Norac UC4+ User manual

Generic (Fixed Boom)
Installation Manual
Spray Height Controller
Improving the competitiveness of Industry and
Agriculture through Precision Measurement

Printed in Canada
Copyright ©2005-08 by NORAC Systems International Inc.
Reorder P/N: UC4+BC+GN2-INST Rev D (Generic Fixed Boom)
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
1INTRODUCTION ..................................................................................................................................................1
2GENERAL SYSTEM DESCRIPTION ..................................................................................................................2
3PARTS LISTS ......................................................................................................................................................3
4INSTALLATION PROCEDURE ...........................................................................................................................5
4.1 WING SENSOR INSTALLATION ........................................................................................................................5
4.2 ELECTRICAL INSTALLATION............................................................................................................................7
4.2.1 Control Panel 7
4.2.2 Inside Cab 8
4.2.3 Outside Cab 9
4.2.4 Electrically Teed Installation 10
4.3 COMPLETING THE INSTALLATION ..................................................................................................................12
5CALIBRATING THE SLANT VALVE ................................................................................................................13
5.1 OVERVIEW...................................................................................................................................................13
5.2 VALVE DEADZONE TEST ..............................................................................................................................14
5.3 VALVE GAIN TEST .......................................................................................................................................15
6ELECTRICAL REFERENCE – CABLE DRAWINGS........................................................................................16
6.1 ITEM C02: 44668 –SENSOR BRANCH CABLE...............................................................................................16
6.2 ITEM C10: 44650-35/39 –POWER CABLE GENERIC .....................................................................................17
6.3 ITEM C11: 44651-03 –EXTENSION CABLE VALVE GENERIC .........................................................................18
6.4 ITEM C12A: 44658-35 –GENERIC INTERFACE CABLE ..................................................................................19
6.5 ITEM C12B: 44658-36 –GENERIC WING INTERFACE CABLE.........................................................................20
6.6 ITEM C14: 44658-28 –INTERFACE CABLE POWER PIGTAIL ..........................................................................21
6.7 ITEM C15: 44658-31 –INTERFACE CABLE HAND CONTROL PIGTAIL .............................................................22
6.8 ITEM C17: 44658-42 –GENERIC INTERFACE ROLL CABLE ...........................................................................23

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 have suggestions regarding
the parts list or the installation procedure, please don’t hesitate to contact us via the information
given below:
Phone: [phone] Canada (Toll Free)
1 866 306 6722 United States (Toll Free)
([phone] Europe
([phone] All other regions
E-mail: [email protected]
Web: www.norac.ca

2
2 GENERAL SYSTEM DESCRIPTION
Figure 1 depicts the general system layout of the UC4+ Spray Height 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 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+ Spray Height Control
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.

3
3 PARTS LISTS
The parts that come with your UC4+ Sprayer Boom System 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 – Generic Fixed Boom Spray Height Control System Parts
Item Part Number Name Quantity
B05 44706-01 KIT CABLE TIE BLACK 10 PCS 21 IN 150 PCS 7.5 IN 1
B13 44728 MOUNTING BRACKET COMPLETE UC4 BREAKAWAY EXTENDED 2
C02 44668 CABLE UC3 SENSOR BRANCH 1 AMP RECEPT 3 AMP PLUG BC 1
E01 4461BC+ UC4 PLUS BOOM CONTROL PANEL 1
E02 44631 UC4 ULTRASOUND SENSOR 2
M01 4476BC+MAN7 OPERATOR MANUAL UC4+ SPRAY HEIGHT CONTROL (FIXED BOOM) 1
M02 UC4+BC+GN2-INST MANUAL INSTALLATION UC4+ GENERIC FIXED BOOM 1
M03 UC4+BC+GN2-INSTE MANUAL INSTALLATION UC4+ END USER GENERIC FIXED BOOM 1
Generic interface cables are shown in this manual. They are available separately from
NORAC. Please see UC4-BC-AN-CBL, UC4 Generic Cable Ordering Guide, for more
information.

