clearance when the center section is raised and lowered.
Mount this sensor pointing behind the boom, but try to keep it ahead of the
spray nozzles. (See Figure 9)
2. Aim the sensor perpendicular to the ground. Tighten all the sensor bracket
bolts.

17
Figure 9 – Center Sensor Mounting
General mounting rules for ultrasonic main lift sensors:
•The sensor must have a 12-inch diameter clear view of the ground
without any obstructions.
•The sensor is to be mounted as far outward from the center of the boom
as possible.
•Do not mount the sensor and target directly behind the tire. If mounted
behind the tire there will be inadequate crop canopy to reflect the
signal when using CROP mode.
•Ensure that there will be no contact between the sensor and the booms
when folding and unfolding.
•Mount the sensor as low as possible while maintaining about 12-in or
more above the target (i.e. The crop or the ground) and ensure that the
sensor is safely high enough given the terrain and possible
obstructions.
NOTE: The standard kit will include an alignment fixture (Item M14). This
fixture is NOT required when performing installations on sprayers
that do not support boom roll movement. Discard or return M14 to
NORAC.

18
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.
4
4. .5 5. .1 1 Valve Assembly (Single-acting cylinders)
1. On a clean surface remove the plastic plugs from the "A", "B", "P", and "T" ports
of the Hydraulic Valve (Item V1).
2. Install the 6MB-6MJ (Item H51) fittings on the "P" and "T" ports and tighten to
18 ft-lbs.
3. Install the orifices (Item H50) into the “A” and “B” ports as shown. An O-ring
pick can be used to ease installing the orifices into their locations. Install the
"B" port orifices with the notch facing outwards and the “A” orifices
with the notch facing inwards.
4. Install the 6MB-6MJ fittings (H51) into the “A” and "B" ports and tighten to 18
ft-lbs.
5. Install the 6FJCN caps (Item H18) on each “A” fitting and tighten to 18 ft-lbs.
Figure 10 – Valve Block Port Assembly (Single-Acting Cylinders)