4
The parts that come with your UC4+ Spray Height Control system are shown below in their general
installation configuration.
Figure 2 – UC4+ Spray Height Control Components

5
4 INSTALLATION PROCEDURE
4.1 WING SENSOR INSTALLATION
1. Assemble the Breakaway Sensor Mounting
Brackets (B11) as show in Figure 3 and
Figure 4.
Figure 3 – Breakaway Sensor Bracket
Exploded View
Figure 4 – 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 sensor mounting brackets can be
installed with the mounting base behind
(Figure 7) or in front of the tube (Figure 5).
It is advised to avoid mounting the
sensor bracket to a breakaway portion
of the boom because a breakaway
action can cause the UC4+ Spray
Height Control system to force a boom
close to the ground.
4. Mount the NORAC UC4+ ultrasonic sensor
(E02) into the sensor brackets. The sensors
should be oriented forward (ahead) of the
boom (see Figure 5 and Figure 7).
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.

6
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 5).
Figure 5 – Another Acceptable Mounting
Avoid mounting sensors in locations
where they may read from parts of the
boom as shown in Figure 6.
Figure 6 – 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 7 – Sensor Mounting Guidelines
A
B
B
D
C
Ultrasonic
Acoustic Cone

7
ROP
4.2 ELECTRICAL INSTALLATION
4.2.1 Control Panel
1. Install the UC4+ Control Panel (E01) in the
cab of the sprayer. Mount the panel where it
will be clearly visible and within easy reach
of the operator.
A good spot to mount the UC4+ control
panel is on the right hand side of the cab to
the Roll Over Protection Bar (ROP). Four
pilot holes for the screws provided need to be
drilled to facilitate the control panel
mounting.
Another option is to purchase an adapter for
the flexible panel mount that has a 3/8" NC
threaded stud on the end to bolt through an
existing mount. You can find these at your
local outdoor store as a RAM mount part
number RAM-B-236. (See
http://www.ram-mount.com/)
Figure 8 – Control Panel Mounting
ROP

8
4.2.2 Inside Cab
Figure 9 – Cable Configurations: C10 and C11
1. Connect the UC4+ power cable (C10) to the
UC4+ Control Panel in the sprayer cab.
Ensure that both plugs (P16A and P4) are
connected to the panel (Figure 9).
Ensure the UC4 control panel’s power
is OFF for the remaining installation
(Bottom of switch pressed IN). Use
caution when handling the 12 V power
line of the sprayer wiring.
2. Connect the 3-pin AMP connector (P3) of
C10 to an auxiliary power connection inside
the cab. If an appropriate connector can not
be found, it may be necessary to cut off the
connector(s) and splice into the existing
wiring.
For a clean connection to the sprayer’s
power supply, NORAC provides
optional power interface cables. Please
see NORAC Generic Cable List for
details.
3. Route the receptacle end (R16) of C10 to the
exterior of the cab.
4. Connect the 16-pin AMP plug (P16) of the
valve extension cable (C11) to R16 of C10.
For a pull type sprayer, connect at the
hitch. This connection will provide
your hitch disconnect.

9
4.2.3 Outside Cab
Figure 10 – Cable Configurations: Electrically Teed Installation
1. Route C11 to the rear of the sprayer near the
sprayer valve block (Figure 10).
2. Connect the sensor branch cable (C02) to the
4-pin AMP plug (P4) (Figure 11).
3. Route C02 out to the wing sensors. Connect
them using the 4-pin AMP connectors.
Follow existing cables and/or hydraulic lines
along the boom.
4. Cable-tie the installed cables every 12 inches.
IMPORTANT:
Provide enough slack in the valve
extension cable (C11), interface cables
(C12A, C17 and/or C12B) and sensor
branch cable (C02), to account for the
movement of the main section, parallel lift,
and FOLDING boom movement.
Figure 11 – Cable Configurations: C11 and
C02

10
4.2.4 Electrically Teed Installation
For Electrically Teed Installation, there are two different methods of cable installation to tee in to
the sprayer’s control system. The first is teeing the NORAC system in to the sprayer’s wiring
inside the cab (Section 4.2.4.1). The second is teeing the NORAC system in to the sprayer’s
wiring at the valve block (Section 0). Choose one of the two methods, whichever is suitable for
your sprayer.
4.2.4.1 Cable Connections Inside Cab
1. Connect the 16-pin AMP plug (P16B)of
C10 to the 16-pin AMP receptacle (R16) of
C15 (Figure 12).
2. Strip the cable jacket off the pigtail (N15)
on C15.
Figure 12 – Cable configurations: C10 and
C15
3. Splice the wires (N15) of C15 into the
existing wiring to tee in to appropriate
functions of the sprayer’s control system.
The wire colors and functions are shown in
Table 2. Some wires may not be used for this
installation. Before connecting the wire of
N15,check each sprayer wire you will be
splicing to.
Table 2 – N15: Wire Colors and Functions
COLOR FUNCTION
Green / White Main Up
Blue / White Main Down
Green Left Up
White Left Down
Green / Black Right Up
White / Black Right Down
Black Roll CW
Red / White Roll CCW
Orange / Black Bypass
Blue Remote Manual
Blue / Black Remote Auto
Orange Motion Inhibit
Red/Black 12 V
Red N/A
Black / White N/A

11
4.2.4.2 Cable Connections at Valve Block
Figure 13 – Cable Configurations: Electrically Teed Installation
Figure 14 – Schematic Diagram: Electrically Teed Installation
1. Connect the 6-pin Shroud (S6) on the generic
interface cable (C12A) to the mating 6-pin
Tower (T6A) on C11.
2. Connect the 3-pin Tower (T3) on the roll
interface cable (C17) to the mating 3-pin
Shroud (S3) on C11.
3. If there is an enable valve on the sprayer
block, connect 3-pin Shroud (S3) of C12B to
T3 on C11.
4. Route the free ends of C12A, C17 and C12B
to the existing valve block.
5. Splice the loose wires of C12A, C17 and
N1C of C12B into the existing wiring to tee
in to appropriate functions of the sprayer’s
control system.
The following wires are not used for
this installation:
•C12A: N1D, N1E, N1F, N1G
•C12B: N1A, N1B

12
4.3 COMPLETING THE INSTALLATION
1. Start up your sprayer and test the sprayer’s
functionality. The NORAC Control Panel
does not need to be powered up for the
original switches to function. Unfold the
booms and raise/lower each boom and main
section.
Confirm that the cabling is agreeable
to the entire range of motion.
2. If any functions do not work, review the
hydraulic and electrical portions of this
manual to check for proper installation. If
you still have trouble, contact NORAC for
assistance.
3. Turn on the power for the UC4+ Control
Panel using the switch on the side of its
chassis.
4. Begin the AUTOMATIC SYSTEM SETUP
procedure as described in the UC4+ Spray
Height Control Operator’s Manual (M01).
Performance may be limited during
the Control System Test in the
Automatic Setup since the slant valve
has not been calibrated yet. It is
recommended to repeat the control
system test again after the slant valve
has been calibrated.
5. After the AUTOMATIC SYSTEM SETUP,
you will need to manually calibrate the slant
valve as described in Section 5 .
6. The procedure for the installation of the
UC4+ Spray Height Control system is now
complete.
7. For a pull type sprayer, there should be very
little play at the hitch clevis for optimal
performance of the UC4 system. The
addition of polymer washers can help tighten
up this connection (Figure 15).
Figure 15 – Hitch Point

13
5 CALIBRATING THE SLANT VALVE
5.1 OVERVIEW
There are two key settings for each valve
direction. These settings are valve DeadZone,
"DZ", and valve GAIN, "KP".
The DeadZone ("DZ") setting represents the size
of electrical signal required at the solenoid valve
to cause a boom speed of one inch per second
(Section 5.2).
The GAIN ("KP") setting is inversely related to
the maximum speed of the boom. That is, the
faster the boom the lower the GAIN setting
(Section 5.3).
IMPORTANT:
Before you start setting up the slant valve,
ensure you complete the following steps.
1. Unfold the sprayer in a location that is
relatively level, and where the sensors are
over bare soil or gravel. Do not conduct the
setup procedure over standing crop, or tall
weeds/grass.
2. Check the pads between the sprayer boom
and the boom carrier frame to ensure no
friction because of wear. Use grease or other
lubricants, if necessary. This is important
and will increase the UC4+ Spray Height
Control system performance significantly.
3. Start the solution pump and run the sprayer’s
engine at a normal working RPM for the
entire setup. Make sure that you can
manually adjust the height of all your booms.
For best results, the hydraulic system should
be under a normal load and at a normal
working temperature. An effective way to
warm the oil is to cycle all boom sections up
and down manually for 5 minutes. Longer
warm up times may be required in cold
weather. For pull-type sprayers, ensure any
hydraulic flow controls are adjusted for
normal field operation. Changing the flow
controls during or after the setup will affect
the UC4+ operation.
Table 3 – Roll Channel SETUP Menus
Navi
g
atin
g
past the end of the menu will
return the panel to the Setup…”More” Menu
Roll OnU
Informs you that the roll valve
channel is ON. To change the
status to OFF, use the " +/- "
switch.
DZ 20
Informs you that the roll cw
(clockwise) DeadZone setting is
20. To adjust the reading use the "
+/- " switch.
KP 10
Informs you that the roll cw GAIN
setting is 10. To adjust the
reading use the " +/- " switch.
DZ 20
Informs you that the roll ccw
(counter clockwise) DeadZone
setting is 20. To adjust the
reading use the " +/- " switch.
KP 10
Informs you that the roll ccw
GAIN setting is 10. To adjust the
reading use the " +/- " switch.
Navi
g
atin
g
past the end of the menu will
return the panel to the Setup…”More” Menu

14
5.2 VALVE DEADZONE TEST
1. Ensure the UC4+ control panel is in
MANUAL mode, at the Normal Operating
Screen.
2. Navigate to the "More ?" menu prompt in
the SETUP menu. Toggle the "AUTO
(YES)" switch to confirm.
3. Navigate to the roll section. Toggle the
"AUTO (YES)" switch to confirm.
4. Toggle the "SETUP (NO)" switch to access
the next menu prompt, in this case the roll cw
DeadZone (" DZ "). Toggle and hold the
"MANUAL" switch.
5. The valve will turn on at the indicated setting
for exactly one-second. The LCD screen will
show the actual change in height.
Ensure the boom moves in the
clockwise direction (left boom up, right
boom down). If the boom moves in the
opposite direction, check your wiring
and/or hydraulics for an installation
error.
6. The change in height reading is live as long
as you hold the "MANUAL" switch. Wait
until the height reading has settled to a stable
value and record this reading.
Some sprayers may exhibit unwanted
movement in the boom due to
mechanical play. This may cause some
of the tests to show no movement at all
if the mechanics of the boom are loose.
It is recommended you take at least
five readings to ensure your tests are
accurate.
7. Average your five readings. The acceptable
average change in height should be from 13
to 38 mm (0.5 to 1.5 inches) (ideal would be
25 mm (1 inch) exactly).
8. If the average is less, increase the DZ setting
with the " +/- " switch. If the average is
more, decrease the DZ setting with the " +/- "
switch.
9. Repeat the Dead Zone Test until the average
falls into the acceptable range.
10. When you are satisfied with the DeadZone
roll clockwise test (" DZ "), repeat this test
for the roll counter clockwise (" DZ ").

15
5.3 VALVE GAIN TEST
1. Ensure the UC4+ control panel is in
MANUAL mode, at the Normal Operating
Screen.
2. Navigate to the "More ?" menu prompt in
the SETUP menu Toggle the "AUTO
(YES)" switch to confirm.
3. Navigate to the roll section. Toggle the
"AUTO (YES)" switch to confirm.
4. Toggle the "SETUP (NO)" switch twice to
access the roll cw GAIN (" KP ") menu
prompt.
IMPORTANT:
Before continuing make sure the boom has
room to move at full speed for one second.
Ensure the main lift is up to allow room for
the boom to move.
5. Toggle and hold the "MANUAL" switch.
6. The valve will turn on at 100 percent speed
for exactly one-second. The LCD screen will
show the actual change in height.
7. The change in height reading is live as long
as you hold the "MANUAL" switch. Wait
until the height reading has settled to a stable
value and record this reading. This is your
boom speed in mm per second (mm/s) or
inches per second (in/s) if inches is the
selected units.
8. Repeat the Manual Gain Test three times,
repositioning the boom as necessary.
9. Average your three readings.
10. Set the Gain value using the " +/- " switch.
Use the following table as a guideline.
Table 4 – Roll Section Parameters
Boom Speed
(mm/s)
Gain Setting
(KP)
> 2200 1
2200 - 1000 1 - 5
1000 - 400 5 - 9
400 - 100 9 - 11
< 100 11 - 12
11. When you are satisfied with the Gain roll
clockwise test (" KP "), repeat this test for
the roll counter clockwise (" KP ").
It is recommended to repeat the
Control System Test in the Automatic
System Setup after the slant valve has
been calibrated.

16
6 ELECTRICAL REFERENCE – CABLE DRAWINGS
6.1 ITEM C02: 44668 –SENSOR BRANCH CABLE

17
6.2 ITEM C10: 44650-35/39 –POWER CABLE GENERIC